Front edge protection film of wind power blade, preparation method of front edge protection film, wind power blade and wind turbine generator system

Abstract

This invention provides a leading-edge protective film for wind turbine blades, a method for preparing the leading-edge protective film, a wind turbine blade, and a wind turbine generator set. The leading-edge protective film comprises: a protective paint layer having a first surface and a second surface opposite to each other in the thickness direction; and a fiber layer including a first portion and a second portion connected to each other in the thickness direction, wherein the first portion of the fiber layer is impregnated into the protective paint layer from the first surface, and the second portion of the fiber layer is exposed to the outside from the first surface. According to this invention, by impregnating a portion of the fiber layer in the protective paint layer and exposing another portion to the outside of the protective paint layer, using the fiber layer as an adhesive interface, the problem of low adhesion strength between the protective paint and the leading edge of the blade is solved, resulting in excellent adhesion performance and avoiding the risk of the leading-edge protective material detaching from the wind farm.

Description

Technical Field

[0001] This invention relates to the field of wind power technology, specifically to a leading edge protective film for a wind turbine blade, a method for preparing the leading edge protective film, a wind turbine blade, and a wind turbine generator set. Background Technology

[0002] Wind turbine blades are the core components of wind turbine generators, and the leading edge is the most important wind-cutting part of the wind turbine blade.

[0003] With the increasing size of wind turbine blades, the maximum linear velocity at the leading edge of the blade tip has exceeded 90 m / s, and some even reach 100 m / s. Under such high-speed rotation, the fatigue effect of long-term impact from raindrops, sand, dust and other particles will cause damage to the leading edge. In mild cases, the coating on the leading edge surface will wear off, and in severe cases, sand holes will appear in the fiberglass substrate, resulting in reduced aerodynamic efficiency, reduced power generation and endangering the service life of the blade.

[0004] Currently, wind turbine blades use highly elastic protective materials for corrosion inhibition at the leading edge, including protective paint, segmented prefabricated shells, and ultra-high molecular weight polyethylene (UHMWPE) leading edge films. However, all of these leading edge protection processes suffer from low adhesion strength between the protective material and the leading edge. Furthermore, these processes also present the following problems.

[0005] Protective paint requires multiple coats by roller or trowel to achieve the required dry film thickness, resulting in a long application cycle. Furthermore, air bubbles are introduced during the mixing and application of the A / B components of the protective paint. During the recoating interval, dust and impurities in the air can easily settle on the wet film surface, causing interlayer defects and resulting in actual protective performance lower than expected. The segmented prefabricated shell layer has a thicker middle section, which has a certain impact on the aerodynamic shape of the wind turbine blades. In addition, the ultra-high molecular weight polyethylene leading edge film has high rigidity and poor conformability to the leading edge shape. Summary of the Invention

[0006] One object of the present invention is to provide a leading edge protective film that can improve the adhesion strength between the protective paint and the leading edge of the blade, and a method for preparing the leading edge protective film.

[0007] Another object of the present invention is to provide a pre-fabricated leading edge protective film with a dense and uniform film layer and a method for preparing the leading edge protective film.

[0008] Another objective of this invention is to provide a leading edge protective film that can improve the conformability to the blade and thus avoid affecting the aerodynamic performance of the wind turbine blade, and a method for preparing the leading edge protective film.

[0009] According to one aspect of the present invention, a leading edge protective film for a wind turbine blade is provided, the leading edge protective film comprising: a protective paint layer having a first surface and a second surface opposite to each other in a thickness direction; a fiber layer including a first portion and a second portion connected to each other in a thickness direction, the first portion of the fiber layer being impregnated into the protective paint layer from the first surface, and the second portion of the fiber layer being exposed to the outside from the first surface.

[0010] Optionally, the thickness of the first portion of the fiber layer is 40%-95% of the total thickness of the fiber layer.

[0011] Optionally, the fiber layer is a single layer of fiber, and the thickness of the fiber layer is 0.2mm-1.0mm.

[0012] Optionally, the first portion of the fiber layer is spaced apart from the second surface.

[0013] Optionally, the leading edge protective film is a film of uniform thickness, or the leading edge protective film is a film of gradually varying thickness.

[0014] Optionally, the leading edge protective film is a thickness gradient film, the second surface is an arc surface, the thickness of the leading edge protective film in the middle region in the width direction is 1mm-3mm, and the thickness of the leading edge protective film decreases from the middle region to both sides in the width direction to 0.4mm-0.6mm.

[0015] Optionally, the leading edge protective film further includes a release film disposed on the second surface.

[0016] Optionally, the protective coating layer includes a polyurethane system, a polyaspartic acid ester system, or a polyaspartic polyurea system.

[0017] According to another aspect of the present invention, a method for preparing a leading edge protective film is provided, the method comprising: coating a protective varnish on a molding die; laying a fiber layer on the protective varnish; immersing a first portion of the fiber layer in the protective varnish and exposing a second portion of the fiber layer to the outside from the protective varnish; and curing the protective varnish to form a protective varnish layer.

[0018] Alternatively, the first portion of the fiber layer can be impregnated with the protective varnish using a pressure roller.

[0019] Optionally, the preparation method further includes: demolding the leading edge protective film from the molding die; and providing a release film on the side surface of the protective paint layer that contacts the molding die.

[0020] According to another aspect of the present invention, a wind turbine blade is provided, the wind turbine blade including a leading edge protective film as described above, wherein a second portion of the fiber layer is bonded to the leading edge of the wind turbine blade.

[0021] Optionally, the second portion of the fiber layer is bonded to the leading edge by an adhesive layer, a resin layer, a prepreg layer, or a resin-impregnated fiber layer.

[0022] According to another aspect of the present invention, a wind turbine generator set is provided, the wind turbine generator set comprising the wind turbine blades as described above.

[0023] According to the present invention, by immersing a portion of the fiber layer in the protective paint layer and exposing the other portion to the outside of the protective paint layer, the fiber layer serves as the bonding interface, thereby solving the problem of low bonding strength between the protective paint and the leading edge of the blade, resulting in excellent bonding performance and avoiding the risk of the wind farm leading edge protective material falling off.

[0024] According to the present invention, the protective paint pre-film technology is used to ensure that the pre-film layer is dense and uniform, overcome the interlayer defects generated during multiple roller coating or scraping processes, and maximize the performance of the protective paint.

[0025] According to the present invention, by using the protective paint pre-film technology, the conformability to the blade can be improved, thereby avoiding affecting the aerodynamic performance of the wind turbine blade. Attached Figure Description

[0026] The above and other objects, features and advantages of the present invention will become clearer from the following detailed description taken in conjunction with the accompanying drawings.

[0027] Figure 1 It is a leading edge protective film for wind turbine blades according to an embodiment of the present invention.

[0028] Figure 2 It is a leading edge protective film for wind turbine blades according to another embodiment of the present invention.

[0029] Figure 3 It is used for manufacturing Figure 1 The cross-sectional view of the forming mold for the leading edge protective film is shown.

[0030] Figure 4 It is used for manufacturing Figure 2 The cross-sectional view of the forming mold for the leading edge protective film is shown.

[0031] Figure 5 This is a schematic diagram of manufacturing a pressure roller according to an embodiment of the present invention.

[0032] Figure 6 This is a schematic diagram of applying a release film to the leading edge protective film according to an embodiment of the present invention.

[0033] Figure 7 This is a schematic diagram of a leading edge protective film being adhered to the leading edge of a wind turbine blade according to an embodiment of the present invention.

[0034] Explanation of reference numerals in the attached figures: 100 Leading edge protective film 110 Protective paint layer 111 First Surface 112 Second Surface 120 fiber layers 121 Part One 122 Part Two 130 release film 200 Molding Die 210 Mold Body 211 Mold Surface 220 mold flange 300 pressure roller 310 Roller Body 320 support shaft 330 rollers 400 wind turbine blades 410 Prelude 420 Resin Layer. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0037] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0038] Wind turbine blade leading edge protective film First, refer to Figure 1 and Figure 2 A leading-edge protective film for a wind turbine blade according to an embodiment of the present invention is described. Figure 1 It is a leading edge protective film for wind turbine blades according to the first embodiment of the present invention. Figure 2 It is a leading edge protective film for wind turbine blades according to the second embodiment of the present invention.

[0039] like Figure 1 and Figure 2 As shown, the leading edge protective film 100 of the wind turbine blade according to an embodiment of the present invention may include: a protective paint layer 110 having a first surface 111 and a second surface 112 opposite to each other in the thickness direction; a fiber layer 120 including a first portion 121 and a second portion 122 connected to each other in the thickness direction, the first portion 121 of the fiber layer 120 being impregnated into the protective paint layer 110 from the first surface 111, and the second portion 122 of the fiber layer 120 being exposed to the outside from the first surface 111.

[0040] According to an embodiment of the present invention, the fiber layer 120 in the leading edge protective film 100 can serve as an adhesive transition layer, thereby solving the problem of low adhesion strength between the protective paint and the leading edge. Specifically, the first portion 121 of the fiber layer 120 is impregnated and laminated with the protective paint layer 110, and the second portion 122 of the fiber layer 120 is exposed to the outside from the first surface 111 of the protective paint layer 110 for subsequent bonding to the leading edge of the wind turbine blade. Thus, the high-strength fiber layer 120 can serve as a connecting link between the protective paint layer 110 and the leading edge, improving the connection strength between the two, preventing the risk of delamination and detachment of the leading edge protective film 100, and improving the reliability of protection.

[0041] According to an embodiment of the present invention, by pre-forming the protective paint into a leading edge protective film, it is beneficial to form a uniform and dense film layer with few internal defects, thereby solving the problem that the actual protective performance of blade protective paint is lower than the expected protective performance due to construction defects.

[0042] According to an embodiment of the present invention, by pre-forming the protective paint into a leading edge protective film, it is beneficial to achieve conformity with the wind turbine blade and prevent adverse effects on the aerodynamic shape of the wind turbine blade.

[0043] The following is a detailed description of each component of the leading edge protective film 100.

[0044] like Figure 1 and Figure 2 As shown, the leading edge protective film 100 may include a protective paint layer 110 and a fiber layer 120. The protective paint layer 110 has a thickness direction (i.e., Figure 1 and Figure 2 The fiber layer 120 may include a first portion 121 and a second portion 122 connected to each other in the thickness direction, the first portion 121 being impregnated into the protective varnish layer 110 from the first surface 111, and the second portion 122 being exposed to the outside from the first surface 111.

[0045] According to embodiments of the present invention, the protective paint used to form the protective paint layer 110 may be a polyurethane system, a polyaspartic ester system, or a polyaspartic polyurea system. However, the present invention is not limited thereto, and other coating systems may also be used for the protective paint. In addition, the specific components of the polyurethane system, polyaspartic ester system, or polyaspartic polyurea system are not limited, as long as it is a coating system suitable for wind turbine blades.

[0046] The following description uses the protective coating 110, which is a polyaspartic acid ester system, as an example to illustrate its specific composition.

[0047] As an example, component A of the polyaspartic ester system is made from the following parts by weight: 25-65 parts by weight of polyaspartic ester, 0-2 parts by weight of light stabilizer, 15-25 parts by weight of filler, 0-0.5 parts by weight of mildew inhibitor, 0-0.5 parts by weight of catalyst, 0-0.5 parts by weight of defoamer, 0-0.5 parts by weight of wetting and dispersing agent, 0-1 parts by weight of leveling agent, and 20-45 parts by weight of solvent. Component B of the polyaspartic ester system is made from the following parts by weight: 40-100 parts by weight of isocyanate and 0-60 parts by weight of solvent.

[0048] As examples, the light stabilizer can be at least one of benzotriazoles, hindered amines, salicylates, triazines, substituted acrylonitriles, and benzophenones. The filler can be at least one of fumed silica, barium sulfate, titanium dioxide, calcium carbonate, and talc. The fungicide can be at least one of broad-spectrum, high-efficiency bactericides such as DCOIT, OIT, IPBC, ZPT, BBIT, CIT, and MIT. The catalyst can be at least one of tertiary amine catalysts, organotin catalysts, organobismuth catalysts, and organozirconium catalysts. The defoamer can be at least one of organopolysiloxane defoamers and water-based mineral oil defoamers. The wetting and dispersing agent can be at least one of anionic types such as sulfonate succinates, dodecyl sulfonates, lauryl sulfate, and butyl oleate sulfate; or nonionic types such as alkylphenol polyoxyethylene ethers and alkyl alcohol polyoxyethylene ethers; or cationic types such as amine salts, quaternary ammonium salts, and pyridinium salts; or traditional types such as polyacrylates and polycarboxylates. The leveling agent can be at least one of silicone-based leveling agents, acrylate-based leveling agents, and fluorocarbon-based leveling agents. The solvent can be at least one of ketones, esters, alcohols, and alkane solvents, such as xylene, ethylbenzene, ethyl acetate, and butyl acetate. The isocyanate can be at least one of aliphatic isocyanates and alicyclic isocyanates.

[0049] According to embodiments of the present invention, the fiber layer 120 may be a blended fabric of at least one fiber selected from glass fiber, carbon fiber, basalt fiber, aramid fiber, natural fiber, ultra-high molecular weight polyethylene fiber, POE fiber, etc. Preferably, the fiber layer 120 may be a plain weave fabric or a biaxial fabric. Furthermore, according to embodiments of the present invention, the fiber layer density may be 60-1600 g / m². 2 Preferably 200-600g / m 2 .

[0050] According to one embodiment of the present invention, such as Figure 1 As shown, the leading edge protective film 100 can be a film of uniform thickness. That is, the thickness of each portion of the leading edge protective film 100 is substantially equal within a tolerance range. As an example, the thickness of the leading edge protective film 100 can be, for example, about 1 mm to 3 mm; however, the present invention is not limited thereto.

[0051] According to another embodiment of the present invention, such as Figure 2 As shown, the leading edge protective film 100 can be a film with a gradually varying thickness. Specifically, the second surface 112 can be an arc surface, and the leading edge protective film 100 is in the width direction (i.e., Figure 1 and Figure 2 The thickness of the middle region (in the horizontal direction perpendicular to the vertical direction) shown can be 1mm-3mm, and the thickness of the leading edge protective film 100 decreases from the middle region to 0.4mm-0.6mm on both sides of the width direction. According to an embodiment of the present invention, when the leading edge protective film 100 is a thickness-gradient film, the step after bonding with the leading edge of the blade can be reduced, the conformability can be improved, and the aerodynamic performance of the wind turbine blade can be avoided from being adversely affected.

[0052] According to an embodiment of the present invention, at least a portion of the fiber layer 120 may be exposed from the protective varnish layer 110 to serve as an adhesive transition layer between the protective varnish layer 110 and the leading edge. The thickness of the portion of the fiber layer 120 exposed from the protective varnish layer 110 is not specifically limited; that is, as long as a portion of the fiber layer 120 is exposed from the protective varnish layer 110, an appropriate increase in adhesive strength can be achieved.

[0053] Preferably, the first portion 121 of the fiber layer 120 (i.e., the portion immersed in the protective coating layer 110) accounts for 40%-95% of the total thickness of the fiber layer 120. If the thickness of the first portion 121 of the fiber layer 120 is less than 40% of the total thickness of the fiber layer 120, the portion of the fiber layer 120 bonded to the protective coating layer 110 may be small, potentially leading to the risk of the fiber layer 120 detaching from the protective coating layer 110. If the thickness of the first portion 121 of the fiber layer 120 is greater than 95% of the total thickness of the fiber layer 120, the portion of the fiber layer 120 exposed from the protective coating layer 110 may be small, resulting in an insufficiently small bonded portion between the fiber layer 120 and the leading edge, and the bond strength may not be significantly improved.

[0054] As an optional example, the thickness of the first portion 121 of the fiber layer 120 is 50%-85% of the total thickness of the fiber layer 120, or 60%-75% of the total thickness of the fiber layer 120.

[0055] Furthermore, according to embodiments of the present invention, the number of fiber layers 120 is not specifically limited. Preferably, the fiber layer 120 can be a single layer of fiber. When the fiber layer 120 is a single layer of fiber, it is more beneficial to improve the adhesion strength between the leading edge protective film 100 and the leading edge.

[0056] According to an embodiment of the present invention, the thickness of the fiber layer 120 can be 0.2 mm to 1.0 mm. When the thickness of the fiber layer 120 is in the range of 0.2 mm to 1.0 mm, it helps to improve the bonding strength while reducing the thickness of the leading edge protective film.

[0057] According to embodiments of the present invention, such as Figure 1 and Figure 2 As shown, the first portion 121 of the fiber layer 120 may be spaced apart from the second surface 112. That is, the fiber layer 120 is not impregnated over the entire thickness of the protective coating layer 110, but only over a portion of the thickness of the protective coating layer 110, which helps to reduce the overall weight of the leading edge protective film 100.

[0058] According to an embodiment of the present invention, the leading edge protective film 100 may further include a release film 130 disposed on the second surface 112 (e.g., as shown in the figure). Figure 6 (As shown). The main function of the release film 130 is to prevent surface contamination and damage to the leading edge protective film 100 during packaging, transportation, and bonding processes. Preferably, the thickness of the release film 130 is 0.1mm-0.8mm.

[0059] According to an embodiment of the present invention, the release film 130 can be a composite film of at least one of PE, PET and OPP, and a silicone release agent can be coated on its surface to ensure that there is no residue or damage when it is removed.

[0060] Preparation method of leading edge protective film The following is for reference Figures 3 to 6 A method for preparing a leading-edge protective film according to an embodiment of the present invention is described. Figure 3 It is used for manufacturing Figure 1 The cross-sectional view of the forming mold for the leading edge protective film is shown. Figure 4 It is used for manufacturing Figure 2 The cross-sectional view of the forming mold for the leading edge protective film is shown. Figure 5 This is a schematic diagram of manufacturing a pressure roller according to an embodiment of the present invention. Figure 6This is a schematic diagram of applying a release film to the leading edge protective film according to an embodiment of the present invention.

[0061] The method for preparing the leading edge protective film according to an embodiment of the present invention may include: coating a protective varnish on a molding die 200; laying a fiber layer 120 on the protective varnish; immersing a first portion 121 of the fiber layer 120 into the protective varnish and exposing a second portion 122 of the fiber layer 120 to the outside of the protective varnish; and curing the protective varnish to form a protective varnish layer 110.

[0062] According to an embodiment of the present invention, the first portion 121 of the fiber layer 120 can be impregnated into the protective varnish using a pressure roller 300. Additionally, the method for preparing the leading edge protective film according to an embodiment of the present invention may further include: demolding the leading edge protective film 100 from the molding die 200; and providing a release film 130 on the surface of the protective varnish layer 110 that contacts the molding die 200.

[0063] The following describes a specific method for preparing a leading-edge protective film according to an embodiment of the present invention. It should be understood that the order of the following descriptions may be adjusted if there is no obvious sequential relationship.

[0064] First, a molding die 200 can be prepared. As an example, it can be selected based on the thickness of the leading edge protective film 100. Figure 3 or Figure 4 The molding die 200 shown, wherein, Figure 3 The molding die 200 is used to form a leading edge protective film 100 of uniform thickness. Figure 4 The molding die 200 is used to form the leading edge protective film 100 with a gradually varying thickness.

[0065] like Figure 3 and Figure 4 As shown, the molding die 200 may include a die body 210 and a die flange 220. Figure 3 The mold surface 211 of the mold body 210 shown is a flat surface. Figure 4 The mold surface 211 of the mold body 210 shown includes an arcuate surface. As an example, a heating device (not shown) may be pre-embedded in the mold body 210. The heating device is mainly used to accelerate curing or to preheat the protective paint when the ambient temperature is low in winter.

[0066] To ensure a good release effect, a non-stick design can be applied to the mold surface 211. This can be done by attaching a polytetrafluoroethylene film, spraying a non-stick coating (silicone coating, Teflon coating, nano-ceramic coating, polyethersulfone coating), or applying a release agent / wax.

[0067] Then, the protective paint can be mixed and vacuum degassed. Specifically, the main agent of the protective paint (component A of the protective paint described above, not described in detail here) can be placed in a vacuum degassing machine for 15-30 minutes (e.g., vacuum degree of 0.1 MPa), then removed, and the curing agent (component B of the protective paint described above, not described in detail here) can be added and stirred for 5-10 minutes. The mixture can then be filtered through a 100-120 mesh filter, and the filtrate can be placed in a vacuum degassing machine for 15-30 minutes (e.g., vacuum degree of 0.1 MPa).

[0068] Next, a protective varnish is evenly applied to the molding mold 200. Specifically, the degassed protective varnish can be evenly poured into the molding mold 200, and the varnish surface can be leveled along the upper surface of the mold flange 220 using a scraper.

[0069] Next, a fiber layer 120 is laid on the protective paint and a pressure roller 300 is used to immerse the fiber layer 120 in the protective paint. Specifically, the fiber layer 120 can be laid flat on the paint surface of the protective paint, and the pressure roller 300 is used to immerse the fiber layer 120 in the protective paint, ensuring that the protective paint immerses 40%-95% of the thickness of the fiber layer 120.

[0070] like Figure 5 As shown, the pressure roller 300 may include a roller body 310, a support shaft 320 supporting the roller body 310, and a roller 330 that drives the roller body 310 to roll back and forth. The roller 330 can contact the fiber layer 120 and is used to press the fiber layer 120 downward into the protective varnish. For example, the pressing depth of the fiber layer 120 can be adjusted by adjusting the diameter of the roller 330, thereby adjusting the thickness ratio of the fiber layer 120 immersed in the protective varnish. The roller 330 can roll back and forth (corresponding to the length direction of the leading edge protective film 100) to drive the roller body 310 to roll back and forth, thereby pressing a portion of the fiber layer 120 into the protective varnish.

[0071] Next, after confirming that the impregnation thickness meets the requirements, cure at room temperature for 10 to 24 hours. Then, demold the leading edge protective film 100 from the molding mold 200. If the release effect is not good, the curing time can be appropriately extended. In addition, if necessary, after demolding, a release film 130 can be placed on the surface of the protective paint layer 110 that contacts the molding mold 200 (i.e., the second surface 112 mentioned above) on the coating mold to ensure that the surface of the film layer is not contaminated during cutting, packaging, transportation, and bonding. Finally, the leading edge protective film can be cut to the required length and packaged in rolls.

[0072] Wind turbine blades Figure 7 This is a schematic diagram of a leading edge protective film being adhered to the leading edge of a wind turbine blade according to an embodiment of the present invention.

[0073] like Figure 7 As shown, the wind turbine blade 400 according to an embodiment of the present invention may include the leading edge protective film 100 as described above, and the leading edge protective film 100 may be adhered to the leading edge 410 of the wind turbine blade 400.

[0074] Specifically, the second portion 122 of the fiber layer 120 can be bonded to the leading edge 410 of the wind turbine blade 400. As an example, the second portion 122 of the fiber layer 120 can be bonded to the leading edge 410 via a resin layer 420. However, the present invention is not limited thereto, and the second portion 122 of the fiber layer 120 can also be bonded to the leading edge 410 via an adhesive layer, a prepreg layer, or a resin-impregnated fiber layer.

[0075] Wind turbine generator set The present invention may also provide a wind turbine generator set including the above-mentioned wind turbine blades.

[0076] The following will describe specific embodiments according to the present invention.

[0077] Example Prepare the protective coating components A and B according to Table 1 below. Place component A in a vacuum degassing machine for 20 minutes (vacuum degree 0.1MPa) and remove it. Add component B at a ratio of A:B=1:1.6 and stir for 5 minutes. Filter with a 100-mesh filter and place the filtrate in a vacuum degassing machine for 15 minutes (vacuum degree 0.1MPa).

[0078] Pour the degassed protective paint evenly into the molding mold, and use a scraper to smooth the paint surface along the upper end of the flange. (600g / m²) 2 A fiberglass woven fabric with a surface density of 1.5 g is laid flat on the painted surface. A pressure roller is used to immerse the fiber layer in the paint, ensuring that the paint surface submerges the fiber layer by 0.3 mm. After standing at room temperature for 24 hours, the leading edge protective film is demolded from the molding mold. The thickness of the insulating protective film in the center area (the aforementioned middle area) is 2 mm, decreasing to 0.5 mm at the edges.

[0079] [Table 1]

[0080] Next, the performance and rain erosion resistance of the prepared leading edge protective film and the leading edge protective paint with the same formula were tested. The test standards and test results are shown in Table 2.

[0081] [Table 2]

[0082] As shown in Table 2, the leading edge protective film of the present invention exhibits excellent rain erosion resistance, achieving a standard rain erosion resistance test result of 20 hours, significantly improving upon the rain erosion resistance (9 hours) achievable by roller or squeegee application of the same formula of leading edge protective paint. Furthermore, the leading edge protective film possesses a tensile strength as high as 4.1 MPa and a 90° peel strength as high as 18 N / cm, while the tensile strength of the same formula of leading edge protective paint is 3.8 MPa and the 90° peel strength is 12.4 N / cm. Therefore, the leading edge protective film according to the embodiments of the present invention possesses higher mechanical properties and adhesive strength. In other words, the leading edge protective film according to the embodiments of the present invention exhibits excellent overall mechanical properties and high adhesive strength.

[0083] According to the wind turbine blade leading edge protective film, the method for preparing the leading edge protective film, the wind turbine blade and the wind turbine generator set as described above, beneficial technical effects, not limited to those described below, can be achieved.

[0084] According to the present invention, by immersing a portion of the fiber layer in the protective paint layer and exposing the other portion to the outside of the protective paint layer, the fiber layer serves as the bonding interface, thereby solving the problem of low bonding strength between the protective paint and the leading edge of the blade, resulting in excellent bonding performance and avoiding the risk of the wind farm leading edge protective material falling off.

[0085] According to the present invention, the protective paint pre-film technology is used to ensure that the pre-film layer is dense and uniform, overcome the interlayer defects generated during multiple roller coating or scraping processes, and maximize the performance of the protective paint.

[0086] According to the present invention, by using the protective paint pre-film technology, the conformability to the blade can be improved, thereby avoiding affecting the aerodynamic performance of the wind turbine blade.

[0087] According to the present invention, a protective varnish is applied by using a molding die and a portion of the fiber layer is impregnated into the protective varnish by a pressure roller. The process is easy to implement, has a high forming rate, and offers a large degree of adjustability.

[0088] The leading edge protective film of the present invention has excellent rain erosion performance, and the standard rain erosion resistance test can reach 20h, which is far superior to the rain erosion resistance performance that can be achieved by roller or scraper application of the same formula protective paint.

[0089] The leading edge protective film of the present invention has excellent resistance to rain erosion and sand erosion, and is suitable for various complex wind field environments. It enables the blade to be maintenance-free or require only one maintenance throughout its entire life cycle, and can reduce maintenance costs by 400,000 RMB per unit compared to existing protective paint systems.

[0090] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention; the objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments, and any modifications or variations of the embodiments of the present invention may be made without departing from the stated principles.

Claims

1. A leading edge protective film for wind turbine blades, characterized in that, The leading edge protective film (100) includes: The protective paint layer (110) has a first surface (111) and a second surface (112) that are opposite to each other in the thickness direction. The fiber layer (120) includes a first portion (121) and a second portion (122) connected to each other along the thickness direction, wherein the first portion (121) of the fiber layer (120) is impregnated into the protective paint layer (110) from the first surface (111), and the second portion (122) of the fiber layer (120) is exposed to the outside from the first surface (111).

2. The leading edge protective film of the wind turbine blade according to claim 1, characterized in that, The thickness of the first portion (121) of the fiber layer (120) is 40%-95% of the total thickness of the fiber layer (120).

3. The leading edge protective film of the wind turbine blade according to claim 1, characterized in that, According to claim 1, the leading edge protective film of the wind turbine blade is characterized in that the fiber layer (120) is a single layer of fiber and the thickness of the fiber layer (120) is 0.2mm-1.0mm.

4. The leading edge protective film of the wind turbine blade according to any one of claims 1 to 3, characterized in that, The first portion (121) of the fiber layer (120) is spaced apart from the second surface (112).

5. The leading edge protective film of the wind turbine blade according to any one of claims 1 to 3, characterized in that, The leading edge protective film (100) is a film of uniform thickness, or the leading edge protective film (100) is a film of gradually varying thickness.

6. The leading edge protective film of the wind turbine blade according to claim 5, characterized in that, The leading edge protective film (100) is a thickness gradient film, the second surface (112) is an arc surface, the thickness of the leading edge protective film (100) in the middle region of the width direction is 1mm-3mm, and the thickness of the leading edge protective film (100) decreases from the middle region to both sides of the width direction to 0.4mm-0.6mm.

7. The leading edge protective film of a wind turbine blade according to any one of claims 1 to 3, characterized in that, The leading edge protective film (100) also includes a release film (130) disposed on the second surface (112).

8. The leading edge protective film of a wind turbine blade according to any one of claims 1 to 3, characterized in that, The protective coating layer (110) includes a polyurethane system, a polyaspartic acid ester system, or a polyaspartic polyurea system.

9. A method for preparing a leading-edge protective film, characterized in that, The preparation method includes: Apply a protective coating to the molding die (200); The fiber layer (120) is laid on the protective paint; The first portion (121) of the fiber layer (120) is immersed in the protective varnish, and the second portion (122) of the fiber layer (120) is exposed to the outside from the protective varnish; The protective paint is cured to form a protective paint layer (110).

10. The method for preparing the leading edge protective film according to claim 9, characterized in that, The first portion (121) of the fiber layer (120) is impregnated into the protective varnish using a pressure roller (300).

11. The method for preparing the leading edge protective film according to claim 9, characterized in that, The preparation method further includes: Demold the leading edge protective film (100) from the molding die (200); A release film (130) is provided on the side surface of the protective paint layer (110) that contacts the molding die (200).

12. A wind turbine blade, characterized in that, The wind turbine blade (400) includes a leading edge protective film (100) according to any one of claims 1 to 8, wherein the second portion (122) of the fiber layer (120) is bonded to the leading edge (410) of the wind turbine blade (400).

13. The wind turbine blade according to claim 12, characterized in that, The second portion (122) of the fiber layer (120) is bonded to the leading edge (410) by an adhesive layer, a resin layer, a prepreg layer or a resin-impregnated fiber layer.

14. A wind turbine generator set, characterized in that, The wind turbine generator set includes wind turbine blades according to claim 12 or 13.

Images