Flexible Edge Coating Applicator for Curved Rotor Blade Surfaces
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Solution Overview
Problem
Existing methods struggle to apply erosion-resistant coatings uniformly and efficiently to the highly curved surfaces of components like rotor blades and wings without compromising their aerodynamic properties.
Innovation Solution
A squeegee-like device with a flexible base plate and toothed structure is used to apply coating materials evenly and continuously to curved surfaces, featuring a channel for material feed and outlet openings, ensuring precise adaptation to component contours and controlled layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional applicators and dispensing tips are used to apply coating material to highly curved surfaces, then the coating can be applied to repair erosion damage, but the application is difficult and cannot achieve uniform layer thickness on highly curved surfaces
Solution Approach 1:
The base plate is segmented into multiple rigid sections connected by flexible elements, allowing the applicator to conform to highly curved surfaces while maintaining structural integrity and enabling uniform coating application through the toothed structure
Solution Approach 2:
The applicator incorporates a flexible base plate with flexible connections between rigid sections, enabling the tool to adapt to highly curved surfaces like rotor blade leading edges while maintaining the ability to apply uniform coating layers through its toothed dispensing structure
2Reliability
If coating material is applied to the entire surface of a component, then erosion protection is achieved, but the aerodynamic properties are compromised due to excess material application
Solution Approach 1:
The toothed structure of the base plate enables localized coating application with precise control over layer thickness, allowing erosion protection to be applied only where needed while maintaining the component's aerodynamic shape and properties
3Shape
If repairs address only damaged areas of the coating, then the aerodynamic properties are maintained, but the erosion protection is insufficient compared to full surface coating
Solution Approach 1:
The applicator enables precise local coating application on damaged areas while maintaining aerodynamic properties, and can also be used for partial surface coating to provide enhanced erosion protection without the need for complete surface coverage
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables uniform application of protective coatings with controlled layer thicknesses, particularly at edges, maintaining aerodynamic integrity and preventing erosion on components like rotor blades and wings.
Implementation Method 1
the flexible base plate achieves a bending radius of up to 10 mm. Therefore, plastics with elastic moduli in the range of 1000 to 1600 MPa
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a device for applying coatings to strongly curved component surfaces. The device comprises a flexible base plate (1) having a toothing (3) on the side, a channel (4) arranged parallel to the toothed side, and a sealing lip (7). The device can primarily be used to produce a coating on the edges of a component, in particular for applying a liquid or paste-like coating material. The invention also relates to methods for producing erosion protection coatings on component edges, in particular methods for producing edge protection coatings for rotor blades, wings or hydrofoils.