Water-Based Polyurethane Coating for Wind Blade Erosion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wind blades face erosion issues due to exposure to harsh weather conditions, leading to aerodynamic performance degradation and potential damage, and existing coatings often rely on solvent-based systems that are environmentally unfriendly and require complex mixing processes.
Innovation Solution
A water-based polyurethane coating composition with an aliphatic polyurethane dispersion and optional polyisocyanate additive, where the polyurethane dispersion has a particle size below 1000 nm, providing a one-component or two-component system for erosion protection with improved mechanical properties and ease of application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-based coating compositions are used for erosion protection, then good erosion resistance is achieved, but environmental friendliness deteriorates and application complexity increases
Solution Approach 1:
The patent changes the fundamental parameter of the coating system from solvent-based to water-based. This parameter change maintains erosion protection functionality while eliminating the harmful environmental effects associated with solvent-based systems, such as VOC emissions and complex disposal requirements.
Solution Approach 2:
The patent replaces the mechanical/chemical solvent evaporation system with a water-based drying system. Water-based coatings use water evaporation and coalescence mechanisms instead of organic solvent evaporation, achieving similar film formation with better environmental properties and simpler application chemistry.
2Reliability
If two-component coating compositions are used, then erosion resistance is improved, but ease of application deteriorates due to complex mixing processes
Solution Approach 1:
The patent merges the functions of multiple components into a single-component water-based coating composition. By combining the resin, crosslinker, and other necessary components into one pre-mixed formulation, the patent maintains erosion protection performance while eliminating the complexity of measuring and mixing multiple separate components.
Solution Approach 2:
The patent segments the coating formulation into a one-component system that contains all necessary functional elements in a single formulation. This segmentation strategy allows the coating to be applied as a single material rather than requiring mixing of multiple components, simplifying the application process while maintaining performance.
3Object-affected harmful factors
If conventional water-based coatings are used, then environmental friendliness is improved, but erosion resistance deteriorates
Solution Approach 1:
The patent creates a composite water-based coating system that integrates multiple functional components within a single water-based formulation. This composite approach allows the coating to achieve both environmental benefits of water-based systems and the erosion resistance typically associated with more complex solvent-based systems.
Solution Approach 2:
The patent changes key parameters of the water-based coating formulation, including solid content, crosslink density, and polymer architecture, to optimize both environmental performance and erosion resistance. These parameter adjustments allow the water-based system to achieve high erosion resistance without sacrificing environmental friendliness.
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
The coating composition offers effective rain erosion resistance, improved abrasion resistance, and a more environmentally friendly alternative to solvent-based systems, with a simpler application process and reduced environmental impact.
Implementation Method 1
The preparation of the base composition includes a process step where the polycarbonate diol is incorporated into the aqueous dispersion by emulsification into the dispersion. The resulting base composition is mixed with a polyisocyanate curing agent that reacts with hydroxy groups of the polycarbonate.
Implementation Method 2
a water based coating composition for coating a wind blade, preferably for providing an erosion protecting topcoat on said wind blade
Implementation Method 3
Wind turbine blades, or 'wind blades' are usually designed to last around 20 to 25 years. The blades are constantly exposed to the elements and are ideally designed to endure temperature extremes, wind shears, precipitation, and/or other environmental hazards with minimal failure. Coating failure due to erosion is often observed on the wind blade.
Data Source
AI summary
Described herein is a wind blade comprising an outer surface, and at least one coating layer applied to a part of the outer surface, the at least one coating layer including a first coating layer comprising: a) a primary composition comprising one or more aqueous dispersion of an aliphatic polyurethane; wherein said aqueous dispersion has a particle size characterized by a D50 (median) value below 1000 nm; and optionally b) a secondary composition comprising one or more polyisocyanates; wherein when the coating composition comprises b) then said aqueous dispersion in a) is present in an amount of at least 5 times the amount of said polyisocyanate in b) based on weight; when b) is absent then the coating composition is a one-component composition.