CN111231369B - Protective shell, preparation method thereof and manufacturing method of wind power blade - Google Patents

Protective shell, preparation method thereof and manufacturing method of wind power blade Download PDF

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Publication number
CN111231369B
CN111231369B CN202010100619.5A CN202010100619A CN111231369B CN 111231369 B CN111231369 B CN 111231369B CN 202010100619 A CN202010100619 A CN 202010100619A CN 111231369 B CN111231369 B CN 111231369B
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China
Prior art keywords
protective shell
wind power
protective
power blade
blade
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CN202010100619.5A
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CN111231369A (en
Inventor
牟书香
张丹凤
吕兵
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Sinomatech Wind Power Blade Co Ltd
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Sinomatech Wind Power Blade Co Ltd
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Priority to CN202010100619.5A priority Critical patent/CN111231369B/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Abstract

The invention provides a protective shell, a preparation method thereof and a manufacturing method of a wind power blade, wherein under the vacuum condition, air existing in a first fiber material layer and a first resin material is exhausted, the first resin material permeates into the first fiber material layer, and a fiber reinforced material layer is formed after the first resin material is cured, so that the strength of the protective shell is improved, and meanwhile, the interface bonding force between the first resin material and the first fiber material layer is effectively enhanced; the wind power blade skin substrate is manufactured in the protective shell, so that the interface bonding force between the blade skin substrate and the protective shell is enhanced, and the protective shell does not have internal stress inside, so that the possibility of peeling of the wind power blade is reduced; the protective shell can be used for overall protection of the wind power blade and can also be used for local protection of the wind power blade to achieve local protection enhancement, and therefore the protective effect of the wind power blade is improved.

Description

Protective shell, preparation method thereof and manufacturing method of wind power blade
Technical Field
The invention relates to the technical field of wind power blades, in particular to a protective shell and a preparation method thereof, and a manufacturing method of a wind power blade.
Background
Wind energy has been paid more and more attention to all countries in the world as a clean renewable energy source, and effective utilization of wind energy is beneficial to realizing diversification of energy structures and reducing environmental pollution. The design service life of the wind power blade is 20 years, once the wind power blade starts to operate, the wind power blade is corroded by rainwater, wind sand and the atmosphere, and meanwhile, the wind power blade is also subjected to aging of strong ultraviolet. In the high-speed operation process of the blade, erosion of wind sand and raindrops on the wind power blade is equivalent to plasma cutting, and cavities are easily formed on the surface of the blade. Research has shown that an increase in the surface roughness of the blades and the accumulation of defects will result in a 5% -30% reduction in the efficiency of power generation and may also result in a failure of the gearbox due to a destabilization of the operation of the blades. It is therefore important how to maintain efficient operation of the blade for a 20 year life cycle.
Chinese patent document CN108223264A proposes that a plurality of protective tapes are directly adhered to the surface of a blade, and adjacent protective tapes are butted at a zero distance to form a protective base layer, and a resin protective coating is coated on the protective base layer, wherein the protective tapes are composed of a glass fiber fabric and a pressure sensitive adhesive. The interface bonding force is relatively weak because the glass fiber fabric is adhered to the surface of the blade through the pressure-sensitive adhesive; the coating of the resin protective coating on the protective base layer causes the interface bonding force between the glass fiber fabric and the resin protective coating to be insufficient; meanwhile, when the protective tape is stuck to an area with large curvature change of the blade, the interior of the protective tape is pulled, so that internal stress exists in the interior of the protective tape; in summary, the blade protection shell and the construction method thereof have certain stripping hidden danger, and the protection effect of the blade is influenced.
Disclosure of Invention
Therefore, the invention aims to overcome the defect of potential stripping hazard of the conventional blade protective shell, and provides the protective shell, a preparation method of the protective shell and a manufacturing method of a wind power blade.
The invention provides a preparation method of a protective shell, which comprises the following steps:
(1) Forming a first release agent layer on the inner surface of the protective shell mold;
(2) Forming a protective coating on the first release agent layer and drying it;
(3) Forming a first fiber material layer on the dried protective coating;
(4) Forming a first resin material in the first fiber material layer under a vacuum condition, and curing the first resin material to obtain a fiber reinforced material layer;
(5) And demolding after the first resin material is cured to obtain the protective shell.
Further, after the first fiber material layer is formed on the dried protective coating, a step of forming a release cloth on the first fiber material layer is also included, and the release cloth is torn off after the release.
Further, in the step of forming the first resin material in the first fiber material layer, a degree of vacuum is not more than 40mbar.
Further, a step of forming a first release agent layer on the inner surface of the shell mold includes coating a first release agent in the shell mold and curing the first release agent at 20 to 60 ℃ to form a first release agent layer;
and forming a protective coating on the first release agent layer, wherein the step of forming the protective coating comprises coating the coating on the first release agent layer and drying the coating at 5-80 ℃ to form the protective coating with the thickness of 100-500 mu m, and preferably, the thickness of the protective coating is 150-300 mu m.
Further, the thickness of the layer of fibrous reinforcing material does not exceed 3mm, preferably the thickness of the layer of fibrous reinforcing material is the same as the thickness of the protective coating.
Further, the first resin material is at least one of epoxy resin, vinyl resin, unsaturated polyester resin and polyurethane resin;
the first fiber material layer adopts at least one of glass fiber, carbon fiber and aramid fiber as a fiber material;
the first fiber material layer is one of chopped strand mats, fiber woven cloth and fiber paper;
the protective coating comprises polyurethane, polyaspartic acid ester resin, acrylic resin or fluoropolymer.
Further, the shape of the inner surface of the protective shell mold is the same as that of at least part of the inner surface of the wind power blade mold; or at least two protective shell molds are assembled into a protective shell mold assembly, and the shape of the inner surface of the protective shell mold assembly is the same as that of at least part of the inner surface of the wind power blade mold.
Further, the protective coating is not formed on the inner surface of the protective shell mold or the protective shell mold assembly in the area corresponding to the front edge and the rear edge of the wind power blade.
The invention provides a protective shell which is prepared by adopting the preparation method.
The invention also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Forming a second release agent layer on the inner surface of the wind power blade mould;
(2) Placing the protective shell in the wind power blade mold and on the second release agent layer;
(3) Forming a wind power blade skin base body on the protective shell to obtain the wind power blade skin base body with the protective shell;
(4) And manufacturing the wind power blade with the protective shell by using the wind power blade skin substrate with the protective shell.
Further, the step of preparing the wind power blade with the protective shell from the wind power blade skin substrate with the protective shell comprises the steps of sequentially carrying out bonding, die assembly and curing on the wind power blade skin substrate, and removing the wind power blade skin substrate from a wind power blade die;
the number of the protective shells is at least two, in the step of placing the protective shells in the wind power blade mould and on the second release agent layer, the adjacent protective shells are in butt joint or reserved gaps, and after the wind power blade with the protective shells is released from the wind power blade mould, paint is coated at the butt joint or the reserved gaps for repairing.
The technical scheme of the invention has the following advantages:
1. the protective shell and the preparation method thereof provided by the invention have the advantages that after a first release agent layer, a protective coating and a first fiber material layer are sequentially formed on the inner surface of a protective shell mold, a first resin material is formed in the first fiber material layer under a vacuum condition, and the protective shell is obtained after the first resin material is cured and then is subjected to demolding. Under the vacuum condition, the air existing at the interface of the first fiber material layer, the first resin material, the first fiber material layer and the first resin material is discharged, the first resin material permeates into the first fiber material layer, and the fiber reinforced material layer is formed after the first resin material is cured, so that the strength of the protective shell is improved, and meanwhile, the interface bonding force between the first resin material and the first fiber material layer is effectively enhanced, the probability of stripping of the protective shell is reduced, the protective effect of the protective shell is ensured, and the protective life of the protective shell is prolonged.
2. According to the manufacturing method of the wind power blade, the wind power blade skin substrate is manufactured in the protective shell, so that the interface bonding force between the blade skin substrate and the protective shell is enhanced, the possibility that the protective shell is peeled from the surface of the wind power blade is effectively reduced, and the protective effect is improved; when the shape of the inner surface of the protective shell mold or the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold, the protective shell or the protective shell assembly obtained by preparation and the wind power blade skin substrate have the same aerodynamic shape, so that internal stress does not exist in the protective shell or the protective shell assembly when the protective shell or the protective shell assembly is used in the wind power blade, the possibility that the protective shell is peeled from the surface of the wind power blade is effectively reduced, and the protective effect is improved; when the shape of the inner surface of the protective shell mold or the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold, the protective shell or the protective shell assembly obtained through preparation partially covers the wind power blade base body so as to locally protect and reinforce the region of the blade and improve the protection effect of the wind power blade.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a schematic structural diagram of a protective shell obtained by a preparation method according to an embodiment of the invention;
FIG. 2 is a schematic structural diagram of a wind turbine blade skin substrate with a protective shell according to an embodiment of the invention;
FIG. 3 is a top view of a first embodiment of a wind blade skin base with a protective shell assembly according to the present invention;
FIG. 4 is a top view of a second embodiment of a wind blade skin base with a protective shell assembly according to the present invention;
FIG. 5 is a schematic structural diagram of a mold for a protective shell according to an embodiment of the present invention;
FIG. 6 is a schematic structural view of a mold assembly of a shield shell in an embodiment of the present invention;
description of the drawings:
1-protective coating; 2-a layer of fibrous reinforcing material; 3-wind power blade skin base body; 4-protecting the shell mold front edge; 5-protecting the shell mold trailing edge; 6-protecting the shell mold assembly leading edge; 7-protecting the shell mold assembly trailing edge.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it is to be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplification of description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In addition, the technical features involved in the different embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Example 1
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Forming a first release agent layer on the inner surface of the protective shell mold;
(2) Forming a protective coating on the first release agent layer and drying it;
(3) Forming a first fiber material layer on the dried protective coating;
(4) Forming a first resin material in the first fiber material layer under a vacuum condition, and curing the first resin material to obtain a fiber reinforced material layer;
(5) And demolding after the first resin material is cured to obtain the protective shell, wherein the structure of the protective shell is shown in figure 1.
According to the preparation method of the protective shell, under the vacuum condition, air existing at the interface of the first fiber material layer, the first resin material and the first fiber material layer is exhausted, the first resin material permeates into the inside of the first fiber material layer, and the fiber reinforced material layer is formed after the first resin material is cured, so that the interface bonding force between the first resin material and the first fiber material layer is effectively enhanced while the strength of the protective shell is improved, the possibility of stripping of the protective shell is reduced, the protective effect of the protective shell is guaranteed, and the protective life of the protective shell is prolonged.
Further, after the first fiber material layer is formed on the dried protective coating, the step of forming the demolding cloth on the first fiber material layer is also included, and the demolding cloth is torn off after demolding, so that the inner surface of the prepared protective shell has certain roughness.
Further, in the step of forming the first resin material within the first fiber material layer, a vacuum degree is not more than 40mbar. When the vacuum degree is more than 40mbar, the first resin material diffuses at a very slow speed, and the wettability is very poor, so that the preparation process and the preparation effect of the first resin material are adversely affected, and the preparation of the protective shell is further affected. Further, the forming method of the first resin material is a vacuum infusion molding process or a vacuum bag hand lay-up method.
Further, a step of forming a first release agent layer on the inner surface of the shell mold includes coating a first release agent in the shell mold and curing the first release agent at 20 to 60 ℃ to form a first release agent layer; and forming a protective coating on the first release agent layer, wherein the step of forming the protective coating comprises coating the coating on the first release agent layer and drying the coating at 5-80 ℃ to form the protective coating with the thickness of 100-500 μm, and preferably, the thickness of the protective coating is 150-300 μm. The quality of the protective coating is improved by controlling the drying temperature of the coating, and the thickness of the protective coating is controlled to control the protective effect of the protective shell.
Further, the thickness of the layer of fibrous reinforcing material does not exceed 3mm, preferably the thickness of the layer of fibrous reinforcing material is the same as the thickness of the protective coating. The strength of the protective shell is mainly determined by the strength of the fiber reinforced material layer, and the strength of the protective shell is controlled by controlling the strength of the fiber reinforced material layer.
Further, the first resin material is at least one of epoxy resin, vinyl resin, unsaturated polyester resin and polyurethane resin; the first fiber material layer adopts at least one of glass fiber, carbon fiber and aramid fiber as a fiber material; the first fiber material layer is one of chopped strand mats, fiber woven cloth and fiber paper; the protective coating comprises polyurethane, polyaspartic acid ester resin, acrylic resin or fluoropolymer. The strength of the protective shell is controlled by the choice of the type of fibers, the structural form of the fiber-reinforced material layer and the type of first resin material.
The protective coating can be an existing paint system for the wind power blade, and due to the fact that paint construction and curing are carried out in a protective shell mold, an in-mold gel coat paint system suitable for a coating process in the wind power blade mold can be adopted, a paint system of an external post-coating process of the wind power blade mold can also be adopted, and the paint selection range is wide.
Further, the shape of the inner surface of the protective shell mold is the same as that of at least part of the inner surface of the wind power blade mold; or at least two protective shell molds are assembled into a protective shell mold assembly, and the shape of the inner surface of the protective shell mold assembly is the same as that of at least part of the inner surface of the wind power blade mold. It should be noted that, this application wind-powered electricity generation blade mould refer to skin mould on the wind-powered electricity generation blade or skin mould under the wind-powered electricity generation blade, wind-powered electricity generation blade skin base member refer to skin base member on the wind-powered electricity generation blade or skin base member under the wind-powered electricity generation blade, consequently the protection casing or protection casing subassembly that this application preparation obtained is the same with the at least local interior surface shape of skin on the wind-powered electricity generation blade or skin under the wind-powered electricity generation blade.
Further, the protective coating is not formed in the region of the inner surface of the protective shell mold or the protective shell mold assembly corresponding to the front edge and the rear edge of the wind power blade, so that the protective coating is used in the wind power blade to obtain the wind power blade with the protective shell, and then the region is subjected to post-treatment such as reinforcement.
It should be noted that, the region of the inner surface of the protective shell mold corresponding to the front and rear edges of the wind turbine blade is referred to as the front and rear edges of the protective shell mold in this application, as shown in fig. 5, the front and rear edges of the protective shell mold are located at the edge of the inner surface of the protective shell mold, the length of the region without the protective coating from the edge of the protective shell mold is 50-250mm, the width of each part in the region along the edge of the protective shell mold may be the same, or different widths may be reserved locally according to the design of local reinforcement of the front and rear edges of the blade; specifically, the process can be realized by the following method: before preparing the protective coating, sticking masking paper on the front edge 4 of the protective shell mold and the rear edge 5 of the protective shell mold respectively, and tearing off the masking paper before the surface of the protective coating is dried;
the region of the inner surface of the protective shell mold assembly corresponding to the front edge and the rear edge of the wind power blade is referred to as the front edge and the rear edge of the protective shell mold assembly in the present application, as shown in fig. 6, the front edge and the rear edge of the protective shell mold assembly are located at the edge of the inner surface of the protective shell mold assembly, the length of the region without the protective coating from the edge of the protective shell mold assembly is 50-250mm, the width of each part in the region along the edge of the protective shell mold can be the same, or different widths can be reserved locally according to the design of local reinforcement of the front edge and the rear edge of the blade; specifically, the process can be realized by the following method: before preparing the protective coating, masking paper is respectively stuck on the front edge 6 of the protective shell mold component and the rear edge 7 of the protective shell mold component, and the masking paper is torn off before the surface of the protective coating is dried.
The embodiment provides a protective shell which is prepared by adopting the preparation method.
The invention also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Forming a second release agent layer on the inner surface of the wind power blade mould;
(2) Placing the protective shell in the wind power blade mould and on the second release agent layer;
(3) Forming a wind power blade skin base body 3 on the protective shell to obtain the wind power blade skin base body with the protective shell;
(4) And manufacturing the wind power blade skin substrate with the protective shell into the wind power blade with the protective shell.
According to the manufacturing method of the wind power blade, the wind power blade skin base body is manufactured in the protective shell, so that the interface bonding force between the blade skin base body and the protective shell is enhanced, the possibility that the protective shell is peeled off from the surface of the wind power blade is effectively reduced, and the protective effect is improved.
Specifically, when the shape of the inner surface of the protective shell mold or the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold, the protective shell or the protective shell assembly prepared by the method has the same aerodynamic shape as the wind power blade skin substrate, so that internal stress does not exist in the protective shell or the protective shell assembly when the protective shell or the protective shell assembly is used in the wind power blade, the possibility that the protective shell is peeled from the surface of the wind power blade is effectively reduced, and the protective effect is improved; the protective shell or the protective shell assembly obtained by preparation completely covers the surface of the blade, so that the operations such as large-area coating of protective materials on the surface of the blade and the like are not required after the wind power blade is manufactured, and the protective shell is prepared in the protective shell mold and does not occupy the main molding time of the blade skin, so that the overall time of blade preparation and protective coating is effectively reduced, and the working efficiency is effectively improved; meanwhile, the protection of the region with irregular shape and large local curvature change in the wind power blade is simpler and more effective, and the whole protection effect of the wind power blade is ensured. When the shape of the inner surface of the protective shell mold or the protective shell mold assembly is the same as that of the local inner surface of the wind power blade mold, the prepared protective shell or the protective shell assembly locally covers the wind power blade base body so as to locally protect and strengthen the region of the blade, and the protection effect of the wind power blade is improved. In addition, as the surface of the first fiber material layer is covered with the demolding cloth in the preparation process of the protective shell, the inner surface of the prepared protective shell has certain roughness, so that the protective shell and the blade skin base body have good interface performance, and the protective shell is further prevented from being stripped from the surface of the wind power blade.
Further, the step of manufacturing the wind power blade with the protective shell by using the wind power blade skin base body with the protective shell is to sequentially perform bonding, mold closing and curing on the wind power blade skin base body and to release the wind power blade skin base body from a wind power blade mold.
Further, the step of forming a second release agent layer on the inner surface of the wind power blade mould comprises the steps of coating a second release agent in the wind power blade mould and curing the second release agent at 20-60 ℃ to form the second release agent layer.
Further, the step of forming the wind turbine blade skin substrate in the protective shell comprises: forming a second fiber material layer, a core material layer, and a second resin material. The preparation of the wind power blade skin substrate adopts a method universal to the existing blade industry, and the specific steps comprise: and sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-infusing a second resin material and pre-curing the second resin material in the protective shell. The wind power blade upper skin substrate and the wind power blade lower skin substrate are respectively manufactured through the method. And sequentially carrying out bonding and die assembly on the upper skin substrate of the wind turbine blade and the lower skin substrate of the wind turbine blade, curing the second resin material, and demolding after the second resin material and the bonding material are completely cured to obtain the skin substrate of the wind turbine blade, which at least partially covers the protective shell.
Further, after the wind power blade skin substrate 3 with the protective shell is obtained, reinforcing, trimming and priming paint coating are carried out on the area without the protective coating on the front edge and the rear edge of the wind power blade, and the concrete operation can be reinforcing, polishing, large putty trimming, polishing, pinhole putty pinhole repairing, polishing and priming paint coating on the area without the protective coating on the front edge and the rear edge of the wind power blade; after the operation is finished, the front edge of the blade is coated with front edge protection paint or pasted with a front edge protection film.
Specifically, when the shape of the inner surface of a protective shell mold or a protective shell mold component is the same as that of the inner surface of a wind power blade mold, the prepared protective shell or protective shell component completely covers the surface of the wind power blade, and after the wind power blade is demolded, only the area without the protective coating on the front edge and the rear edge of the wind power blade is required to be treated, so that the whole blade is prevented from being treated, the protective coating efficiency is improved, the generation of dust in the polishing process and the release of volatile organic compounds in the coating process are reduced, and the environment is more friendly; meanwhile, the method also solves the problem of large difficulty in zero-distance butt joint operation of adjacent protective shells. Furthermore, in the step of placing a plurality of protective shells in the protective shell assembly in the wind power blade skin mold and on the second mold release agent layer, abutting or reserving gaps between adjacent protective shells, and after the wind power blade upper skin base body and the wind power blade lower skin base body with the protective shells are sequentially bonded, matched, cured and removed from the wind power blade skin mold, painting paint at the abutting position or reserved gap for repairing; further, when the reserved gap between the adjacent protective shells is placed in the wind power blade mould of the wind power blade skin mould, the gap is less than 3cm; in addition, the operation of painting the paint at the butt joint or the reserved gap for repairing can be performed simultaneously with the painting operation of the front edge and the rear edge.
As another embodiment, when the shape of the inner surface of the protective shell mold or the protective shell mold component is the same as that of the inner surface of the local part of the wind power blade mold, the prepared protective shell or the protective shell component covers the surface of the wind power blade locally, and the area which is not covered by the protective shell or the protective shell component can be protected by adopting other existing protection technologies; further, when at least two protective shells in the protective shell assembly are placed in the wind power blade skin mold and positioned on the second release agent layer, the adjacent protective shells are in butt joint or a gap is reserved, and after the wind power blade upper skin base body and the wind power blade lower skin base body with the protective shells are sequentially bonded, matched, cured and released from the wind power blade skin mold, paint is coated on the butt joint or the reserved gap for repairing; the operation of painting the joint or the reserved gap for repairing can be performed simultaneously with the painting operation of the uncovered area or the front and rear edges of other protective shells.
It should be understood that the protective shell and the method of making described above are equally applicable to other blade forming processes. Similarly, the protective shell is placed between the wind power blade mould and the blade skin material, and when the blade is released from the mould after being solidified and formed in the mould, the protective shell is at least partially covered on the surface of the blade.
It should be noted that, the protective shell mold or the protective shell mold assembly only needs to ensure that the shape of the inner surface of the protective shell mold is the same as the shape of at least a partial inner surface of the wind turbine blade mold, and does not require high mechanical strength, so that the protective shell mold is low in preparation cost.
Example 2
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in a protective shell mold, and curing the first release agent at 20 ℃ to form a first release agent layer, wherein as shown in fig. 5, the shape of the inner surface of the protective shell mold is the same as that of the inner surface of the wind power blade mold;
(2) Pasting masking paper at the edges of the front edge 4 of the protective shell mold and the rear edge 5 of the protective shell mold, wherein the area pasted with the masking paper is 250mm away from the edge of the protective shell mold, and the widths of the pasted masking paper are the same;
(3) Coating polyurethane on the first release agent layer, tearing off the masking paper, and drying the polyurethane at 40 ℃ to form a protective coating 1 with the thickness of 100 mu m;
(4) Laying glass fiber on the protective coating 1, wherein the fiber is in a chopped fiber mat form, depositing epoxy resin in the glass fiber and at the interface between the glass fiber and demolding cloth through a vacuum infusion molding process when the vacuum degree is 40mbar, and curing the epoxy resin to obtain a fiber reinforced material layer 2 with the thickness of 100 microns;
(5) And demolding after the epoxy resin is cured to obtain the protective shell, wherein the shape of the protective shell is the same as that of the wind power blade, and the structure of the protective shell is shown in figure 1.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 20 ℃ to form a second release agent layer;
(2) Placing the protective shell in the wind power blade mould and on the second release agent layer;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-pouring a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post-curing on the prepared upper wind blade skin substrate with the protective shell and the prepared lower wind blade skin substrate, and demolding after the second resin material and the bonding material are completely cured to obtain the wind blade skin substrate with the protective shell, wherein the structure of the wind blade skin substrate is shown in fig. 2;
(5) After the wind power blade skin substrate with the protective shell is obtained, reinforcing, polishing, large putty shaping, polishing, pinhole putty pinhole repairing, polishing and priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and front edge protective paint is coated or front edge protective films are pasted on the front edge of the blade.
The wind power blade has no stripping hidden trouble in practical application.
Example 3
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in a protective shell mold, and curing the first release agent at 60 ℃ to form a first release agent layer, wherein 5 protective shell molds form a protective shell mold assembly, and the shape of the inner surface of the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold;
(2) Pasting masking paper at the edges of the front edge 6 of the protective shell mold assembly and the rear edge 7 of the protective shell mold assembly, wherein the region pasted with the masking paper is 50mm away from the edge of the protective shell mold, and the widths of the pasting masking paper at all positions are the same;
(3) Coating polyaspartic ester resin on the first release agent layer, tearing off the figure paper, and drying the polyaspartic ester resin at 80 ℃ to form a protective coating 1 with the thickness of 500 mu m;
(4) Laying carbon fibers and demolding cloth on the protective coating 1, wherein the fibers are in the form of fiber woven cloth, and when the vacuum degree is 25mbar, depositing polyurethane resin in the carbon fibers and at the interface of the carbon fibers and the demolding cloth by a vacuum bag hand pressing paste method, and curing the polyurethane resin to obtain a fiber reinforced material layer 2 with the thickness of 3 mm;
(5) And demolding after the polyurethane resin is cured and tearing off the demolding cloth on the inner surface to obtain a protective shell, wherein 5 protective shells form a protective shell assembly, and the protective shell assembly is the same as the wind power blade in shape.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 60 ℃ to form a second release agent layer;
(2) Placing 5 protective shells in the wind power blade mould and assembling the protective shell on the second release agent layer to form a protective shell assembly, and butting adjacent protective shells;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-infusing a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post-curing on the prepared wind turbine blade upper skin substrate and the prepared wind turbine blade lower skin substrate with the protective shell, demolding after the second resin material and the bonding material are completely cured, coating paint on a butt joint, and repairing to obtain the wind turbine blade skin substrate with the protective shell, wherein the structure of the wind turbine blade skin substrate is shown in fig. 3;
(5) After the wind power blade skin substrate with the protective shell is obtained, reinforcing, polishing, large putty shaping, polishing, pinhole putty pinhole repairing, polishing, priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and protective paint is coated or protective films are pasted on the front edge of the blade.
The wind power blade has no stripping hidden trouble in practical application.
Example 4
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in the protective shell mold, and curing the first release agent at 38 ℃ to form a first release agent layer, wherein two protective shell molds form a protective shell mold assembly, and the shape of the inner surface of the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold;
(2) Pasting the masking paper at the edges of the front edge 6 of the protective shell mold assembly and the rear edge 7 of the protective shell mold assembly, wherein the distance between the area pasted with the masking paper and the edge of the protective shell mold is 50-250mm, and the width of the pasted masking paper is different according to the design of local reinforcement of the front edge and the rear edge of the blade;
(3) Coating acrylic resin on the first release agent layer, tearing off the masking paper, and drying the acrylic resin at 5 ℃ to form a protective coating 1 with the thickness of 300 mu m;
(4) Laying aramid fiber on the protective coating 1, wherein the fiber is fiber paper, depositing vinyl resin in the aramid fiber and at the interface of the aramid fiber and demolding cloth through a vacuum infusion molding process when the vacuum degree is 15mbar, and curing the vinyl resin to obtain a fiber reinforced material layer 2 with the thickness of 300 mu m;
(6) And demolding after the vinyl resin is cured to obtain a protective shell, wherein 2 protective shells form a protective shell assembly, and the protective shell assembly is the same as the wind power blade in shape.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 38 ℃ to form a second release agent layer;
(2) Placing two protective shells in the wind power blade mould and on the second release agent layer, and reserving a gap with the length of 1.5cm between the adjacent protective shells;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-pouring a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post-curing on the prepared wind power blade upper skin matrix with the protective shell and the wind power blade lower skin matrix, demolding after the second resin material and the bonding material are completely cured, coating paint at the reserved gap for repairing, and thus obtaining the wind power blade skin matrix with the protective shell, wherein the structure of the wind power blade skin matrix is shown in fig. 4;
(5) After the wind power blade skin matrix with the protective shell is obtained, reinforcing, polishing, large putty dressing, polishing, pinhole putty repairing, polishing and priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and front edge protective paint is coated or front edge protective films are pasted on the front edge of the blade.
The wind power blade has no stripping hidden trouble in practical application.
Example 5
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in a protective shell mold, and curing the first release agent at 45 ℃ to form a first release agent layer, wherein 3 protective shell molds form a protective shell mold assembly as shown in fig. 6, and the shape of the inner surface of the protective shell mold assembly is the same as that of the inner surface of the wind power blade mold;
(2) Pasting decorative pattern paper on the edges of the front edge 6 of the protective shell mold assembly and the rear edge 7 of the protective shell mold assembly, wherein the distance between the region pasted with the decorative pattern paper and the edge of the protective shell mold is 50-250mm, and the width of the decorative pattern paper pasted on each position is different according to the design of local reinforcement of the front edge and the rear edge of the blade;
(3) After coating the fluoropolymer on the first release agent layer, the crepe paper is torn off and the fluoropolymer is dried at 60 ℃ to form a protective coating 1 with a thickness of 150 μm;
(4) Laying glass fiber on the protective coating 1, wherein the fiber is in the form of fiber woven cloth, coating unsaturated polyester resin in the glass fiber and at the interface of the glass fiber and demolding cloth by a vacuum infusion molding process when the vacuum degree is 25mbar, and curing the unsaturated polyester resin to obtain a fiber reinforced material layer 2 with the thickness of 150 mu m;
(6) And demolding after the unsaturated polyester resin is cured to obtain a protective shell, wherein 3 protective shells form a protective shell assembly, and the protective shell assembly is the same as the wind power blade in shape.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 45 ℃ to form a second release agent layer;
(2) Placing 3 protective shells in the wind power blade mould and on the second release agent layer, and reserving a gap with the length of 1cm between every two adjacent protective shells;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-pouring a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post-curing on the prepared wind power blade upper skin matrix with the protective shell and the wind power blade lower skin matrix, demolding after the second resin material and the bonding material are completely cured, coating paint at the reserved gap for repairing, and thus obtaining the wind power blade skin matrix with the protective shell, wherein the structure of the wind power blade skin matrix is shown in fig. 4;
(5) After the wind power blade skin substrate with the protective shell is obtained, reinforcing, polishing, large putty shaping, polishing, pinhole putty pinhole repairing, polishing and priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and front edge protective paint is coated or front edge protective films are pasted on the front edge of the blade.
The wind power blade has no stripping hidden trouble in practical application.
Example 6
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in a protective shell mold, and curing the first release agent at 20 ℃ to form a first release agent layer, wherein the shape of the inner surface of the protective shell mold is the same as that of the local inner surface of the wind power blade mold;
(2) Pasting masking paper at the edges of the front edge 4 of the protective shell mold and the rear edge 5 of the protective shell mold, wherein the area pasted with the masking paper is 250mm away from the edge of the protective shell mold, and the widths of the pasted masking paper are the same;
(3) Coating polyurethane on the first release agent layer, tearing off the masking paper, and drying the polyurethane at 40 ℃ to form a protective coating 1 with the thickness of 100 mu m;
(4) Laying glass fibers on the protective coating 1, wherein the glass fibers are chopped strand mats, depositing epoxy resin in the glass fibers and at the interface between the glass fibers and the demolding cloth through a vacuum infusion molding process when the vacuum degree is 40mbar, and curing the epoxy resin to obtain a fiber reinforced material layer 2 with the thickness of 100 microns;
(5) And demolding after the epoxy resin is cured to obtain the protective shell, wherein the shape of the protective shell is the same as the local shape of the wind power blade.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 20 ℃ to form a second release agent layer;
(2) Placing the protective shell in the wind power blade mould and on the second release agent layer;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-pouring a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post curing on the prepared upper wind blade skin substrate with the protective shell and the prepared lower wind blade skin substrate, and demolding after the second resin material and the bonding material are completely cured to obtain the wind blade skin substrate partially covered with the protective shell;
(5) Reinforcing, polishing, large putty dressing, polishing, pinhole putty repairing, polishing and priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and front edge protective paint is coated or front edge protective films are pasted on the front edge of the blade; the areas not covered by the protective shell may be protected using other existing protection techniques.
The wind power blade has a good protection effect in practical application, and the hidden stripping trouble does not exist in the area covered with the protection shell.
Example 7
The embodiment provides a protective shell, and a preparation method of the protective shell comprises the following steps:
(1) Coating a first release agent in a protective shell mold, and curing the first release agent at 60 ℃ to form a first release agent layer, wherein 2 protective shell molds form a protective shell mold assembly, and the shape of the inner surface of the protective shell mold assembly is the same as that of the local inner surface of the wind power blade mold;
(2) Pasting masking paper at the edges of the front edge 6 of the protective shell mold assembly and the rear edge 7 of the protective shell mold assembly, wherein the distance between the area pasted with the masking paper and the edge of the protective shell mold is 50mm, and the widths of the pasted masking paper are the same;
(3) Coating polyaspartic ester resin on the first release agent layer, tearing off the figure paper, and drying the polyaspartic ester resin at 80 ℃ to form a protective coating 1 with the thickness of 500 mu m;
(4) Laying carbon fibers and demolding cloth on the protective coating 1, wherein the fibers are in the form of fiber woven cloth, and when the vacuum degree is 25mbar, depositing polyurethane resin in the carbon fibers and at the interface of the carbon fibers and the demolding cloth by a vacuum bag hand pressing paste method, and curing the polyurethane resin to obtain a fiber reinforced material layer 2 with the thickness of 3 mm;
(5) And demolding after the polyurethane resin is cured and tearing off the demolding cloth on the inner surface to obtain the protective shell, wherein the shape of the protective shell assembly formed by the 2 protective shells is the same as the local shape of the wind power blade.
The embodiment also provides a manufacturing method of the wind power blade, which comprises the following steps:
(1) Coating a second release agent in the wind power blade mould, and curing the second release agent at 60 ℃ to form a second release agent layer;
(2) Placing 2 protective shells in the wind power blade mould and assembling the protective shells on the second release agent layer to form a protective shell assembly, and butting adjacent protective shells;
(3) Sequentially paving a second fiber material, paving a core material, paving a vacuum material, vacuum-infusing a second resin material and pre-curing the second resin material in the protective shell, and respectively preparing an upper skin matrix and a lower skin matrix of the wind power blade by the method;
(4) Sequentially carrying out bonding, mold closing and post-curing on the prepared upper wind blade skin substrate with the protective shell and the prepared lower wind blade skin substrate, demolding after the second resin material and the bonding material are completely cured, coating paint at the butt joint, and repairing to obtain the wind blade skin substrate partially covered with the protective shell;
(5) Reinforcing, polishing, large putty repairing, polishing, pinhole putty repairing, polishing and priming paint coating are carried out on the area without the protective coating 1 on the front edge and the rear edge of the wind power blade, and protective paint is coated or protective films are pasted on the front edge of the blade; the area not covered by the protective shell assembly can be protected by other existing protection technologies.
The wind power blade has a good protection effect in practical application, and the hidden stripping trouble does not exist in the area covered with the protection shell.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. This need not be, nor should it be exhaustive of all embodiments. And obvious variations or modifications derived therefrom are intended to be within the scope of the invention.

Claims (9)

1. A manufacturing method of a wind power blade is characterized by comprising the following steps:
(1) Forming a first release agent layer on the inner surface of the protective shell mold;
(2) Forming a protective coating on the first release agent layer and drying it;
(3) Forming a first fibrous material layer on the dried protective coating;
(4) Forming a first resin material in the first fiber material layer under a vacuum condition, and curing the first resin material to obtain a fiber reinforced material layer;
(5) Demolding after the first resin material is cured to obtain the protective shell;
(6) Forming a second release agent layer on the inner surface of the wind power blade mould;
(7) Placing at least two protective shells in the same area in the wind power blade mould and on the second release agent layer, wherein a gap is formed between the adjacent protective shells in a butt joint mode or a reserved gap is formed between the adjacent protective shells;
(8) Forming a wind power blade skin base body on the protective shell to obtain the wind power blade skin base body with the protective shell;
(9) And manufacturing the wind power blade with the protective shell by using the wind power blade skin substrate with the protective shell.
2. The method of manufacturing a wind blade according to claim 1, wherein in the step of forming a first resin material within the first layer of fibrous material, a vacuum of not more than 40mbar.
3. The method for manufacturing the wind blade according to claim 2, wherein the step of forming the first mold release layer on the inner surface of the protective shell mold comprises coating the first mold release agent in the protective shell mold and curing the first mold release agent at 20 ℃ to 60 ℃ to form the first mold release layer;
and forming a protective coating on the first release agent layer, wherein the step of forming the protective coating comprises coating the coating on the first release agent layer and drying the coating at the temperature of 5-80 ℃ to form the protective coating with the thickness of 100-500 mu m.
4. The method for manufacturing a wind turbine blade according to claim 3, wherein the protective coating has a thickness of 150 μm to 300 μm.
5. The method of manufacturing a wind blade according to claim 3 wherein the layer of fibre-reinforced material has a thickness of no more than 3mm.
6. The method of manufacturing a wind blade according to claim 5, wherein the layer of fibrous reinforcement material has the same thickness as the protective coating.
7. The method for manufacturing the wind blade according to claim 1, wherein the protective coating comprises polyurethane, polyaspartic acid ester resin, acrylic resin or fluoropolymer.
8. The method for manufacturing the wind blade according to claim 1, wherein the protective coating is not formed on the inner surface of the protective shell mold in the region corresponding to the front edge and the rear edge of the wind blade.
9. The manufacturing method of the wind power blade as claimed in claim 1, wherein the step of manufacturing the wind power blade with the protective shell by using the wind power blade skin substrate with the protective shell comprises the steps of sequentially carrying out bonding, mold closing, curing and stripping from a wind power blade mold on the wind power blade skin substrate; and after the wind power blade with the protective shell is released from the wind power blade mould, painting paint at the butt joint or the reserved gap for repairing.
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