CN116624349A - Blade electric heating deicing and lightning protection function integrated module and preparation method thereof - Google Patents

Blade electric heating deicing and lightning protection function integrated module and preparation method thereof Download PDF

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Publication number
CN116624349A
CN116624349A CN202310669288.0A CN202310669288A CN116624349A CN 116624349 A CN116624349 A CN 116624349A CN 202310669288 A CN202310669288 A CN 202310669288A CN 116624349 A CN116624349 A CN 116624349A
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CN
China
Prior art keywords
layer
lightning protection
electric heating
blade
film
Prior art date
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Pending
Application number
CN202310669288.0A
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Chinese (zh)
Inventor
王冰佳
张丽辉
童博
敖海
文军
谭光道
徐超
赵江
杨文云
胡辉
吴孝伟
刘勇
付荣方
周世银
孟鹏飞
邬烔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Huaneng Weining Wind Power Co ltd
Huaneng Clean Energy Research Institute
China Huaneng Group Co Ltd
Xian Thermal Power Research Institute Co Ltd
Original Assignee
Huaneng Weining Wind Power Co ltd
Huaneng Clean Energy Research Institute
China Huaneng Group Co Ltd
Xian Thermal Power Research Institute Co Ltd
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Publication date
Application filed by Huaneng Weining Wind Power Co ltd, Huaneng Clean Energy Research Institute, China Huaneng Group Co Ltd, Xian Thermal Power Research Institute Co Ltd filed Critical Huaneng Weining Wind Power Co ltd
Priority to CN202310669288.0A priority Critical patent/CN116624349A/en
Publication of CN116624349A publication Critical patent/CN116624349A/en
Pending legal-status Critical Current

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    • 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
    • F03D80/60—Cooling or heating of wind motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • F03D80/40—Ice detection; De-icing means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/10—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material voltage responsive, i.e. varistors
    • H01C7/105—Varistor cores
    • H01C7/108—Metal oxide
    • H01C7/112—ZnO type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/10—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material voltage responsive, i.e. varistors
    • H01C7/12—Overvoltage protection resistors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/02—Details
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/02—Details
    • H05B3/06—Heater elements structurally combined with coupling elements or holders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/206—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/302—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • 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

Abstract

The invention discloses an integrated module with the functions of electric heating deicing and lightning protection of a blade and a preparation method thereof, belonging to the technical field of new energy wind power generation, wherein the integrated module comprises an electric heating layer, a heat conducting insulating layer and a lightning protection surface layer; the heat conduction insulating layer comprises a BN heat conduction layer and a ZnO insulating layer; the BN heat conduction layer is arranged on the electric heating layer, the ZnO insulating layer is arranged on the BN heat conduction layer, and the lightning protection surface layer is arranged on the ZnO insulating layer. As a further development of the invention, the electrically heated layer comprises electrically heated film resistance wires, which are regularly arranged on the blade tip portion and the blade root portion. The module can realize the function of high blade deicing efficiency, simultaneously has the functions of lightning protection, high strength and impact resistance, can meet the requirements of blade deicing and lightning protection, and simplifies the installation process on the blade.

Description

Blade electric heating deicing and lightning protection function integrated module and preparation method thereof
Technical Field
The invention belongs to the technical field of new energy wind power generation, and relates to an integrated module with blade electric heating deicing and lightning protection functions and a preparation method thereof.
Background
The low wind speed area and partial high wind speed area wind fields commonly have the problem of freezing in winter, the load can be increased after the blades are frozen, the service life of the blades is also directly influenced, and the unbalanced load of the unit is increased due to different ice loads on each blade, if countermeasures are not timely taken, serious harm can be generated to the unit, the fan blades which are not subjected to ice control and protection can face the possibility of off-grid shutdown, the whole annual energy generation capacity is greatly reduced in the low temperature area, the annual energy generation capacity loss is 1% -10%, and the severe area is close to 20% -50%.
The electric heating materials such as carbon fiber fabrics, carbon glass mixed fiber fabrics, carbon fiber felts, graphene, carbon nanotubes, epoxy resin-conductive carbon black and the like are paved on the surfaces of the blades, so that ice on the surfaces of the blades can be effectively removed. However, the electric heating material does not have a lightning protection function, lightning strike can cause damage to the result of a heating film or failure of a heating system, in order to improve the lightning protection capability of the electric heating material, a lightning protection metal net is generally required to be added on the outer surface of the electric heating film, but the process of independently paving the metal net is difficult, the indirect lightning protection effect of the metal net on the heating film is poor, and the heating system failure still can be failed.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an integrated module with the functions of electric heating deicing and lightning protection for blades and a preparation method, wherein the integrated module has the function of heating deicing, can protect 200kA lightning current, can not directly break down a lightning protection layer to an electric heating layer, and can not damage the heating layer due to induced current generated by the lightning current in the electric heating layer.
In order to achieve the above purpose, the invention adopts the following technical scheme:
the invention provides a blade electric heating deicing and lightning protection function integrated module which comprises an electric heating layer, a heat conducting insulating layer and a lightning protection surface layer; the heat conduction insulating layer comprises a BN heat conduction layer and a ZnO insulating layer;
the BN heat conduction layer is arranged on the electric heating layer, the ZnO insulating layer is arranged on the BN heat conduction layer, and the lightning protection surface layer is arranged on the ZnO insulating layer.
As a further development of the invention, the electrically heated layer comprises electrically heated film resistance wires, which are regularly arranged on the blade tip portion and the blade root portion.
As a further improvement of the invention, the electric heating film resistance wire material of the electric heating layer is Cr-Ni alloy resistance wire.
As a further improvement of the invention, the resistance wires of the electric heating film are arranged at the blade tip part in a zigzag manner in a spanwise manner, and the resistance wires at the blade root part in a zigzag manner in a chordwise manner; the length of the resistance wire at the blade tip part accounts for 15% -20% of the total length of the resistance wire of the heating film, and the length of the resistance wire at the blade root part accounts for 80% -85% of the total length of the resistance wire of the heating film.
As a further development of the invention, the blade tip portion resistance wire and the blade root portion resistance wire have different resistances, the blade tip resistance being greater than the blade root portion resistance wire resistance.
As a further improvement of the invention, the diameter of the blade tip part resistance wire is smaller than that of the blade root part resistance wire, and the diameter of the blade tip part resistance wire is 50% -75% of that of the blade root part resistance wire; the tip portion resistance wire and the root portion resistance wire have different Cr-Ni ratios.
As a further improvement of the invention, the ZnO insulating layer is a nonlinear resistor valve plate material, and the ZnO insulating layer is a heat conduction two-dimensional nanomaterial.
As a further improvement of the invention, the lightning protection surface layer comprises an epoxy resin adhesive film layer and a lightning protection layer, wherein the lightning protection layer is arranged on the ZnO insulating layer through the epoxy resin adhesive film layer, and the lightning protection layer is a lightning protection copper net or a lightning protection aluminum net.
A preparation method of a blade electric heating deicing and lightning protection function integrated module comprises the following steps:
manufacturing an electric heating layer;
pressing the electric heating layer into the BN film through a film pressing machine and forming a BN heat conducting layer;
and depositing a ZnO layer on the surface of the BN film by a vapor deposition method, and continuously depositing a ZnO insulating layer on the surface of the BN film by the vapor deposition method.
The lightning protection layer is manufactured, and the lightning protection layer and the electric heating heat conduction insulating layer are pressed through the molding press to form the blade electric heating deicing and lightning protection function integrated module.
As a further improvement of the present invention, the manufacturing of the electric heating layer includes:
manufacturing Cr-Ni alloy metal wires with different Cr-Ni alloy proportions and or different diameters, wherein the metal wires are divided into two parts, namely a blade tip part and a blade root part, the length of the blade tip part is 15-20%, and the length of the blade root part is 80-85%; welding the two metal wires into a whole in an argon arc welding mode; and winding and arranging the metal wires according to a set arrangement rule, performing zigzag winding on the blade tip part in a spreading mode, and performing zigzag winding on the blade root part along the chord direction to form an electric heating layer.
Compared with the prior art, the invention has the beneficial effects that:
compared with the traditional heating deicing material, the invention comprises the electric heating layer, the heat conduction insulating layer and the lightning protection surface layer, wherein the heat conduction insulating layer can realize insulation in a conventional state and surface conduction in a lightning stroke state, charges are rapidly and uniformly distributed, the lightning surface breaks down, and the BN filler of the high heat conduction layer can simultaneously improve the longitudinal insulativity of the BN filler on the premise of providing the high heat conduction of the layer. Under normal state, the heat of electrical heating membrane is very easy to be conducted to the surface through this layer, makes the surface have very high heat flux density, consequently, has fine deicing effect, and simultaneously, under the thunderbolt state, this layer BN has very high dielectric strength, avoids the thunderbolt directly to hit the electrical heating layer, but breaks down along the ZnO layer of surface transversely, consumes a part of lightning energy in breaking down this ZnO in-process, and unnecessary lightning current energy then is conducted to the downlead through surface lightning protection layer and this broken down ZnO layer. The integrated module has the heating deicing function, and can protect 200kA lightning current, the lightning current can not directly break down the lightning protection layer to the electric heating layer, and induced current generated by the lightning current on the electric heating layer can not damage the heating layer. The composite material not only can realize the function of high blade deicing efficiency through structural design, but also can have the functions of lightning protection, high strength and impact resistance, can meet the requirements of blade deicing and lightning protection, and simultaneously simplifies the construction process.
Drawings
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. In addition, the shapes, proportional sizes, and the like of the respective components in the drawings are merely illustrative for aiding in understanding the present invention, and are not particularly limited. In the drawings:
FIG. 1 is a schematic diagram of an integrated module with blade electrical heating deicing and lightning protection functions according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of an electric heating film resistance wire structure of an electric heating layer according to an embodiment of the present invention;
in the figure, 1, an electric heating layer 1,2, a BN heat conduction layer, 3, a ZnO insulating layer, 4, an epoxy resin adhesive film layer, 5, a lightning protection layer, 11 and an electric heating film resistance wire.
Detailed Description
In order to make the technical solution of the present invention better understood by those skilled in the art, the technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, shall fall within the scope of the invention.
It will be understood that when an element is referred to as being "disposed on" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like are used herein for illustrative purposes only and are not meant to be the only embodiment.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
In order to improve the lightning protection capability of the electric heating material and prevent the problem of failure of a heating system, a module with electric heating deicing and lightning protection functions is needed to be provided, so that the construction process is simplified, and meanwhile, the direct/indirect lightning protection effect is enhanced.
With reference to fig. 1, a first object of the present invention is to provide an integrated module for blade electric heating deicing and lightning protection, which has a heating deicing function, and can protect 200kA lightning current, which does not directly break down the lightning protection layer to the electric heating layer 1, and the induced current generated by the lightning current in the electric heating layer 1 does not damage the heating layer.
And preparing a module with heating, insulating and lightning protection functions. The integrated module consists of an electric heating layer 1, a heat conducting insulating layer, a lightning protection surface layer and the like. The integrated module consists of a metal electric heating side layer, a heat conducting insulating layer and a lightning protection layer. The metal electric heating side layer is composed of Cr-Ni alloy metal wires arranged according to a certain rule, the heat conduction insulating layer is composed of a BN heat conduction layer and a ZnO insulating layer, and the lightning protection layer is composed of a lightning protection copper net or a lightning protection aluminum net. Meanwhile, the preparation method of the deicing and lightning protection function integrated module is provided, the module can realize the function of high blade deicing efficiency, simultaneously has lightning protection, high strength and impact resistance, can meet the requirements of blade deicing and lightning protection, and simplifies the installation process on the blade.
Specifically, the invention relates to a blade electric heating deicing and lightning protection function integrated module which comprises an electric heating layer 1, a heat conduction insulating layer and a lightning protection surface layer; the heat conduction insulating layer comprises a BN heat conduction layer 2 and a ZnO insulating layer 3;
the BN heat conduction layer 2 is arranged on the electric heating layer 1, the ZnO insulating layer 3 is arranged on the BN heat conduction layer 2, and the lightning protection surface layer is arranged on the ZnO insulating layer 3.
In which, as shown in fig. 2, the embodiment of the present invention provides a specific structure of the electric heating layer 1, where the electric heating layer 1 includes electric heating film resistance wires 11, and the electric heating film resistance wires 11 are regularly arranged on the blade tip portion and the blade root portion. The electric heating film resistance wire 11 material of the electric heating layer 1 is Cr-Ni alloy resistance wire. The electric heating film resistance wires 11 are arranged on the blade tip part in a zigzag manner in a spanwise manner, and the resistance wires on the blade root part in a zigzag manner in a chord direction; the length of the resistance wire at the blade tip part accounts for 15% -20% of the total length of the resistance wire of the heating film, and the length of the resistance wire at the blade root part accounts for 80% -85% of the total length of the resistance wire of the heating film.
And the blade tip portion resistance wire and the blade root portion resistance wire have different resistances, the blade tip resistance being greater than the blade root portion resistance wire resistance. The diameter of the blade tip part resistance wire is smaller than that of the blade root part resistance wire, and the diameter of the blade tip part resistance wire is 50% -75% of that of the blade root part resistance wire; the tip portion resistance wire and the root portion resistance wire have different Cr-Ni ratios.
As a specific scheme, the ZnO insulating layer 3 is a nonlinear resistor valve plate material, and the ZnO insulating layer 3 is a heat conduction two-dimensional nanomaterial.
The lightning protection surface layer comprises an epoxy resin adhesive film layer 4 and a lightning protection layer 5, wherein the lightning protection layer 5 is arranged on the ZnO insulating layer 3 through the epoxy resin adhesive film layer 4, and the lightning protection layer 5 is a lightning protection copper net or a lightning protection aluminum net.
The functions and principles of the specific structures are as follows:
the electric heating layer 1 in the integrated module consists of Cr-Ni alloy resistance wires which are arranged according to a certain rule, wherein the arrangement rule is shown in figure 2, the resistance wires at the blade tip part are arranged in a spanwise manner, and the resistance wires at the blade root part are arranged in a chordwise manner. The length of the resistance wire at the blade tip part accounts for 15% -20% of the total length of the resistance wire of the heating film, and the length of the resistance wire at the blade root part accounts for 80% -85% of the total length of the resistance wire of the heating film. The blade tip portion resistance wire and the blade root portion resistance wire have different resistances, and the blade tip resistance is larger than the blade root portion resistance wire resistance, so that higher heat flux density can be generated. The tip resistance being greater than the root resistance wire resistance may be achieved in two ways: 1. the diameter of the blade tip part resistance wire is smaller than that of the blade root part resistance wire, and the diameter of the blade tip part resistance wire is 50% -75% of that of the blade root part resistance wire; 2. the blade tip portion resistance wire and the blade root portion resistance wire have different Cr-Ni ratios, for example, the blade tip is 20Cr-80Ni, and the blade root is 40Cr-60Ni.
In the integrated module, the heat conduction insulating layer is a non-linear resistance valve sheet material ZnO and heat conduction two-dimensional nanomaterial BN combined film, the heat conduction insulating layer can realize insulation in a conventional state and surface conduction in a lightning stroke state, charges are rapidly and uniformly distributed, lightning surface breakdown is achieved, and the high heat conduction layer BN filler can improve longitudinal insulativity of the high heat conduction layer BN filler on the premise of providing high heat conduction of the layer. Under normal state, the heat of electrical heating membrane is very easy to be conducted to the surface through this layer, makes the surface have very high heat flux density, consequently, has fine deicing effect, and simultaneously, under the thunderbolt state, this layer BN has very high dielectric strength, avoids the thunderbolt directly to hit electrical heating layer 1, but breaks down along the ZnO layer horizontal of surface, consumes a part of lightning energy in breaking down this ZnO in-process, and unnecessary lightning current energy then is conducted to the downlead through surface lightning protection layer and this broken down ZnO layer.
The lightning protection layer in this integrated module is lightning protection copper net or lightning protection aluminum net, and this lightning protection layer has low resistivity, can provide fine lightning protection effect to heat conduction insulating layer and electrical heating layer 1. The lightning current is mainly concentrated on the surface lightning protection layer, and a small part of the lightning current can pass through the heat conduction insulating layer. The lightning protection copper net or the lightning protection aluminum net is used as the lightning protection layer, has a good lightning protection effect and high heat conductivity, and can quickly, efficiently and uniformly conduct the heat of the internal electric heating layer 1 to the surface of the blade. The anti-lightning anti-icing composite material has high anti-lightning performance and simultaneously has high anti-icing performance.
The invention also provides a preparation method of the blade electric heating deicing and lightning protection function integrated module, which comprises the following steps of:
manufacturing an electric heating layer 1;
pressing the electric heating layer 1 into the BN film by a film pressing machine and forming a BN heat conducting layer 2;
a ZnO layer is deposited on the surface of the BN film by a vapor deposition method, and a ZnO insulating layer 3 can be continuously deposited on the surface of the BN film by a vapor deposition method.
The lightning protection layer is manufactured, and the lightning protection layer and the electric heating heat conduction insulating layer are pressed through the molding press to form the blade electric heating deicing and lightning protection function integrated module.
The manufacturing of the electric heating layer 1 comprises the following steps:
manufacturing Cr-Ni alloy metal wires with different Cr-Ni alloy proportions and or different diameters, wherein the metal wires are divided into two parts, namely a blade tip part and a blade root part, the length of the blade tip part is 15-20%, and the length of the blade root part is 80-85%; welding the two metal wires into a whole in an argon arc welding mode; and winding and arranging the metal wires according to a set arrangement rule, and winding the blade tip part in a zigzag manner in a spreading way, wherein the blade root part is wound in a zigzag manner along the chord direction to form the electric heating layer 1.
The specific detailed steps comprise the following steps:
step 1, manufacturing an electric heating layer 1
Manufacturing Cr-Ni alloy metal wires with different Cr-Ni alloy proportions and or different diameters, wherein the metal wires are divided into two parts, namely a blade tip part and a blade root part, the two parts are manufactured respectively, the length of the blade tip part is 15-20%, and the length of the blade root part is 80-85%;
welding the two metal wires into a whole in an argon arc welding mode;
and winding and arranging the metal wires according to a certain arrangement rule, wherein the blade tip part is in zigzag winding in a spreading mode, and the blade root part is in zigzag winding along the chord direction as shown in figure 2.
Step 2, manufacturing a heat conduction insulating layer
The BN with different dimensions and types of fillers is compounded, so that a synergistic effect can be exerted in the aspect of improving the heat conducting property; a series of BN fillers with different contents and various sizes are mixed, so that the packing density of the fillers can be improved, and more heat conduction paths are constructed. Pressing the BN filler after the compounding into a film with a certain thickness by a film pressing machine;
the electric heating layer 1 manufactured in the first step is pressed into the BN film through a film pressing machine, the electric heating layer 1 can stably exist in the BN film, and meanwhile, the electric heating layer plays a role in supporting a framework of the BN film, so that the rigidity of the BN film is enhanced. When in pressing, the pressing force and thickness are controlled, so that the heating film cannot expose the surface of the BN film;
the ZnO layer is deposited on the surface of the BN film by a vapor deposition method, the ZnO layer can be continuously deposited on the surface of the BN film by the vapor deposition method, and the deposited ZnO layer can be ensured to keep uniform thickness by continuously moving forwards at a uniform speed.
Step 3, manufacturing a lightning protection layer
Preparing an epoxy resin adhesive film, and pressing a lightning protection copper net or a lightning protection aluminum net together with the epoxy resin adhesive film through a film pressing machine to form a lightning protection composite film;
and (2) pressing the lightning protection layer and the electric heating heat conduction insulating layer prepared in the step (2) through a molding press to form a final module with integrated heating, insulating and lightning protection functions.
The preparation method of the present invention will be described in further detail with reference to the following specific examples and the accompanying drawings.
Example 1:
step 1, manufacturing an electric heating layer 1
The manufacturing method comprises the steps of manufacturing Cr-Ni alloy wires with the ratio of 20Cr-80Ni to 40Cr-60Ni and the diameter of 1mm, wherein the wires are divided into two parts, namely a blade tip part and a blade root part, the two parts are respectively manufactured, the blade tip part is 20Cr-80Ni, the length is 100 meters, the blade root part is 40Cr-60Ni, and the length is 400 meters;
welding the two metal wires into a whole in an argon arc welding mode;
and winding and arranging the metal wires according to a certain arrangement rule, performing zigzag winding on the part, which is close to the blade tip, by a direction-expanding mode, of 10 line structures of 5 loops, performing zigzag winding on the part, 40 meters, of the blade root along the chord direction, and winding into loops of 10 line structures of 5 loops per meter.
Step 2, manufacturing a heat conduction insulating layer
And (3) the BN fillers with different dimensions and types are compounded, a series of BN fillers with different contents and various sizes are mixed, the packing density of the fillers is improved, and more heat conduction passages are constructed. Pressing the BN filler after the compounding into a BN film with the thickness of 0.2mm by a film pressing machine;
the electric heating layer 1 manufactured in the first step is pressed into the BN film through a film pressing machine, the electric heating layer 1 can stably exist in the BN film, and meanwhile, the electric heating layer plays a role in supporting a framework of the BN film, so that the rigidity of the BN film is enhanced. When in pressing, the pressing force and thickness are controlled, so that the heating film cannot expose the surface of the BN film;
a ZnO insulating layer with the thickness of 0.1mm is deposited on the surface of the BN film by a vapor deposition method, a ZnO layer can be continuously deposited on the surface of the BN film by the vapor deposition method, and the deposited ZnO layer can be ensured to keep the uniform thickness of 0.1mm by continuously moving forwards at a uniform speed.
Step 3, manufacturing a lightning protection layer
Preparing an epoxy resin adhesive film, and pressing a lightning protection copper net or a lightning protection aluminum net together with the epoxy resin adhesive film through a film pressing machine to form a lightning protection composite film;
and (2) pressing the lightning protection layer and the electric heating heat conduction insulating layer prepared in the step (2) through a molding press to form a final module with integrated heating, insulating and lightning protection functions.
Example 2:
step 1, manufacturing an electric heating layer 1
The manufacturing method comprises the steps of manufacturing Cr-Ni alloy wires with the ratio of 20Cr-80Ni and the diameters of 1mm and 1.25mm respectively, wherein the wires are divided into two parts, namely a blade tip part and a blade root part, the two parts are manufactured respectively, the blade tip part is 1mm, the length is 100 m, the blade root part is 1.25mm, and the length is 400 m;
welding the two metal wires into a whole in an argon arc welding mode;
and winding and arranging the metal wires according to a certain arrangement rule, performing zigzag winding on the part, which is close to the blade tip, by a direction-expanding mode, of 10 line structures of 5 loops, performing zigzag winding on the part, 40 meters, of the blade root along the chord direction, and winding into loops of 10 line structures of 5 loops per meter.
Step 2, manufacturing a heat conduction insulating layer
And (3) the BN fillers with different dimensions and types are compounded, a series of BN fillers with different contents and various sizes are mixed, the packing density of the fillers is improved, and more heat conduction passages are constructed. Pressing the BN filler after the compounding into a BN film with the thickness of 0.2mm by a film pressing machine;
the electric heating layer 1 manufactured in the first step is pressed into the BN film through a film pressing machine, the electric heating layer 1 can stably exist in the BN film, and meanwhile, the electric heating layer plays a role in supporting a framework of the BN film, so that the rigidity of the BN film is enhanced. When in pressing, the pressing force and thickness are controlled, so that the heating film cannot expose the surface of the BN film;
a ZnO insulating layer with the thickness of 0.1mm is deposited on the surface of the BN film by a vapor deposition method, a ZnO layer can be continuously deposited on the surface of the BN film by the vapor deposition method, and the deposited ZnO layer can be ensured to keep the uniform thickness of 0.1mm by continuously moving forwards at a uniform speed.
Step 3, manufacturing a lightning protection layer
Preparing an epoxy resin adhesive film, and pressing a lightning protection copper net or a lightning protection aluminum net together with the epoxy resin adhesive film through a film pressing machine to form a lightning protection composite film;
and (2) pressing the lightning protection layer and the electric heating heat conduction insulating layer prepared in the step (2) through a molding press to form a final module with integrated heating, insulating and lightning protection functions.
Example 3:
step 1, manufacturing an electric heating layer 1
The manufacturing method comprises the steps of manufacturing Cr-Ni alloy wires with the proportion of 20Cr-80Ni and 40Cr-60Ni respectively, wherein the diameters of the Cr-Ni alloy wires are 1mm and 1.25mm, the wires are divided into two parts, namely a blade tip part and a blade root part, the two parts are manufactured respectively, the blade tip part is 20Cr-80Ni, the diameter is 1mm, the length is 100 m, the blade root part is 40Cr-60Ni, the diameter is 1.25mm, and the length is 400 m;
welding the two metal wires into a whole in an argon arc welding mode;
and winding and arranging the metal wires according to a certain arrangement rule, performing zigzag winding on the part, which is close to the blade tip, by a direction-expanding mode, of 10 line structures of 5 loops, performing zigzag winding on the part, 40 meters, of the blade root along the chord direction, and winding into loops of 10 line structures of 5 loops per meter.
Step 2, manufacturing a heat conduction insulating layer
And (3) the BN fillers with different dimensions and types are compounded, a series of BN fillers with different contents and various sizes are mixed, the packing density of the fillers is improved, and more heat conduction passages are constructed. Pressing the BN filler after the compounding into a BN film with the thickness of 0.2mm by a film pressing machine;
the electric heating layer 1 manufactured in the first step is pressed into the BN film through a film pressing machine, the electric heating layer 1 can stably exist in the BN film, and meanwhile, the electric heating layer plays a role in supporting a framework of the BN film, so that the rigidity of the BN film is enhanced. When in pressing, the pressing force and thickness are controlled, so that the heating film cannot expose the surface of the BN film;
a ZnO insulating layer with the thickness of 0.1mm is deposited on the surface of the BN film by a vapor deposition method, a ZnO layer can be continuously deposited on the surface of the BN film by the vapor deposition method, and the deposited ZnO layer can be ensured to keep the uniform thickness of 0.1mm by continuously moving forwards at a uniform speed.
Step 3, manufacturing a lightning protection layer
Preparing an epoxy resin adhesive film, and pressing a lightning protection copper net or a lightning protection aluminum net together with the epoxy resin adhesive film through a film pressing machine to form a lightning protection composite film;
and (2) pressing the lightning protection layer and the electric heating heat conduction insulating layer prepared in the step (2) through a molding press to form a final module with integrated heating, insulating and lightning protection functions.
The device elements in the above embodiments are conventional device elements unless otherwise specified, and the structural arrangement, operation or control modes in the embodiments are conventional arrangement, operation or control modes in the art unless otherwise specified.
Finally, it is noted that the above-mentioned embodiments are merely for illustrating the technical solution of the present invention, and that other modifications and equivalents thereof by those skilled in the art should be included in the scope of the claims of the present invention without departing from the spirit and scope of the technical solution of the present invention.

Claims (10)

1. The blade electric heating deicing and lightning protection function integrated module is characterized by comprising an electric heating layer (1), a heat conduction insulating layer and a lightning protection surface layer; the heat conduction insulating layer comprises a BN heat conduction layer (2) and a ZnO insulating layer (3);
the BN heat conduction layer (2) is arranged on the electric heating layer (1), the ZnO insulating layer (3) is arranged on the BN heat conduction layer (2), and the lightning protection surface layer is arranged on the ZnO insulating layer (3).
2. The blade electric heating deicing and lightning protection function integrated module according to claim 1, wherein said electric heating layer (1) comprises electric heating film resistance wires (11), said electric heating film resistance wires (11) being regularly arranged on the blade tip portion and the blade root portion.
3. The blade electric heating deicing and lightning protection function integrated module according to claim 2, wherein the electric heating film resistance wire (11) material of the electric heating layer (1) is a Cr-Ni alloy resistance wire.
4. The blade electric heating deicing and lightning protection function integrated module according to claim 2, wherein the electric heating film resistance wires (11) are arranged in a zigzag manner in which the resistance wires at the blade tip part are in a zigzag manner in which the resistance wires at the blade root part are in a zigzag manner in the chord direction; the length of the resistance wire at the blade tip part accounts for 15% -20% of the total length of the resistance wire of the heating film, and the length of the resistance wire at the blade root part accounts for 80% -85% of the total length of the resistance wire of the heating film.
5. The integrated blade electrical heating deicing and lightning protection module of claim 2, wherein said tip portion resistance wire and said root portion resistance wire have different resistances, the tip resistance being greater than the root portion resistance wire resistance.
6. The integrated module for the electrical heating deicing and lightning protection functions of a blade according to claim 5, wherein the diameter of the resistance wire at the blade tip part is smaller than that of the resistance wire at the blade root part, and the diameter of the resistance wire at the blade tip part is 50% -75% of that of the resistance wire at the blade root part; the tip portion resistance wire and the root portion resistance wire have different Cr-Ni ratios.
7. The blade electric heating deicing and lightning protection function integrated module according to claim 1, wherein the ZnO insulating layer (3) is a nonlinear resistance valve sheet material, and the ZnO insulating layer (3) is a heat conduction two-dimensional nanomaterial.
8. The blade electric heating deicing and lightning protection function integrated module according to claim 1, wherein the lightning protection surface layer comprises an epoxy resin adhesive film layer (4) and a lightning protection layer (5), the lightning protection layer (5) is arranged on the ZnO insulating layer (3) through the epoxy resin adhesive film layer (4), and the lightning protection layer (5) is a lightning protection copper net or a lightning protection aluminum net.
9. The preparation method of the blade electric heating deicing and lightning protection function integrated module is characterized by comprising the following steps of:
manufacturing an electric heating layer (1);
pressing the electric heating layer (1) into the BN film through a film pressing machine and forming a BN heat conducting layer (2);
depositing a ZnO layer on the surface of the BN film by a vapor deposition method, and continuously depositing a ZnO insulating layer (3) on the surface of the BN film by the vapor deposition method;
the lightning protection layer is manufactured, and the lightning protection layer and the electric heating heat conduction insulating layer are pressed through the molding press to form the blade electric heating deicing and lightning protection function integrated module.
10. The method for manufacturing the blade electric heating deicing and lightning protection function integrated module according to claim 9, wherein the manufacturing of the electric heating layer (1) comprises the following steps:
manufacturing Cr-Ni alloy metal wires with different Cr-Ni alloy proportions and or different diameters, wherein the metal wires are divided into two parts, namely a blade tip part and a blade root part, the length of the blade tip part is 15-20%, and the length of the blade root part is 80-85%; welding the two metal wires into a whole in an argon arc welding mode; and (3) winding and arranging the metal wires according to a set arrangement rule, performing zigzag winding on the blade tip part in a spreading mode, and performing zigzag winding on the blade root part along the chord direction to form the electric heating layer (1).
CN202310669288.0A 2023-06-07 2023-06-07 Blade electric heating deicing and lightning protection function integrated module and preparation method thereof Pending CN116624349A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202310669288.0A CN116624349A (en) 2023-06-07 2023-06-07 Blade electric heating deicing and lightning protection function integrated module and preparation method thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202310669288.0A CN116624349A (en) 2023-06-07 2023-06-07 Blade electric heating deicing and lightning protection function integrated module and preparation method thereof

Publications (1)

Publication Number Publication Date
CN116624349A true CN116624349A (en) 2023-08-22

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Country Status (1)

Country Link
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