US20180304605A1 - Multilayer composite component - Google Patents
Multilayer composite component Download PDFInfo
- Publication number
- US20180304605A1 US20180304605A1 US15/769,978 US201615769978A US2018304605A1 US 20180304605 A1 US20180304605 A1 US 20180304605A1 US 201615769978 A US201615769978 A US 201615769978A US 2018304605 A1 US2018304605 A1 US 2018304605A1
- Authority
- US
- United States
- Prior art keywords
- layer
- polyurethane
- composite
- composite component
- plastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 93
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- XITRBUPOXXBIJN-UHFFFAOYSA-N bis(2,2,6,6-tetramethylpiperidin-4-yl) decanedioate Chemical compound C1C(C)(C)NC(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)NC(C)(C)C1 XITRBUPOXXBIJN-UHFFFAOYSA-N 0.000 description 1
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- 230000007774 longterm Effects 0.000 description 1
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- FTWUXYZHDFCGSV-UHFFFAOYSA-N n,n'-diphenyloxamide Chemical class C=1C=CC=CC=1NC(=O)C(=O)NC1=CC=CC=C1 FTWUXYZHDFCGSV-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000000016 photochemical curing Methods 0.000 description 1
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- 239000000047 product Substances 0.000 description 1
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- 150000003839 salts Chemical class 0.000 description 1
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- 239000004408 titanium dioxide Substances 0.000 description 1
- 238000010518 undesired secondary reaction Methods 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N urethane group Chemical group NC(=O)OCC JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
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- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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- C—CHEMISTRY; METALLURGY
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- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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- B32B2603/00—Vanes, blades, propellers, rotors with blades
-
- 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
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
- F03D1/0675—Rotors characterised by their construction elements of the blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2280/00—Materials; Properties thereof
- F05B2280/40—Organic materials
- F05B2280/4003—Synthetic polymers, e.g. plastics
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- 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
Definitions
- the present invention relates to a composite component, to the use of a composite component of the invention, to a wind turbine for a wind power installation, and to a method for producing a composite component.
- Rotor blades for wind power installations have been known for some considerable time and are described for example in DE 10 2004 007 487 A1 and DE 10 319 246 A1. In their operation they are subject to high loads as a result of wind pressure, erosion, temperature fluctuations, UV radiation and also by precipitation. Particularly at locations with a tropical climate, distinguished by highly changeable weathering effects and a high atmospheric humidity, such as in Brazil or Taiwan, for example, but also in Germany, rotor blades tend to suffer erosion.
- the rotor blades are to be extremely lightweight, in order to minimize the bending loads acting on any rotor blade hub present and also on the associated bearings and the tower of the wind power installation.
- Rotor blades and rotor blade elements are customarily produced in a molding process in which fiber materials and/or core materials, especially balsa wood, are inserted into a rotor blade element mold and are treated with a hardening resin so as to form a potentially load-bearing composite material.
- epoxy resins are frequently employed as resin. They are highly suitable for the construction of the base of a rotor blade or rotor blade element from fiber material and resin.
- UHMW-PE ultrahigh molecular weight polyethylene
- UHMW-PE is notable for very good wear resistances and abrasion resistances even in the face of abrasive media. Its abrasion resistance is six times higher than that of polyurethane.
- UHMW-PE possesses excellent chemical resistance and also a low coefficient of friction, outstanding dimensional stability, and high impact strength even at low temperatures.
- UHMW-PE is very difficult to bond using conventional adhesives and in particular does not adhere to resins, such as epoxy resins, for example.
- the polyethylene foil is joined, by means of two rubber attachment layers, to an underlying base comprising a fiber material impregnated with curable resin.
- a total of three curing or vulcanizing steps are needed in order to coat a rotor blade element.
- the plastic composite component described in WO 2010/118860 consists of a thermosetting synthetic resin as outer layer, an elastomer layer, and a metal and/or plastic support layer. The layers are assembled in a single operation with heat treatment or under irradiation with UV light.
- WO 2010/118860 also describes the use of the plastic composite component in rotor blades of helicopters or wind turbines.
- a component more particularly a rotor blade, which is notable for very high wear resistance and abrasion resistance and at the same time requires little time and low temperatures in production.
- a composite component ( 10 ) characterized by the following layer construction:
- the layer ( 12 ) is disposed directly between the layer ( 11 ) and the layer ( 13 ),
- the wording that the layer “consists” at least partly of a “polyurethane and an elastomer” or “includes at least” means that the material referred to is also a polyurethane elastomer.
- the wording “polyurethane or elastomer” means that either a nonelastomeric polyurethane or an elastomer is meant that is not a urethane elastomer.
- a preferred polyurethane in the present context is a thermoplastic polyurethane.
- an advantageous feature of the design is that the laminate composite comprising the layers ( 11 ) and ( 12 ) is already fully cured and need not also be cured further by exposure to heat. In the design, therefore, the temperature needed for assembling can be kept lower than would be the case if the polyurethane layer ( 12 ) or the elastomer layer ( 12 ) likewise required curing. As a result, the significant advantage is achieved of simplification and acceleration of the assembly. In comparison to a layer construction in which the polyurethane layer ( 12 ) or the elastomer layer ( 12 ) is cured simultaneously with the layer ( 13 ) and where equal temperatures are employed for both curing procedures, the adhesion of the individual layers is increased.
- the individual layers of the composite component ( 10 ), and therefore the composite component ( 10 ) as a whole, has better properties if the layers ( 11 ) and ( 12 ) have been joined in a first operation to form a laminate composite and the layer ( 13 ) have been joined in a second operation onto the laminate composite comprising the layers ( 11 ) and ( 12 ).
- the polyethylene is a high molecular polyethylene (HMW-PE), an ultrahigh molecular polyethylene (UHMW-PE) or polytetrafluoroethylene (PTFE), preferably an ultrahigh molecular polyethylene (UHMW-PE).
- HMW-PE high molecular polyethylene
- UHMW-PE ultrahigh molecular polyethylene
- PTFE polytetrafluoroethylene
- the ultrahigh molecular polyethylene (UHMW-PE), in particular, is distinguished by very good wear resistances and abrasion resistances even in the face of abrasive media.
- a layer ( 11 ) which consists at least partly of UHMW-PE, in the composite component it is possible to improve significantly the wear resistance and abrasion resistance of the composite component, more particularly of rotor blades.
- a high molecular polyethylene (HMW-PE) for the purposes of the present invention is a high molecular polyethylene having an average molar mass of 500 to 1000 kg/mol.
- An ultrahigh molecular polyethylene (UHMW-PE) in the context of the present invention is an ultrahigh molecular polyethylene having an average molar mass of more than 1000 kg/mol.
- the UHMW-PE used has an average molar mass of between 1000 kg/mol to 10 000 kg/mol, more preferably an average molar mass of between 1000 kg/mol and 5000 kg/mol, especially preferably between 3000 kg/mol and 5000 kg/mol.
- the average molar mass is determined arithmetically by the Margolies equation.
- the polyethylene used may be a linear or a crosslinked polyethylene.
- the ultrahigh molecular polyethylene used preferably has a density of 0.93 to 0.94 g/cm 3 .
- the layer ( 11 ) further comprises a UV stabilizer which protects the polyethylene against aging caused by ultraviolet light.
- Preferred UV stabilizers are organic and inorganic UV absorbers, selected more particularly from the list encompassing benzophenones, benzotriazoles, oxalanilides, phenyltriazines, carbon black, titanium dioxide, iron oxide pigments, and zinc oxide, or 2,2,6,6-tetramethylpiperidine derivatives such as bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (“hindered amine light stabilizer (HALS)”).
- HALS hinderetramethyl-4-piperidyl
- the layer ( 11 ) which consists at least partly of polyethylene consists predominantly of polyethylene, more particularly consists of polyethylene to an extent of more than 50 wt %, preferably more than 80 wt %, more preferably more than 95 wt %, more particularly of ultrahigh molecular polyethylene (UHMW-PE), based on the total weight of the layer.
- UHMW-PE ultrahigh molecular polyethylene
- a polyurethane in the context of this invention is a polyaddition product of at least dialcohols (diols) and/or polyols (e.g., long-chain diols) with polyisocyanates with formation of urethane groups (—NH—CO—O—).
- the elastomer is an ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM) or acrylonitrile-butadiene rubber (NBR), preferably an ethylene-propylene-diene rubber (EPDM).
- EPM ethylene-propylene rubber
- EPDM ethylene-propylene-diene rubber
- EAM ethylene-acrylate rubber
- FKM fluorocarbon rubber
- ACM acrylate rubber
- NBR acrylonitrile-butadiene rubber
- EPDM ethylene-propylene-diene rubber
- polyurethanes and elastomers (especially those which are preferred) produce particularly effective bonding between the layer ( 11 ), which consists at least partly of polyethylene, and the layer ( 13 ).
- polyurethane and also ethylene-propylene-diene rubber (EPDM) have particularly good adhesion properties when the polyethylene of the layer ( 11 ) is ultrahigh molecular polyethylene (UHMW-PE) and when the layer ( 13 ) is a at least partly of a plastic reinforced by fibers ( 14 ).
- the polyurethane is a thermoplastic polyurethane.
- thermoplastic polyurethane in the context of this invention is a polyurethane which within a particular temperature range can be (thermoplastically) reversibly deformed.
- Thermoplastic polyurethanes are to be distinguished in particular from thermoset polyurethanes, which after they have cured can no longer be thermoplastically deformed.
- the polyurethane is a polyurethane elastomer.
- a polyurethane elastomer in the context of this invention is a polyurethane which is elastically deformable and preferably have a glass transition temperature (Tg) (determined by differential scanning calorimetry (DSC) with a heating rate of 10 K/min) of at most 20° C.
- Tg glass transition temperature
- the polyurethane elastomer has a glass transition temperature T g of between ⁇ 5° C. and ⁇ 45° C. (determined by differential scanning calorimetry (DSC) with a heating rate of 10 K/min).
- the polyurethane elastomer has a Shore A hardness as per DIN ISO 7619-1 of at most 95, preferably of at most 85, more preferably of at most 75.
- the polyurethane elastomer has a Shore A hardness as per DIN ISO 7619-1 of more than 40, preferably of more than 50, more preferably of more than 60.
- the polyurethane elastomer has a Shore A hardness as per DIN ISO 7619-1 in the range from 40 to 95, preferably in the range from 50 to 85, more preferably in the range from 60 to 75.
- thermoplastic polyurethane elastomers having the above-designated Shore A hardness values or ranges (according to DIN ISO 7619-1) have particularly good properties in the context of the use of the plastic composite component in rotor blades of helicopters or wind turbines.
- thermoplastic polyurethane is a condensation product of a polyol (long-chain diol) (preferably a polyester diol or polyether diol), a diisocyanate, and a short-chain diol.
- a short-chain diol is a diol having a molecular weight of below 500 g/mol
- a long-chain diol is a diol having a molecular weight of 500 g/mol or more, preferably up to 8000 g/mol.
- polyurethane preferably thermoplastic polyurethane and/or polyurethane elastomer
- UHMW-PE ultrahigh molecular polyethylene
- This combination of polyurethane (preferably thermoplastic polyurethane and/or polyurethane elastomer) in the layer ( 12 ) and ultrahigh molecular polyethylene (UHMW-PE) in the layer ( 11 ) combines excellent adhesion to plastics reinforced at least partly by fibers ( 14 ) with wear resistances and abrasion resistances that were hitherto unachievable with other combinations of polymers and polyethylenes. It has emerged that the combination of polyurethane (preferably thermoplastic polyurethane and/or polyurethane elastomer) in the layer ( 12 ) and ultrahigh molecular polyethylene (UHMW-PE) in the layer ( 11 ) exhibits a synergistic effect, since the combined positive effect of the individual layers is increased.
- the layer ( 12 ) is disposed directly between the layer ( 11 ) and the layer ( 13 ) and there are no further (polymer) layers between the layer ( 11 ) and the layer ( 13 ).
- the layer ( 12 ) is disposed directly between the layer ( 11 ) and the layer ( 13 ) and there are no further (polymer) layers between the layer ( 11 ) and the layer ( 13 ).
- composite components of the invention with only one layer ( 12 ) can be distinguished from other composite components which include a plurality of (polymer) layers.
- Composite components of the invention are likewise distinguishable from noninventive components wherein there has not first been joining of a laminate composite from the layers ( 11 ) and ( 12 ) and, in a further, second operation, joining of the layer ( 13 ) in a to the laminate composite comprising the layers ( 11 ) and ( 12 ). This is possible in particular by considering the boundary layers, especially the boundary layer between the layers ( 12 ) and ( 13 ).
- the layer ( 12 ) which consists at least partly of a polyurethane preferably thermoplastic polyurethane and/or polyurethane elastomer
- a polyurethane preferably thermoplastic polyurethane and/or polyurethane elastomer
- the layer ( 12 ) which consists at least partly of a polyurethane preferably thermoplastic polyurethane and/or polyurethane elastomer
- consists predominantly of polyurethane more particularly consists of polyurethane to an extent of more than 50 wt %, preferably more than 80 wt %, more preferably more than 95 wt %, based on the total weight of the layer.
- the layer ( 12 ) which consists at least partly of an elastomer consists predominantly of elastomer, more particularly consists of elastomer to an extent of more than 50 wt %, preferably more than 80 wt %, more preferably more than 95 wt %, more particularly of ethylene-propylene-diene rubber (EPDM), based on the total weight of the layer.
- EPDM ethylene-propylene-diene rubber
- the layer ( 12 ) further comprises at least one additive selected from the group consisting of acrylates, methacrylates, epoxy resins, phenolic resins, novolacs, hexamethylenetetramine, hexamethoxymethylmelamine, and guanidines. These additives are particularly preferred if the elastomer of the layer ( 12 ) is an ethylene-propylene-diene rubber (EPDM). These additives are suitable for improving the strength of the layer ( 12 ) and/or for improving the adhesion of the layer ( 12 ) to the other layers.
- EPDM ethylene-propylene-diene rubber
- the plastic reinforced by fibers ( 14 ) is a plastic reinforced by UHMW-PE fibers (e.g., Dyneema fibers), a carbon fiber reinforced plastic (CRP) or a glass fiber reinforced plastic (GRP), preferably a glass fiber reinforced plastic (GRP).
- UHMW-PE fibers e.g., Dyneema fibers
- CRP carbon fiber reinforced plastic
- GRP glass fiber reinforced plastic
- GPP glass fiber reinforced plastic
- Fiber reinforced plastics and especially glass fiber reinforced plastics are distinguished by high mechanical and thermal stability in conjunction with a low specific weight and are therefore exceptionally suitable for the construction of the base of a rotor blade or rotor blade element.
- a composite component wherein the plastic reinforced by fibers ( 14 ) is a plastic resin system having an epoxy resin matrix which prior to curing takes the form of a multicomponent system and at least one component which comprises an amine curing agent further comprises at least one additive selected from the list consisting of hexamethylenetetramine, hexamethoxymethylmelamine, and guanidines.
- the layer ( 11 ) and/or layer ( 12 ) independently of one another to have a thickness of 100 to 5000 ⁇ m, preferably a thickness of 300 to 900 ⁇ m, more preferably a thickness of 400 to 600 ⁇ m.
- the laminate composite comprising the layers ( 11 ) and ( 12 ) to have notches on the surface which in the second operation is joined to the layer ( 13 ).
- the notches increase the area of the surface and the adhesion of the layer ( 13 ) to the laminate composite after joining in the second operation is enhanced.
- the dialcohols (diols) and/or polyols have undergone reaction with the polyisocyanates to form the polyurethane, and the catalysts used for the reaction have been consumed by reaction or are inactive, insofar as the polycondensation has taken place with chemical catalysis.
- the laminate composite comprising the layers ( 11 ) and ( 12 ) contains less than 0.5 pph (parts per hundred, i.e., fractions of the catalyst per hundred parts of polyurethane) of (active) catalyst, preferably less than 0.2 pph of (active) catalyst, and very preferably no (active) catalyst.
- the laminate composite comprising the layers ( 11 ) and ( 12 ) contains less than 0.5 pph (parts per hundred, i.e., fractions of the crosslinker per hundred parts of elastomer) of crosslinkers, preferably less than 0.2 pph of crosslinkers, and very preferably no crosslinkers.
- the plastics matrix of the plastic reinforced by fibers ( 14 ) is produced shortly before the assembling by the mixing of a two-component mixture.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of at least 20° C., preferably of at least 35° C., more preferably of at least 55° C., especially preferably of at least 75° C., insofar as the layer ( 12 ) comprises polyurethane.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of at most 120° C., preferably of at most 110° C., more preferably of at most 95° C., especially preferably of at most 85° C., insofar as the layer ( 12 ) comprises polyurethane.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of 20 to 120° C., more preferably at temperatures of 35 to 110° C., more preferably at temperature of 55 to 95° C., and with very particular preference at temperatures of 75° C. to 85° C., insofar as the layer comprises polyurethane.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of 70 to 120° C., more preferably at temperatures of 80 to 115° C., and with very particular preference at temperatures of 105° C. to 115° C., insofar as the layer ( 12 ) comprises an elastomer.
- the composite component is designed such that the layer ( 13 ) consists at least partly of an adhesive and this adhesive is or comprises an epoxy resin adhesive or is or comprises a polyurethane adhesive. It is particularly preferred here for the adhesive containing layer ( 13 ) to join the laminate composite to a layer ( 15 ) consisting at least partly of a plastic reinforced by fibers.
- the epoxy resin adhesive or the polyurethane adhesive is made thixotropic prior to curing. By this means it is possible for the adhesive prior to curing to fill gaps even with a thickness of several millimeters.
- the layer ( 15 ) is a fiber reinforced plastic (FRP), a plastic reinforced by UHMW-PE fibers (e.g. Dyneema fibers), a carbon fiber reinforced plastic (CRP), or a glass fiber reinforced plastic (GRP), preferably a glass fiber reinforced plastic (GRP).
- FRP fiber reinforced plastic
- UHMW-PE fibers e.g. Dyneema fibers
- CRP carbon fiber reinforced plastic
- GRP glass fiber reinforced plastic
- GRP glass fiber reinforced plastic
- the layer ( 15 ) is a plastic resin system having an epoxy resin matrix, polyurethane resin matrix, poly(meth)acrylate matrix, polymethyl (meth)acrylate matrix, or poly(meth)acrylamide matrix, especially preferably a plastic resin system having an epoxy resin matrix.
- the layer ( 13 ) it is preferred for the layer ( 13 ) to have a thickness of 1 to 5000 ⁇ m, preferably a thickness of 5 to 4000 ⁇ m, more preferably a thickness of 10 to 3000 ⁇ m.
- a further aspect of the present invention relates to a wind turbine comprising a composite component of the invention. It is particularly preferred here for this to be a wind turbine of a wind power installation and for the composite component to be disposed on at least one rotor blade element, more particularly on at least one rotor blade edge, preferably a leading rotor blade edge. It is particularly preferred that the composite component is disposed on all rotor blade edges, preferably on all leading rotor blade edges, of a wind power installation.
- a further aspect in connection with the present invention relates to use of the plastic composite component of the invention in wind turbines, rotor blades of wind turbines, wings of aircraft or helicopters, airfoils of aircraft or helicopters, rotor blades of aircraft or helicopters, turbine blades of power units, bodywork components of vehicles, hull or keel region of watercraft, or effective surfaces of sports equipment.
- Use in accordance with the invention in rotor blade edges, preferably on leading rotor blade edges, of a wind power installation is particularly preferred.
- the composite component of the invention may also, however, be employed in other sectors where surface erosion is to be avoided.
- such areas are, for example:
- a further aspect in connection with the present invention relates to a method for producing a composite component of the invention, comprising the following steps:
- Preferred in accordance with the invention is a method wherein the polyurethane of the layer ( 12 ) is a thermoplastic polyurethane and/or a polyurethane elastomer and/or the elastomer of the layer ( 12 ) is an ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM) or acrylonitrile-butadiene rubber (NBR), preferably an ethylene-propylene-diene rubber (EPDM).
- EPM ethylene-propylene rubber
- EPDM ethylene-propylene-diene rubber
- EAM ethylene-acrylate rubber
- FKM fluorocarbon rubber
- ACM acrylate rubber
- NBR acrylonitrile-butadiene rubber
- EPDM ethylene-propylene-diene rubber
- the polyethylene of the layer ( 11 ) is a high molecular polyethylene (HMW-PE), an ultrahigh molecular polyethylene (UHMW-PE) or polytetrafluoroethylene (PTFE), preferably an ultrahigh molecular polyethylene (UHMW-PE).
- HMW-PE high molecular polyethylene
- UHMW-PE ultrahigh molecular polyethylene
- PTFE polytetrafluoroethylene
- the elastomer of the layer ( 12 ) is a polyurethane (preferably thermoplastic polyurethane and/or polyurethane elastomer) and the polyethylene of the layer ( 11 ) is ultrahigh molecular polyethylene (UHMW-PE).
- a polyurethane preferably thermoplastic polyurethane and/or polyurethane elastomer
- UHMW-PE ultrahigh molecular polyethylene
- the elastomer of the layer ( 12 ) is an ethylene-propylene-diene rubber (EPDM) and the polyethylene of the layer ( 11 ) is ultrahigh molecular polyethylene (UHMW-PE).
- EPDM ethylene-propylene-diene rubber
- UHMW-PE ultrahigh molecular polyethylene
- the plastic of the layer ( 13 ), reinforced by fibers ( 14 ), comprises plastic reinforced by UHMW-PE fibers (e.g., Dyneema fibers), a carbon fiber reinforced plastic (CRP), or a glass fiber reinforced plastic (GRP), preferably a glass fiber reinforced plastic (GRP).
- UHMW-PE fibers e.g., Dyneema fibers
- CRP carbon fiber reinforced plastic
- GRP glass fiber reinforced plastic
- GRP glass fiber reinforced plastic
- the polyurethane of the layer ( 12 ) is a thermoplastic polyurethane and/or polyurethane elastomer and the polyethylene of the layer ( 11 ) is an ultrahigh molecular polyethylene (UHMW-PE), and the plastic of the layer ( 13 ), reinforced by fibers ( 14 ), is a glass fiber reinforced plastic (GRP).
- UHMW-PE ultrahigh molecular polyethylene
- GRP glass fiber reinforced plastic
- a method which comprises the following steps:
- the uncured layer ( 13 ) is an epoxy resin, preferably a two-component epoxy resin which is mixed up prior to the assembling with the laminate composite produced or provided.
- adhesion promoters primary and/or chemical strippers
- thermal surface treatment especially plasma activation, plasma surface treatment, and gas flame treatment
- pretreating of the layer ( 11 ) and/or layer ( 12 ) takes place preferably on that side of the layer which, on production of the laminate composite comprising the layers ( 11 ) and ( 12 ), is joined to the other respective layer ( 12 ) or ( 11 ).
- adhesion promoters primary and/or chemical strippers
- thermal surface treatment especially plasma activation, plasma surface treatment, and gas flame treatment
- pretreating of the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place preferably on the layer ( 12 ).
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of at least 20° C., preferably of at least 35° C., more preferably of at least 55° C., especially preferably of at least 75° C.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of at most 120° C., preferably of at most 110° C., more preferably of at most 95° C., especially preferably of at most 85° C.
- the assembling of the layer ( 13 ) to the laminate composite comprising the layers ( 11 ) and ( 12 ) takes place with exposure to heat, preferably at temperatures of 20 to 120° C., more preferably at temperatures of 35 to 110° C., more preferably at temperature of 55 to 95° C., and with very particular preference at temperatures of 75° C. to 85° C.
- a further aspect in connection with the present invention relates to a composite component produced by a method of the invention.
- a further aspect in connection with the present invention relates to a method for repairing and/or restoring a rotor blade element (in the sense of this specification, likewise a production method; see above), preferably a rotor blade element of a wind power installation with a composite component, comprising the following steps:
- the uncured layer 13 being located between the rotor blade element and the layer 12 of the laminate composite
- adhesion promoters primary and/or chemical strippers
- thermal surface treatment especially plasma activation, plasma surface treatment, and gas flame treatment
- FIG. 1 shows a schematic representation of a wind power installation with rotor blade element according to the invention
- FIG. 2 shows schematically one embodiment of a rotor blade element according to the invention
- FIG. 3 shows in a schematic representation a detail of the rotor blade element from FIG. 2 ;
- FIG. 4 shows in a schematic representation an alternative detail of the rotor blade element.
- FIG. 1 shows a wind power installation 1000 with a tower 1200 and a nacelle 1300 .
- a rotor 1400 Disposed on the nacelle 1300 is a rotor 1400 having three rotor blades 1100 and a spinner 1500 .
- the wind places the rotor 1400 into a rotary movement and so drives a generator in the nacelle 1300 .
- the rotor blades 1100 of the wind power installation 1000 possess a base (layer 13 ) comprising a plastic reinforced at least partly by fibers, and are coated in places with a surface foil (layer 11 ) of polyethylene, there being a polyurethane layer and/or elastomer layer (layer 12 ) located between the surface foil and the base.
- This construction is elucidated in more detail with the following figures.
- FIG. 2 shows a rotor blade element 1110 of the rotor blade 1100 , namely the rotor blade nose.
- the rotor blade nose 1100 possesses a surface foil 11 .
- said foil consists of polyethylene of ultrahigh molecular weight (UHMW-PE).
- the surface foil 11 (layer 11 ) is joined via an attachment layer 12 (layer 12 ) to the base of the rotor blade element 13 (layer 13 ).
- the base 13 (layer 13 ) of the rotor blade element here consists at least partly of a plastic reinforced by fibers 14 .
- the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin.
- the attachment layer 12 (layer 12 ) consists at least partly of a polyurethane and/or an elastomer. Through the attachment of the surface foil 11 (layer 11 ) to the base 13 (layer 13 ) by means of an elastic attachment layer, it is possible to join UHMW-PE to epoxy resin.
- the surface foil 11 (layer 11 ) of UHMW-PE is particularly resistant toward abrasive loads of the kind which occur in the operation of wind power installations, particularly on the rotor edges.
- FIG. 3 shows a detail of a composite component 10 of the rotor blade element 1110 .
- the rotor blade element 1110 possesses the following layer construction: A first layer 11 which consists at least partly of polyethylene; a layer 12 which consists at least partly of a polyurethane and/or an elastomer; and at least one layer 13 as base, consisting at least partly of a plastic reinforced by fibers 14 .
- the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin
- the polyethylene is a polyethylene of ultrahigh molecular weight (UHMW-PE)
- the polyurethane is a thermoplastic polyurethane elastomer or the elastomer is an ethylene-propylene-diene rubber (EPDM).
- FIG. 4 shows an alternative detail of a composite component 10 of the rotor blade element 1110 .
- the rotor blade element 1110 possesses the following layer construction: A first layer 11 which consists at least partly of polyethylene; a layer 12 which consists at least partly of a polyurethane and/or an elastomer; at least one layer 13 which consists at least partly of an adhesive; and a layer 15 which consists at least partly of a plastic reinforced by fibers 14 .
- the fiber material is glass fiber reinforced plastic (GRP) and the curable resin is an epoxy resin
- the polyethylene is a polyethylene of ultrahigh molecular weight (UHMW-PE)
- the polyurethane may be a thermoplastic polyurethane elastomer, a thermoplastic polyurethane or a polyurethane elastomer, or the elastomer is an ethylene-propylene-diene rubber (EPDM)
- the adhesive is in each case an epoxy resin adhesive.
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Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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DE102015220672.6A DE102015220672A1 (de) | 2015-10-22 | 2015-10-22 | Mehrschichtiges Verbundbauteil |
DE102015220672.6 | 2015-10-22 | ||
DE102016213206.7A DE102016213206A1 (de) | 2016-07-19 | 2016-07-19 | Mehrschichtiges Verbundbauteil |
DE102016213206.7 | 2016-07-19 | ||
PCT/EP2016/075448 WO2017068152A1 (de) | 2015-10-22 | 2016-10-21 | Mehrschichtiges verbundbauteil |
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PCT/EP2016/075448 A-371-Of-International WO2017068152A1 (de) | 2015-10-22 | 2016-10-21 | Mehrschichtiges verbundbauteil |
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US17/087,272 Division US20210070026A1 (en) | 2015-10-22 | 2020-11-02 | Multilayer composite component |
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US20180304605A1 true US20180304605A1 (en) | 2018-10-25 |
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US17/087,272 Abandoned US20210070026A1 (en) | 2015-10-22 | 2020-11-02 | Multilayer composite component |
US17/831,314 Pending US20230125200A1 (en) | 2015-10-22 | 2022-06-02 | Multilayer composite component |
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US17/087,272 Abandoned US20210070026A1 (en) | 2015-10-22 | 2020-11-02 | Multilayer composite component |
US17/831,314 Pending US20230125200A1 (en) | 2015-10-22 | 2022-06-02 | Multilayer composite component |
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US (3) | US20180304605A1 (de) |
EP (1) | EP3365166B2 (de) |
JP (1) | JP6744914B2 (de) |
KR (1) | KR102119613B1 (de) |
CN (1) | CN108136716B (de) |
BR (1) | BR112018007902B1 (de) |
CA (1) | CA3002485C (de) |
DK (1) | DK3365166T4 (de) |
ES (1) | ES2741277T5 (de) |
PT (1) | PT3365166T (de) |
WO (1) | WO2017068152A1 (de) |
Cited By (3)
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US20220128040A1 (en) * | 2019-02-11 | 2022-04-28 | Wobben Properties Gmbh | Method for repairing a rotor blade of a wind turbine |
US11371483B2 (en) * | 2019-11-15 | 2022-06-28 | Siemens Gamesa Renewable Energy A/S | Method of manufacturing a shell of a wind turbine blade having improved leading edge erosion protection, method for manufacturing the wind turbine blade, shell, wind turbine blade and wind turbine |
CN114683624A (zh) * | 2022-04-14 | 2022-07-01 | 山东莱威新材料有限公司 | 一种基于超高分子量聚乙烯纤维的多层复合板材及其制备方法 |
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CN109268203A (zh) * | 2018-09-26 | 2019-01-25 | 江苏金风科技有限公司 | 用于风力发电机组的叶片、制造其的方法及风力发电机组 |
CN110815879A (zh) * | 2019-10-15 | 2020-02-21 | 青岛正爱科技有限公司 | 一种超高分子量聚乙烯复合膜的制备方法及应用 |
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DE102011114362A1 (de) * | 2011-09-27 | 2013-03-28 | Gummiwerk Kraiburg Gmbh & Co. Kg | Verbundbauteil aus thermoplastischem Kunststoff und Elastomeren sowie Verfahren zur Herstellung eines solchen Verbundbauteils |
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GB201217212D0 (en) * | 2012-09-26 | 2012-11-07 | Blade Dynamics Ltd | Windturbine blade |
GB201305325D0 (en) * | 2013-03-22 | 2013-05-08 | Hexcel Composites Ltd | Composite material |
EP2784106B1 (de) * | 2013-03-28 | 2018-09-05 | Siemens Aktiengesellschaft | Verbundwerkstoffstruktur |
GB201313779D0 (en) * | 2013-08-01 | 2013-09-18 | Blade Dynamics Ltd | Erosion resistant aerodynamic fairing |
DE102013217128A1 (de) * | 2013-08-28 | 2015-03-05 | Wobben Properties Gmbh | Rotorblattelement für eine Windenergieanlage, Rotorblatt, sowie ein Herstellungsverfahren dafür und Windenergieanlage mit Rotorblatt |
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2016
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- 2016-10-21 DK DK16784914.0T patent/DK3365166T4/da active
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- 2016-10-21 CN CN201680061729.7A patent/CN108136716B/zh active Active
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- 2016-10-21 US US15/769,978 patent/US20180304605A1/en not_active Abandoned
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220128040A1 (en) * | 2019-02-11 | 2022-04-28 | Wobben Properties Gmbh | Method for repairing a rotor blade of a wind turbine |
US11920566B2 (en) * | 2019-02-11 | 2024-03-05 | Wobben Properties Gmbh | Method for repairing a rotor blade of a wind turbine |
US11371483B2 (en) * | 2019-11-15 | 2022-06-28 | Siemens Gamesa Renewable Energy A/S | Method of manufacturing a shell of a wind turbine blade having improved leading edge erosion protection, method for manufacturing the wind turbine blade, shell, wind turbine blade and wind turbine |
CN114683624A (zh) * | 2022-04-14 | 2022-07-01 | 山东莱威新材料有限公司 | 一种基于超高分子量聚乙烯纤维的多层复合板材及其制备方法 |
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DK3365166T4 (da) | 2023-08-28 |
DK3365166T3 (da) | 2019-08-12 |
BR112018007902A2 (pt) | 2018-10-30 |
EP3365166B2 (de) | 2023-08-16 |
CN108136716B (zh) | 2021-01-08 |
WO2017068152A1 (de) | 2017-04-27 |
BR112018007902B1 (pt) | 2022-10-04 |
KR20180070643A (ko) | 2018-06-26 |
EP3365166A1 (de) | 2018-08-29 |
JP2018532619A (ja) | 2018-11-08 |
US20230125200A1 (en) | 2023-04-27 |
EP3365166B1 (de) | 2019-05-29 |
CA3002485A1 (en) | 2017-04-27 |
CN108136716A (zh) | 2018-06-08 |
JP6744914B2 (ja) | 2020-08-19 |
PT3365166T (pt) | 2019-09-11 |
KR102119613B1 (ko) | 2020-06-05 |
US20210070026A1 (en) | 2021-03-11 |
CA3002485C (en) | 2022-04-05 |
ES2741277T3 (es) | 2020-02-10 |
ES2741277T5 (es) | 2024-02-22 |
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