Disclosure of Invention
Aiming at the problems of the existing forming scheme of the in-mold gel coat for the blade of the wind driven generator, an efficient forming scheme of the in-mold gel coat for the blade of the wind driven generator is needed.
Therefore, the invention aims to provide a coating forming method of an in-mold gel coat for a blade of a wind driven generator, which can avoid the occupation of a blade forming mold during the in-mold gel coat forming and greatly improve the use efficiency of the blade forming mold; moreover, the invention further provides a forming method of the wind driven generator blade, so that the production efficiency of the wind driven generator blade is improved, and the production cost is reduced.
In order to achieve the above object, the present invention provides a method for coating and forming an in-mold gel coat for a blade of a wind turbine generator, comprising:
directly coating a forming in-mold gel coat in an in-mold gel coat forming mold matched with the blade of the wind driven generator outside the blade forming mold;
and demolding the in-mold gel coat from the in-mold gel coat forming mold, and transferring the in-mold gel coat into a blade forming mold to perform blade pouring.
Further, the forming method also comprises a step of preparing an in-mold gel coat forming mold, and the method comprises the following steps:
after the demoulding and the shaping of the blade are finished, a layer of demoulding layer is formed on the surface of the blade; the demoulding layer is formed by a layer of demoulding paper or a layer of demoulding agent which is integrally adhered;
and (3) preparing an in-mold gel coat forming mold by using epoxy resin and fiber fabric on the blade coated with the demolding paper or the construction demolding agent, and separating the mold from the blade after the in-mold gel coat forming mold is cured and formed.
Further, the process for preparing the in-mold gel coat forming mold comprises the following steps:
(1) uniformly mixing all components of the epoxy resin, and fully infiltrating the fiber fabric;
(2) the fully soaked fiber fabric is flatly and uniformly laid on the surface of the blade with the demolding layer;
(3) exhausting air in an in-mold gel coat forming mold to be prepared and formed;
(4) and curing and forming the in-mold gel coat forming mold.
Furthermore, in the step (4), a heating and baking manner may be used to accelerate the reaction rate of the epoxy group and the amine group in the epoxy resin, so as to accelerate the curing molding of the in-mold gel coat forming mold, or a natural drying manner may be used to react and cure the epoxy group and the amine group in the epoxy resin, so as to cure and mold the in-mold gel coat forming mold.
Furthermore, the epoxy resin used in the preparation of the in-mold gel coat forming mold can be replaced by rigid polyurethane, plastic or rigid materials with similar properties.
Further, when the forming method is based on the in-mold gel coat forming mold, the method comprises the following steps:
forming a demoulding layer in the in-mould gel coat forming mould;
constructing a liquid in-mold gel coat in an in-mold gel coat forming mold with a demoulding layer to form a prefabricated film;
and after the prefabricated film is dried and formed, the formed in-mold gel coat prefabricated film is taken off from the in-mold gel coat forming mold and transferred to the blade forming mold.
Furthermore, the demoulding layer in the in-mold gel coat forming mold is formed by a constructed demoulding agent or bonded demoulding paper.
Further, the formed in-mold gel coat is a polyurethane layer.
Further, the formed in-mold gel coat is composed of a polyurethane layer and a hard layer covering the surface of the polyurethane layer.
Furthermore, the formed in-mold gel coat is composed of a polyurethane layer and a surface sizing agent layer covering the polyurethane layer.
Furthermore, the formed in-mold gel coat is composed of a polyurethane layer, a hard layer covering the surface of the polyurethane layer and a surface sizing agent layer covering the hard layer.
Furthermore, the formed in-mold gel coat is composed of a polyurethane layer and a diversion layer covering the surface of the polyurethane layer.
Furthermore, the formed in-mold gel coat is composed of a polyurethane layer, a hard layer covering the surface of the polyurethane layer and a diversion layer covering the hard layer.
Furthermore, the coating forming method of the in-mold gel coat also comprises the step of arranging the protective coating with the special protective requirement part in the blade, so that the protective coating and the in-mold gel coat are constructed, formed, transferred, poured and demoulded simultaneously, and finally appear on the surface of the blade simultaneously.
Further, the in-mold gel coat prefabricated film can be prepared in one or more sections.
In order to achieve the above object, the present invention provides a method for forming a blade of a wind turbine, comprising:
directly placing the in-mold gel coat prefabricated and molded outside the blade molding mold into the blade molding mold;
and (4) pouring and forming the blade forming die for placing the preformed in-mold gel coat.
Further, the wind driven generator blade forming method further comprises the step of prefabricating the in-mold gel coat on the basis of the in-mold gel coat forming die formed by blade rollover.
The coating and forming scheme of the in-mold gel coat provided by the invention has the following advantages:
1. the time of the blade occupying the mold is sharply reduced from more than four hours of the traditional mold to zero hours, so that the blade forming mold is not occupied in the in-mold gel coat forming process;
2. the design material range of the in-mold gel coat system is increased, and the traditional polyurethane type or epoxy type single coating is increased into various and multi-coating; meanwhile, paint or gel coat protective coatings on the front edge or the blade tip can be built in, so that the coating with the gel coat in the mold can be realized at the same time;
3. the blade formed based on the gel coat in the prefabricated mould is easy to demould, the demoulding success rate is greatly improved, the demoulding force application strength to the blade forming mould is greatly reduced, and the service life of the blade forming mould is prolonged;
4. the bionic effect of the blade can be realized based on the gel coat in the prefabricated mould, and a coating with better pneumatic effect can be simply constructed;
5. the simple in-mold gel coat forming mold enables the shape of the in-mold gel coat to be consistent with that of a mold used during blade pouring, so that an in-mold gel coat prefabricated film can be perfectly attached to the blade, and interface deformation caused by long-term and tiny stress can be avoided;
6. when the blade formed based on the gel coat in the prefabricated mold is demoulded from the blade forming mold, the demould can be carried out at a high temperature without waiting for the temperature of the blade to be reduced to the normal temperature, so that the use efficiency of the mold is greatly improved, and the yield of the blade is improved;
7. the in-mold gel coat forming die in the scheme is low in cost, the in-mold gel coat is prefabricated outside the blade forming die, the procedure of coating, constructing and forming the in-mold gel coat in the blade forming die is avoided, and the in-mold gel coat forming die has high economic value.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific examples.
The in-mold gel coat used by the existing wind driven generator nonmetal composite material blade can be well attached to the blade, and meanwhile, construction is convenient, the existing in-mold gel coat is directly coated in a blade forming mold for construction and forming, but the mode has a lot of problems, and the contents of the background technology are specifically seen.
In this embodiment, a brand new coating and forming scheme of an in-mold gel coat used for a nonmetal composite blade of a wind driven generator is provided, the scheme abandons the existing scheme that the in-mold gel coat needs to be coated and constructed in a blade forming mold, and innovatively adopts an in-mold gel coat prefabrication scheme, wherein the in-mold gel coat is prefabricated by constructing an in-mold gel coat forming mold matched with the blade of the wind driven generator outside the blade forming mold; the in-mold gel coat is then released from the in-mold gel coat forming mold and transferred to the blade forming mold for blade infusion.
This scheme forms simple and easy mould internal gel coat forming die through the mould that turns over and carries out the mould internal gel coat prefabrication, effectively avoids the time that occupies to blade forming die when mould internal gel coat shaping in the current scheme, improves blade forming die rate of utilization, promotes blade production efficiency, reduction in production cost.
And based on the scheme, besides the basic protective capability of the traditional gel coat on the blade matrix can be met, the controllable thickness of the gel coat in the die, the diversification of coating materials and the matching of the coating materials can be realized, and higher selectivity is given to deal with the blade operation working environment of wind fields under different working conditions. Secondly, can significantly reduce blade aftertreatment process and engineering time, realize the blade drawing of patterns back, the surface is exempted from to polish or is polished a little, saves work load.
The following describes the specific implementation of the present solution.
In the implementation of the scheme, a simple in-mold gel coat forming mold is constructed at first.
In this example, the mold rollover forming is performed on the basis of the demoulded and reshaped blade, and the method mainly comprises the following steps:
(1) after the demoulding and the shaping of the blade are finished, a layer of demoulding paper or a construction demoulding agent is integrally adhered to the surface of the blade;
(2) preparing a simple female die (namely an in-mold gel coat forming die) of the blade by using epoxy resin and fiber fabric on the blade coated with release paper or construction release agent, and separating the simple female die (namely the in-mold gel coat forming die) of the blade from the blade after the simple female die (namely the in-mold gel coat forming die) of the blade is cured.
This is done in a simple female blade making operation as follows:
(21) uniformly mixing all components of the epoxy resin, and fully infiltrating the fiber fabric;
(22) the fully soaked fiber fabric is leveled and uniformly paved on the surface of the blade adhered with the demolding paper or the construction demolding agent;
(23) exhausting air in the in-mold gel coat forming mold to be prepared, wherein the air can be exhausted in a pressing or vacuumizing mode;
(24) and curing and forming the in-mold gel coat forming mold.
The reaction rate of epoxy groups and amino groups in the epoxy resin can be accelerated by heating and baking, so that the curing and forming of the in-mold gel coat forming mold are accelerated, or the epoxy groups and the amino groups in the epoxy resin are reacted and cured by natural drying, so that the in-mold gel coat forming mold is cured and formed.
In this embodiment, when the simple female mold for blade is prepared, the materials used are not limited to epoxy resin and fiber fabric, and other materials with the same or similar properties may be used, for example, rigid materials such as rigid polyurethane and plastic may be used.
When the simple in-mold gel coat forming mold is demolded, the demolding temperature is-20 ℃ to 100 ℃, and preferably 30 ℃ to 80 ℃.
Moreover, the prepared simple in-mold gel coat forming mold can be finished by selecting one section or multiple sections due to the fact that the blades are long in length and large in size.
In addition, this simple and easy bed die of blade (i.e. the interior gel coat forming die) can be formed with corresponding pneumatic bionical design structure in its inboard, makes the interior gel coat prefabricated membrane surface that the simple and easy bed die of blade (i.e. the interior gel coat forming die) was prefabricated in view of the above have different outward appearance forms, possesses different pneumatic bionical functions then.
It should be noted that, when the simple in-mold gel coat forming mold is prepared by mold-flipping, the mold-flipping material and method used are not limited to the specific materials and specific steps described above, but also include derivative materials and derivative steps with similar properties.
During specific implementation, the turnover of the simple in-mold gel coat forming mold is not limited by the overall dimension of the blade, and turnover construction can be performed on the blade in any shape.
And then, after the construction of the in-mold gel coat forming mold is finished, prefabricating the in-mold gel coat according to the construction.
The process of performing in-mold gel coat prefabrication mainly comprises the following steps:
(1) and forming a demoulding layer in the in-mold gel coat forming mold.
The release layer is formed by sticking release paper or a setting release agent in an in-mold gel coat forming mold. Preferably, the release paper is applied so as to remove the effect of the residual release agent and avoid the process of polishing the inner gel coat of the inner mold at certain coating intervals.
(2) And constructing a liquid in-mold gel coat in the in-mold gel coat forming mold with the demoulding layer to form a prefabricated film.
The construction mode of constructing the liquid type in-mold gel coat in the in-mold gel coat forming mold can select roller coating, airless spraying or air spraying, and the construction number can select one or more than one, thereby preparing the in-mold gel coat prefabricated film.
(3) After the prefabricated film is dried and formed, the formed in-mold gel coat prefabricated film is taken off from the in-mold gel coat forming die and transferred to a blade forming die (i.e. a die used for filling the blade), so that the blade can be conventionally filled, and the blade can be demoulded after being cured.
When the blade is poured and formed on the basis of the in-mold gel coat prefabricated film, the demolding temperature of the formed blade from the blade forming mold can be-20 ℃ to 100 ℃, the blade is usually demolded after being cured, and the mold and the blade are not required to be cooled.
Moreover, when the in-mold gel coat prefabricated film is prefabricated based on the in-mold gel coat prefabricated film mold, the solidification of the in-mold gel coat prefabricated film can be accelerated in modes of heating, humidifying and the like.
The in-mold gel coat in the embodiment is prefabricated in a simple in-mold gel coat forming mold, and is not directly constructed in an expensive blade forming mold, so that the thickness of the in-mold gel coat can be uniform and the film thickness can be controlled; when carrying out the interior gel coat of prefabrication based on simple and easy interior gel coat forming die, whole prefabrication process does not occupy blade forming die for the blade accounts for the mould time and directly falls to zero hour by the four hours of the interior gel coat of construction tradition type mould more, and can realize that interior gel coat constitutes diversified, the pluralism of system, and concrete constitution can be decided according to actual demand.
By way of example, the in-mold gel coat preformed in this example may be of the following type.
a. The in-mold gel coat may be formed from a polyurethane layer.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) and uniformly mixing all the components of the polyurethane type in-mold gel coat, and constructing the mixture in the processed mold to form the in-mold gel coat with a single polyurethane layer. The construction mode can be selected from rolling coating, brush coating, blade coating, air spraying, airless spraying and the like.
b. The in-mold gel coat may be comprised of a polyurethane layer and a hard layer.
The stiff layer here is mainly formed of epoxy type (fibre fabric can be embedded in the coating) or other rigid material.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) uniformly mixing all components of the polyurethane type in-mold gel coat, and constructing in the mold after the treatment, wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying;
(3) and (3) after the polyurethane type in-mold gel coat in the step (2) is dried, uniformly mixing all components of the epoxy type in-mold gel coat, and constructing the mixture on the surface of the polyurethane type in-mold gel coat, wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying and the like.
c. The in-mold gel coat may be comprised of a polyurethane layer and a surface sizing layer.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) uniformly mixing all components of the polyurethane in-mold gel coat, and constructing in the mold treated in the step (1), wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying;
(3) and (3) after the polyurethane type in-mold gel coat is dried in the step (2), applying a layer of surface wetting agent on the surface of the polyurethane type in-mold gel coat, wherein the application mode can be roller coating, brush coating, air spraying or airless spraying.
d. The in-mold gel coat may be comprised of a polyurethane layer, a hard layer, and a surface sizing layer.
The stiff layer here consists mainly of epoxy type (possibly with a fabric embedded in the coating) or other rigid material.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) uniformly mixing all components of the polyurethane type in-mold gel coat, and constructing in the mold treated in the step (1), wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying and the like;
(3) after the polyurethane type in-mold gel coat in the step (2) is dried, uniformly mixing all components of the epoxy type in-mold gel coat, and constructing on the surface of the polyurethane type in-mold gel coat, wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying and the like;
(4) and (3) after the epoxy in-mold gel coat is dried, applying a layer of surface wetting agent on the surface of the epoxy in-mold gel coat, wherein the application mode can be roller coating, brush coating, air spraying or airless spraying and the like.
e. The in-mold gel coat can be formed by matching a polyurethane layer and a diversion layer.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) uniformly mixing all components of the polyurethane in-mold gel coat, and constructing in the mold treated in the step (1), wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying;
(3) and (3) after the polyurethane type in-mold gel coat in the step (2) is dried, paving and adhering a flow guide layer on the surface of the polyurethane type in-mold gel coat.
f. The in-mold gel coat can be composed of a polyurethane layer, a hard layer and a diversion layer.
The stiff layer here is mainly made of epoxy type (fibre fabric can be embedded in the coating) or other rigid material.
When the in-mold gel coat formed in this way is prefabricated, the specific forming process is as follows:
(1) stripping paper or construction release agent is stuck inside the in-mold gel coat forming mold;
(2) uniformly mixing all components of the polyurethane in-mold gel coat, and constructing in the mold treated in the step (1), wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying;
(3) after the polyurethane type in-mold gel coat in the step (2) is dried, uniformly mixing all components of the epoxy type in-mold gel coat, and constructing on the surface of the polyurethane type in-mold gel coat, wherein the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying;
(4) and (4) after the epoxy in-mold gel coat in the step (3) is dried, paving and adhering a flow guide layer on the surface of the epoxy in-mold gel coat.
The formed a-type in-mold gel coat can provide the base material performance required by the blade, and can completely replace the traditional in-mold gel coat;
the formed b-type in-mold gel coat adopts a mode of combining a polyurethane type material with softer property and an epoxy type material (fiber fabric can be embedded in a coating) with harder property or other rigid materials, so that the performance of the a-type in-mold gel coat can be provided, and the rigidity support of the prefabricated film foundation of the in-mold gel coat can be provided when the prefabricated film is demolded and the prefabricated film is transferred, so that the in-mold gel coat can be demolded and transferred more conveniently and is not easy to damage in the process;
the formed c and e in-mold gel coats are correspondingly improved in the aspect of blade perfusion on the basis of the a type in-mold gel coats, namely, a surface sizing agent layer or a flow guide layer is further introduced on the basis of the a type in-mold gel coats, and the surface sizing agent layer and the flow guide layer are beneficial to uniform and sufficient contact and adhesion of perfusion resin with the in-mold gel coat layer when the blade is perfused, so that the perfusion efficiency is improved.
The formed d and f in-mold gel coats are correspondingly improved in the aspect of blade perfusion on the basis of the b type in-mold gel coats, namely, a surface sizing agent layer or a flow guide layer is further introduced on the basis of the b type in-mold gel coats, and the two layers are beneficial to uniform and sufficient contact and adhesion of perfusion resin with the in-mold gel coat layer when the blade is perfused, so that the perfusion efficiency is improved.
The coating forming scheme of the in-mold gel coat provided by the embodiment can also embed liquid paint or protective coatings of liquid gel coats at the front edge or the blade tip of the blade and other parts with special protection requirements, and the liquid paint or the protective coatings and the in-mold gel coat are constructed, formed, transferred, poured and demoulded simultaneously and finally appear on the surface of the blade simultaneously.
The specific implementation process is as follows:
(1) after demolding paper is pasted or demolding agent is constructed inside the in-mold gel coat forming mold, liquid front edge protective gel coat or paint is constructed in the mold in advance corresponding to the part of the blade tip or the front edge of the blade with special protection requirements, and the construction mode can be roller coating, brush coating, blade coating, air spraying or airless spraying and the like;
(2) after the thickness of the liquid front edge protective gel coat or the cured dry film of the paint meets the specified requirement, integrally constructing the in-mold gel coat, wherein the construction mode can select roller coating, brush coating, blade coating, air spraying or airless spraying and the like;
(3) and (5) subsequently carrying out the construction step of the in-mold gel coat.
Finally, the present embodiment further provides a method for forming a blade of a wind turbine generator based on the coating forming scheme of the in-mold gel coat, which specifically includes:
(1) after the blade is demoulded and repaired, a demoulding layer is formed on the surface of the blade, and the demoulding layer can be formed by coating a layer of demoulding paper on the whole surface of the blade or applying a layer of demoulding agent.
(2) Preparing a simple female die (namely an in-die gel coat prefabricated film die) of the blade by using epoxy resin (or other materials) and fiber fabrics (or other materials) on the blade with the surface provided with the demolding layer, and after the simple female die is cured, detaching the die from the blade. In actual operation, the prepared simple female die can be finished by selecting one section or multiple sections due to the fact that the length of the blade is long and the volume is large.
(3) And (3) coating release paper or construction release agent in the simple female die prepared in the step (2), wherein the release paper is preferably used, so that the influence of the residual release agent can be removed, and the step of polishing the in-die gel coat in a certain coating interval is omitted.
(4) And (4) constructing the liquid in-mold gel coat in the simple mold obtained in the step (3), wherein the construction mode can be roll coating or airless spraying or air spraying, and one or more construction channels can be selected, so that the in-mold gel coat prefabricated film is prepared.
(5) After the prefabricated film prepared by the scheme in the step (4) is prepared, after the prefabricated film is dried, the in-mold gel coat prefabricated film is taken off from the simple mold and directly transferred to a mother mold (namely, a mold used for filling the blade), and then the subsequent blade filling and forming step is carried out.
Compared with the existing wind driven generator blade forming process, the wind driven generator blade forming process has the following advantages:
1. the problem that the time of the traditional in-mold gel coat is occupied in the mold (the blade mold is occupied) when the traditional in-mold gel coat is constructed and cured in the blade mold can be effectively solved;
2. the problem that the traditional in-mold gel coat cannot be coated repeatedly for multiple times can be effectively solved;
3. the problem that the thickness of the traditional in-mold gel coat is uncontrollable can be effectively solved;
4. the problems of incomplete demolding of the traditional in-mold gel coat and large blade post-treatment repairing amount can be effectively solved;
5. the problem that dust generated by polishing after demoulding of the traditional in-mould gel coat harms construction environment and health of constructors can be effectively solved.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.