CN115449183A - Preparation method of wind power blade conductive beam cap - Google Patents
Preparation method of wind power blade conductive beam cap Download PDFInfo
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Abstract
The invention discloses a preparation method of a wind power blade conductive beam cap, which comprises the following steps: 1) Blending, processing and modifying a resin material and a conductive filler to obtain conductive pultrusion resin and conductive infusion resin; 2) Injecting the conductive pultrusion resin into pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers under the pultrusion action, and then curing, cooling and molding the conductive pultrusion resin to obtain a conductive pultrusion plate; 3) Laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, pouring conductive infusion resin by using a vacuum bag pressing process, and then carrying out curing molding to obtain a wind power blade conductive beam cap; the conductive resin provided by the invention relates to blade spar cap pultrusion resin and infusion resin, insulating resin is converted into conductive resin by adding conductive filler with a preset proportion into the traditional resin, so that the risk of lightning stroke damage of a blade is reduced by a conductive path, and the strength and modulus of a pultrusion plate and a spar cap are increased, so that the blade spar cap can bear larger ultimate load.
Description
Technical Field
The invention relates to the field of wind power blades and conductive resin material manufacturing, in particular to a method for manufacturing a wind power blade conductive beam cap.
Background
The crossbeam of the fan blade is used as a main bearing structure of the blade component, bears more than 80% of load of external wind power, plays an important role in the aspects of preventing the blade from being damaged by external force resistance, ensuring the safe operation of the blade and the like, and the I-shaped girder is composed of an upper beam cap, a lower beam cap and a middle web plate. The preparation process of the blade beam cap at the early stage mainly adopts vacuum infusion molding, the beam cap has lower strength and rigidity, in recent years, along with the continuous increase of the single-machine power of a fan, the length of the blade is also continuously increased, and higher requirements on the mechanical property and the weight of the blade beam cap are also provided, so that the pultruded plate molding process with high cost performance is produced. Compared with a beam cap prepared by a fabric filling process, the modulus of a glass fiber pultrusion plate for pultrusion can be improved by more than 25%, the weight of a blade can be reduced by more than 5% under the same structural rigidity design, the design optimization of a large blade is facilitated, meanwhile, a pultrusion plate can be directly laid on a shell mold, prefabrication is not needed, the production efficiency of a blade shell can be greatly improved, the investment of the beam cap mold is not needed, and the using amount of auxiliary materials of the beam cap is reduced. The blade can be made longer by the application of the novel material of the pultrusion plate, and the power generation efficiency of the wind generating set is further improved.
At present, a beam cap of a large offshore blade mainly adopts a carbon fiber pultrusion plate or a carbon glass hybrid pultrusion plate so as to meet the requirements of high strength and modulus of the large blade. Because the carbon fiber used by the spar cap also belongs to a conductive substance, but the conductivity is not very good and is close to that of a semiconductor material, when the blade is struck by lightning and current passes through the spar cap, local overhigh heat is easily generated under the influence of larger resistance to damage the mechanical and fatigue properties of the spar cap, and the serious consequence that the current breaks through the spar cap can also occur under the serious condition.
In the lightning protection design of large-scale blade, blade lightning protection structure sketch map is as shown in fig. 1, the mode of lightning protection metal mesh has generally been adopted, and couple together lightning protection metal mesh 01 and roof beam cap 03 at some point location through connecting conductor 02, in order to form the equipotential, when the blade suffered the thunderbolt, some electric current switched on through lightning protection metal mesh, some electric current passes through the roof beam cap in addition and transmits the electric current from apex arrester 04 to blade root direction 05, transmit to lightning protection metal mesh 01 through the connecting point location simultaneously, in order to realize that the electric current switches on. The lightning protection metal mesh 01 can greatly reduce the damage of current to the beam cap 03.
However, carbon fibers have a relatively high electrical resistance and a volume resistivity of about 10 -3 Omega cm, when part of current of lightning stroke passes through the beam cap structure, high resistance heat is generated, irreversible damage is caused to the mechanical strength and the fatigue property of the beam cap, and even the result that the beam cap is punctured by lightning can be directly generated when the current is overlarge. At present, large-scale marine blade beam cap adopts carbon fiber pultrusion plates or carbon glass hybrid pultrusion plates, and because glass fiber is non-conductive, carbon fiber conductivity is poor, so the whole blade beam cap can be conductive, namely the lightning conduction effect can be generated, but higher resistance enables the blade girder cap to effectively conduct current, and even if the protection of a lightning protection metal net is provided, the risk that the blade beam cap is struck by lightning under lightning weather is increased to a certain extent. It is desirable that the blade spar cap have good electrical conductivity, even up to the same resistance of the metal mesh, so that the spar cap remains close to the lightning protection metal meshThe potential can smoothly conduct current when lightning strike large current comes, and more heat can not be generated due to overlarge resistance, so that the influence of the current on the performance of the beam cap material is avoided.
Disclosure of Invention
The invention aims to overcome the defects and shortcomings of the prior art and provides a preparation method of a wind power blade conductive beam cap, wherein insulating resin is converted into conductive resin by adding conductive filler into the traditional resin, so that a conductive path is realized, and the risk of blade lightning damage is reduced; meanwhile, the strength and modulus of the fiber reinforced composite material are enhanced, so that the blade beam cap can bear larger ultimate load.
In order to achieve the purpose, the technical scheme provided by the invention is as follows: a preparation method of a wind power blade conductive beam cap comprises the following steps:
1) Blending, processing and modifying a resin material and a conductive filler to obtain conductive pultrusion resin and conductive infusion resin;
2) Injecting conductive pultrusion resin into pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers under the pultrusion action, and then curing, cooling and molding the conductive pultrusion resin to obtain a conductive pultrusion plate;
3) And laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, pouring conductive filling resin by using a vacuum bag pressing process, and then carrying out curing molding to obtain the wind power blade conductive beam cap.
Further, in the step 1), the conductive pultrusion resin is prepared from the following components in parts by weight:
the conductive infusion resin is prepared from the following components in parts by weight:
further, the resin main agent is one or a combination of more of epoxy resin, polyurethane resin, unsaturated polyester resin, acrylic resin, vinyl resin and polydicyclopentadiene resin.
Further, the conductive filler is one or a combination of more of graphene, carbon nanotubes, conductive carbon black, conductive graphite, nano silver powder, nano copper powder, nano nickel powder and nano tin powder.
Further, the coupling agent is one or a combination of more of a silane coupling agent, a titanate coupling agent and an aluminate coupling agent.
Further, in the step 1), the step of obtaining the conductive pultruded resin after blending, processing and modifying the resin material and the conductive filler comprises the following steps:
1.1.1 Dispersing a preset mass part of conductive filler in absolute ethyl alcohol, and stirring and mixing by using a high-speed stirrer to form a conductive filler dispersion solution;
1.1.2 Adding a coupling agent in a mass ratio with the conductive filler into absolute ethyl alcohol, and stirring and mixing to form a coupling agent dispersion solution;
1.1.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.1.4 Preheating the resin main agent in an oven, mixing the surface-treated conductive filler with the resin main agent, continuously heating and stirring to fully and uniformly mix the surface-treated conductive filler with the resin main agent, and completely evaporating the solvent to obtain the conductive pultruded resin main agent;
1.1.5 Adding a resin curing agent, a resin diluent and an internal release agent into the conductive pultrusion resin main agent according to a preset proportion, and mixing and stirring the mixture in a vacuum environment to obtain the conductive pultrusion resin.
Further, in the step 1.1.1), the high-speed stirring speed of stirring and mixing by using a high-speed stirrer is 500 r/min-3000 r/min, and the stirring time is 5 min-30 min; in the step 1.1.2), a coupling agent with the mass ratio of 1-2% to the conductive filler is used, and the stirring and mixing time is 5-30 min; in the step 1.1.3), the time of ultrasonic vibration is 10-60 min; in the step 1.1.4), the temperature of the oven is 50-80 ℃, the preheating time is 20-60 min, the conductive filler subjected to surface treatment is mixed with the resin main agent, and then the mixture is continuously heated and stirred at 50-80 ℃ for 30-120 min; in the step 1.1.5), the vacuum degree is less than 10mbar, and the mixing and stirring time is 20-60 min.
Further, in the step 1), the step of obtaining the conductive infusion resin after blending, processing and modifying the resin material and the conductive filler comprises the following steps:
1.2.1 Dispersing a preset mass part of conductive filler in absolute ethyl alcohol, and stirring and mixing by using a high-speed stirrer to form a conductive filler dispersion solution;
1.2.2 Adding a coupling agent which forms a preset mass ratio with the conductive filler into absolute ethyl alcohol, and stirring and mixing to form a coupling agent dispersion solution;
1.2.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.2.4 Preheating the resin main agent in an oven, mixing the surface-treated conductive filler with the resin main agent, continuously heating and stirring to fully and uniformly mix the surface-treated conductive filler with the resin main agent, and completely evaporating the solvent to obtain a conductive perfusion resin main agent;
1.2.5 Adding a resin curing agent and a resin diluent into the main agent of the conductive infusion resin according to a preset proportion, and mixing and stirring the mixture in a vacuum environment to obtain the conductive infusion resin.
Further, in the step 1.2.1), the high-speed stirring speed of stirring and mixing by using a high-speed stirrer is 500 r/min-3000 r/min, and the stirring time is 5 min-30 min; in the step 1.2.2), a coupling agent with the mass ratio of 1-2% to the conductive filler is used, and the stirring and mixing time is 5-30 min; in the step 1.2.3), the time of ultrasonic vibration is 10-60 min; in the step 1.2.4), the temperature of the oven is 50-80 ℃, the preheating time is 20-60 min, the conductive filler subjected to surface treatment is mixed with the resin main agent, and then the mixture is heated and stirred for 30-120 min at the temperature of 50-80 ℃; in the step 1.2.5), the vacuum degree is less than 10mbar, and the mixing and stirring time is 20-60 min.
Further, the step 2) comprises the following steps:
inject electrically conductive pultrusion resin into the resin tank in the pultrusion equipment, under the traction action of the pultrusion equipment, the reinforcing fiber is impregnated with the electrically conductive pultrusion resin and then is cured and formed by the mold heating section and the curing and forming section: and controlling the conductive pultrusion resin to impregnate the reinforcing fiber in a preset temperature for a preset time, sequentially passing through three sections of die heating sections after impregnation, namely a die heating section, a die heating section and a die heating section, sequentially passing through three sections of die heating sections, and sequentially passing through three sections of curing and forming sections, namely a curing and forming section, a curing and forming section and a curing and forming section to obtain a completely cured pultrusion plate, and cutting after curing and cooling to obtain the conductive pultrusion plate.
Further, the temperature of the conductive pultrusion resin is controlled to be 25-50 ℃, the time for impregnating the reinforced fiber is 15-60 s, the heating temperature of the first heating section of the die is 100-130 ℃, the heating temperature of the second heating section of the die is 130-160 ℃, the heating temperature of the third heating section of the die is 160-200 ℃, the heating temperature of the first curing molding section is 160-200 ℃, the heating temperature of the second curing molding section is 130-160 ℃, the heating temperature of the third curing molding section is 100-130 ℃, and the traction speed of the pultrusion plate is 0.3-0.8 m/min.
Further, the step 3) comprises the following steps:
and laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, completing infusion of conductive infusion resin by using a vacuum bag pressing process, raising the temperature to 70-90 ℃ from room temperature at a speed of 1-2 ℃/min, and curing for 5-10 h to complete curing and forming, thus obtaining the wind power blade conductive beam cap.
Compared with the prior art, the invention has the following advantages and beneficial effects:
1. the conductive resin provided by the invention relates to blade cap pultrusion resin and infusion resin, insulating resin is converted into conductive resin by adding conductive filler with a preset proportion into the traditional resin, a conductive path is realized, the risk of blade lightning damage is reduced, and compared with an unmodified carbon fiber pultruded plate cap or a carbon glass hybrid pultruded plate cap, the resistance of the cap modified by the conductive filler can be reduced by 2-3 orders of magnitude;
2. the conductive filler and the carbon fiber are combined in different forms, and the conductive fillers in different shapes such as a point shape, a linear shape, a planar shape and the like are compounded on the basis of the original conductive mode of the carbon fiber in a single direction microscopically, so that the comprehensive combination of the point shape, the linear shape and the planar shape is realized, a three-dimensional mesh conductive structure is formed in space, and the conductive performance is further enhanced;
3. the resin conductive filler is subjected to modification design, one end of the resin conductive filler is connected with inorganic matters such as the conductive filler and the like through grafting of the coupling agent, the other end of the resin conductive filler is connected with organic matters of a resin matrix, and the inorganic matters and the organic matters of the resin matrix are organically combined together, so that the conductive filler is well dispersed in the resin matrix, the performance of the conductive filler is greatly improved, and the damage caused by lightning is reduced;
4. according to the invention, the conductive filler is simultaneously applied to the pouring resin of the beam cap, so that the conductive system penetrates through the whole beam cap, and good conductive performance can be realized in the length direction, the width direction and the thickness direction of the beam cap;
5. according to the invention, the conductive filler is introduced, so that the conductive fillers with different shapes and the resin matrix realize good bonding, when the conductive filler is acted by an external force, the conductive filler can be used as a rigid conductive filler to effectively resist the influence of the external force, the energy brought by the external force is conducted and consumed, the composite material structure cannot generate overlarge deformation, the strength and modulus of the pultruded plate and the beam cap are increased, and the blade beam cap can bear larger ultimate load.
Drawings
Fig. 1 is a schematic view of a lightning protection structure of a conventional large blade.
FIG. 2 is a process flow diagram of a method for manufacturing a conductive spar cap of a wind turbine blade.
Fig. 3 is a schematic structural diagram of a carbon nanotube and carbon fiber composite conductive network.
Fig. 4 is a schematic structural diagram of a conductive carbon black, carbon nanotube, graphene and carbon fiber composite conductive network.
Fig. 5 is a structural cross-sectional view of a conductive carbon black, carbon nanotubes, graphene and carbon fiber composite conductive network.
FIG. 6 is a structural cross-sectional view of a wind blade conductive spar cap.
Detailed Description
The invention is further illustrated below with reference to a number of specific examples.
Example 1
The raw materials are as follows:
the conductive pultrusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Daosheng 5560A) 100phr
Resin curing agent: epoxy resin curing agent (Daosheng 5560B) 108phr
Resin diluent: resin diluent (HK-66) 5phr
Conductive filler: carbon nanotubes (Tiannai science FT 7000) 1phr
Coupling agent: silane coupling agent (KH 550) 0.015phr
Internal mold release agent: 3phr of internal mold release agent (NODA-1890M);
the conductive infusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Daosheng 180) 100phr
Resin curing agent: epoxy curing agent (Daosheng 185) 32phr
Resin diluent: resin diluent (HK-66) 5phr
Conductive filler: carbon nanotubes (Tiannai science FT 7000) 1phr
Coupling agent: 0.015phr of silane coupling agent (KH 550).
The process flow for preparing the wind power blade conductive beam cap is shown in fig. 2, and comprises the following specific steps:
1) Blending, processing and modifying the resin material to obtain conductive pultrusion resin and conductive infusion resin;
the method for preparing the conductive pultrusion resin by blending, processing and modifying the resin material comprises the following steps:
1.1.1 1phr of carbon nano tube conductive filler is dispersed in absolute ethyl alcohol and stirred and mixed by a high-speed stirrer, the high-speed stirring speed is 1500r/min, and the stirring time is 10min, so as to form a conductive filler dispersion solution;
1.1.2 0.015phr of silane coupling agent is added into absolute ethyl alcohol, and stirring and mixing are carried out for 20min, so as to form a coupling agent dispersion solution;
1.1.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 30min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.1.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min, the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 60min at the temperature of 60 ℃ continuously, the conductive filler and the epoxy resin are mixed evenly, and the solvent is evaporated completely to obtain the conductive pultrusion resin main agent;
1.1.5 108phr of epoxy resin curing agent, 5phr of resin diluent and 3phr of internal mold release agent are added into the conductive pultrusion resin main agent, and the mixture is mixed and stirred for 20min under the vacuum environment with the vacuum degree of less than 10mbar, and the mixed viscosity is 800 mPa.s, so as to obtain the conductive pultrusion resin.
The method for preparing the conductive infusion resin by blending, processing and modifying the resin material comprises the following steps:
1.2.1 1phr of carbon nano tube conductive filler is dispersed in absolute ethyl alcohol and stirred and mixed by a high-speed stirrer, the high-speed stirring speed is 1500r/min, and the stirring time is 10min, so as to form a conductive filler dispersion solution;
1.2.2 0.015phr of silane coupling agent is added into absolute ethyl alcohol, and stirring and mixing are carried out for 20min, so as to form a coupling agent dispersion solution;
1.2.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 30min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.2.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min, the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 60min at the temperature of 60 ℃ continuously, the conductive filler and the epoxy resin are mixed evenly, and the solvent is evaporated completely to obtain the conductive perfusion resin main agent;
1.2.5 32phr of epoxy resin curing agent and 5phr of resin diluent are added into the conductive infusion resin main agent, and are mixed and stirred for 20min under a vacuum environment with the vacuum degree of less than 10mbar to obtain the conductive infusion resin.
2) Injecting conductive pultrusion resin into pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers under the pultrusion action, curing and cooling the conductive pultrusion resin to obtain a conductive pultrusion plate, and comprising the following steps of: inject electrically conductive pultrusion resin into the resin tank in the pultrusion equipment, under the traction action of the pultrusion equipment, the reinforcing fiber (24K carbon fiber) is impregnated with the electrically conductive pultrusion resin and then is cured and formed by the mold heating section and the curing and forming section: controlling the temperature of the conductive pultrusion resin to be 40 ℃, impregnating the reinforcing fiber for 40s, sequentially passing through three sections of die heating sections after impregnation, respectively heating a first section of the die, a second section of the die and a third section of the die heating section, wherein the heating temperature of the first section of the die heating section is 120 ℃, the heating temperature of the second section of the die heating section is 150 ℃, the heating temperature of the third section of the die heating section is 180 ℃, sequentially passing through three sections of curing and forming sections, respectively a first section of curing and forming section, a second section of curing and forming section and a third section of curing and forming section after passing through the three sections of die heating sections, wherein the heating temperature of the first section of curing and forming section is 180 ℃, the heating temperature of the second section of curing and forming section is 150 ℃, obtaining a completely cured pultrusion plate, the traction speed of the pultrusion plate is 0.5m/min, and cutting is carried out after curing and cooling, thus obtaining the conductive pultrusion plate.
3) And laying the conductive pultrusion plate and the flow guide fabric in a wind power blade beam cap mould, completing infusion of conductive infusion resin by using a vacuum bag pressing process, raising the temperature from room temperature to 70 ℃ at a speed of 1 ℃/min, curing for 7h, and completing curing and forming to obtain the wind power blade conductive beam cap.
Through the formula modification design of the resin in the traditional blade beam cap, the beam cap is endowed with good conductivity, the performance of the beam cap in lightning protection can be improved, the overall mechanical strength and modulus of the beam cap are enhanced, and the ultimate load resistance is improved. The type of the conductive filler is reasonably selected, so that the common conductive capacity of the original carbon fiber can be increased by orders of magnitude. The carbon nanotubes and the carbon fibers are compounded to form a conductive network as shown in fig. 3, and it can be seen that a better three-dimensional conductive path is formed after the ordered uniaxial carbon fibers 1 and the disordered carbon nanotubes 2 are combined under the conductive resin matrix 3.
Example 2
The raw materials are as follows:
the conductive pultrusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Hui Bai AP 3230A) 100phr
Resin curing agent: epoxy curing agent (Hui Bai AP 3230B) 80phr
Resin diluent: resin diluent (501) 7phr
Conductive filler: 0.5phr of carbon nanotube (Tiannai science FT 7000), 2phr of conductive carbon black (Carbot VXC 72) and 0.3phr of graphene (sixth element SE 1232)
Coupling agent: titanate coupling agent (201) 0.015phr
Internal mold release agent: 2phr of internal mold release agent (NODA-1890M);
the conductive infusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Hui Bai LT-5078A) 100phr
Resin curing agent: epoxy curing agent (Hui Bai LT-5078B 3) 30phr
Resin diluent: resin diluent (501) 7phr
Conductive filler: 0.5phr of carbon nanotube (Tiannai science FT 7000), 2phr of conductive carbon black (Carbot VXC 72) and 0.3phr of graphene (sixth element SE 1232)
Coupling agent: titanate coupling agent (201) 0.015phr.
The wind power blade conductive beam cap is produced according to the same process as the embodiment 1, and the method comprises the following specific steps:
1) Blending, processing and modifying the resin material to obtain conductive pultrusion resin and conductive infusion resin;
the method for preparing the conductive pultrusion resin by blending, processing and modifying the resin material comprises the following steps:
1.1.1 0.5phr of carbon nano tube, 2phr of conductive carbon black and 0.3phr of graphene conductive filler are dispersed in absolute ethyl alcohol and stirred and mixed by a high-speed stirrer, wherein the high-speed stirring speed is 2000r/min, and the stirring time is 15min, so as to form a conductive filler dispersion solution;
1.1.2 0.015phr of titanate coupling agent is added into absolute ethyl alcohol and stirred and mixed for 20min to form a coupling agent dispersion solution;
1.1.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 45min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.1.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min to reduce the viscosity of the epoxy resin, then the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 100min at the temperature of 60 ℃ continuously, the two are mixed evenly, and the solvent is evaporated completely to obtain the conductive pultrusion resin main agent;
1.1.5 80phr of epoxy resin curing agent, 7phr of resin diluent and 2phr of internal mold release agent are added into the conductive pultrusion resin main agent, and the mixture is mixed and stirred for 30min under the vacuum environment with the vacuum degree of less than 10mbar, and the mixing viscosity is 700 mPa.s, so as to obtain the conductive pultrusion resin.
The method for preparing the conductive infusion resin by blending, processing and modifying the resin material comprises the following steps:
1.2.1 0.5phr of carbon nano tube, 2phr of conductive carbon black and 0.3phr of graphene conductive filler are dispersed in absolute ethyl alcohol and stirred and mixed by a high-speed stirrer, wherein the high-speed stirring speed is 2000r/min, and the stirring time is 15min, so as to form a conductive filler dispersion solution;
1.2.2 0.015phr of titanate coupling agent is added into absolute ethyl alcohol and stirred and mixed for 20min to form a coupling agent dispersion solution;
1.2.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 45min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.2.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min, the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 100min at the temperature of 60 ℃ continuously, the conductive filler and the epoxy resin are mixed evenly, and the solvent is evaporated completely to obtain the conductive perfusion resin main agent;
1.2.5 30phr of epoxy resin curing agent and 7phr of resin diluent are added into the conductive infusion resin main agent, and are mixed and stirred for 30min under the vacuum environment with the vacuum degree of less than 10mbar, so as to obtain the conductive infusion resin.
2) Injecting conductive pultrusion resin into pultrusion equipment, curing and cooling the conductive pultrusion resin for molding after the reinforced fiber is used for impregnating the conductive pultrusion resin under the pultrusion action, and obtaining a conductive pultrusion plate, which comprises the following steps of: injecting conductive pultrusion resin into a resin tank in pultrusion equipment, under the traction action of the pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers (24K carbon fibers and 1200tex glass fibers, wherein the volume ratio of the 24K carbon fibers to the 1200tex glass fibers is 3:4, and the glass fibers surround and surround the carbon fibers) and then carrying out curing molding through a mold heating section and a curing molding section: controlling the temperature of the conductive pultrusion resin to be 30 ℃, impregnating the reinforcing fiber for 30s, sequentially passing through three sections of die heating sections after impregnation, respectively heating a first section of the die, a second section of the die and a third section of the die heating section, wherein the heating temperature of the first section of the die heating section is 110 ℃, the heating temperature of the second section of the die heating section is 140 ℃, the heating temperature of the third section of the die heating section is 170 ℃, sequentially passing through three sections of die heating sections, respectively a first section of the curing molding section, a second section of the curing molding section and a third section of the curing molding section, wherein the heating temperature of the first section of the curing molding section is 180 ℃, the heating temperature of the second section of the curing molding section is 150 ℃, the heating temperature of the third section of the curing molding section is 110 ℃, obtaining a completely cured pultrusion plate, the traction speed of the pultrusion plate is 0.4m/min, and cutting is carried out after curing and cooling, thus obtaining the conductive pultrusion plate.
3) And laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, completing infusion of conductive infusion resin by using a vacuum bag pressing process, raising the temperature from room temperature to 70 ℃ at the speed of 1 ℃/min, and curing for 7h to complete curing and forming to obtain the wind power blade conductive beam cap.
Referring to fig. 4 and 5, when the conductive carbon black 4, the carbon nanotube 5, the graphene 6, the carbon fiber 7 and the conductive resin matrix 8 are combined, a better three-dimensional conductive network with point, line and surface combination is formed, so that the single conductive network of the original carbon fiber is expanded into a diversified conductive network system through the selection and use of the conductive filler, and the conductivity is improved by several orders of magnitude.
Meanwhile, when the composite system is impacted by external force, stretched and the like, the rigid conductive filler can effectively resist the influence of the external force, and the energy brought by the external force is conducted and consumed through the formed network structure, so that the composite material structure cannot deform too much, and the strength and modulus of the pultruded plate and the beam cap are increased.
Referring to fig. 6, the conductive properties of the cap in the length, width and thickness directions are further improved by applying the conductive filler to the potting resin of the cap, and the conductive network of the cap in the cross section, in which the number of the pultruded panels in the width and thickness directions are arranged according to the design requirements.
Example 3
The raw materials are as follows:
the conductive pultrusion resin is prepared from the following components in parts by weight:
resin main agent: 100phr of epoxy resin (Zhongbo ER 6136X)
Resin curing agent: epoxy resin curing agent (Zhongbo EH 6136X) 105phr
Resin diluent: resin diluent (622) 6phr
Conductive filler: 0.8phr of carbon nano-tube (Tiannai technology FT 7000), 1phr of nano nickel powder (Yamei Ni-0060) and 1phr of conductive graphite (Yanhai YKS-20)
Coupling agent: silane coupling agent (KH 550) 0.015phr
Internal mold release agent: internal mold release agent (NODA-1890M) 3phr;
the conductive infusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Zhongbo ER 5310) 100phr
Resin curing agent: epoxy resin curing agent (Zhongbo EH 5310) 30phr
Resin diluent: resin diluent (622) 6phr
Conductive filler: 0.8phr of carbon nano-tube (Tiannai technology FT 7000), 1phr of nano nickel powder (Yamei Ni-0060) and 1phr of conductive graphite (Yanhai YKS-20)
Coupling agent: 0.015phr of silane coupling agent (KH 550).
The wind power blade conductive beam cap is produced according to the same process as the embodiment 1, and the method comprises the following specific steps:
1) Blending, processing and modifying the resin material to obtain conductive pultrusion resin and conductive infusion resin;
the method for preparing the conductive pultrusion resin by blending, processing and modifying the resin material comprises the following steps:
1.1.1 0.8phr of carbon nano tube, 1phr of nano nickel powder and 1phr of conductive filler of conductive graphite are dispersed in absolute ethyl alcohol and stirred and mixed by a high-speed stirrer, wherein the high-speed stirring speed is 1500r/min, and the stirring time is 20min, so as to form a conductive filler dispersion solution;
1.1.2 0.015phr of silane coupling agent is added into absolute ethyl alcohol, and stirring and mixing are carried out for 20min, so as to form a coupling agent dispersion solution;
1.1.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 45min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.1.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min to reduce the viscosity of the epoxy resin, then the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 45min at the temperature of 60 ℃ continuously, the two are mixed evenly, and the solvent is evaporated completely to obtain the conductive pultrusion resin main agent;
1.1.5 105phr of epoxy resin curing agent, 6phr of resin diluent and 3phr of internal mold release agent are added into the conductive pultrusion resin main agent, and the mixture is mixed and stirred for 30min under the vacuum environment with the vacuum degree of less than 10mbar, and the mixing viscosity is 1000 mPa.s, so as to obtain the conductive pultrusion resin.
The method for preparing the conductive infusion resin by blending, processing and modifying the resin material comprises the following steps:
1.2.1 0.8phr of carbon nano tube, 1phr of nano nickel powder and 1phr of conductive filler of conductive graphite are dispersed in absolute ethyl alcohol and are stirred and mixed by a high-speed stirrer, the high-speed stirring speed is 1500r/min, and the stirring time is 20min, so as to form a conductive filler dispersion solution;
1.2.2 0.015phr of silane coupling agent is added into absolute ethyl alcohol and stirred and mixed for 20min to form a coupling agent dispersion solution;
1.2.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration for 45min to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.2.4 100phr of epoxy resin is preheated in an oven at 60 ℃ for 30min, the conductive filler with the surface treatment is mixed with the epoxy resin, the mixture is heated and stirred for 100min at the temperature of 60 ℃ continuously, the conductive filler and the epoxy resin are mixed evenly, and the solvent is evaporated completely to obtain the conductive perfusion resin main agent;
1.2.5 30phr of epoxy resin curing agent and 6phr of resin diluent are added into the conductive infusion resin main agent, and are mixed and stirred for 30min under the vacuum environment with the vacuum degree of less than 10mbar, so as to obtain the conductive infusion resin.
2) Injecting conductive pultrusion resin into pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers under the pultrusion action, curing and cooling the conductive pultrusion resin to obtain a conductive pultrusion plate, and comprising the following steps of: inject electrically conductive pultrusion resin into the resin tank in the pultrusion equipment, under the traction effect of pultrusion equipment, carry out curing molding through mould heating section and curing molding section behind the electrically conductive pultrusion resin of reinforcing fiber (24K carbon fiber) impregnation: controlling the temperature of the conductive pultrusion resin to be 40 ℃, soaking the reinforcing fibers for 40s, sequentially passing through three sections of die heating sections after soaking, namely a die heating first section, a die heating second section and a die heating third section, wherein the heating temperature of the die heating first section is 120 ℃, the heating temperature of the die heating second section is 150 ℃, the heating temperature of the die heating third section is 180 ℃, sequentially passing through three sections of die heating sections, and sequentially passing through three sections of curing and forming sections, namely a curing and forming first section, a curing and forming second section and a curing and forming third section, wherein the heating temperature of the curing and forming first section is 190 ℃, the heating temperature of the curing and forming second section is 150 ℃, the heating temperature of the curing and forming third section is 110 ℃, obtaining a completely cured pultrusion plate, the pultrusion plate traction speed is 0.4m/min, and cutting is carried out after curing and cooling, thus obtaining the conductive pultrusion plate.
3) And laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, completing infusion of conductive infusion resin by using a vacuum bag pressing process, raising the temperature from room temperature to 70 ℃ at the speed of 1 ℃/min, and curing for 7h to complete curing and forming to obtain the wind power blade conductive beam cap.
Example 4
Unlike examples 1 to 3, the resin material was not modified by blending processing in this example as a control.
The raw materials are as follows:
the pultrusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Daosheng 5560A) 100phr
Resin curing agent: epoxy resin curing agent (Daosheng 5560B) 108phr
Internal mold release agent: internal mold release agent (NODA-1890M) 3phr;
the perfusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Daosheng 180) 100phr
Resin curing agent: epoxy curing agent (Daosheng 185) 32phr.
The process flow for preparing the wind power blade conductive beam cap comprises the following specific steps:
a) Mixing 100phr of epoxy resin, 108phr of epoxy resin curing agent and 3phr of internal mold release agent to obtain pultrusion resin, injecting the pultrusion resin into a resin tank in pultrusion equipment, impregnating 24K carbon fibers with the pultrusion resin through a pultrusion die and carrying out curing molding under the traction action of the pultrusion equipment, controlling the temperature of the pultrusion resin to be 40 ℃, the impregnation time to be 40s, passing through three sections of heating mold sections after impregnation, respectively a mold heating section, a mold heating section and a mold heating section, wherein the heating temperature of the mold heating section is 120 ℃, the heating temperature of the mold heating section is 150 ℃, the heating temperature of the mold heating section is 180 ℃, passing through the three sections of mold heating sections, sequentially passing through three sections of curing molding sections, respectively a curing molding section, a curing molding section and a curing molding section, wherein the heating temperature of the curing molding section is 180 ℃, the heating temperature of the curing molding section is 150 ℃, the heating temperature of the curing molding section is 120 ℃, the traction speed is 0.5m/min, and cutting is carried out after curing and cooling the carbon fibers to obtain a common pultrusion plate;
b) And paving the common carbon fiber pultruded plate and the flow guide fabric in a beam cap mould as required, completing infusion by using infusion resin (180/185 per cent, the ratio is 100phr: 32phr) under the vacuum bag pressing process, raising the temperature from room temperature to 70 ℃ at the speed of 1 ℃/min, curing for 7h, and completing curing molding to obtain the wind power blade carbon pultruded plate beam cap.
Example 5
Unlike examples 1-3, the resin material was not modified by blending in this example as a control.
The raw materials are as follows:
the pultrusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Hui Bai AP 3230A) 100phr
Resin curing agent: epoxy curing agent (Hui Bai AP 3230B) 80phr
Internal mold release agent: 2phr internal mold release agent (NODA-1890M);
the perfusion resin is prepared from the following components in parts by weight:
resin main agent: epoxy resin (Hui Bai LT-5078A) 100phr
Resin curing agent: epoxy curing agent (Hui Bai LT-5078B 3) 30phr.
The process flow for preparing the wind power blade conductive beam cap comprises the following specific steps:
a) Mixing 100phr of epoxy resin, 80phr of epoxy resin curing agent and 2phr of internal mold release agent to obtain pultrusion resin, injecting the pultrusion resin into a resin tank in pultrusion equipment, impregnating the pultrusion resin with 24K carbon fiber and 1200tex glass fiber under the traction action of the pultrusion equipment, then passing through a pultrusion die and carrying out curing molding, wherein the volume ratio of the glass fiber to the carbon fiber is 4:3, the glass fiber surrounds the carbon fiber, the temperature of the pultrusion resin is controlled to be 30 ℃, the impregnation time is 30s, after impregnation, passing through three sections of heating mold sections, respectively passing through a first heating section of the mold, a second heating section of the mold and a third heating section of the mold, wherein the heating temperature of the first heating section of the mold is 110 ℃, the heating temperature of the second heating section of the mold is 140 ℃, the heating temperature of the third heating section of the mold is 170 ℃, passing through the third heating section of the mold, sequentially passing through three sections of curing molding sections, respectively passing through a first curing molding section, a second curing molding section and a curing molding section, curing molding section and a curing section, wherein the heating temperature of the curing molding section is 180 ℃, the heating temperature of the curing molding section is 150 ℃, the heating temperature of the curing molding is 110 ℃, the traction speed is 0.4 min, and cutting the common carbon fiber to obtain a plate after pultrusion;
b) And (2) paving the common carbon fiber pultruded plate and the guide fabric in a beam cap mould according to requirements, completing infusion by using infusion resin (180/185 of Daosheng, the ratio of 100phr to 32phr) under a vacuum bag pressing process, raising the temperature from room temperature to 70 ℃ at the speed of 1 ℃/min, and curing for 7h to complete curing and forming, thereby obtaining the wind power blade carbon pultruded plate beam cap.
Results of the implementation
Cutting the wind power blade beam cap prepared in the embodiment 1-5 into a length of 1 meter and a thickness of 40mm, and carrying out resistance tests in the length direction and the thickness direction;
the pultruded panels prepared and molded in the above examples were cut into standard tensile and compressive test bars by a data machine and tested according to the tensile ISO 527-5 and compressive ISO 14126 test standards.
The test results are analyzed in comparison as shown in table 1 below.
TABLE 1 comparison of the tensile and compression panel and cap indicators in examples 1-5
The data above were analysed comparing example 1 and example 3 with example 4 and example 2 with example 5 using the same reinforcing fibre material; it can be seen that in embodiments 1 to 3, the conductive filler is added and well dispersed in the resin matrix, so that the resistance of the finally prepared blade spar cap in the length direction is reduced by 2 to 3 orders of magnitude, and in the thickness direction, the resistance is more prominent, and the surface of the common carbon-glass mixed pultrusion spar cap in the thickness direction is wrapped by the insulating material, i.e., glass fiber, so that the spar cap added with the conductive filler can effectively conduct current through the low resistance performance of the resin, so that the resistance of the conductive spar cap in the thickness direction is far lower than that of the common spar cap; on the other hand, because the added conductive filler is also dispersed in the pultrusion resin as a reinforcing substance, the mechanical strength and the modulus of the pultrusion plate are enhanced to a certain degree when the pultrusion plate is subjected to the stretching and compressing actions.
The above-mentioned embodiments are merely preferred embodiments of the present invention, and the scope of the present invention is not limited thereto, so that variations based on the shape and principle of the present invention should be covered within the scope of the present invention.
Claims (12)
1. A preparation method of a wind power blade conductive beam cap is characterized by comprising the following steps:
1) Blending, processing and modifying a resin material and a conductive filler to obtain conductive pultrusion resin and conductive infusion resin;
2) Injecting the conductive pultrusion resin into pultrusion equipment, impregnating the conductive pultrusion resin with reinforcing fibers under the pultrusion action, and then curing, cooling and molding the conductive pultrusion resin to obtain a conductive pultrusion plate;
3) And laying the conductive pultrusion plate and the flow guide fabric in a wind power blade beam cap mould, pouring conductive pouring resin by using a vacuum bag pressing process, and then carrying out curing molding to obtain the wind power blade conductive beam cap.
2. The method for preparing the conductive beam cap of the wind turbine blade as claimed in claim 1, wherein in the step 1), the conductive pultruded resin is prepared from the following components in parts by weight:
the conductive infusion resin is prepared from the following components in parts by weight:
3. the method for preparing the conductive beam cap of the wind power blade according to claim 2, wherein the resin main agent is one or more of epoxy resin, polyurethane resin, unsaturated polyester resin, acrylic resin, vinyl resin and polydicyclopentadiene resin.
4. The method for preparing the conductive beam cap of the wind power blade as claimed in claim 2, wherein the conductive filler is one or more of graphene, carbon nanotube, conductive carbon black, conductive graphite, nano silver powder, nano copper powder, nano nickel powder and nano tin powder.
5. The method for preparing the conductive beam cap of the wind turbine blade according to claim 2, wherein the coupling agent is one or a combination of silane coupling agent, titanate coupling agent and aluminate coupling agent.
6. The method for preparing the conductive beam cap of the wind turbine blade as claimed in claim 1, wherein in the step 1), the step of obtaining the conductive pultruded resin after blending, processing and modifying the resin material and the conductive filler comprises the following steps:
1.1.1 Dispersing a preset mass part of conductive filler in absolute ethyl alcohol, and stirring and mixing by using a high-speed stirrer to form a conductive filler dispersion solution;
1.1.2 Adding a coupling agent in a mass ratio with the conductive filler into absolute ethyl alcohol, and stirring and mixing to form a coupling agent dispersion solution;
1.1.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surface of conductive filler particles to obtain a surface-treated conductive filler;
1.1.4 Preheating the resin main agent in an oven, mixing the surface-treated conductive filler with the resin main agent, continuously heating and stirring to fully and uniformly mix the surface-treated conductive filler with the resin main agent, and completely evaporating the solvent to obtain the conductive pultruded resin main agent;
1.1.5 Adding a resin curing agent, a resin diluent and an internal release agent into the conductive pultrusion resin main agent according to a preset proportion, and mixing and stirring the mixture in a vacuum environment to obtain the conductive pultrusion resin.
7. The method for preparing the wind power blade conductive beam cap according to claim 6, wherein in the step 1.1.1), the high-speed stirring speed of stirring and mixing by using a high-speed stirrer is 500r/min to 3000r/min, and the stirring time is 5min to 30min; in the step 1.1.2), a coupling agent with the mass ratio of 1-2% to the conductive filler is used, and the stirring and mixing time is 5-30 min; in the step 1.1.3), the time of ultrasonic vibration is 10-60 min; in the step 1.1.4), the temperature of the oven is 50-80 ℃, the preheating time is 20-60 min, the conductive filler subjected to surface treatment is mixed with the resin main agent, and then the mixture is heated and stirred for 30-120 min at the temperature of 50-80 ℃; in the step 1.1.5), the vacuum degree is less than 10mbar, and the mixing and stirring time is 20-60 min.
8. The preparation method of the conductive beam cap of the wind turbine blade as claimed in claim 1, wherein in the step 1), the step of obtaining the conductive infusion resin by blending, processing and modifying the resin material and the conductive filler comprises the following steps:
1.2.1 Dispersing a preset mass part of conductive filler in absolute ethyl alcohol, and stirring and mixing by using a high-speed stirrer to form a conductive filler dispersion solution;
1.2.2 Adding a coupling agent which forms a preset mass ratio with the conductive filler into absolute ethyl alcohol, and stirring and mixing to form a coupling agent dispersion solution;
1.2.3 Mixing the conductive filler dispersion solution and the coupling agent dispersion solution, and then carrying out ultrasonic vibration to enable the conductive filler dispersion solution and the coupling agent dispersion solution to be in contact with each other to generate a grafting reaction, wherein the coupling agent is connected to the surfaces of conductive filler particles to obtain a surface-treated conductive filler;
1.2.4 Preheating the resin main agent in an oven, mixing the surface-treated conductive filler with the resin main agent, continuously heating and stirring to fully and uniformly mix the surface-treated conductive filler with the resin main agent, and completely evaporating the solvent to obtain a conductive perfusion resin main agent;
1.2.5 Adding a resin curing agent and a resin diluent into the conductive infusion resin main agent according to a preset proportion, and mixing and stirring under a vacuum environment to obtain the conductive infusion resin.
9. The method for preparing the wind power blade conductive beam cap according to claim 8, wherein in the step 1.2.1), the high-speed stirring speed of stirring and mixing by using a high-speed stirrer is 500r/min to 3000r/min, and the stirring time is 5min to 30min; in the step 1.2.2), a coupling agent with the mass ratio of 1-2% to the conductive filler is used, and the stirring and mixing time is 5-30 min; in the step 1.2.3), the time of ultrasonic vibration is 10-60 min; in the step 1.2.4), the temperature of the oven is 50-80 ℃, the preheating time is 20-60 min, the conductive filler subjected to surface treatment is mixed with the resin main agent, and then the mixture is heated and stirred for 30-120 min at the temperature of 50-80 ℃; in the step 1.2.5), the vacuum degree is less than 10mbar, and the mixing and stirring time is 20-60 min.
10. The method for preparing the conductive beam cap of the wind power blade according to claim 1, wherein the step 2) comprises the following steps:
inject electrically conductive pultrusion resin into the resin tank in the pultrusion equipment, under the traction action of the pultrusion equipment, the reinforcing fiber is impregnated with the electrically conductive pultrusion resin and then is cured and formed by the mold heating section and the curing and forming section: and controlling the conductive pultrusion resin to impregnate the reinforcing fiber at a preset temperature for a preset time, sequentially passing through three sections of die heating sections after impregnation, namely a die heating section, a die heating section and a die heating section, sequentially passing through three sections of die heating sections, then sequentially passing through three sections of curing and forming sections, namely a curing and forming section, a curing and forming section and a curing and forming section to obtain a completely cured pultrusion plate, and cutting after curing and cooling to obtain the conductive pultrusion plate.
11. The method for preparing the conductive beam cap of the wind power blade according to claim 10, wherein the temperature of the conductive pultrusion resin is controlled to be 25-50 ℃, the time for impregnating the reinforcing fiber is 15-60 s, the heating temperature of the first heating section of the die is 100-130 ℃, the heating temperature of the second heating section of the die is 130-160 ℃, the heating temperature of the third heating section of the die is 160-200 ℃, the heating temperature of the first curing section is 160-200 ℃, the heating temperature of the second curing section is 130-160 ℃, the heating temperature of the third curing section is 100-130 ℃, and the pulling speed of the pultrusion plate is 0.3-0.8 m/min.
12. The method for preparing the conductive beam cap of the wind power blade according to claim 1, wherein the step 3) comprises the following steps:
and laying the conductive pultrusion plate and the guide fabric in a wind power blade beam cap mould, completing infusion of conductive infusion resin by using a vacuum bag pressing process, raising the temperature to 70-90 ℃ from room temperature at a speed of 1-2 ℃/min, and curing for 5-10 h to complete curing and forming, thus obtaining the wind power blade conductive beam cap.
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| WO2022096416A1 (en) * | 2020-11-03 | 2022-05-12 | Blade Dynamics Limited | Hybrid pultrusion plates for a spar cap of a wind turbine blade |
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