SYSTEMS AND METHODS FOR FORMING PROTECTIVE COATINGS

Abstract

Embodiments relate to a method for forming a protective coating on a substrate and a wind power generation system which comprises a blade and a protective coating on the blade.

Claims

1. A method for forming a protective coating on a substrate, the method comprising: providing a substrate; forming a first polyurethane coating layer on the substrate, the first polyurethane coating layer formed on the substrate in such a way that the first polyurethane coating layer reaches a touch dry state within a first time period (T1) after the first polyurethane coating layer is provided on the substrate; applying a first evaporable solvent on the first polyurethane coating layer, wherein the first evaporable solvent is applied on the first polyurethane coating layer within a second time period (T2) after the first polyurethane coating layer reaches the touch dry state; and forming a second polyurethane coating layer on the first polyurethane coating layer, wherein: the second polyurethane coating layer is formed on the first polyurethane coating layer within a third time period (T3) after applying the first evaporable solvent; the first evaporable solvent applied on the first polyurethane coating layer is partially evaporated before the second polyurethane coating layer is provided on the first polyurethane coating layer; and the second polyurethane coating layer reaches the touch dry state within a fourth time period (T4) after the second polyurethane coating layer is provided on the first polyurethane coating layer.

2. The method of claim 1, further comprising: applying a second evaporable solvent on the second polyurethane coating layer, wherein the second evaporable solvent is applied on the second polyurethane coating layer within a fifth time period (T5) after the second polyurethane coating layer reaches the touch dry state; and forming a third polyurethane coating layer on the second polyurethane coating layer within a sixth time period (T6) after applying the second evaporable solvent, wherein the second evaporable solvent applied on the second polyurethane coating layer is partially evaporated before the third polyurethane coating layer is provided on the second polyurethane coating layer; and the third polyurethane coating layer reaches the touch dry state within a seventh time period (T7) after the third polyurethane coating layer is provided on the second polyurethane coating layer.

3. The method of claim 2, further comprising: applying a third evaporable solvent on the third polyurethane coating layer, wherein the third evaporable solvent is applied on the third polyurethane coating layer within an eighth time period (T8) after the third polyurethane coating layer reaches the touch dry state; and forming a fourth polyurethane coating layer on the third polyurethane coating layer within a ninth time period (T9) after applying the third evaporable solvent, wherein the third evaporable solvent applied on the third polyurethane coating layer is partially evaporated before the fourth polyurethane coating layer is provided on the third polyurethane coating layer.

4. The method of claim 1, wherein a summation of the first time period (T1) and the second time period (T2) does not exceed 60 minutes; and the third time period (T3) is between 0-300 minutes.

5. The method of claim 1, wherein a summation of the first time period (T1) and the second time period (T2) is between 15-45 minutes.

6. The method of claim 2, wherein a summation of the fourth time period (T4) and the fifth time period (T5) does not exceed 60 minutes; and the sixth time period (T6) is between 0-300 minutes.

7. The method of claim 2, wherein a summation of the fourth time period (T4) and the fifth time period (T5) is between 15-45 minutes.

8. The method of claim 3, wherein a summation of the seventh time period (T7) and the eighth time period (T8) does not exceed 60 minutes; and the ninth time period (T9) is between 0-300 minutes.

9. The method of claim 3, wherein a summation of the seventh time period (T7) and the eighth time period (T8) is between 15-45 minutes.

10. The method of claim 3, wherein at least one of the following apply: T2(0.310)*T1; T5(0.310)*T4; and T8(0.310)*T7.

11. The method of claim 1, wherein at least one of the following apply: the first evaporable solvent includes at least one of the following: ethanol, butyl acetate, xylene, and Dipropylene glycol dimethyl ether; the applying of the first evaporable solvent includes: soaking the first evaporable solvent with a paper or a cloth; and wiping the soaked paper or cloth until the first polyurethane coating layer is in a state of loss of gloss; the first polyurethane coating layer includes amino polyurethane (polyurea) or hydroxy polyurethane; and the second polyurethane coating layer includes amino polyurethane (polyurea) or hydroxy polyurethane.

12. The method of claim 2, wherein at least one of the following apply: the second evaporable solvent includes at least one of the following: ethanol, butyl acetate, xylene, and Dipropylene glycol dimethyl ether; the applying of the second evaporable solvent includes: soaking the second evaporable solvent with a paper or a cloth; and wiping the soaked paper or cloth until the second polyurethane coating layer is in a state of loss of gloss; and the third polyurethane coating layer includes amino polyurethane (polyurea) or hydroxy polyurethane.

13. The method of claim 3, wherein at least one of the following apply: the third evaporable solvent includes at least one of the following: ethanol, butyl acetate, xylene, and Dipropylene glycol dimethyl ether; the applying of the third evaporable solvent includes: soaking the third evaporable solvent with a paper or a cloth; and wiping the soaked paper or cloth until the third polyurethane coating layer is in a state of loss of gloss; and the fourth polyurethane coating layer includes amino polyurethane (polyurea) or hydroxy polyurethane.

14. The method of claim 1, wherein the first evaporable solvent is Dipropylene glycol dimethyl ether.

15. The method of claim 2, wherein the second evaporable solvent is Dipropylene glycol dimethyl ether.

16. The method of claim 3, wherein the third evaporable solvent is Dipropylene glycol dimethyl ether.

17. The method of claim 1, wherein the first polyurethane coating layer has a thickness of 30-3000 microns.

18. The method of claim 1, wherein the second polyurethane coating layer has a thickness of 30-3000 microns.

19. The method of claim 2, wherein the third polyurethane coating layer has a thickness of 30-3000 microns.

20. The method of claim 1, further comprising forming one or more polyurethane coating layer on the substrate before forming the first polyurethane coating layer on the substrate.

21. A method for forming a protective coating on a substrate, the method comprising: providing a substrate; forming a first polyurethane coating layer on the substrate; applying a first evaporable solvent on the first polyurethane coating layer, wherein the first evaporable solvent is applied on the first polyurethane coating layer within a first time period (T21) after forming the first polyurethane coating layer; and forming a second polyurethane coating layer on the first polyurethane coating layer, wherein: the second polyurethane coating layer is formed on the first polyurethane coating layer within a second time period (T22) after applying the first evaporable solvent; the first evaporable solvent applied on the first polyurethane coating layer is partially evaporated before the second polyurethane coating layer is provided on the first polyurethane coating layer.

22. The method of claim 21, further comprising: applying a second evaporable solvent on the second polyurethane coating layer, wherein the second evaporable solvent is applied on the second polyurethane coating layer within a third time period (T23) after forming the second polyurethane coating layer; and forming a third polyurethane coating layer on the second polyurethane coating layer within a fourth time period (T24) after applying the second evaporable solvent, wherein the second evaporable solvent applied on the second polyurethane coating layer is partially evaporated before the third polyurethane coating layer is provided on the second polyurethane coating layer.

23. The method of claim 22, further comprising: applying a third evaporable solvent on the third polyurethane coating layer, wherein the third evaporable solvent is applied on the third polyurethane coating layer within a fifth time period (T25) after forming the third polyurethane coating layer; and forming a fourth polyurethane coating layer on the third polyurethane coating layer within a sixth time period (T26) after applying the third evaporable solvent, wherein the third evaporable solvent applied on the third polyurethane coating layer is partially evaporated before the fourth polyurethane coating layer is provided on the third polyurethane coating layer.

24. The method of claim 21, the first time period (T21) does not exceed 60 minutes; and the second time period (T22) is between 0-300 minutes.

25. The method of claim 22, the third time period (T23) does not exceed 60 minutes; and the fourth time period (T24) is between 0-300 minutes.

26. The method of claim 23, the fifth time period (T25) does not exceed 60 minutes; and the sixth time period (T26) is between 0-300 minutes.

27. A wind power generation system, the wind power generation system comprising: a blade, the blade configured to rotate around a central axis; a first polyurethane coating layer formed on the blade; and a second polyurethane coating layer formed on the first polyurethane coating layer, wherein: the second polyurethane coating layer is formed on the first polyurethane coating layer within a second time period (T32) after a first evaporable solvent is applied on the first polyurethane coating layer, wherein the first evaporable solvent is applied on the first polyurethane coating layer within a first time period (T31) after forming the first polyurethane coating layer; the first evaporable solvent applied on the first polyurethane coating layer is partially evaporated before the second polyurethane coating layer is provided on the first polyurethane coating layer.

28. The wind power generation system of claim 27, further comprising: a third polyurethane coating layer formed on the second polyurethane coating layer, the third polyurethane coating layer formed within a fourth time period (T34) after a second evaporable solvent is applied on the second polyurethane coating layer, wherein the second evaporable solvent is applied on the second polyurethane coating layer within a third time period (T33) after forming the second polyurethane coating layer, wherein the second evaporable solvent applied on the second polyurethane coating layer is partially evaporated before the third polyurethane coating layer is provided on the second polyurethane coating layer.

29. The wind power generation system of claim 28, further comprising: a fourth polyurethane coating layer formed on the third polyurethane coating layer, the fourth polyurethane coating layer formed within a sixth time period (T36) after a third evaporable solvent is applied on the third polyurethane coating layer, wherein the third evaporable solvent is applied on the third polyurethane coating layer within an fifth time period (T35) after forming the third polyurethane coating layer, wherein the third evaporable solvent applied on the third polyurethane coating layer is partially evaporated before the fourth polyurethane coating layer is provided on the third polyurethane coating layer.

30. The wind power generation system of claim 27, the first time period (T31) does not exceed 60 minutes; and the second time period (T32) is between 0-300 minutes.

31. The wind power generation system of claim 28, the third time period (T33) does not exceed 60 minutes; and the fourth time period (T34) is between 0-300 minutes.

32. The wind power generation system of claim 29, the fifth time period (T35) does not exceed 60 minutes; and the sixth time period (T36) is between 0-300 minutes.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0087] For a more complete understanding of the present disclosure, example embodiments, and their advantages, reference is now made to the following description taken in conjunction with the accompanying figures, in which like reference numbers indicate like features, and:

[0088] FIG. 1 illustrates an example embodiment of a method for producing multi-layer protective coating;

[0089] FIG. 2 illustrates the reaction mechanism of method 100;

[0090] FIG. 3 illustrates comparison adopting dipropylene glycol dimethyl ether as solvent with no solvent; and

[0091] FIG. 4 illustrates comparison of different solvents, i.e. ethanol, xylene, and butyl acetate, with no solvent.

[0092] Although similar reference numbers may be used to refer to similar elements in the figures for convenience, it can be appreciated that each of the various example embodiments may be considered to be distinct variations.

[0093] Example embodiments will now be described with reference to the accompanying figures, which form a part of the present disclosure and which illustrate example embodiments which may be practiced. As used in the present disclosure and the appended claims, the terms embodiment, example embodiment, exemplary embodiment, and present embodiment do not necessarily refer to a single embodiment, although they may, and various example embodiments may be readily combined and/or interchanged without departing from the scope or spirit of example embodiments. Furthermore, the terminology as used in the present disclosure and the appended claims is for the purpose of describing example embodiments only and is not intended to be limitations. In this respect, as used in the present disclosure and the appended claims, the term in may include in and on, and the terms a, an, and the may include singular and plural references. Furthermore, as used in the present disclosure and the appended claims, the term by may also mean from, depending on the context. Furthermore, as used in the present disclosure and the appended claims, the term if may also mean when or upon, depending on the context. Furthermore, as used in the present disclosure and appended claims, the words and/or may refer to and encompass any or all possible combinations of one or more of the associated listed items.

DETAILED DESCRIPTION

[0094] When producing protective multi-layer coating on a wind power blade using conventional methods, an adhesion strength between layers is often insufficient when the wind power blade is exposed in real natural environment for wind power generation. Single-layer coating often has insufficient thickness. Other conventional methods either requires alteration to the composition of coating materials or requires complex and high operation standards. Conventional protective coatings often have undesired inter-layer bonding and low stripping resistance, and thus require frequent maintenance, especially when exposed in natural environment.

[0095] Present example embodiments relate generally to and/or include systems, subsystems, devices, methods, and processes for addressing conventional problems, including those described above and in the present disclosure, and more specifically, example embodiments relate to systems, subsystems, devices, methods, and processes for manufacturing a wind power blade, and more specifically, improving stripping resistance between multi-layered protective coating of a wind power blade, including, but not limited to, improving stripping resistance under sand and/or rain erosion, improving interlayer adhesion and bonding, processing and/or treating surface, altering over-coating window of multi-layered product, protecting the surface of a wind power blade, protecting the leading edge of wind power blade, and/or improving multi-layer polyurethane protective coating.

[0096] As described in the present disclosure, example embodiments offer various technical advantages and/or improvements over conventional methods, including but not limited to, providing a simplified, time-effective and environment friendly manufacturing method without altering the preparation of the polyurethane coating material. Example embodiments of the present disclosure and achieve sufficient thickness and meet natural and critical operation environment.

[0097] It is to be understood that, while example embodiments are mostly described in the present disclosure as pertaining to polyurethane coating, the principles described in the present disclosure may also be applied outside of the context of polyurethane coating, such as polymeric coating comprising epoxy coating, acrylic coating etc., without departing from the teachings of the present disclosure.

[0098] It is to be understood that, while example embodiments are mostly described in the present disclosure as pertaining to improve stripping resistance and/or adhesion between layers, the present disclosure is not limited to the designated purpose.

[0099] It is also to be understood that, while example embodiments are mostly described in the present disclosure as pertaining to protective coating on a wind power blade, particularly the leading edge of a wind power blade, the principles described in the present disclosure may also be applied outside of the context of wind power blade, such as protective coating for airplanes, helicopters, fan blades, drone blades, hydroturbine, steam turbine etc., without departing from the teachings of the present disclosure. It is recognized that the present disclosure is universally applicable to general protective coating, and methods of manufacturing thereof.

[0100] It is also to be understood in the present disclosure that one or more elements and/or aspects of example embodiments may include and/or implement, in part or in whole, solely and/or in cooperation with other elements, using, for example, hybrid multi-layered products.

[0101] Unless otherwise defined, all technical terms used in the present disclosure have the same meaning as commonly understood by those skilled in the art. The terminology used herein is only for the purpose of describing specific example embodiments, and is not intended to limit the scope of protection. Unless otherwise specified, the various raw materials, reagents, instruments and equipment used in the present disclosure can be purchased from the market and/or can be prepared by existing methods.

[0102] The terms over-coating or re-coating is understood by those skilled in the art as applying an additional layer on a previously coated layer. The term over-coating window is understood by those skilled in the art as the suitable time window for over-coating or re-coating of the additional layer. The terms touch dry, shiatsu dry, finger dry, or surface dry is understood by those skilled in the art as a condition where the surface of a polymeric coating layer is dry to touch without sticking to fingers, and refers to the initial drying of the surface after a certain period of time after the coating layer is applied to a substrate during painting process but yet to completely dry.

[0103] Example embodiments will now be described below with reference to the accompanying figures, which form a part of the present disclosure.

Embodiment 1

[0104] FIG. 1 illustrates an example embodiment of a method according to the present disclosure. These and other elements of the system 100 will now be described with reference to the accompanying figures.

[0105] As illustrated in FIG. 1, the method 100 includes

[0106] Step one 101: providing a substrate;

[0107] Step two 102: forming a first polyurethane coating layer on the substrate, wherein the first polyurethane coating layer reaches touch dry in a first time period (T1);

[0108] Step three 103: applying a first evaporable solvent on the first polyurethane coating layer, wherein the first evaporable solvent is applied on the first polyurethane coating layer within a second time period (T2) after the first polyurethane coating layer reaches touch dry;

[0109] Step four 104: forming a second polyurethane coating layer on the first polyurethane coating layer within a third time period (T3) after applying the first evaporable solvent, wherein the first evaporable solvent applied on the first polyurethane coating layer is partially evaporated before forming the second polyurethane coating layer on the first polyurethane coating layer, wherein the second polyurethane coating layer reaches touch dry in a fourth time period (T4); and

[0110] Step five 105: obtaining the substrate with the multi-layer coating, wherein the multi-layer coating includes the first polyurethane coating layer and the second polyurethane coating layer.

Embodiment 2

[0111] FIG. 2 illustrates the reaction mechanism of method 100.

[0112] As illustrated in FIG. 2(a), after a first curing time, a first polyurethane coating layer has solidified into three layers. For the bottom layer (Sub-layer 1), it is still in liquid state and only a small amount of cross-linking reaction occurs; for the middle layer (Sub-layer 2), partial cross-linking reaction occurs; for the top layer (Sub-layer 3), most of the cross-linking reaction has been completed. Then the solvent is applied onto the first polyurethane coating layer. As illustrated in FIG. 2(b), the solvent will dissolve the sub-layer 3.

[0113] As illustrated in FIG. 2(c), the second polyurethane coating layer will be provided on the first polyurethane coating layer.

Embodiment 3

[0114] FIG. 3 illustrates comparison adopting dipropylene glycol dimethyl ether as solvent with no solvent

[0115] This invention applies amino-polyurethane (MEGA 3650 PF) to a substrate with a length of 22-23 cm and a width of around 5 cm. The thickness of the coating is around 300 micrometer. The coating reaches touch dry in a first time period (T1). Within a second time period (T2) after the first polyurethane coating layer reaches touch dry, soak the solvent, i.e. dipropylene glycol dimethyl ether, with a paper or a cloth; and wipe the soaked pater or cloth for a time period of 5-10 seconds till the first polyurethane coating layer is in a state of loos of gloss. Then provide a second polyurethane coating layer on the first polyurethane coating layer within a third time period (T3) of 10-20 min after applying the first evaporable solvent.

[0116] Then subject the multi-layer coating to a rain erosion test (ASTM G73-10, raindrop size of 1-2 mm, tip velocity of 207 m/s and rain intensity of 70-90 ml/h) for a time period T (rain).

[0117] The test condition are as below. Please refer to FIG. 3 for test results.

TABLE-US-00003 Examples T1 + T2 (min) T3 (min) T(rain) 3-1 30 10 0 3-2 30 10 60 3-3 30 10 120 3-4 40 10 0 3-5 40 10 60 3-6 40 10 120 3-7 40 10 180 3-8 40 15 0 3-9 40 15 60 3-10 40 15 120 3-11 40 15 180 3-12 40 20 0 3-13 40 20 60 3-14 40 20 120 3-15 40 20 180 3-16 60 10 0 3-17 60 10 60 3-18 60 10 120 3-19 60 10 180 3-20 60 20 0 3-21 60 20 60 3-22 60 20 120 3-23 60 20 180 3-24 (Comparative Example) 30 / (No solvent) 0 3-25(Comparative Example) 30 / (No solvent) 60 3-26(Comparative Example) 30 / (No solvent) 120 3-27(Comparative Example) 45 / (No solvent) 0 3-28(Comparative Example) 45 / (No solvent) 60 3-29(Comparative Example) 90 10 0 3-30(Comparative Example) 90 10 60

Embodiment 4

[0118] FIG. 4 illustrates comparison of different solvents, i.e. ethanol, xylene, and butyl acetate, with no solvent.

[0119] The test conditions are the same as FIG. 3, but with different solvents.

TABLE-US-00004 Examples T1 + T2 (min) T3 (min) T(rain) 4-1 45 10 0 4-2 45 10 60 4-3 45 10 120 4-4 45 10 180 4-5 40 10 0 4-6 40 10 10 4-7 40 10 30 4-8 40 10 60 4-9 40 10 120

Embodiment 5

[0120] The gloss is tested according to Standard GB/T 9754.

TABLE-US-00005 Dipropylene glycol Test No dimethyl Butyl Conditions solvent ether Ethanol Xylene acetate The first coating 88-91 / / / / is solidified for 40 min The first coating / 48-50 6-8 32-34 24-27 is solidified for 40 min; solvent applied and evaporated for 1 min The first coating / 48-50 6-8 32-34 24-27 is solidified for 45 min; solvent applied and evaporated for 5 min The first coating / 48-50 6-8 32-34 24-27 is solidified for 45 min; solvent applied and evaporated for 10 min The first coating / 48-50 6-8 32-34 24-27 is solidified for 45 min; solvent applied and evaporated for 20 min The first coating / 48-50 6-8 32-34 24-27 is solidified for 45 min; solvent applied and evaporated for 30 min The first coating 88-91 88-91 88-91 88-91 88-91 is solidified for over 12 h; solvent applied

[0121] Various terms used herein have special meanings within the present technical field. Whether a particular term should be construed as such a term of art depends on the context in which that term is used. Terms are to be construed in light of the context in which they are used in the present disclosure and as one of ordinary skill in the art would understand those terms in the disclosed context. Definitions provided herein are not exclusive of other meanings that might be imparted to those terms based on the disclosed context.

[0122] Words of comparison, measurement, and timing such as at the time, equivalent, during, complete, and the like should be understood to mean substantially at the time, substantially equivalent, substantially during, substantially complete, etc., where substantially means that such comparisons, measurements, and timings are practicable to accomplish the implicitly or expressly stated desired result.

[0123] Additionally, the section headings and topic headings herein are provided for consistency with the suggestions under various patent regulations and practice, or otherwise to provide organizational cues. These headings shall not limit or characterize the embodiments set out in any claims that may issue from this disclosure. Specifically, a description of a technology in the Background is not to be construed as an admission that technology is prior art to any embodiments in this disclosure. Furthermore, any reference in this disclosure to invention in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings herein.