Erosion Protection for Wind Turbine Blades

A polyurea-ceramic composite coating for wind turbine blade leading edges that provides improved resistance to rain erosion and weathering compared to conventional coatings. The coating is made by compounding polyaspartate polyurea and ceramics. The polyaspartate polyurea is made from polyetheramine, diisocyanate, and polyaspartate resin. The ceramics are made from silane coupling agent, silicone resin, and functional fillers. The ceramics are compounded separately and then mixed with the polyurea components to create the composite coating. This provides a coating with rain corrosion resistance, wear resistance, and weather resistance for the leading edges of wind turbine blades.

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A blade made of layered composite material is better resistant to delamination and detachment failures when exposed to fluid flows, especially fluctuating loads. The blade has skins with overlapping layers that extend from body portions between the skins towards the trailing edge. The internal layers have body portions and skin portions that form the skin. This integral layer arrangement prevents delamination by providing overlapping connections between the skins. The idea is that adjacent layers of the composite material overlap rather than join at the spar, skins, or leading/trailing edges. This keeps the layers connected along the blade instead of having detached sections.

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Wind turbine blade leading edge erosion protection that improves erosion resistance while minimizing impact on aerodynamics and optimizing material usage. The blade leading edge has a segmented erosion protection element that transitions from a high resistance material near the tip to a lower resistance material closer to the root. This allows targeted protection where erosion is highest while reducing weight and cost compared to uniform high resistance protection.

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Bustard metal leading edge cover for wind turbine rotor blades to protect them from erosion and corrosion. The cover is made of bustard metal, a high-density tungsten alloy, that reduces erosion from particles and liquids. It attaches to the blade surfaces using adhesive or mechanical bonds. The bustard metal section covers the blade tip. The cover shape matches the blade curvature. It can be formed using techniques like additive manufacturing, electroforming, or rolling. The bustard metal section provides erosion resistance while the rest of the cover can be a different material.

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Method for applying wind turbine blade leading edge erosion shields that provides improved durability and longevity compared to existing methods. The method involves activating and cleaning the shield's inner surface, applying wet adhesive to both surfaces, and curing the adhesive to bond the shield to the blade. This creates a durable bond between the shield and blade that prevents delamination. It involves activating the shield surface, cleaning it, applying wet adhesive to both surfaces, and curing the adhesive to bond the shield.

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Wind turbine blade erosion shield that can easily be installed on a blade to protect the leading edge from erosion. The shield attaches to the blade using fasteners through aligned holes in the shield and blade. The shield has multiple layers of erosion-resistant material bonded together. When the outermost layer gets eroded, it delaminates from the shield to present a smooth surface. This allows the shield to be removable for replacement if needed. The shield attaches to a recessed area on the blade. Sealant can be injected around the shield edges to prevent gaps.

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Leading edge anti-corrosion wind power blades with improved durability at the most vulnerable part of the blade where wear, pitting, and corrosion occur. The blades have core materials and surfaces sprayed with a special coating. The core materials are made of cubic boron nitride laminates that resist wear and pitting. The surfaces are coated with cemented carbide paint to prevent corrosion. This coating system provides superior protection against the harsh environmental conditions at the blade leading edge.

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Wind turbine blade design with improved erosion resistance. The blade has a leading edge protector with a softer main body layer covered by a harder coating layer. If the protector gets damaged, repair involves inserting a long, compressible material into the damaged area, deforming it to match the shape, and removing excess. This repairs the protector without requiring full replacement.

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Abrasion-resistant coating for the leading edge of wind power blades that provides long-term protection against wear from impact and abrasion. The coating consists of multiple layers with specific formulations to optimize properties like adhesion, impact resistance, wear resistance, corrosion resistance, and weather resistance. The bottom layer is an epoxy coating. The middle layer is a silicon carbide-reinforced polyurethane-modified epoxy coating. The top layer is a solvent-based polyurethane coating. The layered structure provides a tight internal bond, high adhesion, and good compatibility between layers. The coating can be directly applied to the blade substrate without a primer, improving adhesion compared to multi-layer coatings.

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A wind turbine blade with a durable erosion shield that can be easily and quickly repaired without removing the blade from the turbine. The blade has a composite shell body made of fibers and resin. Along the leading edge is an erosion shield with two layers. The first layer is a thermoplastic material that can be heat welded to the composite shell. The second layer is a tougher thermoplastic for erosion resistance. The shield layers can be welded in place, and then repaired by welding on new material if eroded. This avoids removing and replacing the entire shield.

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Profiled protective tape for wind turbine blades to improve erosion resistance without negatively impacting aerodynamics. The tape has a thicker center section and thinner lateral sections. The tape cross-section is outwardly curved or trapezoidal. The thicker center covers the leading edge. The lateral sections are directed towards the trailing edge. The tape is attached to the blade with an adhesive bond. The thicker center protects the leading edge better while the thinner lateral sections maintain aerodynamics.

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Method to retrofit older wind turbine blades with erosion-resistant coatings that protect against particle erosion. The method involves creating a copy of the blade's surface geometry using 3D printing or foam molding, coating the copy with a fiber-reinforced polymer to create a mold, and then applying the erosion-resistant coating to the original blade surface using the mold. The coating is built up in layers with fiber reinforcement closest to the blade surface for impact resistance. This avoids the need to access the blades at height for coating and provides accurate replication of the blade geometry.

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Coating system for protecting surfaces subject to erosion. The system has a flexible carrier layer sandwiched between two adhesive layers. The carrier allows the coating to be peeled off for repair without damaging the substrate. The first adhesive layer bonds to the substrate and the second adhesive layer bonds to the coating. The adhesive layers have lower cohesive strength than adhesive strength to allow delamination at the carrier. This enables damaged coatings to be removed by peeling off the carrier layer, exposing the adhesive layer for replacement.

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Wind turbine blade design to improve blade durability and prevent rusting during long-term use. The blade has a composite structure with an inner steel shell inside an outer aluminum shell. The inner steel shell has vent holes and moisture-absorbing silica gel to prevent moisture buildup. The composite structure protects the carbon fiber blade core from corrosion, and the vented inner shell allows moisture evacuation to prevent rusting even if the outer coating peels.

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Wind turbine blade with improved erosion resistance and aerodynamic performance. A metal strip is attached to the leading edge of the blade tip to suppress erosion. This strip covering the leading edge helps protect against rain and dust erosion.

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Preparing wind turbine blades with improved leading edge protection that provides better corrosion resistance compared to traditional methods. The leading edge protection is applied as a coating with a fiber layer sandwiched between two paint layers. This provides a single-layer leading edge protection with uniform thickness and reduced interfaces compared to stacked layers. The fiber layer impregnated with paint bonds the coating to the blade and eliminates delamination issues. The method involves applying the paint layers on the blade's leading edge, partially or fully impregnating a fiber layer, and curing the coating. This provides a stronger and more uniform leading edge protection compared to separate layers.

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Blade design with a composite leading edge shield to protect against impacts without weakening the blade. The shield is made of a stronger material than the composite blade body to resist impacts better. It attaches to the blade end and has a trough plate and back plate. The trough plate overlaps the back plate to prevent separation if the shield contacts the engine housing. This prevents blade damage and improves durability compared to traditional metal shields that can detach.

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Wind turbine blade with improved erosion resistance without damaging the base material. The blade has an intermediate layer between the base and erosion-resistant coating. The intermediate layer has a higher porosity than the erosion coating. This gradual reduction in porosity prevents damage to the base material during thermal spraying. The erosion-resistant coating is a dense thermal spray film with low porosity. The intermediate layer is made of materials like cermet or metal tapes. The lower-porosity coating on top protects against erosion without harming the base material.

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Wind blade with long service life designed to withstand harsh environments with high temperatures, corrosive chemicals, oil, and ozone. The blade has a multi-layer protective coating on the exterior. It starts with ceramic fibers, then carbon fibers, followed by urethane, corrosion-resistant epoxy, furan resin, and phenolic resin. This sequence provides high temperature resistance, corrosion protection, oil repellency, and UV stability for long blade durability in demanding environments.

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Wear-resistant and anti-adhesive turbine blade design that reduces erosion and particle buildup compared to conventional blades. The blade has a unique frame structure with reinforcing ribs between the frame and rotating shaft. The blades themselves have a specific configuration with connected upper and lower sections and reinforcement ribs between them. This design reduces erosion by dispersing particles and preventing adhesion.

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