Project: Multi Nano Modified Epoxy Gelcoats for Wind Mill Blades
The project will create moisture proof and dirt repellent composite surface coatings for wind mill blades based on a variety of innovative nano technologies. The platform for the development of these so called gel coats is a patented, Finnish method to disperse agglomerated carbon nano tubes (CNT) in liquid polymers with a covalent bond between the CNT`s and polymer molecules._x000D__x000D_There are today 53 wind mill producers world wide, of which 32 in China. The wind mill blade industry is at present growing at a rate of 40 % annually. Large companies in Denmark have up till now been the market leaders in modern wind mill technology. Today most companies also are producing windmill parts in low cost countries like in India and China._x000D__x000D_The modern wind mill production is based on new materials and innovative composite technology. This has, however, also caused several severe technical problems and failures of vital parts in the mills The surface coating on the wind mill blades is an area where large improvements will be possible, which will help solving a lot of the technical problems. The creation of high performance nano modified epoxy composite gelcoats i.e. thick, in mould surface coatings, will be made in co-operation with the Finnish P, Amroy Oy ._x000D__x000D_Limited nano technologies have been used in a smaller scale by the composite industry for some years. In 2004 Amroy Oy solved the difficult problem to disperse agglomerated, multi walled nano carbon tubes in liquid polymers by using a new technology, which they have patented. They are now producing CNT-modified epoxies in Finland and recently became a P, who is producing large volumes of modified epoxy under license from Amroy in China. _x000D__x000D_Amroy is commercially marketing their products worldwide and COly targeting the wind mill industry. Their total nameplate capacity including China, is 14000 T/yr. As Amroy is a pure raw material supplier, they will not use their limited R&D-capacity to develop finished products from their raw material and avoid competition with their coating customers. Their CO customer and P in the coating area is Re-Turn AS, who has more than 30 years of experience in formulating speciality epoxy coatings. Here a marine coating project was started 3 years ago. This project is already showing promising results and has lead Re-Turn into participation in a EU7-project under the acronym MUST. _x000D__x000D_The major part of wind blade industry is using modified unsaturated polyester (UP) gelcoats. Because of porosity caused by styrene emission from the UP, these composites in the blades tend to absorb water and pick up dirt causing fouling. The porosity also reduces the mechanical properties. The mono styrene in the UP based coatings also causes several environmental and practical problems. The styrene emission causes severe health and safety problems in the working environment. In Western Europe the use of UP-gelcoats therefore requires extensive investments in ventilation etc. _x000D__x000D_Several of the shortcomings of UP-based gelcoats can be overcome by formulating with solvent free epoxy resins, which also will give safer, lighter and longer lasting wind mill blades. None of the present 4 European producers of epoxy gelcoats seem so far to have obtained approvals for their products to the windmill industry. This normally will take from 1 – 5 years , dependent on country and the size of the wind mill. For the European market regulatory bodies like Germanische Lloyd etc. are used to certify new wind mill parts. _x000D__x000D_Based on research done by Re-Turn, SINTEF (Norw. national R&D institute) , Icetech (Icelandic Technological Institute ), Re-Turn will utilise new nano- and polymer technology in new, solvent free gelcoats. These systems will reduce surface friction, water absorption, fouling and dirt pick up. _x000D__x000D_This will be achieved by incorporating hydrophobic and hydrophilic nano particles together with CNT-reinforcement and different functionalized polymers. The mechanical properties, like dynamic strength, scratch resistance and UV-resistance will also be improved by modifying epoxy systems with nano modifications. _x000D__x000D_In addition to the P Amroy Oy and several of their wind mill producing customers, the project will involve assistance from key raw material suppliers like Bayer with their Baytubes (CNT) and leading European institutes specialized in nano technology._x000D_
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Acronym
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NMEG
(Reference Number: 4620)
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Duration
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01/04/2009 - 01/03/2012
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Project Topic
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Create innovative surface gelcoats for epoxy composite wind mill blades improving barrier, mechanical and dirt repellent properties and improve UV-resistance. The project is based on a patented CNT-dispering process and other novel nano technologies.
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Network
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Eurostars
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Call
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Eurostars Cut-Off 2
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Project partner
