WO2023088951A1 - Procédé de fabrication d'un élément structural à partir de pales d'éolienne usagées et élément structural constitué de pales d'éolienne usagées - Google Patents

Procédé de fabrication d'un élément structural à partir de pales d'éolienne usagées et élément structural constitué de pales d'éolienne usagées Download PDF

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Publication number
WO2023088951A1
WO2023088951A1 PCT/EP2022/082110 EP2022082110W WO2023088951A1 WO 2023088951 A1 WO2023088951 A1 WO 2023088951A1 EP 2022082110 W EP2022082110 W EP 2022082110W WO 2023088951 A1 WO2023088951 A1 WO 2023088951A1
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WIPO (PCT)
Prior art keywords
structural element
wind turbine
cut
used wind
turbine blades
Prior art date
Application number
PCT/EP2022/082110
Other languages
English (en)
Inventor
Pål Francis HANSEN
Stein Dietrichson
Original Assignee
Wingbeam As
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from SE2200045A external-priority patent/SE2200045A1/en
Application filed by Wingbeam As filed Critical Wingbeam As
Publication of WO2023088951A1 publication Critical patent/WO2023088951A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B2017/001—Pretreating the materials before recovery
    • B29B2017/0021—Dividing in large parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades

Definitions

  • the present disclosure relates generally to recycling of composites, specifically used wind turbine blades and sections thereof. More specifically, the present disclosure relates to a method for producing a structural element based on used wind turbine blades, such as railway sleepers or load-carrying beams, and to such structural elements.
  • downcycling In general, separating and recirculating raw materials directly to identical or similar applications is considered most appropriate in circular economy thinking. Use of materials in new applications is considered “downcycling”.
  • the present disclosure is an example that downcycling can be highly appropriate, better for the environment and cheaper for all stakeholders such as wind turbine blades suppliers, recycling companies, customers for long-lived articles of use such as railway sleepers or construction elements, and society.
  • a railway sleeper is but one example of a useful application of used composites from the wind industry.
  • beams and load-carrying components are required, typically in the form of steel, wood.
  • the invention allows to replace steel and wood, and as composites can be cut-out to meet specific requirements, the invention meets an existing market demand.
  • Typical composite materials are:
  • Sandwich core materials for increased stiffness and weight reduction (PVC, BALSA, PET).
  • the objective of the present disclosure is to provide novel structural elements, especially but not limited to railway sleepers, based on used wind turbine blade parts and binding agents, with excellent or very acceptable properties regarding strength, processability, ability to manufacture cheaply, and other properties, all allowing to use waste such as used wind turbine blades in a better and more sustainable manner.
  • a method for producing a structural element based on used wind turbine blades comprising the steps: cutting at least one composite section from a used wind turbine blade; placing the at least one cut composite section in a mould which defines the dimensions of the structural element; adding a binding agent to the mould; and allowing the binding agent to solidify to obtain the structural element, wherein at least one dimension of the cut composite section substantially corresponds to at least one dimension of the structural element.
  • the present disclosure enables maintaining the material properties of the composite section and impart these material properties to the final structural element.
  • material properties imparted to the structural element include fibre content, fibre orientation/direction, fibre type, lay-up type, durability, elasticity, flexibility, hardness, stiffness, toughness, etc.
  • An additional advantage is that the method requires significantly less energy compared to the known recycling methods in which the used material is milled to powder or small elements and used as reinforcement or filler in production of new raw materials. This leads to lower production costs as well as reducing environmental impact.
  • the at least one composite section is cut from the spar component of the used wind turbine blade.
  • the composite section is the load bearing component of the wind turbine blade.
  • the length of the at least one cut composite section substantially corresponds to the length of the structural element.
  • the material properties of the composite section are imparted to substantially the whole length of the structural element.
  • the term substantially corresponding should be interpreted as meaning within a tolerance range of 10 %.
  • the additional material used for the structural element encapsulates the cut composite section, especially the ends thereof.
  • the mould is made of shredded and/or ground composite material from used wind turbine blades and at least one thermoplastic polymer. In this way, more composite material from the used wind turbine blade may be recycled and incorporated in the structural element, leading to a further reduction in cost and environmental impact
  • the mould comprises an open or closed vessel or a prefabricated matrix.
  • the method enables using different methods of casting and forming the structural element.
  • the method further comprises shredding and/or grinding composite material from used wind turbine blades; and mixing up to 50% by weight of the shredded/ground composite material and at least one thermoplastic polymer in a compounding device to form the binding agent.
  • the cost of the binding agent may be reduced by recycling composite materials from the used wind turbine blade.
  • the method further comprises shredding and/or grinding composite material from used wind turbine blades; mixing the shredded/ground composite material and at least one thermoplastic polymer in a compounding device; extruding a longitudinal bar of the mixture from the compounding device; and adding at least one extruded block to the mould.
  • the at least one extruded block has a length which substantially corresponds to the length of the structural element.
  • the method further comprises prestressing the at least one cut composite section and/or the at least one extruded block prior to adding the binding agent. In this way, it is possible to produce structural elements with predetermined shapes and/or load/stress adapted to the intended use thereof.
  • thermoplastic polymer is selected from one or more of polyethylene, polypropylene, polyolefin, polyesters, polyurethanes, elastomers such as SBS, SEBS, PVB, either as recycled material or virgin polymer or a mixture thereof.
  • a structural element made from used wind turbine blades comprising: at least one composite section cut from a used wind turbine blade; and a solidified binding agent bonding the at least one cut composite section, wherein at least one dimension of the cut composite section substantially corresponds to at least one dimension of the structural element.
  • the at least one composite section is cut from the spar component of the used wind turbine blade.
  • the length of the at least one cut composite section substantially corresponds to the length of the structural element.
  • the structural element further comprises at least one extruded longitudinal block made of shredded and/or ground composite material from used wind turbine blades and at least one thermoplastic polymer.
  • the structural element further comprises a prefabricated matrix defining a plurality of longitudinal recesses, each recess being arranged to receive a cut composite section to form the structural element.
  • each recess comprises one or more raised ridges extending the length of the recess on an interior surface thereof.
  • the ridges act as spacer elements ensuring optimal positioning of the cut composite section in the recess to facilitate an even distribution of the binding agent in the gap between the cut composite section and the interior surface of the recess.
  • the prefabricated matrix is made of shredded and/or ground composite material from used wind turbine blades and at least one thermoplastic polymer.
  • the structural element is a railway sleeper, a beam or a pillar.
  • Other possible structural elements encompassed by the present disclosure include rods, posts, struts and ties.
  • Fig. 1 shows a perspective view of an exemplary wind turbine blade.
  • Fig. 2 shows a cross-sectional view of an exemplary wind turbine blade.
  • Fig. 3 is a schematic view of a structural element according to one embodiment of the present disclosure, in the form of a railway sleeper.
  • Figs. 4-7 show exemplary cross-sectional views of the railway sleeper in Fig. 3.
  • Figs. 8a and 8b show perspective views of an exemplary cut composite section from a used wind turbine blade and an extruded block comprising shredded/ground composite material from a used wind turbine blade, respectively.
  • Fig. 9 is a schematic drawing of the production process for structural elements according to one embodiment of the present disclosure.
  • Figs. 10a and 10b show an exemplary structural element according to one embodiment of the present disclosure in the form of an I-beam in an exploded and an assembled view, respectively.
  • Figs. I la and 1 lb shows an exemplary structural element according to one embodiment of the present disclosure in the form of a pillar in an exploded and an assembled view, respectively.
  • Fig. 12 shows a close-up view of a detail of the structural element in Figs. 10a and 10b.
  • Composites shall be understood as materials comprising inorganic and organic materials including glass fibre or carbon fibre and wood, and binding agent materials, including thermosets such as epoxy or polyurethane or thermoplastics, see below.
  • thermosets such as epoxy or polyurethane or thermoplastics
  • wind turbine blades or sections thereof are composites according to the invention, and sections cut-to-size for use in the present disclosure may comprise carbon or glass fibres, wooden support or beam structures, epoxy or polyurethane coatings and binding agents and hard foam sections.
  • Thermoplastics shall be considered as the group of polymers which melt at a temperature in the range 60 - 200 °C, specifically comprising polyolefins, including polyethylene (PE), polypropylene (PP), polyesters including polyethylene terephthalate (PET) and polylactic acid (PLA), polystyrene, polyvinylchloride (PVC), thermoplastic elastomers such as SBS, SIS, SEBS and other plastics and mixtures or compounds of said plastic types, also collectively called “polymer” or “thermoplastics” below, which can be processed in compounding devices such as twin-screw compounding machines or in extruders.
  • polyolefins including polyethylene (PE), polypropylene (PP), polyesters including polyethylene terephthalate (PET) and polylactic acid (PLA), polystyrene, polyvinylchloride (PVC), thermoplastic elastomers such as SBS, SIS, SEBS and other plastics and mixtures
  • Compounding device(s) shall denote any intensive mixer, such as kneaders, batch mixers, continuous mixers, extruders capable of mixing materials, such as planetary extruders and twin-screw compounders which are able to mix polymer blends under pressure. Venting and removal of gases such as water vapour in a controlled manner, e.g. by pressure relief valves or extruder sections which allow controlled gas removal, are advantageous in the present disclosure as some raw materials for the articles-of-use described later may be humid.
  • intensive mixer such as kneaders, batch mixers, continuous mixers, extruders capable of mixing materials, such as planetary extruders and twin-screw compounders which are able to mix polymer blends under pressure. Venting and removal of gases such as water vapour in a controlled manner, e.g. by pressure relief valves or extruder sections which allow controlled gas removal, are advantageous in the present disclosure as some raw materials for the articles-of-use described later may be humid.
  • Figs. 1 and 2 there is shown perspective and cross-sectional views, respectively, of a wind turbine blade 1.
  • the wind turbine blade 1 has an airfoil shape with a leading edge 3 and a trailing edge 4.
  • the main load bearing structure of the wind turbine blade 1 is the spar component 2, which is either integrated in the shell as a spar cap 5 or a separate spar structure comprising shear webs 6.
  • the spar component 2 is usually made of thick glass fibre-reinforced materials (GFRM) or carbon fibre-reinforced materials (CFRM) with a high modulus of elasticity for structural solidity.
  • GFRM thick glass fibre-reinforced materials
  • CFRM carbon fibre-reinforced materials
  • the spar component 2 is a composite laminate built up in a plurality of layers with a thickness of several centimetres.
  • the composite laminate material is typically GFRM and/or CFRM comprising fibres oriented parallel to the longitudinal extension L of the wind turbine blade 1 (known as the 0 direction), in a direction ⁇ 45° to the longitudinal extension L (double bias), and/or in a direction perpendicular to the longitudinal extension L.
  • the 0 direction longitudinal extension L of the wind turbine blade 1
  • double bias longitudinal extension L
  • at least 70 % of the fibres are oriented in the 0 direction.
  • Fig. 1 illustrates which areas (spar component 2) of the wind turbine blade 1 are suitable for cutting into composite sections 11 of desired geometry to be used in structural elements, and which areas are (leading edge 3 and trailing edge 4 constituting the remaining shell components) suitable for shredding/grinding to powder or fibres and mixing with additional materials (e.g. thermoplastics) to form the matrix material and/or binding agent 12 of the structural element 10, or act as a filler/reinforcement.
  • additional materials e.g. thermoplastics
  • the wind turbine blade 1 is cut in the transverse direction in suitable lengths as indicated by the hatched lines. It has been found that cut composite sections from a used wind turbine blade 1 made of GFRM shows an elastic modulus of higher than 60 GPa in the 0 direction, and up to 300 GPa in used wind turbine blade 1 made of CFRM.
  • the composite section 11 cut from a used wind turbine blade has at least one dimension substantially corresponding to at least one dimension of the structural element.
  • the length of the cut composite section 11 substantially corresponds to the length of the structural element 10.
  • the term ‘substantially correspond’ should be interpreted as representing a tolerance range, e.g. about 10%, of the dimension in question. This enables maintaining the material properties of the composite section 11 and imparting these material properties to the final structural element 10. Examples of material properties imparted to the structural element include fibre content, fibre orientation/direction, fibre type, lay-up type, durability, elasticity, flexibility, hardness, stiffness, toughness, etc.
  • a structural element 10 with substantially the same or corresponding material properties as the used wind turbine blade 1 may be obtained.
  • a structural element 10 made of cut composite sections 11 from a used wind turbine blade 1 and other materials.
  • the structural element 10 may be a railway sleeper having typical dimensions of about 3 m in length, about 16 cm in height and about 25 cm in width.
  • Other types and dimensions of structural elements are also foreseen by the present disclosure, such as beams and pillars for building construction.
  • FIG. 4-7 a number of exemplary cross-sectional views of the structural element 10 in Fig. 3 according to different embodiments of the present disclosure are shown.
  • Each of the embodiments comprise the same or similar components, wherein the number and/or placement within the structural element 10 can be varied.
  • 11 indicates a composite section of multi-axial glass and/or carbon fibre reinforced thermoset or thermoplastic laminate from a used wind turbine blade 1, precisely cut to desired geometry and surface treated for best bonding in the beam matrix system. Fibre content is minimum 40% by weight of the laminate.
  • a surface liner may be applied to the cut composite section 11 which introduces optimal bonding between laminate surface and a beam matrix system.
  • 13 indicates an extruded block or bar made from minimum 50% shredded/ground composite laminates from used wind turbine blade 1 or other components with minimum 40% glass fibre content by weight, and mixed with maximum 50% thermoplastic (recycled and/or virgin materials) and other additives for improved flow and bonding so that a solid block consolidation is achieved.
  • a surface liner with high content of thermoplastic may be used for optimal bonding to a beam matrix system.
  • 12 indicates a binding agent, e.g. a thermoplastic or thermoset or other possible beam matrix systems which by injection moulding processing makes the components of the structural element 10 completely fixed and bonded together, and as well giving the structural element 10 precise geometry and approved environmental resistance requirements.
  • FIG. 4 there is shown a cross-sectional view of an exemplary structural element 10.
  • the cross-section is a sandwich system comprising two horizontally oriented, cut composite sections 11 sandwiching a single horizontally oriented block 13 comprising shredded/ground composite material from a used wind turbine blade 1, taken from the leading edge 3 and/or trailing edge 4.
  • FIG. 5 there is shown a cross-sectional view of another exemplary structural element 10.
  • the single block 13 comprising shredded/ground composite material from Fig. 4 has been replaced by alternating cut composite sections 11 and blocks 13 comprising shredded composite material which are arranged with their long sides in a vertical orientation, substantially perpendicular to the long sides of the two horizontally oriented cut composite sections 11.
  • FIG. 6 there is shown a cross-sectional view of another exemplary structural element 10.
  • the cross-section is a sandwich system comprising six horizontally oriented, cut composite sections 11 sandwiching a single block 13 comprising shredded/ground composite material with three cut composite sections 11 arranged on top of each other on either side.
  • FIG. 7 there is shown a cross-sectional view of another exemplary structural element 10.
  • the cross-section is a sandwich system comprising eight horizontally oriented, cut composite sections 11 sandwiching a single block 13 comprising shredded/ground composite material with four cut composite sections 11 arranged side by side on either side.
  • FIGs. 8a and 8b there is shown perspective views of an exemplary strong laminate composite section 11 cut from a used wind turbine blade 1 and an extruded block 13 comprising shredded/ground composite material from a used wind turbine blade 1, respectively.
  • the geometry and profile of the composite section 11 and extruded block 13 may vary according to the desired configuration and shape, as well as the intended use, of the finished structural element 10.
  • the block 13 may be a reinforced thermoplastic profile with a minimum of 25 % by weight of short fibres.
  • step SI 00 at least one composite section 11 is cut from a used wind turbine blade 1, preferably from the spar component 2 as shown in Figs. 1 and 2.
  • step SI 02 the cut composite section 11 is placed into a mould.
  • a binding agent 12 is added to the mould.
  • the binding agent 12 may comprise a mixture of thermoplastics, preferably containing other solids, to form a suitable beam matrix system 12 as explained above.
  • step S106 the binding agent 12 is allowed to solidify, e.g. by cooling the mould.
  • Injection of materials, such as the binding agent 12, into the mould may proceed at atmospheric or elevated pressure, and may be batch-wise or (semi-)continuous.
  • Fig. 9 is just one potential embodiment in accordance with the present disclosure.
  • Various modifications of injection moulding, inlet moulding, 2- component moulding and even semi-continuous or continuous processes similar to pultrusion are conceivable and encompassed by the present disclosure.
  • the method according to the present disclosure may further comprise a step SI 03 in which raw materials such as shredded/ground composite material 7 from the used wind turbine blade 1 and a thermoplastic polymer 8 are fed into a compounding device (e.g. an extruder or mixing device) which may receive further feedstocks 9, such as granulated solid waste, through a side feeder.
  • a compounding device e.g. an extruder or mixing device
  • the shredded/ground composite material 7 and the thermoplastic polymer 8 are mixed to form the binding agent 12, which is subsequently added to the mould in step SI 04.
  • the binding agent 12 thus formed may contain up to 50% by weight of the shredded/ground composite material 7.
  • Figs. 10a and 10b there is shown an example of an I-beam 20 made of cut composite sections 11 which are placed into a prefabricated matrix 14 which acts as a mould.
  • the matrix 14 comprises a plurality of recesses or cavities 15 arranged to receive the cut composite sections 11.
  • the matrix 14 may be obtained by mixing shredded/ground composite material 7 from the used wind turbine blade 1 and a thermoplastic polymer 8 in suitable amounts, and extruding a longitudinal profile. Subsequently, the cut composite sections 11 may be bonded to the matrix 14 by a injecting a binding agent and connected using further composite parts 16 to form the I- beam 20 as shown in Fig. 10b.
  • a pillar 30 made of cut composite sections 11 which are placed into a prefabricated matrix 14 which acts as a mould.
  • the matrix 14 comprises a plurality of recesses or cavities 15 arranged to receive the cut composite sections 11.
  • the matrix 14 may consist of fibre- reinforced thermoplastic polymer (ideally recycled) and obtained in a similar manner to the matrix described in connection with Figs. 10a and 10b above.
  • the cut composite sections 11 may be bonded to the matrix 14 by a binding agent (e.g. glue) to form the pillar 30 as shown in Fig. 1 lb.
  • the composite parts, and the final pillar 30 may be covered by an extra protective layer 17, such as a film or as extruded polymer.
  • Fig. 12 there is shown a close-up view of a recess 15 in the prefabricated matrix 14 of Figs. lOa-b and 1 la-b in cross-section.
  • One or more raised ridges 18 are provided on the interior surface of the recess 15 and extend along the length of the matrix 14.
  • the ridges 18 act as spacer elements to ensure that the cut composite section 11 is positioned at a distance from the interior surface of the recess 15, thus forming a gap therebetween. This gap facilitates injection and even distribution of the binding agent 12 between the cut composite section 11 and the interior surface of the recess 15.
  • Example 1 relates to a railway sleeper consisting of 40% by weight of a cut composite section 11 from a used wind turbine blade 1, the remainder being thermoplastic polymer comprising 40% by weight solid waste, mainly consisting of granulate and fibres from shredded/ground wind turbine blades 1.
  • the cut composite section 11 is selected from certain areas, i.e. the spar component 2 of the wind turbine blade 1 as explained above, see Figs. 1 and 2.
  • flat geometries are preferred for standardized processes and certification. If several sections are used, these may be glued together, e.g. using a polyurethane based glue which exhibits good adhesion to composite materials. The gluing may be performed in an open mould at atmospheric pressure.
  • Example 2 relates to construction of buildings, such as commercial greenhouses. Load-carrying pillars, 4-10 m in height, and horizontal beams e.g. to carry the roof, 5-22 m in length, are made by combining cut composite sections 11 from used wind turbine blades 1 and matrices 14 e.g. made by extrusion. Figs. lOa-b and l la-b show possible configurations.
  • thermoplastics are mixed with solid powders and fibres prepared from wind turbine blades 1 in a kneading or mixing device such as an extruder, in particular a planetary roll extruder, and injected into a mould already containing at least one composite element, i.e. a cut-out turbine blade section or a plurality of such sections.
  • a kneading or mixing device such as an extruder, in particular a planetary roll extruder
  • thermoplastic binding agent one or more of polyethylene, polypropylene, polyolefins, polyester is used as thermoplastic binding agent.
  • elastic materials such as styrene-butadiene block copolymers or polyvinyl butyrate (PVB) is added, among others to improve binding of solid materials.
  • structural elements of thermoplastic binding agent mixed with solid powders or fibres are prepared independently and used in the same manner as cut-out sections from turbine blades.
  • the plurality of cut-out sections and binding agent/ solid beams or sections are glued together prior to filling the mould with additional binding agent material.
  • glues and adhesives based on polyurethane, epoxy or acryl, i.e. thermosetting or permanently cross-linking adhesives are used as binding agent materials.
  • composite sections 11 When composite sections 11 are filled in a prefabricated matrix 14 (see below), they may not fill the whole cavity, and it may be difficult to cut composite sections 11 which exactly fit a cavity such as shown in figures, see e.g. Figs. lOa-b and 1 la-b. An expanding adhesive will fill out the whole cavity and provide excellent adhesion between matrix 14 and the cut composite sections 11.
  • bio-based fibres such as wood fibres or olive residues are used as fillers.
  • minerals are used as additional fillers.
  • flame-retarding materials are used as additional fillers.
  • the mould is formed such that sensors, mechanical fastening elements, cable ducts and the like can easily be connected to the final products, e.g. by leaving holes or cavities in the otherwise bar-like geometry.
  • the finished structural element 10 is encapsulated in a protective outer layer 17 which may be thermoplastic or a thermoset.
  • hollow sections are left in the final product for easier cooling of the final product, or as functional cavity, e.g. serving as cable duct.
  • the structural element 10 is further subjected to a finishing step selected from one or more of mechanical treatment, fastening of further elements such as eyelets, hooks, brackets and/or drilling holes.
  • the structural element 10 may be adapted to the intended use.
  • the at least one cut composite section 11, and the at least one extruded block 13 is prestressed prior to adding the binding agent 12. In this way, it is possible to produce structural elements 10 with predetermined shapes and/or load/stress adapted to the intended use thereof. Similar to glued laminated timber (glulam), prestressing the cut composite section 11 may be used to obtain bent or arched structural elements 10 as desired.
  • a matrix 14 is produced, e.g. based on fibres and other residues from the inner parts of wind turbine blades 1 and e.g. a thermoplastic binding agent.
  • prefabricated matrices 14 in many geometries can be provided. Recesses or cavities 15 in this prefabricated matrix 14 can be filled with cut composite sections 11 from the used wind turbine blade 1 such as rods, plates or other geometries. These sections can be glued to the matrix 14 using adhesives such as described above. Different sections can be glued together, using even more wind turbine sections. Beams and pillars can be produced in this manner.
  • thermosetting adhesives which expand slightly upon hardening are useful, as the recesses or cavities 15 will be completely filled, resulting in strength of the finished article.
  • the prefabricated matrix 14 may contain a thermoplastic binding agent such as low density polyethylene (LDPE) and elastic materials such as ethylene-vinyl acetate (EVA) which accommodate deformation of the finished article in use.
  • LDPE low density polyethylene
  • EVA ethylene-vinyl acetate
  • the density of a sleeper will be the weighted average of the components, it will thus be in the range of 0,8-1, 2 g/cm 3 , to be compared with 1,4 for wood/creosote and >2 for concrete, at comparable strength and reduced brittleness (versus concrete).
  • the finished article such as shown in fig 9 and 10 is used as load-carrying beam for construction of private or commercial buildings.
  • Load-carrying beams need to be able to carry heavy loads, and the downward deflection of a beam must typically be lower than 0,5% of its length, i.e. a beam of 10 m length may not deform downwards more than 50 mm. This is achievable using wind power sections according to the present disclosure.
  • beams designed according to one of the attached figures can be used as vertical pillars or as horizontally (plus or minus inclination for roof construction, e.g. 4 to 30%) placed beams.
  • the same connection devices for connecting beams and pillars as known in the prior art may be used.
  • the structural elements according to the invention can be used for construction purposes in wet environments where there would be a risk for corrosion of metal or degradation of wood.
  • the walls of swimming pools, district or solar heating tanks or fish pools can be constructed using structural elements of the present disclosure, together with suitable fastening elements, insulation materials, liners to prevent water leakage etc.
  • the structural elements of the present disclosure can replace significant amounts of concrete.
  • wood-plastic-composites are improved in the following manner: WPC are used as flooring material e.g. for terraces. Often, WPC flooring material is provided as long extrudates, and they can be produced with cavities. Composite sections 11 from used wind turbines can be inserted into these cavities, and the remaining volume can be filled with binding agent such as polyurethane or hot-melting glues based e.g. on thermoplastic elastomers. The resulting flooring slabs are significantly more stable than the ones with cavities. This technique is cheaper, easier and CO2 saving compared to the alternative where shredded wind turbine blade 1 powder is used to fill the cavities or the WPC as such.
  • binding agent such as polyurethane or hot-melting glues
  • % weight cut-out sections in sleeper range 10 -50%, possibly more;
  • % weight solid powder/fibre in sleeper 10 - 60%
  • % weight thermoplastic polymer in sleeper 10- 50%

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Abstract

L'invention concerne un procédé de production d'un élément structural (10) à partir de pales d'éolienne usagées (1), le procédé comprenant les étapes consistant à : découper (S100) au moins une section composite (11) à partir d'une pale d'éolienne usagée (1) ; mettre en place (S102) ladite au moins une section composite découpée (11) dans un moule qui définit les dimensions de l'élément structural (10) ; ajouter (S104) un agent de liaison (12) dans le moule ; et laisser (S106) l'agent de liaison (12) se solidifier pour obtenir l'élément structural (10). Au moins une dimension de la section composite découpée (11) correspond sensiblement à au moins une dimension de l'élément structural (10). L'invention concerne également un élément structural (10).
PCT/EP2022/082110 2021-11-16 2022-11-16 Procédé de fabrication d'un élément structural à partir de pales d'éolienne usagées et élément structural constitué de pales d'éolienne usagées WO2023088951A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
SE2100173 2021-11-16
SE2100173-0 2021-11-16
SE2200045A SE2200045A1 (en) 2021-11-16 2022-05-03 A composition for a sleeper and methods to produce sleepers based on used wind turbine blades
SE2200045-9 2022-05-03

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WO2023088951A1 true WO2023088951A1 (fr) 2023-05-25

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Citations (2)

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