Recycled fan blade fiber reinforced concrete decorative article and method of making

Abstract

The application discloses a kind of recycled fan blade fiber reinforced concrete decorative articles and preparation method, belong to concrete composite material technical field, decorative article includes decorative layer, structural layer and anchoring piece, decorative layer and structural layer are successively poured in mould, anchoring piece is pre-embedded in structural layer;Preparation method is: design-preparation and mould-preparation mortar-pouring-demoulding and maintenance-finishing;Decorative layer and the production material of structural layer all include cement, mineral admixture, sand, recycled fan blade fiber, recycled fan blade fiber in decorative layer is combined crack self-repairing agent can improve the crack resistance and durability of decorative article, recycling fan blade promotes resource recycling;The elastic property of dispersible latex in structural layer can increase the toughness and ductility of decorative article, so that it has better mechanical properties and durability.The decorative article of the application is added with recycled fan blade fiber, has excellent durability and environmental protection performance, and is suitable for popularization and application.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of concrete composite materials, and particularly relates to a recycled wind turbine blade fiber reinforced concrete decorative product and a preparation method thereof. BACKGROUND

[0002] GRC is a kind of fiber reinforced concrete composite material, which uses alkali-resistant glass fiber as reinforcing material and cement mortar as matrix material. Because GRC can be made into components of various shapes and sizes, and can easily realize details and complex surface textures in the production process, it has become the ideal choice for designers and architects. However, the manufacturing cost of GRC decorative products has been relatively high, mainly because a large amount of expensive alkali-resistant glass fiber is used. Therefore, it is necessary to find a low-cost fiber material to replace alkali-resistant glass fiber.

[0003] With the rapid development of wind power generation, the number of discarded wind turbine blades increases year by year, which has attracted great attention from many countries on environmental and social impact. Since the design service life of wind turbine blades is 20-25 years, it means that about 500,000 tons of blade waste will be generated globally by 2034. Discarded wind turbine blades are large in size and non-biodegradable, and wind turbine blades are made of composite materials such as epoxy resin and glass fiber or carbon fiber. Because the polymers used in the composite materials are produced in an irreversible process to obtain the required material durability and strength while maintaining a relatively low weight, researchers have conducted a lot of research on their recycling technology. Among them, the most commonly used technology for recycling blades is mechanical grinding, which is a direct, economically viable physical recycling scheme for wind turbine blades, unlike pyrolysis recycling and chemical recycling technology. Physical recycling technology provides a fast and efficient method to reduce the size of waste and recycle low aspect ratio fibers. However, the fibers recovered by mechanical grinding are severely damaged and cannot obtain long fibers, resulting in low value of recycling and poor reutilization. SUMMARY

[0004] The purpose of the present application is to provide a recycled wind turbine blade fiber reinforced concrete decorative product and a preparation method thereof, aiming to solve the technical problems of high cost of fiber reinforced concrete composite material and low recycling rate of wind turbine blade fibers in the prior art.

[0005] To solve the above technical problems, the technical solution adopted by the present application is:

[0006] A recycled wind turbine blade fiber reinforced concrete decorative product, the decorative product comprising a decorative layer, a structural layer and an anchor, the decorative layer and the structural layer being successively cast in a mold, and the anchor being pre-embedded in the structural layer;

[0007] The manufacturing material of the decorative layer comprises the following components by weight:

[0008] Cement 35-50 parts;

[0009] Mineral admixture 15-20 parts;

[0010] Sand 45-65 parts;

[0011] Stone chips 25-35 parts;

[0012] Calcium acetate monohydrate powder 3.5-5.0 parts;

[0013] Recycled wind turbine blade fiber 2.5-4.5 parts;

[0014] Microbial-induced calcium-based crack self-healing agent 0.25-0.5 parts;

[0015] Water reducing agent 0.1-0.3 parts;

[0016] Water 14-20 parts;

[0017] The manufacturing material of the structural layer comprises the following components by weight:

[0018] Cement 45-50 parts;

[0019] Mineral admixture 15-20 parts;

[0020] Sand 35-55 parts;

[0021] Alkali-resistant glass fiber 2.5-4.5 parts;

[0022] Recycled wind turbine blade fiber 2.5-4.5 parts;

[0023] Dispersible latex 3.5-5 parts;

[0024] Polymer reinforcing agent 0.03-0.06 parts;

[0025] Water reducing agent 0.1-0.3 parts;

[0026] Water 14-20 parts;

[0027] Laminating glass fiber reinforced material in the structural layer, laying a layer every 3-5 mm.

[0028] Preferably, the regenerated fan blade fibers in the decorative layer are mineralized Type I regenerated fan blade fibers, and the regenerated fan blade fibers in the structural layer are mineralized Type II regenerated fan blade fibers; the fan blade fibers are obtained by cutting-crushing-continuous screening, and the length range of Type I regenerated fan blade fibers is 1.18mm~4.75mm, of which particles with a diameter of less than 0.6mm account for no more than 20%, and the length range of Type II regenerated fan blade fibers is 4.75mm~32.5mm, of which particles with a diameter of less than 0.6mm account for no more than 5%.

[0029] Preferably, the cement is one of fast-hardening sulphoaluminate cement or P.O42.5 ordinary Portland cement, with a specific surface area of ​​250 to 450 m 2 / kg, density is between 3.0~3.2g / cm 3 between.

[0030] Preferably, the mineral admixture is composed of one or more of slag, fly ash and silica fume, and the specific surface area of ​​slag is 200 to 600 m 2 / kg, density is between 2.8~3.2g / cm 3 The specific surface area of ​​fly ash is between 300 and 600 m 2 / kg, density is 2.0~2.5g / cm 3 The SiO2 content is between 40% and 70%; the specific surface area of ​​silica fume is between 15,000 and 30,000 m 2 / kg, density is between 2.2~2.4g / cm 3 The SiO2 content is between 85% and 98%.

[0031] Preferably, the sand is quartz sand with a relative density of 2.65 and an average particle size between 40 mesh and 80 mesh; the specific surface area of ​​the stone chips is in the range of 100 to 800 m 2 / kg.

[0032] Preferably, the alkali-resistant glass fiber has a fiber diameter of 9 to 15 μm, a length of 12 to 25 mm, and a density of 2.4 to 2.7 g / cm 3 The tensile strength is between 2000 and 4000 MPa, and the elastic modulus is between 70 and 80 GPa.

[0033] Preferably, the microbial-induced calcium-based crack self-repairing agent is a mixed solution of 10% volume fraction of Bacillus pasteurianus mother liquor, 5g / L soy peptone, 3g / L beef extract, 20g / L urea and 1.0L deionized water.

[0034] Preferably, the dispersible latex is one of acrylic latex, polyurethane latex or ethylene vinyl acetate copolymer latex, with a solid content of 40% to 60%; a pH value of 6 to 9; and a density of 1.0 to 1.2 g / cm 3 between.

[0035] Preferably, the water reducer is a polycarboxylate water reducer, such as polycarboxylate (PCA) or polycarboxylate ether (PCE), with a solid content of 30 to 50% and a water reduction rate of 30 to 40%.

[0036] Preferably, the polymer enhancer is a silane coupling agent-sodium hexametaphosphate (KH550-SHMP) polymer composite aqueous solution, the mass ratio of the silane coupling agent to the sodium hexametaphosphate is 1:1, the concentration is between 0.5 and 1%, and the pH value ranges from 7 to 9.

[0037] Preferably, the glass fiber reinforced material is fiber mesh cloth or fiber felt.

[0038] The present invention also provides a method for preparing a recycled wind turbine blade fiber-reinforced concrete decorative product, comprising the following steps:

[0039] (1) Design: Designing a decorative article and determining its size, shape, pattern, texture and / or text;

[0040] (2) Prepare raw materials: prepare materials for the decorative layer and structural layer;

[0041] (3) Prepare the mold: According to the design drawings, make the mold required for the decorative product and apply a release agent on the inner surface of the mold to ensure that the decorative product can be smoothly demoulded after casting;

[0042] (4) Preparation of mortar: Prepare the materials required for the decorative layer and the structural layer according to the proportions;

[0043] (5) Pouring mortar: Fill the mixed materials for the decorative layer and the structural layer into the corresponding prefabricated molds in layers (cast the decorative layer first, then the structural layer), lay a layer of fiber mesh cloth every 3-5 mm, and bury the connectors according to the design requirements to enhance the strength and stability of the decorative products; then vibrate evenly to remove air bubbles.

[0044] (6) Demolding and curing: Curing is performed on the cast decorative products to prevent plastic cracking. After 24 hours, the decorative products are removed from the mold and continued to be cured to ensure the strength and stability of the decorative products.

[0045] (7) Finishing: Finish the surface after the curing period.

[0046] Preferably, in step (5), mortar is poured by spraying through a spray gun, the spray gun comprising a spray gun body, a slurry pipe, a nozzle and a vibration directional dispersion platform, the spray gun body being connected to the slurry pipe and the air pipe, the slurry pipe being used to transport materials for the decorative layer and the structural layer, the slurry pipe being connected to the vibration directional dispersion platform through a clamp, and the nozzles being multiple and arranged in parallel at the corresponding outlet ends of the vibration directional dispersion platform.

[0047] Preferably, in step (3), the mold is made of a wooden board or a steel board; and the texture, pattern or text on the decorative product is carved by an engraving machine.

[0048] The beneficial effects of the above technical solution are as follows: Compared with existing technologies, the decorative products provided by the present invention utilize mineralized recycled fan blade fibers, combined with a microbially induced calcium-based crack self-healing agent, effectively improving the performance and durability of the decorative products. This transforms discarded fan blade resources into valuable building materials, helping to reduce waste accumulation and disposal costs and promoting resource recycling. The elastic properties of the dispersible latex can also increase the flexibility and ductility of the decorative products, giving them improved crack resistance and good durability. The decorative products obtained by the present invention, incorporating recycled fan blade fibers, exhibit excellent durability and environmental performance, making them suitable for widespread application. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present invention will be further described in detail below with reference to the accompanying drawings.

[0050] Figure 1 Schematic diagram of the structure of a spray gun used for preparing a fiber-reinforced concrete decorative product for recycled wind turbine blades provided by an embodiment of the present invention;

[0051] Figure 2 yes Figure 1 Top view of the middle nozzle and vibrating directional dispersion platform;

[0052] Figure 3 Schematic diagram of the structure of a fiber-reinforced concrete decorative product for regenerative fan blades prepared in one embodiment of the present invention;

[0053] In the figure: 1-spray gun body, 2-slurry delivery pipe, 3-clamp, 4-nozzle, 5-vibration directional dispersion platform, 6-air delivery pipe. DETAILED DESCRIPTION

[0054] The following is a clear and complete description of the technical solutions in the embodiments of the present invention, in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts are within the scope of protection of the present invention.

[0055] An embodiment of the present invention provides a fiber-reinforced concrete decorative product for recycled wind turbine blades. The decorative product includes a decorative layer, a structural layer, and an anchor. The decorative layer and the structural layer are sequentially cast in a mold (after demolding, the decorative layer is located outside the structural layer), and the anchor is pre-embedded in the structural layer.

[0056] The materials for making the decorative layer include the following components by weight:

[0057] 35-50 parts of cement;

[0058] 15-20 parts of mineral admixture;

[0059] 45-65 parts of sand;

[0060] 25-35 parts of stone chips;

[0061] 3.5-5.0 parts of calcium acetate monohydrate powder;

[0062] 2.5-4.5 parts of recycled fan blade fiber;

[0063] 0.25-0.5 parts of microbial-induced calcium-based crack self-repairing agent;

[0064] 0.1-0.3 parts of water reducing agent;

[0065] 14-20 parts water;

[0066] The materials for making the structural layer include the following components in parts by weight:

[0067] 45-50 parts of cement;

[0068] 15-20 parts of mineral admixture;

[0069] 35-55 parts of sand;

[0070] 2.5-4.5 parts of alkali-resistant glass fiber;

[0071] 2.5-4.5 parts of recycled fan blade fiber;

[0072] 3.5-5 parts of dispersible latex;

[0073] 0.03-0.06 parts of polymer reinforcing agent;

[0074] 0.1-0.3 parts of water reducing agent;

[0075] 14-20 parts water;

[0076] Lay the glass fiber reinforcement material in layers within the structural layer, with one layer every 3-5mm.

[0077] Among them, the cement used is one of the fast-hardening sulphoaluminate cement or P.O42.5 ordinary Portland cement, with a specific surface area of ​​250 to 450 m 2 / kg, density is between 3.0~3.2g / cm 3 The setting time and strength can be determined according to the specific model and production standards.

[0078] Mineral admixture: composed of one or more of slag, fly ash and silica fume, with the slag specific surface area ranging from 200 to 600m 2 / kg, density is between 2.8~3.2g / cm 3 The specific surface area of ​​fly ash is between 300 and 600 m 2 / kg, density is 2.0~2.5g / cm 3 The SiO2 content is between 40% and 70%; the specific surface area of ​​silica fume is between 15,000 and 30,000 m 2 / kg, density is between 2.2~2.4g / cm 3 The SiO2 content is between 85% and 98%. Among them, fly ash was purchased from Henan Hengyuan New Materials Co., Ltd., and the first-grade fly ash was selected; silica fume was purchased from Henan Borun New Materials, model WGF-6018; slag was purchased from Xincheng Mineral Products, and the S95 grade slag was selected.

[0079] When the mineral admixture consists of slag, fly ash and silica fume, the fly ash: silica fume: slag = 2:1:1; when the mineral admixture consists of fly ash and silica fume, the fly ash: silica fume = 2:1:1; when the mineral admixture consists of slag and fly ash, the fly ash: slag = 2:1; when the mineral admixture consists of slag and silica fume, silica fume: slag = 1:1.

[0080] Sand: Quartz sand with a relative density of 2.65 and an average particle size between 40 mesh and 80 mesh.

[0081] Stone chips: According to the specific design requirements and decorative effects, the particle size of stone chips can be selected from fine to coarse. The specific surface area range is 100~800m 2 / kg.

[0082] Calcium acetate monohydrate: white loose fine powder, odorless, easily soluble in water, with a solubility of 34.7 grams at 20°C.

[0083] Alkali-resistant glass fiber: fiber diameter between 9-15 μm, length between 12-25 mm, depending on application requirements. Density between 2.4-2.7 g / cm 3 Tensile strength between 2000-4000 MPa, elastic modulus between 70-80 GPa.

[0084] Microbial-induced calcium-based crack self-healing agent: a mixed solution of 10% volume fraction of Paenibacillus barellus mother liquor, 5 g / L of soybean peptone, 3 g / L of beef extract, 20 g / L of urea, and 1.0 L of deionized water.

[0085] Dispersible latex: one of acrylate latex, polyurethane latex, or ethylene-vinyl acetate copolymer latex, solid content between 40%-60%, pH value between 6-9, density between 1.0-1.2 g / cm 3 .

[0086] Water-reducing agent: polycarboxylic acid water-reducing agent, such as polycarboxylate (PCA) or polycarboxylic ether (PCE) can be selected, solid content between 30-50%, water-reducing rate between 30-40%.

[0087] Polymer reinforcing agent: silane coupling agent-sodium hexametaphosphate (KH550-SHMP) high molecular compound aqueous solution, mass ratio of silane coupling agent to sodium hexametaphosphate 1:1, concentration between 0.5-1%, pH value range between 7-9.

[0088] The glass fiber reinforced material uses fiber mesh or fiber felt, and the actual size of the component is used as the standard. One layer is laid every 3-5 mm in the structural layer.

[0089] As a preferred solution, the recycled fan blade fiber in the decorative layer is a mineralized type I recycled fan blade fiber, and the recycled fan blade fiber in the structural layer is a mineralized type II recycled fan blade fiber. The fan blade fiber is obtained after cutting, crushing, and continuous screening. The length of the type I recycled fan blade fiber ranges from 1.18 mm to 4.75 mm, and the proportion of particles with a diameter of less than 0.6 mm is not more than 20%. The length of the type II recycled fan blade fiber ranges from 4.75 mm to 32.5 mm, and the proportion of particles with a diameter of less than 0.6 mm is not more than 5%. Since the glass fiber in the recycled fan blade fiber is easily eroded by the alkaline matrix of cement, it needs to be treated for alkali resistance. The method for making an alkali-resistant coating on the surface of the fan blade fiber is as follows:

[0090] Based on the microbial mineralization technology, the regenerated fan blade fibers are first cultured in the crack self-repairing agent, then the regenerated fan blade fibers are taken out and evenly scattered in a plastic container, the crack self-repairing liquid and the prepared 20%-30% calcium acetate solution are mixed to fully cover the regenerated fan blade fibers. Through microbial reaction and chemical reaction, a large amount of calcium carbonate is deposited on the surface of the fibers. The regenerated fan blade fibers are dried to fix the calcium carbonate on the surface of the regenerated fan blade fibers, and the mineralized regenerated fan blade fibers with a dense calcium carbonate layer are formed.

[0091] Recycling the fibers in the waste wind turbine blade by mechanical grinding is a direct, economical and feasible wind turbine blade recycling scheme, which can reduce the size of the waste and recycle the low aspect ratio fibers, and the obtained fibers not only retain the surface resin, but also retain the matrix residues on the surface, which greatly increases the roughness of the fiber surface. The present application fully utilizes the special structure of the surface of the regenerated fan blade fibers, improves the mechanical and chemical interaction between the fibers and the concrete matrix, the former is due to the roughness of the fiber surface, and the latter is due to the intermolecular interaction, thereby enhancing the performance of the decorative product.

[0092] The present application also provides a preparation method of the regenerated fan blade fiber reinforced concrete decorative product.

[0093] (1) Design and planning: design and plan the above-mentioned decorative product, determine its size, shape, pattern, texture and / or text. These can be designed by hand-drawing sketches or using 2D drawing software (such as AutoCAD). Use professional three-dimensional modeling software to make detailed three-dimensional models of the decorative product. Commonly used software includes 3dsMax, SketchUp, SolidWorks, etc. During modeling, details, textures, curves and other decorative elements can be added as needed.

[0094] (2) Prepare raw materials: prepare the materials for making the decorative layer and the structural layer according to the components of the respective materials. Glass fiber mat or glass fiber mesh cloth is cut and sized according to the requirements of the decorative product.

[0095] (3) Prepare the mold: according to the design drawing, make the mold needed for the decorative product. The mold is made of wood board, steel plate or other suitable materials. The texture, pattern or text on the decorative product is engraved on the mold by an engraving machine. Ensure that the mold surface is free of impurities, and apply release agent to the inner surface of the mold to ensure that the decorative product can be smoothly demolded after pouring.

[0096] (4) Prepare the mortar: prepare the materials needed for making the decorative layer and the structural layer according to the corresponding proportions. The preparation method is as follows:

[0097] First, cement, mineral fillers, sand and water are mixed together to make concrete paste;

[0098] Then, add the fan blade fibers and other additive components into the concrete paste and stir thoroughly to ensure that all components are evenly mixed.

[0099] Pay attention to the fluidity of the mortar and the dispersion of the fibers to ensure that the quality of the mortar meets the requirements.

[0100] (5) Pouring mortar: The mixed materials for the decorative layer and the structural layer are layered into the corresponding prefabricated molds (the decorative layer is poured first, followed by the structural layer). A layer of fiber mesh is laid every 3-5 mm, and connectors are embedded according to the design requirements to enhance the strength and stability of the decorative product. Then, vibrate the mixture evenly using a vibration device to ensure that the material is evenly filled and to remove air bubbles.

[0101] In order to solve the problem that the traditional cutting and spraying process is difficult to spray high-content recycled wind turbine blade fiber reinforced concrete, in step (5), the mortar is sprayed by a spray gun, and a vibration directional dispersion platform is added at the spray gun mouth to ensure that the materials for the decorative layer and the structural layer can be sprayed smoothly. Figure 1 、 2 As shown, the spray gun includes a spray gun body 1, a slurry pipe 2, a nozzle 4 and a vibration directional dispersion platform 5. The spray gun body 1 is connected to the interface of the slurry pipe 2 and the air pipe 6. The slurry pipe 2 is used to transport the materials for making the decorative layer and the structural layer. The slurry pipe 2 is connected to the vibration directional dispersion platform 5 through a clamp 3. There are several nozzles 4, which are arranged in parallel at the corresponding outlet ends of the vibration directional dispersion platform 5. Figure 2 In the middle of the vibration directional dispersion platform, three partitions are provided, each partition is connected to a nozzle, and an ultrasonic vibration device is provided at the bottom of the vibration directional dispersion platform.

[0102] (6) Demolding and curing: Curing is performed on the finished decorative products to prevent plastic cracking. After 24 hours, the decorative products are removed from the mold and, as required, continue to cure for an appropriate period of time to ensure the strength and stability of the decorative products.

[0103] Curing time may vary depending on the specific project and the materials used. Generally speaking, the curing time for fiber-reinforced concrete decorative products for recycled wind turbine blades is 7 to 28 days. Heating can be used to shorten the curing time, generally not exceeding 75°C. Moisturizing can be carried out by covering with a wet cloth or spraying with water to prevent premature evaporation of moisture. In high temperature environments, humidity control is particularly important, and water spraying or humidity control equipment can be used to maintain appropriate humidity. During the curing period, regularly check the condition of the decorative products to ensure that there are no cracks or other damage on the surface. If necessary, take remedial measures, such as repairing surface defects or re-moistening curing.

[0104] (7) Finishing: Finish the surface after the curing period. Use appropriate tools to trim the edges, surfaces, and details to meet the design requirements. Use spraying, brushing, grinding, polishing, etc. to treat the surface of the decorative products to obtain the desired surface effect.

[0105] According to the "Test Methods for Performance of Glass Fiber Reinforced Cement" (GB / T15231-2008), the recycled wind turbine blade fiber-reinforced concrete (rGRC) decorative products obtained using the formulation and preparation method provided by the present invention were tested for bulk density, moisture content, water absorption, compressive strength, flexural properties, tensile strength, and impact strength. The values ​​were compared with those in the "Glass Fiber Reinforced Cement (GRC) Decorative Products" (JC / T940-2004).

[0106] The following is explained through four specific embodiments:

[0107] Example 1:

[0108] The fiber-reinforced concrete decorative product for regenerative wind turbine blades consists of a decorative layer, a structural layer and anchoring pieces. The decorative layer and the structural layer are cast in a mold in sequence, and the anchoring pieces are pre-embedded in the structural layer.

[0109] The decorative layer is mixed with mineralized regenerated fan blade fibers and microbial-induced calcium-based crack self-repairing agents. The regenerated fan blade fibers have excellent tensile properties and alkali corrosion resistance, which can effectively prevent the decorative layer from cracking and damage. When small cracks appear in the decorative layer, the repair agent can penetrate into the cracks and form calcium carbonate fillers, effectively preventing the cracks from expanding and deepening, which helps to extend the service life of the decorative products.

[0110] The structural layer is mixed with mineralized recycled fan blade fibers, alkali-resistant glass fibers and polymer reinforcements, which can effectively increase the bearing capacity and deformation resistance of the decorative product and improve the stability and safety of the entire structure.

[0111] The materials for making the decorative layer include the following components by weight:

[0112] 40 parts of cement;

[0113] 15 parts of mineral admixture;

[0114] 50 parts of sand;

[0115] 25 parts of stone chips;

[0116] 4.0 parts of calcium acetate monohydrate powder;

[0117] 3.5 parts of mineralized Type I regenerated fan blade fiber;

[0118] 0.25 parts of microbial-induced calcium-based crack self-repairing agent;

[0119] 0.15 parts of water reducing agent;

[0120] 15 parts water.

[0121] The materials for making the structural layer include the following components in parts by weight:

[0122] 48 parts of cement;

[0123] 20 parts of mineral admixture;

[0124] 40 parts of sand;

[0125] 3 parts of alkali-resistant glass fiber;

[0126] 2.5 parts of mineralized type II regenerated fan blade fiber;

[0127] 3.5 parts of dispersible latex;

[0128] 0.04 parts of polymer reinforcing agent;

[0129] 0.1 part of water reducing agent;

[0130] 15 parts water;

[0131] Lay a layer of glass fiber reinforcement material every 3-5mm in the structural layer. The glass fiber reinforcement material is fiber mesh cloth or fiber mat, which is based on the actual size of the component.

[0132] The recycled fan blade fibers are obtained through cutting, crushing, and continuous screening. Type I fibers have a length range of 1.18mm-4.75mm, of which particles with a diameter of less than 0.6mm account for no more than 20%. Type II fibers have a length range of 4.75mm-32.5mm, of which particles with a diameter of less than 0.6mm account for no more than 5%. Because the glass fibers in the recycled fan blade fibers are susceptible to corrosion by the alkaline cement matrix, they require alkali-resistant treatment. The treatment method is to mix the recycled fan blade fibers with a bacterial solution and a calcium acetate solution, then let them stand and dry to obtain recycled fan blade fibers with a dense calcium carbonate layer.

[0133] Cement: refers to one of the fast-hardening and early-strengthening sulphoaluminate cement or P.O42.5 ordinary Portland cement, with a specific surface area of ​​450m 2 / kg, density 3.2g / cm 3 The setting time and strength can be determined according to the specific model and production standards.

[0134] Mineral admixture: refers to slag, slag specific surface area 600m 2 / kg, density 2.9g / cm3.

[0135] Sand: refers to quartz sand with a relative density of 2.65 and an average particle size distribution of 40-80 mesh.

[0136] Stone chips: ordinary limestone with a particle size of 3-5 mm. The specific surface area is 250 m 2 / kg.

[0137] Calcium acetate monohydrate: white loose fine powder, odorless, easily soluble in water, with a solubility of 34.7 grams at 20°C.

[0138] Microbial-induced calcium-based crack self-healing agent: a mixed solution of 10% volume fraction of Bacillus pasteurianus mother liquor, 5g / L soy peptone, 3g / L beef extract, 20g / L urea and 1.0L deionized water.

[0139] Alkali-resistant glass fiber: fiber diameter 13μm, length 16mm, density 2.7g / cm 3 Tensile strength is between 2500MPa and elastic modulus is 70GPa.

[0140] Dispersible latex: Ethylene vinyl acetate copolymer latex. Solid content 40%; pH value generally 7; density 1.2g / cm 3 .

[0141] The water reducer refers to a polycarboxylic acid-based high-efficiency water reducer, polycarboxylate ether (PCE), with a solid content of 45% and a water reduction rate of 40%.

[0142] Polymer enhancer: refers to a silane coupling agent-sodium hexametaphosphate (KH550-SHMP) polymer composite aqueous solution, the mass ratio of silane coupling agent to sodium hexametaphosphate is 1:1, the concentration is 0.5%, and the pH value is 7.

[0143] The preparation method of the above-mentioned waste recycled wind turbine blade fiber reinforced concrete decorative product comprises the following steps:

[0144] (1) Design and planning: Design and plan the decorative products and model them using SketchUp. Determine the dimensions.

[0145] (2) Prepare raw materials: The materials for the rGRC decorative layer include, by weight, 40 parts cement; 15 parts mineral admixture; 50 parts sand; 25 parts stone chips; 4.0 parts calcium acetate monohydrate powder; 3.5 parts mineralized type I regenerative fan blade fiber; 0.25 parts microbial-induced calcium-based crack self-repairing agent; 0.15 parts water reducer; and 15 parts water. The materials for the rGRC structural layer include: 48 parts cement; 20 parts mineral admixture; 40 parts sand; 3 parts alkali-resistant glass fiber; 2.5 parts mineralized type II regenerative fan blade fiber; 3.5 parts dispersible latex; 0.04 parts polymer reinforcing agent; 0.1 parts water reducer; and 15 parts water. Glass fiber mat or glass fiber mesh cloth should be cut and sized appropriately according to the requirements of the decorative product.

[0146] (3) Prepare the template: According to the design drawings, make the mold required for the decorative product. The template material can be wood, steel plate, or other suitable materials. Textures, patterns, or text need to be engraved using an engraving machine. Ensure that the template surface is free of impurities and apply a release agent to the template surface to ensure that the decorative product can be smoothly demolded after pouring.

[0147] (4) Prepare mortar: Prepare cement mortar according to the relevant proportions. First, mix cement, mineral filler, sand, and an appropriate amount of water to form a concrete slurry. Then, add fiber, reinforcement, and other additives to the concrete slurry and stir thoroughly to ensure that all components are evenly mixed. Pay attention to the fluidity of the mortar and the dispersion of the fibers to ensure that the mortar quality meets the requirements.

[0148] (5) Pouring mortar: The mixed materials are filled into the prefabricated mold in layers, with a layer of mesh cloth laid at a certain thickness, and connectors embedded in appropriate locations to enhance the strength and stability of the decorative product. Then, a vibration device is used to ensure that the material is filled evenly and to remove air bubbles.

[0149] (6) Demolding and Curing: After 24 hours, remove the decorative product from the formwork and continue curing. Curing time may vary depending on the specific project and materials used. Generally, the curing time for decorative products is 7 days. The curing temperature is 75°C. Use water spray to maintain appropriate humidity. During the curing period, regularly check the condition of the decorative product to ensure that there are no cracks or other damage on the surface.

[0150] (7) Finishing: After the curing period, use appropriate tools to trim the edges, surfaces and details to meet the design requirements. Use spraying, brushing, grinding, polishing and other methods to treat the surface of the decorative products to obtain the desired surface effect.

[0151] According to the "Test Methods for Properties of Glass Fiber Reinforced Cement" (GB / T15231-2008), the recycled wind turbine blade fiber-reinforced concrete (rGRC) decorative products obtained using the formulation and preparation method provided by the present invention were tested for bulk density, moisture content, water absorption, compressive strength, flexural properties, tensile strength, and impact strength. The values ​​were compared with those in the "Glass Fiber Reinforced Cement (GRC) Decorative Products" (JC / T940-2004).

[0152] Example 2:

[0153] In the preparation method of the waste recycled fan blade fiber reinforced concrete decorative product of this embodiment, the types and contents of each raw material are the same as those in Example 1. The difference is that the structural layer of this embodiment contains 2.5 parts of recycled fan blade fiber and 4.5 parts of alkali-resistant glass fiber.

[0154] Example 3:

[0155] In the preparation method of the waste recycled fan blade fiber reinforced concrete decorative product of this embodiment, the types and contents of each raw material are the same as those in Example 1, except that, in this embodiment, the structural layer contains 4.5 parts of recycled fan blade fiber and 2.5 parts of alkali-resistant glass fiber.

[0156] Example 4:

[0157] In the preparation method of the waste recycled fan blade fiber reinforced concrete decorative product of this embodiment, the types and contents of various raw materials are the same as those in Example 1, except that, in this embodiment, the structural layer contains 1 part of recycled fan blade fiber and 5 parts of alkali-resistant glass fiber.

[0158] The performance of the fiber-reinforced concrete decorative products made from waste recycled fan blades prepared in Examples 1 to 4 was compared, and the results are shown in Table 1.

[0159] Table 1 Test results of Examples 1-4

[0160]

[0161] Figure 3 The figure is a design drawing of a recycled fan blade fiber reinforced concrete decorative product in one embodiment, which can be used as door and window covers. The physical and mechanical properties of the reinforced recycled fan blade fiber reinforced concrete decorative products in different embodiments are shown in Table 1. As can be seen from the table, the density, water absorption rate, bending strength, and impact strength of the products prepared by replacing different proportions of chopped alkali-resistant glass fibers with alkali-resistant treated recycled fan blade fibers in Examples 1-3 all meet the requirements of first-class products (premixing process) in JC / T940-2004 "Glass Fiber Reinforced Cement (GRC) Decorative Products". There is no delamination or peeling after 25 freeze-thaw cycles, so it can be used to make columns, railings, handrails, door and window covers, pediments, supports, moldings, blocks, window sills, window sills, brackets, tubular tiles, tiles, rockery, and sculptures. However, due to the insufficient amount of recycled fan blade fiber added in Example 4, the physical and mechanical properties of the decorative product do not meet the standards.

[0162] Matters not described in the present invention are applicable to the prior art, and the raw materials involved are all obtained through commercial purchase or conventional methods.

[0163] In summary, the present invention fully utilizes the unique surface structure of recycled wind turbine blade fibers to enhance the mechanical and chemical interactions between the fibers and the concrete matrix—the former due to the fiber surface roughness and the latter due to intermolecular interactions—thus enhancing the performance of fiber-reinforced concrete decorative products. This invention not only enables the environmentally friendly disposal of discarded wind turbine blades but also significantly reduces the production cost of fiber-reinforced concrete decorative products, facilitating their widespread application.

[0164] In the above description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed above.

Claims

1. A recycled wind turbine blade fiber reinforced concrete decorative product, characterized by: The decorative product includes a decorative layer, a structural layer, and an anchor. The decorative layer and the structural layer are sequentially cast in a mold, and the anchor is pre-embedded in the structural layer. Mortar is sprayed and cast using a spray gun. The spray gun includes a spray gun body, a slurry pipe, a nozzle, and a vibration directional dispersion platform. The spray gun body is connected to the slurry pipe and an air pipe. The slurry pipe is used to transport materials for the decorative layer and the structural layer. The slurry pipe is connected to the vibration directional dispersion platform via a clamp. There are multiple nozzles, which are arranged in parallel at corresponding outlet ends of the vibration directional dispersion platform. The materials for making the decorative layer include the following components in parts by weight: 35-50 parts of cement; 15-20 parts of mineral admixture; 45-65 parts of sand; 25-35 parts of stone chips; 3.5-5.0 parts of calcium acetate monohydrate powder; 2.5-4.5 parts of recycled fan blade fiber; 0.25-0.5 parts of microbial-induced calcium-based crack self-repairing agent; 0.1-0.3 parts of water reducing agent; 14-20 parts water; The microbial-induced calcium-based crack self-repairing agent is a mixture of Bacillus pasteurianus mother liquor, soy peptone, beef extract, urea and deionized water, wherein the concentration of soy peptone is 5g / L, the concentration of beef extract is 3g / L, the concentration of urea is 20g / L, and the volume fraction of Bacillus pasteurianus mother liquor is 10%; The materials for making the structural layer include the following components in parts by weight: 45-50 parts of cement; 15-20 parts of mineral admixture; 35-55 parts of sand; 2.5-4.5 parts of alkali-resistant glass fiber; 2.5-4.5 parts of recycled fan blade fiber; 3.5 to 5 parts of dispersible latex; 0.03-0.06 parts of polymer reinforcing agent; 0.1-0.3 parts of water reducing agent; 14-20 parts water; The polymer reinforcing agent is a silane coupling agent-sodium hexametaphosphate polymer composite aqueous solution, the mass ratio of the silane coupling agent to the sodium hexametaphosphate is 1:1, the concentration is between 0.5 and 1%, and the pH value ranges from 7 to 9; Lay glass fiber reinforcement materials in layers within the structural layer, with one layer every 3-5 mm; The regenerated fan blade fibers in the decorative layer are mineralized Type I regenerated fan blade fibers, and the regenerated fan blade fibers in the structural layer are mineralized Type II regenerated fan blade fibers; the regenerated fan blade fibers are obtained by cutting-crushing-continuous screening, the length range of Type I regenerated fan blade fibers is 1.18mm~4.75mm, of which particles with a diameter of less than 0.6mm account for no more than 20%, and the length range of Type II regenerated fan blade fibers is 4.75mm~32.5mm, of which particles with a diameter of less than 0.6mm account for no more than 5%.

2. The fiber-reinforced concrete decorative product for regenerative wind turbine blades according to claim 1, characterized in that: The mineral admixture is composed of one or more of slag, fly ash and silica fume, wherein the specific surface area of ​​slag is between 200 and 600 m² / kg and the density is between 2.8 and 3.2 g / cm³; the specific surface area of ​​fly ash is between 300 and 600 m² / kg, the density is between 2.0 and 2.5 g / cm³ and the SiO2 content is between 40 and 70%; the specific surface area of ​​silica fume is between 15,000 and 30,000 m² / kg and the density is between 2.2 and 2.4 g / cm³. 3 The SiO2 content is between 85% and 98%.

3. The fiber-reinforced concrete decorative product for regenerative wind turbine blades according to claim 1, characterized in that: The alkali-resistant glass fiber has a fiber diameter of 9 to 15 μm, a length of 12 to 25 mm, a density of 2.4 to 2.7 g / cm³, a tensile strength of 2000 to 4000 MPa, and an elastic modulus of 70 to 80 GPa.

4. The fiber-reinforced concrete decorative product for regenerative wind turbine blades according to claim 1, characterized in that: The dispersible latex is one of acrylic latex, polyurethane latex or ethylene vinyl acetate copolymer latex, with a solid content between 40% and 60%; a pH value between 6 and 9; and a density between 1.0 and 1.2 g / cm³.

5. The fiber-reinforced concrete decorative product for regenerative wind turbine blades according to claim 1, characterized in that: The water reducer is a polycarboxylic acid water reducer with a solid content of 30 to 50% and a water reduction rate of 30 to 40%.

6. A method for preparing a recycled wind turbine blade fiber-reinforced concrete decorative product, comprising preparing the recycled wind turbine blade fiber-reinforced concrete decorative product according to any one of claims 1 to 5, characterized in that: The following steps are involved: (1) Design: designing a decorative article and determining its size, shape, pattern, texture and / or text; (2) Prepare raw materials: prepare materials for the decorative layer and structural layer; (3) Prepare the mold: Make the mold required for the decorative product according to the design drawings and apply the release agent on the inner surface of the mold; (4) Preparation of mortar: Prepare the materials required for the decorative layer and the structural layer according to the proportions; (5) Pouring mortar: Fill the mixed materials for the decorative layer and the structural layer into the prefabricated corresponding molds in layers, pour the decorative layer first, and then pour the structural layer; lay a layer of fiber mesh cloth every 3-5mm, and bury the connectors according to the installation requirements; then vibrate evenly; (6) Demolding and curing: After 24 hours, remove the decorative product from the mold and perform curing on the finished decorative product; (7) Finishing: After the curing period, the surface should be finished.

7. The method for preparing the fiber-reinforced concrete decorative product for regenerative wind turbine blades according to claim 6, characterized in that: In step (3), the mold is made of a wooden board or a steel board; the texture, pattern or text on the decorative product is carved by an engraving machine.

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