Recycled fan blade fiber reinforced concrete decorative wall panel and method of manufacturing the same

Abstract

The application discloses a kind of recycled fan blade fiber reinforced concrete decorative wallboard and manufacturing method thereof, belong to building decoration material technical field, decorative wallboard includes decorative layer, structural layer, anchoring and steel skeleton, anchoring connects steel skeleton and structural layer, decorative layer is located at the outside of structural layer;Manufacturing method is: design-preparation and mould-preparation mortar-pouring-demoulding and maintenance-finishing.The material of decorative layer and structural layer both contains recycled fan blade fiber, realizes the secondary use of fan blade, can change waste into treasure, reduces the negative influence of waste on environment;Recycled fan blade fiber is used to replace alkali-resistant glass fiber, which can reduce the cost of decorative wallboard, improve the sustainability of products, and make them more competitive.The decorative wallboard manufactured by the application has excellent strength and environmental performance, and can be widely used in the field of building decoration, including residential, commercial buildings and public facilities, etc., contributing to the development of sustainable building materials field.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of building decoration materials, and particularly relates to a recycled wind turbine blade fiber reinforced concrete decorative wallboard and a manufacturing method thereof. BACKGROUND

[0002] Currently, wind energy has become one of the most promising renewable energy sources. The International Energy Agency (IEA) estimates that 15-18% of global electricity will come from wind energy by 2050. Given the large increase in future wind turbine generators, and the 20-25 year design life of wind turbine blades, it can be predicted that the accumulation of retired wind turbine blades will pose a threat to the economy and the environment. It is reported that from 2033, about 200,000 tons of waste wind turbine blades are expected to be disposed of annually. At present, most of the wind turbine blade waste is sent to landfills, but this is not an environmentally friendly solution.

[0003] GRC is a kind of fiber reinforced concrete composite material with alkali-resistant glass fiber as reinforcing material and cement mortar as matrix material, which is widely used in the construction industry, especially for manufacturing decorative wallboards. GRC decorative wallboards are applied in various buildings due to their advantages in strength, durability, design flexibility, non-combustibility and low maintenance, etc. However, a large amount of expensive alkali-resistant glass fiber needs to be mixed in GRC decorative wallboards, which makes its cost always high, limiting its range of use. SUMMARY

[0004] The purpose of the present application is to provide a recycled wind turbine blade fiber reinforced concrete decorative wallboard and a manufacturing method thereof, aiming to solve the technical problems of high cost of fiber reinforced concrete composite material and environmental protection of wind turbine blade waste landfill 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 wallboard, the decorative wallboard comprises a decorative layer, a structural layer, an anchor and a steel framework, the anchor is used to connect the steel framework and the structural layer, and the decorative layer is arranged on the outer side of the structural layer;

[0007] The material of the decorative layer comprises the following components by weight: cement 28.5-35 parts; mineral admixture 10.5-14.3 parts; sand 43-52 parts; stone chips 20.4-30.6 parts; recycled wind turbine blade fiber 2-5 parts; alkali-resistant glass fiber 2-5 parts; water reducing agent 0.8-1.2 parts; water 11.4-14 parts;

[0008] The materials of the structural layer include the following components by weight: 26.5-32 parts of cement; 12.9-15.8 parts of mineral admixture; 8.8-12.5 parts of fine sand; 6.5-10 parts of medium sand; 6.5-10 parts of coarse sand; 5-9 parts of regenerated fan blade fiber; 2-5 parts of short-cut alkali-resistant glass fiber; 0.9-1.5 parts of water reducer; 0.05-1 part of modifier; 10.8-13.5 parts of water; pretreated alkali-resistant glass fiber mesh cloth is arranged at intervals inside the structural layer.

[0009] Preferably, the regenerated fan blade fibers are obtained after cutting-crushing-continuous screening, and the regenerated fan blade fibers are divided into Type I regenerated fan blade fibers and Type II regenerated fan blade fibers. The length of the 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 of the Type II regenerated fan blade fibers is 4.75mm-12.5mm, of which particles with a diameter of less than 0.6mm account for no more than 5%.

[0010] Preferably, the regenerated fan blade fibers are pre-treated with alkali resistance, and the treatment method is as follows:

[0011] First, 3g of nano-ZrO2 was added to 60ml of ethanol solution and stirred thoroughly. Then, 6g of aminopropyltriethoxysilane and 30ml of deionized water were added for ultrasonic pre-dispersion to obtain APTES-ZrO2 particles. The particles were then added to a mixed solution of 1.5g of epoxy resin and 150ml of ethanol to obtain an APTES-ZrO2 sol solution for surface coating. Finally, the regenerated fan blade fiber was placed in the sol solution and fully immersed. After removal and drying, the APTES-ZrO2 coated fiber was finally obtained.

[0012] Preferably, the method for pre-treating the alkali-resistant glass fiber mesh is as follows:

[0013] ① Spray the adhesive on the surface of the mesh cloth. The adhesive is a powder and / or emulsion. The powder used is polyvinyl alcohol powder, and the emulsion used is polyvinyl acetate emulsion. The amount of powder used is 4-5% of the mass of the regenerated fan blade fiber, the mass of the water sprayed is 8-10% of the mass of the regenerated fan blade fiber, and the amount of emulsion used is 5-8% of the mass of the regenerated fan blade fiber;

[0014] ② Take 3-5 pieces of regenerated fan blade fibers and spread them evenly on a flat surface;

[0015] ③ Use the bonding treated mesh cloth to pick up the regenerated fan blade fibers.

[0016] 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.

[0017] 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%.

[0018] Preferably, the sand is quartz sand with a relative density of 2.65, an average particle size between 40 mesh and 80 mesh, a coarse sand particle size distribution range of 2.0 mm to 4.75 mm, a medium sand particle size distribution range of 0.425 mm to 2.0 mm, and a fine sand particle size distribution range of 0.075 mm to 0.425 mm; and a specific surface area range of 100 to 800 m 2 / kg.

[0019] 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.

[0020] 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%.

[0021] Preferably, the modifier is a polyvinyl alcohol-sodium hexametaphosphate (PVA-SHMP) polymer composite aqueous solution, the mass ratio of polyvinyl alcohol to sodium hexametaphosphate is 1:1, the concentration is between 0.5 and 1%, the pH value is between 5 and 8, and the viscosity is between 10 and 1000 mPa·s.

[0022] The present invention also provides a method for manufacturing a recycled wind turbine blade fiber-reinforced concrete decorative wallboard, wherein the method comprises the following steps:

[0023] (1) Design and planning: Design and plan the above-mentioned decorative wall panels to determine the required size, shape, pattern and / or texture;

[0024] (2) Prepare raw materials: prepare the materials required for the decorative layer and the structural layer according to the weight fraction;

[0025] (3) Prepare the mold: according to the design drawing, make the mold required for the decorative wallboard, and apply release agent on the surface of the mold;

[0026] (4) Prepare the mortar: prepare the materials required for the decorative layer and the structural layer according to the ratio;

[0027] (5) Pour the mortar: fill the mixed materials of the decorative layer and the structural layer into the prepared mold in turn, lay a layer of mesh cloth every 3-5mm for the structural layer, and embed the connecting parts according to the installation requirements; then vibrate uniformly;

[0028] (6) Demolding and curing: cure the poured decorative wallboard to prevent plastic cracking, and demold the decorative wallboard from the mold after 24h and continue to cure;

[0029] (7) Finishing: finish the surface after the curing period ends.

[0030] The beneficial effects produced by the above technical scheme are that: compared with the prior art, the present application replaces the alkali-resistant glass fiber with recycled wind turbine blade fiber in the decorative layer and the structural layer of the decorative wallboard, realizes the secondary utilization of the wind turbine blade, can turn waste into treasure, and reduces the negative impact of waste on the environment. At the same time, since the recycled wind turbine blade fiber is a cheap substitute, it can reduce the cost of the decorative wallboard, improve the sustainability of the product, make it more competitive, and thus promote the development of the market. The decorative wallboard manufactured by the present application has excellent strength and environmental performance, and the manufacturing process can be carried out through a standardized production line, which can ensure the consistency and quality of the product; the recycled wind turbine blade fiber reinforced concrete decorative wallboard can be widely used in the field of building decoration, including residential buildings, commercial buildings and public facilities. The present application brings new development opportunities to the decorative wallboard industry, and also contributes to the development of sustainable building materials. BRIEF DESCRIPTION OF DRAWINGS

[0031] The present application will be further described in detail below with reference to the accompanying drawings.

[0032] Figure 1 is a structural schematic view of the spray gun used for preparing the recycled wind turbine blade fiber reinforced concrete decorative wallboard provided by the embodiment of the present application;

[0033] Figure 2 is Figure 1 the top view of the nozzle and the vibration directional dispersion platform in

[0034] 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

[0035] The technical solutions of the present invention are described clearly and completely below with reference to the embodiments. It is obvious that the embodiments described are only a part of the embodiments of the present invention, not all of them. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments of the present invention without creative work are within the scope of protection of the present invention.

[0036] As is well known, discarded wind turbine blades are a type of waste that is difficult to handle and has limited treatment options. Physical recycling methods can reduce the negative impact of waste on the environment by reusing them as recycled fibers. Since recycled wind turbine blade fibers are a low-cost alternative, they help reduce the demand for alkali-resistant glass fibers. Using them can lower the price of GRC (glass fiber reinforced concrete) products, making them more competitive and driving market development.

[0037] An embodiment of the present invention provides a fiber-reinforced concrete decorative wall panel for recycled wind turbine blades, comprising a decorative layer, a structural layer, anchors and a steel frame, wherein the anchors are used to connect the steel frame and the structural layer, and the decorative layer is arranged on the outside of the structural layer.

[0038] The materials of the decorative layer include the following components by weight: 28.5-35 parts of cement; 10.5-14.3 parts of mineral admixture; 43-52 parts of sand; 20.4-30.6 parts of stone chips; 2-5 parts of recycled fan blade fiber; 2-5 parts of alkali-resistant glass fiber; 0.8-1.2 parts of water reducer; 11.4-14 parts of water;

[0039] The materials of the structural layer include the following components by weight: 26.5-32 parts of cement; 12.9-15.8 parts of mineral admixture; 8.8-12.5 parts of fine sand; 6.5-10 parts of medium sand; 6.5-10 parts of coarse sand; 5-9 parts of regenerated fan blade fiber; 2-5 parts of short-cut alkali-resistant glass fiber; 0.9-1.5 parts of water reducer; 0.05-1 part of modifier; 10.8-13.5 parts of water; pretreated alkali-resistant glass fiber mesh cloth is arranged at intervals inside the structural layer.

[0040] As a preferred embodiment, the regenerated fan blade fiber is obtained by cutting-crushing-continuous screening, and the regenerated fan blade fiber is divided into Type I regenerated fan blade fiber and Type II regenerated fan blade fiber. The length of the Type I regenerated fan blade fiber is 1.18mm-4.75mm, of which the particles with a diameter of less than 0.6mm account for no more than 20%, and the length of the Type II regenerated fan blade fiber is 4.75mm-12.5mm, of which the particles with a diameter of less than 0.6mm account for no more than 5%.

[0041] Since the glass fiber in the regenerated wind turbine blade fiber is easily corroded by the cement alkaline matrix, it needs to be treated with alkali resistance. The treatment method is as follows:

[0042] The APTES-ZrO2 surface coating technology based on the sol-gel method first adds 3g of nano-ZrO2 to 60ml of ethanol solution and stirs it thoroughly. Then, 6g of aminopropyltriethoxysilane and 30ml of deionized water are added for ultrasonic pre-dispersion to obtain APTES-ZrO2 particles. Then, it is added to a mixed solution of 1.5g of epoxy resin and 150ml of ethanol to obtain an APTES-ZrO2 sol solution for surface coating. Finally, the regenerated wind turbine blade fiber is placed in the sol solution and fully immersed. After taking it out and drying, the APTES-ZrO2 coated fiber is finally obtained.

[0043] At the same time, in the structural layer, the processing method of the pre-treated alkali-resistant glass fiber mesh used is as follows:

[0044] ① Spray the adhesive on the surface of the mesh cloth. The adhesive is a powder and / or emulsion. The powder used is polyvinyl alcohol powder, and the emulsion used is polyvinyl acetate emulsion. The amount of powder used is 4-5% of the mass of the regenerated fan blade fiber, the mass of the water sprayed is 8-10% of the mass of the regenerated fan blade fiber, and the amount of emulsion used is 5-8% of the mass of the regenerated fan blade fiber;

[0045] ② Take 3-5 pieces of regenerated fan blade fibers and spread them evenly on a flat surface;

[0046] ③ Use the bonding treated mesh cloth to pick up the regenerated fan blade fibers.

[0047] The purpose of pre-treating the alkali-resistant glass fiber mesh is to increase the fiber content in the pre-mixing process to improve the mechanical properties of fiber-reinforced concrete.

[0048] Among them, cement: use one of the fast-hardening sulphoaluminate cement or P.O42.5 ordinary Portland cement, with a specific surface area of ​​250~450m 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.

[0049] 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.

[0050] 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.

[0051] Sand: Quartz sand with a relative density of 2.65 and an average particle size between 40 mesh and 80 mesh. The particle size distribution range of coarse sand is 2.0mm to 4.75mm; the particle size distribution range of medium sand is 0.425mm to 2.0mm; and the particle size distribution range of fine sand is 0.075mm to 0.425mm.

[0052] 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.

[0053] Alkali-resistant glass fiber: Fiber diameter is between 9 and 15 μm, length is between 12 and 25 mm, depending on application requirements. Density is between 2.4 and 2.7 g / cm 3 The tensile strength is between 2000 and 4000 MPa, and the elastic modulus is between 70 and 80 GPa.

[0054] Water reducer: polycarboxylate water reducer, such as polycarboxylate (PCA) and polycarboxylate ether (PCE), with a solid content between 30% and 50% and a water reduction rate between 30% and 40%.

[0055] Modifier: a polyvinyl alcohol-sodium hexametaphosphate (PVA-SHMP) polymer composite aqueous solution, the mass ratio of polyvinyl alcohol to sodium hexametaphosphate is 1:1, the concentration is between 0.5 and 1%, the pH value is between 5 and 8, and the viscosity is between 10 and 1000 mPa·s.

[0056] The present invention also provides a method for manufacturing a recycled wind turbine blade fiber-reinforced concrete decorative wallboard, wherein the method comprises the following steps:

[0057] (1) Design and Planning: Design and plan the decorative wall panels to determine the required size, shape, pattern, and / or texture. Preliminary design can be done by hand sketching or using 2D drawing software such as AutoCAD. Detailed 3D modeling of the decorative products is performed using professional 3D modeling software. Commonly used software includes 3ds Max, SketchUp, SolidWorks, etc. During the modeling process, details, textures, curves, and other decorative elements can be added as needed.

[0058] (2) Prepare raw materials: Prepare the materials required for the decorative layer and the structural layer by weight; the material composition and content of the decorative layer are as follows: 28.5 to 35 parts of cement; 10.5 to 14.3 parts of mineral admixture; 43 to 52 parts of sand; 20.4 to 30.6 parts of stone chips; 2 to 5 parts of type I regenerative fan blade fiber; 2 to 5 parts of alkali-resistant glass fiber; 0.8 to 1.2 parts of water reducer; and 11.4 to 14 parts of water. The material composition and content of the structural layer, by weight, are as follows: 26.5-32 parts cement; 12.9-15.8 parts mineral admixture; 8.8-12.5 parts fine sand; 6.5-10 parts medium sand; 6.5-10 parts coarse sand; 5-9 parts Type II regenerative fan blade fiber; 2-5 parts chopped alkali-resistant glass fiber; alkali-resistant glass fiber mesh (based on the actual size of the component); 0.9-1.5 parts water reducer; 0.05-1 part modifier; and 10.8-13.5 parts water. Ensure the use of high-quality materials and accurate weighing according to the proportions.

[0059] (3) Prepare the mold: According to the design drawings, make the mold required for the decorative wall panel. 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 is flat and free of impurities, and apply a release agent to the template surface to ensure that the decorative wall panel can be smoothly demolded after pouring.

[0060] (4) Prepare mortar: Prepare the materials required for the decorative and structural layers according to the proportions. First, mix cement, mineral filler, sand, and an appropriate amount of water to form a concrete slurry. Then, add the 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.

[0061] (5) Pouring mortar: Fill the mixed decorative layer and structural layer materials into the prefabricated mold in turn, lay a layer of mesh cloth every 3-5mm on the structural layer, and bury the connectors according to the installation requirements to enhance the strength and stability of the rGRC decorative wallboard; then use vibration equipment to ensure that the material is filled evenly and remove air bubbles.

[0062] 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.

[0063] (6) Demolding and curing: Curing is performed on the cast decorative wall panels to prevent plastic cracking. After 24 hours, the decorative wall panels are demoulded from the formwork and continued to be cured. The curing time may vary. The appropriate curing time is carried out according to the requirements to ensure the strength and stability of the rGRC decorative wall panels. Generally speaking, the curing time of decorative wall panels is 7 to 28 days. Heating curing can be adopted to shorten the curing time, generally not exceeding 75°C. Curing can be carried out by covering with a wet cloth or spraying with water to prevent premature evaporation of moisture.

[0064] Humidity control is particularly important in high-temperature environments. Maintaining appropriate humidity levels can be achieved by spraying water or using humidity control equipment. During curing, regularly inspect the condition of the decorative product to ensure there are no cracks or other damage to the surface. If necessary, perform remedial measures, such as repairing surface defects or re-wetting the product.

[0065] (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 decorative wall panels to achieve the desired surface effect.

[0066] 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 wallboards produced 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 then compared with those in the "Fiber Reinforced Concrete Decorative Wallboards" (JG / T 348-2011).

[0067] The following is explained through four specific embodiments:

[0068] Example 1:

[0069] The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades of this embodiment is composed of a decorative layer, a structural layer, anchors and a light steel skeleton, wherein the anchors are used to connect the steel skeleton and the structural layer.

[0070] The composition and content of the concrete of the decorative layer are as follows, by weight: 30 parts of cement; 11 parts of mineral admixture; 45 parts of sand; 22 parts of stone chips; 3 parts of type I regenerative fan blade fiber; 3 parts of alkali-resistant glass fiber; 0.8 parts of water reducer; and 12 parts of water.

[0071] The composition and content of the concrete of the structural layer, calculated by weight, are as follows: 27 parts of cement; 15 parts of mineral admixture; 9 parts of fine sand; 7 parts of medium sand; 88 parts of coarse sand; 6 parts of type II regenerative fan blade fiber; 3 parts of alkali-resistant glass fiber; 1 meter of alkali-resistant glass fiber mesh cloth; 1 part of water reducer; 0.05 parts of modifier; and 12 parts of water.

[0072] The regenerated 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-12.5mm, of which particles with a diameter of less than 0.6mm account for no more than 5%. Because the glass fibers in the regenerated fan blade fibers are easily corroded by the alkaline cement matrix, they require alkali-resistant treatment. The treatment method is: APTES-ZrO2 surface coating technology based on the sol-gel method is first added to an ethanol solution and fully stirred. The ethanol solution is used to improve the dispersion of the nanoparticles. Aminopropyltriethoxysilane and deionized water are then added for ultrasonic pre-dispersion to obtain APTES-ZrO2 particles. These particles are then added to a mixed solution of epoxy resin and ethanol to obtain an APTES-ZrO2 sol solution for surface coating. Finally, the regenerated fan blade fibers are fully immersed in the sol solution, removed, and dried to obtain APTES-ZrO2 coated fibers.

[0073] The method for treating the pretreated alkali-resistant glass fiber mesh cloth is as follows: ① spraying a binder on the surface of the mesh cloth. The binder is a powder and / or emulsion. The powder used is polyvinyl alcohol powder, and the emulsion used is polyvinyl acetate emulsion. The amount of powder used is 4% of the mass of the glass fiber, the amount of water sprayed is 8% of the mass of the glass fiber (watering is for better adhesion of the powder), and the amount of emulsion used is 5% of the mass of the glass fiber. ② Take 4 parts of regenerated fan blade fibers and place them on a plane and spread them evenly. ③ Use the mesh cloth after bonding treatment to stick the regenerated fan blade fibers. The purpose of pretreating the mesh cloth is to increase the fiber content in the premixing process to improve the mechanical properties of fan blade fiber reinforced concrete.

[0074] Cement: PO 42.5 ordinary Portland cement, specific surface area 50m 2 / kg, density 3.0g / cm 3 The setting time and strength can be determined according to the specific model and production standards.

[0075] Mineral admixtures: fly ash and silica fume, with a specific surface area of ​​fly ash of 400m 2 / kg, density is 2.4g / cm 3 The SiO2 content is between 45% and 30,000m2 respectively. 2 / kg, density is 2.2g / cm 3 , SiO2 content is 98%.

[0076] Sand: The relative density of quartz sand is 2.65, and the average particle size is 40-80 mesh; the particle size distribution range of coarse sand is 2.0mm-4.75mm; the particle size distribution range of medium sand is 0.425mm-2.0mm; the particle size distribution range of fine sand is 0.075mm-0.425mm.

[0077] Stone chips: ordinary limestone with a particle size of 3-5 mm. The specific surface area is 250 m 2 / kg.

[0078] Alkali-resistant glass fiber: Fiber diameter is 13μm, length is between 24mm, density is 2.7g / cm 3 The tensile strength is 2500MPa and the elastic modulus is 70GPa.

[0079] Water reducing agent: Polycarboxylate-based high-efficiency water reducing agent, polycarboxylate (PCA), solid content is between 35%. Water reduction rate is 40%.

[0080] Modifier: refers to a polyvinyl alcohol-sodium hexametaphosphate (PVA-SHMP) polymer composite solution with a concentration of 1%, a pH of 7, and a viscosity of 800 mPa·s.

[0081] The method for preparing the above-mentioned recycled wind turbine blade fiber reinforced concrete decorative wallboard comprises the following steps:

[0082] (1) Design and planning: Determine the overall concept and requirements of the decorative wall panels, with a size of 1m×1m×5mm, square, and surface engraving.

[0083] (2) Prepare raw materials: Prepare the materials required for decorative wall panels by weight: 30 parts cement for the decorative layer; 11 parts mineral admixture; 45 parts sand; 22 parts stone chips; 3 parts Type I regenerative fan blade fiber; 3 parts alkali-resistant glass fiber; 0.8 parts water reducer; and 12 parts water. The concrete composition and content of the structural layer, by weight, are as follows: 27 parts cement; 15 parts mineral admixture; 9 parts fine sand; 7 parts medium sand; 88 parts coarse sand; 6 parts Type II regenerative fan blade fiber; 3 parts alkali-resistant glass fiber; 1 meter of alkali-resistant glass fiber mesh; 1 part water reducer; 0.05 parts modifier; and 12 parts water.

[0084] (3) Prepare the template: According to the design drawings, make the mold required for the decorative wall panels. Use polystyrene board as the template material. Use an engraving machine to carve the text. Ensure that the template is flat and free of impurities, and apply a release agent to the template surface to ensure that the decorative wall panels can be smoothly demolded after pouring.

[0085] (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.

[0086] (5) Pouring mortar: Fill the mixed fiber-reinforced concrete material for wind turbine blades into the prefabricated molds one by one, lay a layer of mesh cloth every 2.5 mm, and then use vibration equipment to ensure that the material is filled evenly and remove air bubbles.

[0087] (6) Demolding and Curing: After 24 hours, the fiber reinforced concrete decorative wall panels for wind turbine blades are demoulded from the formwork and cured. Curing time may vary depending on the specific project and the materials used. Generally speaking, the curing time for fiber reinforced concrete decorative wall panels for wind turbine blades is up to 28 days. The curing temperature is 25°C. Moisturizing is carried out by spraying water to prevent premature evaporation of water.

[0088] (7) Finishing: After the curing period, trim the edges, surfaces and details to meet the design requirements. Use spraying to treat the decorative wall panels to obtain the desired surface effect.

[0089] According to the "Test Methods for Properties of Glass Fiber Reinforced Cement" (GB / T15231-2008), the fiber-reinforced concrete decorative wallboards for recycled wind turbine blades, 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 then compared with those in the "Fiber Reinforced Concrete Decorative Wallboards" (JG / T 348-2011).

[0090] Example 2

[0091] The preparation method of the regenerated fan blade fiber reinforced concrete decorative wallboard in this embodiment and the types and contents of various raw materials are the same as those in Example 1, except that, in this embodiment, the structural layer II comprises 7 parts of type II regenerated fan blade fiber and 3 parts of alkali-resistant glass fiber.

[0092] Example 3

[0093] The preparation method of the regenerated fan blade fiber reinforced concrete decorative wallboard in this embodiment and 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 9 parts of type II regenerated fan blade fiber and 2 parts of alkali-resistant glass fiber.

[0094] Example 4

[0095] The preparation method of the regenerated fan blade fiber reinforced concrete decorative wallboard in this embodiment and 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 3 parts of type II regenerated fan blade fiber and 5 parts of alkali-resistant glass fiber.

[0096] The performance of the fiber-reinforced concrete decorative wallboards for regenerative fan blades prepared in Examples 1 to 4 was compared, and the results are shown in Table 1.

[0097] Table 1 Test results of Examples 1-4

[0098]

[0099] Table 1 shows the physical and mechanical properties of reinforced concrete decorative wallboards made from recycled fan blade fibers in different examples. As can be seen from the table, the density, water absorption, flexural strength, and impact strength of the reinforced concrete decorative wallboards prepared in Examples 1-3, using alkali-resistant recycled fan blade fibers in place of varying proportions of alkali-resistant glass fibers, all meet the requirements of "Fiber-Reinforced Concrete Decorative Wallboards" (JG / T 348-2011), and are suitable for architectural decoration applications, including interior and exterior wallboards for residences, commercial buildings, and public facilities. However, the physical and mechanical properties of the decorative wallboard in Example 4 did not meet the standards due to insufficient recycled fan blade fiber content.

[0100] Matters not described in the present invention are applicable to the prior art, and the raw materials involved are commercially available or obtained by conventional methods.

[0101] In summary, the recycled fan blade fiber-reinforced concrete decorative wallboards manufactured by the present invention utilize recycled fan blade fibers, leveraging the unique surface structure of the recycled fan blade fibers to enhance the mechanical and chemical interactions between the fibers and the concrete matrix. The former is due to the roughness of the fiber surface, and the latter is due to intermolecular interactions. This can enhance the performance of the decorative wallboards while reducing their production costs. The recycled fan blade fiber-reinforced concrete decorative wallboards manufactured by the present invention can be widely used in the field of architectural decoration, including residential, commercial buildings, and public facilities. Furthermore, the manufacturing process can be carried out on a standardized production line to ensure product consistency and quality.

[0102] 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 wallboard, characterized by: The decorative wall panel includes a decorative layer, a structural layer, an anchor and a steel frame, the anchor is used to connect the steel frame and the structural layer, and the decorative layer is arranged on the outside of the structural layer; the mortar for the decorative layer and the structural layer is sprayed sequentially by a spray gun, and a vibration directional dispersion platform is added at the spray gun mouth; 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 interface of the slurry pipe and the air pipe, the slurry pipe is used to transport the materials for making the decorative layer and the structural layer, the slurry pipe is connected to the vibration directional dispersion platform through a clamp, and the nozzles are multiple and arranged in parallel at the corresponding outlet ends of the vibration directional dispersion platform; The materials of the decorative layer include the following components by weight: 28.5-35 parts of cement; 10.5-14.3 parts of mineral admixture; 43-52 parts of sand; 20.4-30.6 parts of stone chips; 2-5 parts of recycled fan blade fiber; 2-5 parts of alkali-resistant glass fiber; 0.8-1.2 parts of water reducer; 11.4~14 parts water; The materials of the structural layer include the following components by weight: 26.5-32 parts of cement; 12.9-15.8 parts of mineral admixture; 8.8-12.5 parts of fine sand; 6.5-10 parts of medium sand; 6.5-10 parts of coarse sand; 5-9 parts of regenerated fan blade fiber; 2-5 parts of chopped alkali-resistant glass fiber; 0.9-1.5 parts of water reducer; 0.05-1 part of modifier; 10.8-13.5 parts of water; pre-treated alkali-resistant glass fiber mesh is arranged in intervals inside the structural layer; The regenerated fan blade fibers are obtained by cutting, crushing and continuous screening. The regenerated fan blade fibers are divided into type I regenerated fan blade fibers and type II regenerated fan blade fibers. The length of the type I regenerated fan blade fibers is 1.18 mm to 4.75 mm, of which particles with a diameter of less than 0.6 mm account for no more than 20%. The length of the type II regenerated fan blade fibers is 4.75 mm to 12.5 mm, of which particles with a diameter of less than 0.6 mm account for no more than 5%; The fiber-reinforced concrete decorative wallboard for the regenerative wind turbine blades has a density of 2.1 g / cm3, a compressive strength of 68.1 MPa, a flexural strength of 19.3 MPa, and an impact strength of 11.1 kJ / m2, and meets the frost resistance requirements in a 25-freeze-thaw cycle test.

2. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: The regenerated fan blade fibers are pre-treated for alkali resistance, and the treatment method is as follows: First, 3g of nano-ZrO2 was added to 60ml of ethanol solution and stirred thoroughly. Then, 6g of aminopropyltriethoxysilane and 30ml of deionized water were added for ultrasonic pre-dispersion to obtain APTES-ZrO2 particles. The particles were then added to a mixed solution of 1.5g of epoxy resin and 150ml of ethanol to obtain an APTES-ZrO2 sol solution for surface coating. Finally, the regenerated fan blade fiber was placed in the sol solution and fully immersed. After removal and drying, the APTES-ZrO2 coated fiber was finally obtained.

3. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: The processing method of the pre-treated alkali-resistant glass fiber mesh is as follows: ① Spray the adhesive on the surface of the mesh cloth. The adhesive is a powder and / or emulsion. The powder used is polyvinyl alcohol powder, and the emulsion used is polyvinyl acetate emulsion. The amount of powder used is 4-5% of the mass of the regenerated fan blade fiber, the mass of the water sprayed is 8-10% of the mass of the regenerated fan blade fiber, and the amount of emulsion used is 5-8% of the mass of the regenerated fan blade fiber; ② Take 3-5 pieces of regenerated fan blade fibers and spread them evenly on a flat surface; ③ Use the bonded mesh cloth to pick up the regenerated fan blade fibers.

4. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: 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 m² / kg and a density of 3.0 to 3.2 g / cm³; the mineral admixture is composed of one or more of slag, fly ash and silica fume, with a specific surface area of ​​200 to 600 m² / kg and a density of 2.8 to 3.2 g / cm³; the fly ash has a specific surface area of ​​300 to 600 m² / kg, a density of 2.0 to 2.5 g / cm³, and an SiO2 content of 40 to 70%; the silica fume has a specific surface area of ​​15,000 to 30,000 m² / kg and a density of 2.2 to 2.4 g / cm³. 3 The SiO2 content is between 85% and 98%.

5. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: The sand is quartz sand with a relative density of 2.65, an average particle size between 40 mesh and 80 mesh, a coarse sand particle size distribution range of 2.0 mm to 4.75 mm; a medium sand particle size distribution range of 0.425 mm to 2.0 mm; and a fine sand particle size distribution range of 0.075 mm to 0.425 mm; and a specific surface area of ​​the stone chips range of 100 to 800 m² / kg.

6. The fiber-reinforced concrete decorative wallboard 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.

7. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: The water reducer is a polycarboxylate water reducer, which is selected from polycarboxylate or polycarboxylate ether, with a solid content between 30% and 50% and a water reduction rate between 30% and 40%.

8. The fiber-reinforced concrete decorative wallboard for regenerative wind turbine blades according to claim 1, characterized in that: The modifier is a polyvinyl alcohol-sodium hexametaphosphate polymer composite aqueous solution, the mass ratio of polyvinyl alcohol to sodium hexametaphosphate is 1:1, the concentration is between 0.5 and 1%, the pH value is between 5 and 8, and the viscosity is between 10 and 1000 mPa·s.

9. A method for manufacturing a recycled wind turbine blade fiber reinforced concrete decorative wallboard, comprising manufacturing the recycled wind turbine blade fiber reinforced concrete decorative wallboard according to any one of claims 1 to 8, characterized in that: The following steps are involved: (1) Design and planning: Design and plan the decorative wall panels to determine the required size, shape, pattern and / or texture; (2) Prepare raw materials: Prepare the materials required for the decorative layer and structural layer by weight; (3) Prepare the mold: Make the mold required for the decorative wall panel according to the design drawings; (4) Preparation of mortar: Prepare the materials required for the decorative layer and structural layer according to the proportions; (5) Pouring mortar: Fill the mixed decorative layer and structural layer materials into the prefabricated mold in turn, lay a layer of mesh cloth every 3-5mm on the structural layer, and bury the connectors according to the installation requirements; then vibrate evenly; (6) Demolding and curing: demoulding the decorative wall panels from the formwork and curing the cast decorative wall panels; (7) Finishing: Finish the surface after the curing period.

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