Recycling of pultrusion elements

Abstract

A method of separating a pultrusion element from a wind turbine blade component. The method comprises providing a wind turbine blade component comprising a plurality of embedded pultrusion elements arranged in a stack. The plurality of pultrusion elements includes a first pultrusion element and a second pultrusion element, where each pultrusion element includes a first side and an opposing second side. The wind turbine blade component includes an intermediate layer between a first side of the first pultruded element and a second side of the second pultruded element. The peel strength between the intermediate layer and the first pultrusion element and / or the second pultrusion element is weaker than the peel strength within the first pultrusion element and / or the second pultrusion element. The method includes separating the first pultrusion element from the second pultrusion element at a separation line extending in an intermediate layer disposed between the first pultrusion element and the second pultrusion element.

Description

Technical Field

[0001] This disclosure relates to wind turbine blades, particularly pultruded elements, such as spar caps for wind turbine blade components. This disclosure relates to the reuse of pultruded elements by separating them from wind turbine blade components. This disclosure also relates to the manufacture of composite components using such pultruded elements. Background Technology

[0002] As the need for companies to achieve a green transformation continues to grow, more resources are being invested in the recycling and reuse of components. For example, thermoset materials are being replaced with reusable thermoplastic materials, and easily extractable and intact components from decommissioned wind turbines are being given a new lease on life in new wind turbines. Furthermore, there is a desire to reduce the costs associated with the decommissioning of decommissioned wind turbines and wind turbine blades.

[0003] Wind turbine blades (such as wind turbine blade shell components) are typically constructed from layers of different materials infused and cured with resin. Therefore, the different layers are bonded to each other, and the reuse of these layers and how to reuse them is not straightforward. To provide cost-effective layer reuse, a simple and quick method is needed to separate the layers without causing damage. Furthermore, it is necessary to consider which layers to extract and where to reuse them.

[0004] Finally, there is a need to support methods for the reuse and recycling of components used in wind turbine blades that require minimal or no space, given that the manufacture of new wind turbines already requires a large amount of space. Summary of the Invention

[0005] In this context, the purpose of this disclosure can be regarded as providing a method for separating pultruded elements from wind turbine blade components.

[0006] Another object of this disclosure is to provide a method for manufacturing composite components, preferably wind turbine blade components, from multiple pultruded elements.

[0007] One or more of these objectives can be satisfied by aspects of this disclosure as described below.

[0008] A first aspect of this disclosure relates to a method for separating pultruded elements from a wind turbine blade component. The method includes providing a wind turbine blade component comprising a reinforcing structure. The reinforcing structure includes a plurality of embedded pultruded elements arranged in a stacked manner. The plurality of pultruded elements includes a first pultruded element and a second pultruded element. Each pultruded element includes a first side and an opposing second side. The wind turbine blade component includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element. The peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element.

[0009] The method further includes separating the first pultruded element from the second pultruded element at a separation line extending in an intermediate layer disposed between the first and second pultruded elements. Separating the first pultruded element from the second pultruded element may include, for example, peeling the first pultruded element from the second pultruded element at a separation line extending in an intermediate layer disposed between the first and second pultruded elements.

[0010] At the separation line extending in the intermediate layer disposed between the first and second pultruded elements, the separation or peeling of the first and second pultruded elements is due to the weaker peel strength between the intermediate layer and the first and / or second pultruded elements compared to the peel strength within the first and / or second pultruded elements. In other words, separation will occur at the intermediate layer because the peel strength holding the material together in the intermediate layer is weaker than the peel strength holding the material together in the first and / or second pultruded elements. Accordingly, due to the stronger peel strength in the first and / or second pultruded elements, separation does not occur in the first and / or second pultruded elements prior to separation in the intermediate layer.

[0011] A second aspect of this disclosure relates to a method for manufacturing a composite component, preferably a wind turbine blade component, from a plurality of pultruded elements. The method includes performing the method according to a first aspect of this disclosure to obtain a plurality of individual pultruded elements. The method further includes arranging the plurality of individual pultruded elements in a die, wherein an intermediate layer is arranged between adjacent pultruded elements. The plurality of individual pultruded elements may be connected in a longitudinal direction. The method further includes infusing the plurality of individual pultruded elements with resin. The method further includes causing the resin to cure or allowing the resin to cure to form the composite component.

[0012] By providing methods for separating pultruded elements from wind turbine blade components and methods for manufacturing composite components, pultruded elements can be reused, providing a sustainable lifeline for wind turbine blades.

[0013] Each pultruded element can be a carbon fiber reinforced pultruded element. The carbon fiber reinforced pultruded element preferably consists of carbon fibers embedded in a cured first resin. The cured first resin is preferably made of epoxy resin. The pultruded element preferably comprises multiple tows or rovings of carbon fiber material. Each pultruded element may comprise a total of 20-200 tows of carbon fiber material. The tows typically extend along the length of the pultruded element, i.e., substantially parallel to its longitudinal axis, or parallel to the spanwise direction when arranged in a blade shell. Carbon fiber is an expensive material, and the material in a wind turbine may comprise about 40% or even more carbon fiber. Therefore, the reuse of carbon fiber reinforced pultruded elements can significantly reduce the cost of manufacturing wind turbine blades. Carbon fiber reinforced pultruded elements embedded in epoxy resin provide the necessary tensile strength and resistance to vibration loads to serve as a reinforcing structure. Furthermore, it has been surprisingly found that most failures of carbon fiber pultruded elements occur before or during initial operation. Additionally, it has been found that the fatigue life of carbon fiber pultruded elements is much longer than that of other parts of the wind turbine blade components. Therefore, carbon fiber pultruded components separated after the wind turbine blade assembly is decommissioned (e.g., after 20 years of field operation) can be expected to have at least the same or even lower failure rates compared to new carbon fiber pultruded components.

[0014] The intermediate layer may include a flow medium material embedded in the cured second resin. The intermediate layer may include fibers. The flow medium material of the intermediate layer may include fibers. The fibers are preferably a mixture of carbon fibers and glass fibers. The intermediate layer (e.g., the flow medium material of the intermediate layer) may be conductive to electrically connect the first and second pultruded elements. The flow medium material may provide space for resin flow and / or filling during the infusion of the wind turbine blade component. The intermediate layer may bond adjacent pultruded elements together in a reinforcing structure.

[0015] The cured second resin of the intermediate layer can be a thermosetting resin. Preferably, the thermosetting resin of the intermediate layer is made of vinyl ester. Thermosetting resins are cheaper, stronger, and provide a stronger bond for pultruded elements than thermoplastic resins.

[0016] Alternatively, the cured second resin of the intermediate layer may be a thermoplastic resin. By providing a thermoplastic resin, the resin may be remolded and recyclable. Separating the first pultruded element from the second pultruded element at the intermediate layer may include heating at least the first pultruded element, the second pultruded element, and the intermediate layer to the melting point of the thermoplastic resin in the intermediate layer. The melting point may be the temperature at which the thermoplastic resin transitions from a solid to a non-solid phase (such as a soft, formable state). The melting point may depend on the type of thermoplastic resin provided. The first pultruded element, the second pultruded element, and the intermediate layer may be heated to a temperature between 100-300°C (e.g., between 105-150°C).

[0017] The intermediate layer may have a thickness between 0.05 and 1.5 mm, such as between 0.2 and 0.4 mm, such as 0.3 mm. The intermediate layer may have a width between 200 and 700 mm, such as between 300 and 600 mm, and / or a length between 30 and 120 m, such as between 50 and 100 m.

[0018] Peel strength is used to measure the bond strength of materials. Peel strength is the average load per unit width of bonded line required to separate bonded materials at an angle of 180 degrees. Higher peel strength indicates a tighter bond and requires greater force to separate the bonded materials. A weaker peel strength within the first and / or second pultruded elements than the peel strength between the intermediate layer and the first and / or second pultruded elements can be achieved by making the first resin of the first and / or second pultruded elements different from the second resin of the intermediate layer. For example, the first resin of the pultruded elements may consist substantially of a material different from the second resin of the intermediate layer; for example, the first resin of the pultruded elements may include an epoxy resin, while the second resin of the intermediate layer may include a vinyl ester. Alternatively, the composition of the first resin of the pultruded elements may differ from the composition of the second resin of the intermediate layer. For example, the first resin of the pultruded elements may include additives different from those of the second resin of the intermediate layer. Additionally, or alternatively, the first resin of the pultruded elements may be thermosetting, while the second resin of the intermediate layer may be thermoplastic.

[0019] Separating the first pultruded element from the second pultruded element at an intermediate layer may include applying a peel force between the first and second pultruded elements. For example, the peel force may be applied at the intermediate layer, such as at the separation line. The peel force may be applied by a wedge-shaped element introduced between the first and second pultruded elements. For example, the wedge may be introduced at the intermediate layer (e.g., at the separation line). The peel force may be applied to the wedge-shaped element. The peel force may be applied in a direction substantially parallel to the longitudinal direction of the first and / or second pultruded elements. Alternatively, the peel force may be applied in a direction substantially parallel to the transverse direction of the first and / or second pultruded elements. The method of applying the peel force is simple and can be performed outside the manufacturing site.

[0020] Wind turbine blade components can be shell components for wind turbine blades, spars caps for wind turbine blades, blade sections for wind turbine blades, spars boxes for wind turbine blades, or spars-type beams for wind turbine blades. Wind turbine blade components may include carbon fiber. This method is general, and components of wind turbine blades including pultruded elements can undergo this method.

[0021] Providing wind turbine components may include the steps of: providing a wind turbine blade, which includes wind turbine blade components, preferably spars; and separating the wind turbine blade components from the wind turbine blade. The wind turbine blade components may be cut out from the wind turbine blade. Separating the wind turbine blade components from the wind turbine blade allows other components not subjected to this method to remain at the dismantling site of the wind turbine blade.

[0022] Each pultruded element may be a pultruded sheet or a pultruded plate. A first pultruded element may include a first thickness extending between a first side and a second side of the first pultruded element. The first side may be the top side of the pultruded element, adapted to face the interior of the wind turbine blade component. The second side may be the bottom side of the pultruded element, adapted to face the exterior of the wind turbine blade component. The first thickness of the first pultruded element may be between 3 and 10 mm, such as between 4 and 7 mm. The first pultruded element may include a width extending between a first lateral side and an opposite second lateral side of the first pultruded element. The width of the first pultruded element may be between 20 and 300 mm, such as between 80 and 150 mm. The first pultruded element may include a length extending between a first end and an opposite second end of the first pultruded element. The length of the first pultruded element may be between 30 and 150 m, such as between 50 and 100 m, such as 70 and 100 m. The first pultruded element may have a pre-treated thickness, a pre-treated length, and a pre-treated width. The pretreatment thickness, pretreatment length, and pretreatment width may correspond to the length of the first pultruded element before one or more intermediate layers and / or one or more cover layers and / or one or more transition layers are removed.

[0023] The reinforcing structure may include a length extending between a first end and an opposing second end of the reinforcing structure. The length of the reinforcing structure may be between 30 and 120 m, such as between 50 and 100 m. The reinforcing structure may include a thickness extending between the first and second sides of the reinforcing structure. The thickness of the reinforcing structure may be between 1 and 70 mm, such as between 5 and 60 mm. The reinforcing structure may include a width extending between the first lateral side and the opposing second lateral side of the reinforcing structure. The width of the reinforcing structure may be between 200 and 700 mm, such as between 300 and 600 mm.

[0024] In a preferred embodiment, the reinforcing structure, such as a spar cap, comprises a stack of 1-15 pultruded elements arranged close together, preferably in the lateral direction, and more preferably a stack of 3-9 elements. Each stack may include up to 20 pultruded elements, such as 2-20 pultruded elements or 2-10 pultruded plates, arranged stacked on top of each other. Thus, each reinforcing structure (such as each spar cap) may include 10-200 pultruded elements.

[0025] A wind turbine blade component may include one or more covers overlying multiple embedded pultruded elements. The method may include, preferably by machining, removing one or more covers to expose a first pultruded element among the multiple embedded pultruded elements. Removing one or more covers may include grinding and / or milling one or more covers. One or more covers may be removed (e.g., grinding and / or milling) to expose a second side of the first pultruded element. One or more covers may be removed (e.g., grinding and / or milling) to expose a first side of a second pultruded element.

[0026] A wind turbine blade component may include one or more transition layers disposed between one or more core elements and reinforcing structures of the wind turbine blade shell component. The transition layers may be disposed between each of the stacks of reinforcing structures. The transition layers comprise resin and provide bonding between the core elements and reinforcing structures of the wind turbine blade shell component. The transition layers may provide bonding between adjacent stacks of reinforcing structures. One or more cover layers may be removed (e.g., ground and / or milled) to expose a first lateral side and / or a second lateral side of a first pultruded element and / or a first lateral side and / or a second lateral side of a second pultruded element.

[0027] The method may include the step of removing an intermediate layer or intermediate layer residue from a first side and / or a second side of a first pultruded element. Removing the intermediate layer or intermediate layer residue from the first side and / or the second side of the first pultruded element may include machining. Machining the intermediate layer or intermediate layer residue may include grinding and / or milling the intermediate layer or intermediate layer residue. The intermediate layer or intermediate layer residue may be removed (e.g., grinding and / or milling) to expose a first side of the first pultruded element. The intermediate layer or intermediate layer residue may be removed (e.g., grinding and / or milling) to expose a first side of a second pultruded element.

[0028] Removing the intermediate layer or residue from the first side of the first pultruded element may include machining the first pultruded element to a thickness of 100%, 99%, 95%, or 90% of a first thickness (e.g., pretreatment thickness). Removing the capping layer or residue from the second side of the first pultruded element may include machining the first pultruded element to a thickness of 100%, 99%, 95%, or 90% of the first thickness (e.g., pretreatment thickness).

[0029] Lateral removal of the transition layer or residue from the first side and / or the second side of the first pultruded element may include machining the first pultruded element to a width of 100%, 99%, 95%, or 90% of the pre-processed width. Removal of the transition layer or residue from the first end and / or the second end of the first pultruded element may include machining the first pultruded element to a length of 100%, 99%, 95%, or 90% of the pre-processed length.

[0030] The first pultruded element may have a pre-processed size. The pre-processed size may correspond to the size of the first pultruded element when it is first placed in the die. The pre-processed size may correspond to the size of the first pultruded element before machining. The first pultruded element may be machined to a negative tolerance size, i.e., a size smaller than the pre-processed size, for example, smaller than the length, width, and thickness of the pre-processed element. The negative tolerance size may be a first negative tolerance size, a second negative tolerance size, and / or a third negative tolerance size, respectively, corresponding to 99%, 95%, or 90% of the pre-processed size. By machining the first pultruded element to a negative tolerance size, a pultruded element with a higher carbon ratio can be provided. A pultruded element with a higher carbon ratio can be provided by removing residues of one or more cap layers and / or intermediate layers, or intermediate layers and / or one or more transition layers. By machining the first pultruded element to a negative tolerance size, the probability of removing all layers is higher.

[0031] The method may include the step of winding a first pultruded element. The first pultruded element may be cut before being wound. The first pultruded element may be cut before being arranged in a die.

[0032] The third aspect of this disclosure relates to pultruded elements obtained by the method of the first aspect.

[0033] A fourth aspect of this disclosure relates to the use of the pultruded elements of the third aspect of this disclosure in the methods of the second aspect of this disclosure. The pultruded elements may alternatively be used in methods for manufacturing building components (e.g., building components in buildings requiring structural reinforcement).

[0034] A fifth aspect of this disclosure relates to a separation station for use in a method for separating pultruded elements from a wind turbine blade assembly. The separation station includes a working surface configured to receive a wind turbine blade assembly including a reinforcing structure. The reinforcing structure includes a plurality of embedded pultruded elements arranged in a stacked manner. The plurality of pultruded elements includes a first pultruded element and a second pultruded element. Each pultruded element includes a first side and an opposing second side. The wind turbine blade assembly includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element. The peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element.

[0035] The separation station also includes a separation element configured to separate the first pultruded element from the second pultruded element at a separation line extending in an intermediate layer disposed between the first and second pultruded elements.

[0036] The separating element may be configured to apply a peeling force between the first pultrusion element and the second pultrusion element. The separating element may be a wedge-shaped element. The separating station may also include a first actuator configured to push the separating element between the first pultrusion element and the second pultrusion element.

[0037] The separation station may also include a clamping arrangement configured to clamp portions of the wind turbine blades to the working surface.

[0038] The separation element may include a first component configured to attach to a first longitudinal side of a wind turbine blade assembly extending in the longitudinal direction. The separation element may include a second component configured to attach to a second longitudinal side of the wind turbine blade assembly extending in the longitudinal direction. The separation station may include a second actuator configured to push the first and second components of the separation element apart in the thickness direction to apply a peeling force between the first and second pultruded elements.

[0039] The separation station may also include a machining unit, such as a grinding or milling unit, and a third actuator. The third actuator may be configured to move the machining unit along one or more degrees of freedom to position the machining unit near an intermediate layer or residue of the intermediate layer on the separated first pultruded element. The machining unit may be configured to remove the intermediate layer or residue of the intermediate layer from the separated first pultruded element.

[0040] As used herein, the term "separation" refers to the action of separating the first pultruded element and the second pultruded element so that the first pultruded component can move independently and / or be distinct from each other. The term "separation" can also refer to the action of completely separating the first pultruded element and the second pultruded element, such that they are disconnected, disconnected, detached, or separated.

[0041] Those skilled in the art will recognize that any one or more of the foregoing aspects of this disclosure and its embodiments may be combined with any one or more of the other aspects of this disclosure and its embodiments. Attached Figure Description

[0042] Embodiments of this disclosure will now be described in more detail with reference to the accompanying drawings. The drawings illustrate one mode of carrying out the invention and should not be construed as limiting other possible embodiments to the scope of the appended claims.

[0043] Figure 1 It is a schematic perspective view of a wind turbine; Figure 2 It is used for, for example Figure 1 A schematic perspective view of the wind turbine blades shown. Figure 3This is a schematic perspective view of a wind turbine blade component. Figures 4a to 4b This is a schematic cross-sectional view of an exemplary wind turbine blade component. Figures 5a to 5b This is a schematic cross-sectional view of an exemplary wind turbine blade component, and Figure 6 These are figures illustrating an exemplary method for separating pultruded elements from wind turbine components and an exemplary method for manufacturing composite components. Detailed Implementation

[0044] In the following description of the accompanying drawings, the same reference numerals refer to the same elements, and therefore it is not necessary to describe all the drawings.

[0045] Figure 1 The illustration depicts a conventional modern upwind turbine 2 based on the so-called "Danish concept," which has a tower 4, a nacelle 6, and a rotor with a substantially horizontal rotor shaft that may include an inclination angle of several degrees. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each blade having a blade root 16 closest to the hub and a blade tip 14 furthest from the hub 8.

[0046] Figure 2 A schematic diagram of an exemplary wind turbine blade 10 is shown. The wind turbine blade 10 has the shape of a conventional wind turbine blade, having a root tip 17 and a tip 15, and includes a root region 30 closest to the hub, a profiled or airfoil region 34 furthest from the hub, and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 includes a leading edge 18 facing the direction of rotation of the blade 10 when the blade is mounted on the hub 8, and a trailing edge 20 facing the opposite direction to the leading edge 18.

[0047] Airfoil region 34 (also called the profile region) has an ideal or near-ideal blade shape for generating lift, while root region 30 has a substantially circular or elliptical cross-section for structural reasons, which, for example, makes mounting the blade 10 to the hub easier and safer. The diameter (or chord) of root region 30 may be constant along the entire root region 30. Transition region 32 has a transition profile that gradually changes from the circular or elliptical shape of root region 30 to the airfoil profile of airfoil region 34. The chord length of transition region 32 typically increases with increasing distance r from the hub. Airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and trailing edge 20 of blade 10. The width of the chord decreases with increasing distance from the hub. Shoulder 38 of blade 10 is defined as the location where blade 10 has its maximum chord length. Shoulder 38 is typically located at the boundary between transition region 32 and airfoil region 34.

[0048] It should be noted that the chords of different sections of the blade are usually not located in a common plane because the blade may be twisted and / or bent (i.e., pre-bent), thus providing a corresponding twisted and / or bent path to the chord plane is to compensate for the most common case of the local velocity of the blade depending on the radius from the hub.

[0049] The wind turbine blade 10 includes a blade shell comprising two blade shell components or shell halves, typically made of fiber-reinforced polymer: a first blade shell component 24 and a second blade shell component 26. The wind turbine blade 10 may include additional shell components, such as a third and / or fourth shell component. The first blade shell component 24 is typically a pressure-side or upwind blade shell component. The second blade shell component 26 is typically a suction-side or downwind blade shell component. The first blade shell component 24 and the second blade shell component are fastened together with an adhesive (such as glue) along a bonding line or glued joint 28 extending along the trailing edge 20 and leading edge 18 of the blade 10. Typically, the root ends of the blade shell components 24, 26 have a semi-circular or semi-elliptical external cross-sectional shape.

[0050] Figure 3 As shown Figure 1 The diagram shows a schematic perspective view of a wind turbine blade shell component (such as a first blade shell component 24 or a second blade shell component 26). Blade shell components 24, 26 include wind turbine blade components 42. In a preferred embodiment, the wind turbine blade component 42 includes a reinforcing structure 50, such as a sparsity cap, formed by a plurality of pultruded elements 60 arranged in at least one stack 44 (see FIG. 4). The plurality of pultruded elements 60 include carbon fiber, which is an expensive material, and therefore, it is desirable to separate the plurality of pultruded elements 60 from the wind turbine blade component 42 for reuse. Figure 6 The document also shows an overview of a method 200 for separating multiple pultruded elements from a wind turbine blade component.

[0051] The wind turbine blade component of the present invention may alternatively be a shell component for a wind turbine blade, a blade section for a wind turbine blade, a sparsity box for a wind turbine blade, or a sparsity beam for a wind turbine blade. The reinforcing structure 50 extends in the longitudinal direction L of the blade and has a length Ls between a first end 56 and a second end 58 of the reinforcing structure. A plurality of pultruded elements 60 include a plurality of pultruded carbon fibers, preferably carbon fiber bundles, extending in the longitudinal direction L of the blade. The wind turbine blade component 42 may be separated from the wind turbine blade 10 or the wind turbine blade shell components 24, 26, for example, by cutting the wind turbine blade component 42 out, before the pultruded elements 60 are separated from it.

[0052] Figure 4a and Figure 4b The wind turbine blade component 42 (such as...) is shown as seen from line AA. Figure 3 A cross-sectional view of a wind turbine blade component. Figure 4b yes Figure 4a An enlarged view of the reinforcing structure 50. The wind turbine blade component 42 may be a shell component for a wind turbine blade, a sparsity cap for a wind turbine blade, a blade section for a wind turbine blade, a sparsity box for a wind turbine blade, or a sparsity beam for a wind turbine blade. The wind turbine blade component 42 includes the reinforcing structure 50. The reinforcing structure 50 is formed by a plurality of embedded pultruded elements 60 arranged in one or more stacks 44. The pultruded elements 60 may be embedded in a cured first resin of epoxy resin.

[0053] Figure 4a The diagram also illustrates a reinforcing structure 50 having a width Ws extending between a first lateral side 58 and a second lateral side 59. The width Ws extends in a direction substantially parallel to the chordal direction of the wind turbine blade and / or the wind turbine blade component. The reinforcing structure 50 has a thickness Ts extending between a first side 52 and a second side 54.

[0054] A reinforcing structure 50 is disposed between a cover layer 90, such as a blade shell material, and a core element 92. The core element 92 may be a sandwich structure core and made of a suitable core material. The cover layer 90 may be a reinforced cover sheet and made of a fiber-reinforced material (such as glass fiber) embedded in resin. The cover layer 90 may be removed, for example by machining, to expose a plurality of embedded pultruded elements 60, for example, the second side 64' of the first pultruded element 60' (see...). Figure 4b ).

[0055] A transition layer 84 is disposed between the reinforcing structure 50 and the core element 92. The transition layer 84 is also disposed between each stack of the stacks 44 of the reinforcing structure 50, such as between the first pultruded element 60' and the third pultruded element 60'''. The transition layer 84 may be a resin and serves to bond the reinforcing structure 50 and the core element 92 together or to bond adjacent stacks 44 of the reinforcing structure together. The transition layer 84 may be removed to expose a plurality of embedded pultruded elements 60, for example, the first lateral side 64' of the first pultruded element 60'.

[0056] The intermediate layer 80 is arranged between adjacent pultruded elements 60. Figure 4bThe diagram illustrates an intermediate layer 80 disposed between a first pultruded element 60' and a second pultruded element 60'', and more specifically, between a first side 62' of the first pultruded element 60' and a second side 64'' of the second pultruded element 60''. The purpose of the intermediate layer 80 is to retain and / or dispense a second resin and / or electrically connect adjacent pultruded elements 60. The intermediate layer 80 is made of a flow medium material (such as a mixture of glass fiber and carbon fiber). The second resin in the intermediate layer 80 can be a thermosetting or thermoplastic resin. The intermediate layer has a thickness Ti.

[0057] Figure 4b The diagram also illustrates the separation line L in the intermediate layer 80. The separation line L can be located anywhere in the intermediate layer 80 and represents the separation of the first pultruded element 60' and the second pultruded element 60'' (see [reference]). Figure 5a The splitting positions of the first pultrusion element 60' and the second pultrusion element 60''. For example, a wedge element 86 may be introduced at the splitting line L.

[0058] Figure 5a A separation station 100 for separating pultruded elements from a wind turbine component is shown. The separation station 100 includes a working surface 102 configured to receive a wind turbine blade component 42 and a separation element 104 configured to separate a first pultruded element from a second pultruded element. The separation station 100 may include a clamping arrangement configured to clamp the wind turbine blade component 42 to the working surface (not shown). For illustrative purposes, the wind turbine blade component 42 is illustrated as a first pultruded element 60' and a second pultruded element 60''.

[0059] The separating element 104 may be a wedge-shaped element 86. The station may include a first actuator 106' configured to push the separating element between the first pultrusion element 60' and the second pultrusion element 60''.

[0060] The separating element 104 may include a first component 104' and a second component 104'', the first component 104' being configured to attach to a first longitudinal side of a wind turbine blade component 42 extending in the longitudinal direction, and the second component 104'' being configured to attach to a second longitudinal side of a wind turbine blade component 42 extending in the longitudinal direction. A second actuator 106'' is configured to push the first component 104' and the second component 104'' of the separating element 104 apart in the thickness direction to apply a peeling force between the first pultruded element 60' and the second pultruded element 60''.

[0061] The separation station 100 may also include a machining device 108, such as a grinding or milling device, and a third actuator 106'''. The third actuator 106''' is configured to move the machining device 108 along one or more degrees of freedom to position the machining device 108 near the intermediate layer 80 or residue of the intermediate layer on the separated first pultruded element 60'. The machining device 108 is configured to remove the intermediate layer 80 or residue of the intermediate layer from the separated first pultruded element 60'.

[0062] This figure illustrates the separation of the first pultruded element 60' from the second pultruded element 60''. The first pultruded element 60'' and the second pultruded element 60'' have separated at the intermediate layer 80, preferably at the separation line in the intermediate layer (see Figure 80). Figure 4b Separate at ) location.

[0063] In the case where the second resin in the intermediate layer 80 is a thermoplastic resin, the first pultrusion element 60' and the second pultrusion element 60'' can be separated at the intermediate layer 80 by heating at least the first pultrusion element, the second pultrusion element, and the intermediate layer to the melting point of the thermoplastic resin in the intermediate layer. This melting point can be the temperature at which the thermoplastic resin changes from a solid to a non-solid phase (such as a soft, formable state).

[0064] In cases where the second resin in the intermediate layer 80 is a thermosetting resin (such as vinyl ester), the first pultrusion element 60' and the second pultrusion element 60'' can be separated by applying a peel force between the first pultrusion element 60' and the second pultrusion element 60'' (e.g., at the intermediate layer 80). The peel force can be applied by a wedge-shaped element 86 introduced into the first pultrusion element 60' and the second pultrusion element 60''.

[0065] Due to the weaker peel strength between the intermediate layer 80 and the first pultruded element 60' and / or the second pultruded element 60'' compared to the peel strength within the first pultruded element 60' and / or the second pultruded element 60'', the first pultruded element 60' and the second pultruded element 60'' may separate at the intermediate layer 80. In cases where the pultruded element 60 is embedded in epoxy resin and the intermediate layer 80 is embedded in vinyl ester resin, the peel strength may be weaker between the intermediate layer 80 and the pultruded element 60. Therefore, the difference in peel strength is due to the difference in bonding properties between the first and second resins in the cured state. In cases where the second resin in the intermediate layer 80 is thermoplastic, the difference in peel strength is due to the difference in bonding properties in the uncured heated state. The first side 62' of the first pultruded element 60' and / or the second side 64'' of the second pultruded element 60'' may be milled or ground to remove the intermediate layer 80 and / or residues in the intermediate layer 80.

[0066] Figure 5bThe pultruded element after separation is shown. To remove the intermediate layer 80 and / or its residue, the pultruded element 60 is machined. For example, the first side 62 and / or the second side 64 of the pultruded element 60 may be milled or ground to remove the intermediate layer 80 and / or its residue and / or the capping layer 90 or its residue. The first end and / or the second end of the pultruded element may be milled or ground to remove the transition layer 84 or its residue. The pultruded element 60 may be machined to negative tolerance dimensions S1, S2, S3, which correspond to dimensions smaller than the pre-processing dimension S of the pultruded element. The first negative tolerance dimension S1, the second negative tolerance dimension S2, and the third negative tolerance dimension S3 correspond to 99%, 95%, and 90% of the pre-processing dimension S of the pultruded element, respectively.

[0067] After the intermediate layer 80 has been removed from the pultruded element 60, the pultruded element 60 can be wound up for transport and reuse (e.g., in the manufacture of wind turbine blades).

[0068] Figure 6 Method 200 for separating pultruded elements from wind turbine blade components and method 1200 for manufacturing composite components are shown.

[0069] Method 200 for separating pultruded elements from a wind turbine blade assembly includes the step of providing a wind turbine blade assembly 202. The wind turbine blade assembly can be separated from a wind turbine blade, for example, by cutting the wind turbine blade assembly out. The wind turbine blade assembly includes a reinforcing structure. The reinforcing structure includes a plurality of embedded pultruded elements arranged in a stacked manner, including a first pultruded element and a second pultruded element. Each pultruded element includes a first side and an opposing second side. The wind turbine blade assembly includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element.

[0070] Method 200 may include removing the 204 cover layer to expose a first pultruded element among a plurality of embedded pultruded elements, such as a first side of the first pultruded element. Removing the 204 cover layer may include machining the 204a cover layer (e.g., milling or grinding).

[0071] The peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element. Therefore, method 200 includes separating the first pultruded element from the second pultruded element at a separation line 206, which extends in the intermediate layer disposed between the first pultruded element and the second pultruded element.

[0072] Separating the first pultruded element from the second pultruded element 206 may include applying a peeling force 206a between the first pultruded element and the second pultruded element, or alternatively heating at least the first pultruded element, the second pultruded element and the intermediate layer 206b to the melting point of the thermoplastic resin of the intermediate layer.

[0073] The peeling force can be applied by a wedge-shaped element introduced between the first pultrusion element and the second pultrusion element.

[0074] Method 200 may include removing an intermediate layer or residue of an intermediate layer from a first side of the first pultruded element 208. The intermediate layer or residue of an intermediate layer may be removed by machining 208a. The intermediate layer or residue of an intermediate layer may be removed from the first side of the first pultruded element by machining the first pultruded element to obtain a first pultruded element having a thickness corresponding to 100%, 99%, 95%, or 90% of the thickness prior to the machining step.

[0075] Method 200 may include winding a first pultruded element 210 into a roll, for example, to prepare pultruded elements(s) for transport to a manufacturing facility.

[0076] Repeatable method 200 is used to separate another pultruded element (such as a second pultruded element) from the wind turbine blade component. Repeatable method 200 continues until each of the plurality of pultruded elements is separated from the wind turbine blade component.

[0077] Figure 6 A method 1200 for manufacturing a composite component (preferably a wind turbine blade component) from multiple pultruded elements is also shown. Method 1200 includes performing method 200 1202 to obtain multiple pultruded elements, such as a first pultruded element and a second pultruded element.

[0078] Method 1200 includes arranging a plurality of individual pultruded elements 1204 in a die, wherein an intermediate layer is arranged between adjacent pultruded elements.

[0079] Method 1200 includes resin infusion of 1206 multiple individual pultruded elements, for example, using vacuum-assisted resin transfer molding.

[0080] Method 1200 includes causing 1208 resin to cure or allowing resin to cure to form a composite component.

[0081] project 1. A method for separating a pultruded element from a wind turbine blade component, comprising: - A wind turbine blade component including a reinforced structure comprising a plurality of embedded pultruded elements arranged in a stack, the plurality of pultruded elements including a first pultruded element and a second pultruded element, wherein each pultruded element includes a first side and an opposing second side, wherein the wind turbine blade component includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element, wherein the peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element, and - The first pultruded element is separated from the second pultruded element at a separation line that extends in an intermediate layer disposed between the first and second pultruded elements.

[0082] 2. The method according to Project 1, wherein each pultruded element is a carbon fiber reinforced pultruded element, preferably composed of carbon fibers embedded in a cured first resin, the cured first resin preferably being made of epoxy resin.

[0083] 3. The method according to any one of the preceding items, wherein the intermediate layer comprises a flow medium material embedded in a cured second resin.

[0084] 4. The method according to Project 3, wherein the second resin of the intermediate layer is a thermosetting resin, preferably made of vinyl ester.

[0085] 5. The method according to Project 3, wherein the second resin of the intermediate layer is a thermoplastic resin.

[0086] 6. The method according to item 5, wherein the step of separating the first pultruded element from the second pultruded element at the intermediate layer includes heating at least the first pultruded element, the second pultruded element and the intermediate layer to the melting point of the thermoplastic resin of the intermediate layer.

[0087] 7. The method according to any one of items 3 to 6, wherein the flow medium material of the intermediate layer comprises fibers, preferably a mixture of carbon fibers and glass fibers.

[0088] 8. The method according to any one of items 3 to 7, wherein the flow medium material of the intermediate layer is conductive so as to electrically connect the first pultrusion element and the second pultrusion element.

[0089] 9. The method according to any one of the preceding items, wherein the intermediate layer has a thickness between 0.05 and 1.5 mm, such as between 0.2 and 0.4 mm, such as 0.3 mm.

[0090] 10. The method according to any one of the preceding items, wherein by making the first resin of the first pultrusion element and / or the second pultrusion element different from the second resin of the intermediate layer, the peel strength within the first pultrusion element and / or the second pultrusion element is weaker than the peel strength between the intermediate layer and the first pultrusion element and / or the second pultrusion element.

[0091] 11. The method according to any one of the preceding items, wherein the step of separating the first pultrusion element from the second pultrusion element at the intermediate layer comprises applying a peeling force between the first pultrusion element and the second pultrusion element.

[0092] 12. The method according to any one of the preceding items, wherein the step of separating the first pultruded element from the second pultruded element includes, for example, peeling the first pultruded element from the second pultruded element at an intermediate layer disposed between the first pultruded element and the second pultruded element.

[0093] 13. The method according to item 12, wherein the peeling force is applied by a wedge-shaped element introduced between the first pultrusion element and the second pultrusion element.

[0094] 14. The method according to any one of the preceding items, wherein the wind turbine blade component is a shell component for a wind turbine blade, a spars cap for a wind turbine blade, a blade section for a wind turbine blade, a spars box for a wind turbine blade, or a spars-type beam for a wind turbine blade.

[0095] 15. The method according to any one of the preceding items, wherein the step of providing a wind turbine component includes providing a wind turbine blade and separating the wind turbine blade component from the wind turbine blade, the wind turbine blade including the wind turbine blade component, preferably a spar cap.

[0096] 16. The method according to any one of the preceding items, wherein the wind turbine blade component includes one or more covering layers covering a plurality of embedded pultruded elements, and wherein the method includes preferably removing one or more covering layers by machining to expose a first pultruded element among the plurality of embedded pultruded elements.

[0097] 17. The method according to any one of the preceding items, wherein the first pultruded element includes a first thickness extending between a first side and a second side of the first pultruded element, and wherein the first thickness is between 3 and 10 mm, such as between 4 and 7 mm.

[0098] 18. The method according to any one of the preceding items, wherein the first pultruded element includes a width extending between a first lateral side of the first pultruded element and an opposing second lateral side, and wherein the width is between 20 and 300 mm, such as between 80 and 150 mm.

[0099] 19. The method according to any one of the preceding items, wherein the first pultrusion element includes a length extending between a first end and an opposing second end of the first pultrusion element, wherein the length is between 30 and 150 m, such as between 50 and 100 m, such as between 70 and 100 m.

[0100] 20. The method according to any one of the preceding items, wherein the reinforcing structure includes a length extending between a first end and an opposing second end of the reinforcing structure, wherein the length is between 30 and 120 m, such as between 50 and 100 m.

[0101] 21. The method according to any one of the preceding items, wherein the reinforcing structure includes a thickness extending between a first side and a second side of the reinforcing structure, and wherein the thickness is between 1 and 70 mm, such as between 5 and 60 mm.

[0102] 22. The method according to any one of the preceding items, wherein the reinforcing structure includes a width extending between a first lateral side of the reinforcing structure and an opposing second lateral side, and wherein the width is between 200 and 700 mm, such as between 300 and 600 mm.

[0103] 23. The method according to any one of the preceding items, wherein the method includes the step of removing an intermediate layer or residue of the intermediate layer from a first side and / or a second side of the first pultrusion element.

[0104] 24. The method according to item 23, wherein the step of removing the intermediate layer or residue of the intermediate layer from the first side and / or the second side of the first pultrusion element includes machining.

[0105] 25. The method according to item 23, wherein the step of removing the intermediate layer or residue of the intermediate layer from the first side of the first pultruded element includes machining the first pultruded element to a thickness of 100%, 99%, 95% or 90% of the first thickness.

[0106] 26. The method according to any one of the preceding items, comprising the step of winding the first pultruded element.

[0107] 27. A method for manufacturing a composite component, preferably a wind turbine blade component, from multiple pultruded elements, comprising: - Perform the method according to any one of the foregoing items to obtain multiple individual pultruded elements. - Multiple individual pultruded elements are arranged in a die, with an intermediate layer arranged between adjacent pultruded elements. - Resin-infused multiple individual pultruded elements, and - Causes the resin to cure or allows the resin to cure in order to form a composite component.

[0108] 28. A pultruded element that can be obtained by the method according to any one of items 1 to 26.

[0109] 29. The pultruded element according to item 28 is used for the application of the method according to item 27.

[0110] 30. A separation station for use in the method according to any one of items 1 to 26, comprising: - A working surface configured to receive a wind turbine blade component including a reinforcing structure comprising a plurality of embedded pultruded elements arranged in a stacked manner, the plurality of pultruded elements including a first pultruded element and a second pultruded element, wherein each pultruded element includes a first side and an opposing second side, wherein the wind turbine blade component includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element, wherein the peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element. - A separation element configured to separate the first pultruded element from the second pultruded element at a separation line extending in an intermediate layer disposed between the first and second pultruded elements.

[0111] 31. The separation station according to item 30, wherein the separation element is configured to apply a peeling force between the first pultrusion element and the second pultrusion element.

[0112] 32. The separation station according to any one of items 30 to 31, wherein the separation element is a wedge-shaped element.

[0113] 33. The separation station according to any one of items 30 to 32 further includes a first actuator configured to push the separation element between the first pultrusion element and the second pultrusion element.

[0114] 34. The separation station according to any one of items 30 to 33 further includes a clamping arrangement configured to clamp wind turbine blade components to a working surface.

[0115] 35. The separation station according to any one of items 30 to 34, wherein the separation element comprises: - A first component configured for attachment to a first longitudinal side of a wind turbine blade component extending in the longitudinal direction. - A second component, configured to attach to a second longitudinal side of a wind turbine blade component extending in the longitudinal direction, and The separation station includes a second actuator configured to push a first and a second part of the separation element apart in the thickness direction to apply a peeling force between the first and second pultrusion elements.

[0116] 36. The separation station according to any one of items 30 to 35 further includes a machining device such as a grinding device or a milling device and a third actuator, wherein the third actuator is configured to move the machining device along one or more degrees of freedom to arrange the machining device near an intermediate layer or residue of an intermediate layer on the separated first pultruded element, wherein the machining device is configured to remove the intermediate layer or residue of an intermediate layer from the separated first pultruded element.

[0117] List of reference numerals 2 Wind turbines 4 towers 6. Cabin 8 hubs 10 blades 13 shells 14. Leaf tips 15 distal end 16. Leaf base 17. Root tip 18. Predestined Fate 20 trailing edge 24 First blade shell component (pressure side) 26 Second blade shell component (suction side) 30 Root region 32 Transition Zone 34. Airfoil area 36 terminal area 38 Shoulders 42 Wind turbine blade components 44 Stacking 50 Reinforced Structure 52. The first side of the reinforced structure 54. The second side of the reinforced structure 56. First end of the reinforcing structure 57. The second end of the reinforcing structure 58. First lateral side of the reinforcing structure 59. Second lateral side of the reinforced structure 60 (more than) pultruded elements 60' First pultruded element 60'' Second pultruded element 60''' Third pultruded element 62 First side of pultruded element 62' First side of the first pultruded element 62'' First side of the second pultruded element 64 The second side of the pultruded element 64' Second side of the first pultruded element 64'' Second side of the second pultruded element 66 First lateral side of pultruded element 66' First lateral side of the first pultruded element 66''' First lateral side of the third pultruded element 68 Second lateral side of pultruded element 68' Second lateral side of the first pultruded element 68''' Second lateral side of the third pultruded element 70 First end of pultruded element 70' First end of the first pultruded element 72 The second end of the pultruded element 72' Second end of the first pultruded element 80 Intermediate layer or residue of intermediate layer 82 Separation Line 84 Transition Layer 86 Wedge-shaped elements 90 Covering layer 92-core components 100 Separation Station 102 Working Surface 104 Separation Element 104' First component of the separation element The second component of the 104'' separating element 106 Actuators 106' First actuator 106'' Second Actuator 106''' Third actuator 108 Machining Equipment 200 Separation Methods 202 provides wind turbine blade components. 204 Remove Overlay 204a machining 206 Separation 206a Apply peeling force 206b Heating 208 Remove intermediate layer or residue 208a Machining 210 winding Manufacturing method of 1200 1202 Execution method to obtain multiple pultruded elements 1204 Arranges multiple pultruded elements 1206 Injection of Multiple Pultruded Components 1208 causes resin to cure or allows resin to cure. Te Thickness of pultruded components Le Length of pultruded element We pultruded element width Ts reinforcement structure thickness Ts Reinforcement Structure Length Ws enhances the width of the structure Thickness of Ti interlayer L-separation line S Pre-processing dimensions of pultruded elements S1 First negative tolerance dimension S2 Second negative tolerance dimension S3 is the third negative tolerance dimension.

Claims

1. A method for separating a pultruded element from a wind turbine blade component, comprising: - A wind turbine blade component including a reinforced structure comprising a plurality of embedded pultruded elements arranged in a stack, the plurality of pultruded elements including a first pultruded element and a second pultruded element, wherein each pultruded element includes a first side and an opposing second side, wherein the wind turbine blade component includes an intermediate layer between the first side of the first pultruded element and the second side of the second pultruded element, wherein the peel strength between the intermediate layer and the first pultruded element and / or the second pultruded element is weaker than the peel strength within the first pultruded element and / or the second pultruded element, and - The first pultruded element is separated from the second pultruded element at a separation line that extends in the intermediate layer disposed between the first pultruded element and the second pultruded element.

2. The method according to claim 1, wherein, Each pultruded element is a carbon fiber reinforced pultruded element, preferably composed of carbon fibers embedded in a cured first resin, which is preferably made of epoxy resin.

3. The method according to any one of the preceding claims, wherein, The intermediate layer comprises a flow medium material embedded in a cured second resin.

4. The method according to claim 3, wherein, The second resin in the intermediate layer is a thermosetting resin, preferably made of vinyl ester.

5. The method according to claim 3, wherein, The second resin in the intermediate layer is a thermoplastic resin.

6. The method according to claim 5, wherein, The step of separating the first pultruded element from the second pultruded element at the intermediate layer includes heating at least the first pultruded element, the second pultruded element, and the intermediate layer to the melting point of the thermoplastic resin in the intermediate layer.

7. The method according to any one of claims 3 to 6, wherein, The flow medium material of the intermediate layer comprises fibers, preferably a mixture of carbon fibers and glass fibers.

8. The method according to any one of the preceding claims, wherein, The step of separating the first pultruded element from the second pultruded element at the intermediate layer includes applying a peeling force between the first pultruded element and the second pultruded element.

9. The method according to claim 8, wherein, The peeling force is applied by a wedge-shaped element introduced between the first pultrusion element and the second pultrusion element.

10. The method according to any one of the preceding claims, wherein, The wind turbine blade component includes one or more covering layers that cover the plurality of embedded pultruded elements, and wherein the method includes preferably removing the one or more covering layers by machining to expose the first pultruded element among the plurality of embedded pultruded elements.

11. The method according to any one of the preceding claims, wherein, By making the first resin of the first pultrusion element and / or the second pultrusion element different from the second resin of the intermediate layer, it is possible to achieve a peel strength within the first pultrusion element and / or the second pultrusion element that is weaker than the peel strength between the intermediate layer and the first pultrusion element and / or the second pultrusion element.

12. The method according to any one of the preceding claims, wherein, The method includes the step of removing the intermediate layer or residue of the intermediate layer from the first side and / or the second side of the first pultruded element.

13. A method for manufacturing a composite component, preferably a wind turbine blade component, from multiple pultruded elements, comprising: - Perform the method according to any one of the preceding claims to obtain a plurality of individual pultruded elements. - The plurality of individual pultruded elements are arranged in a die, wherein an intermediate layer is arranged between adjacent pultruded elements. - Infuse the plurality of individual pultruded elements with resin, and - Causing the resin to cure or allowing the resin to cure in order to form the composite component.

14. A pultruded element that can be obtained by the method according to any one of claims 1 to 12.

15. Use of the pultruded element according to claim 14 in the method according to claim 13.

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