Modification and reinforcement processing method for recycled waste pouring auxiliary material of wind power generation blade and fan blade

Abstract

The invention provides a modification and reinforcement processing method for a recycled material of a waste pouring auxiliary material of a wind power generation blade. The method comprises the following steps: recycling thermoplastic resin master batches from the waste pouring auxiliary material of the wind power generation blade; drying the thermoplastic resin master batch, and blending the dried thermoplastic resin master batch with a modified material to obtain a mixture; and carrying out melt extrusion granulation and / or injection molding on the mixture to obtain the reinforced material. Compared with the prior art, the method has the following beneficial effects that the material obtained after the wind power blade waste pouring auxiliary material is recycled and processed is modified and enhanced, mutual mixed utilization of various waste materials is achieved, the material utilization rate and applicability are greatly improved, the problems that the material using scenes are few due to the fact that the mechanical property of the recycled material is poor, and the like are solved; closed-loop recovery (that is, recovered materials can also be used for production of wind power generation blades) is achieved, the environmental and ecological system friendliness of blade manufacturing is improved, and zero-carbon production is achieved.

Description

Technical Field

[0001] This product is applicable to the field of wind turbine technology, specifically relating to a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades and wind turbine blades. Background Technology

[0002] Currently, waste materials generated during blade production, such as vacuum infusion auxiliary materials, foam waste, and fiberglass waste, are directly discarded, resulting in significant material waste. Related technologies have been developed for granulation and injection molding of these waste materials, successfully transforming them into plastic products usable in blade production. However, products made directly from recycled waste cannot fully meet the mechanical properties and other requirements of various applications. Therefore, an economical and effective modification and reinforcement method is urgently needed to improve the applicability of these products. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of this application is to provide a method for modifying and reinforcing recycled materials of waste injection auxiliary materials for wind turbine blades and wind turbine blades, so as to solve the above-mentioned problems existing in the prior art.

[0004] According to some embodiments of this application, one aspect of this application provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, comprising the following steps: Thermoplastic resin masterbatch is recovered from waste injection materials for wind turbine blades; The thermoplastic resin masterbatch is dried and then blended with the modified material to obtain a mixture. The mixture is melt-extruded and / or injection molded to obtain a reinforced material.

[0005] In some embodiments, the method for recycling the thermoplastic resin masterbatch includes: The waste injection auxiliary materials of wind turbine blades are pre-treated to separate the first waste material containing only thermoplastic resin and the second waste material containing thermoplastic resin coupled with thermosetting resin. The second waste material is soaked in an organic solvent. At a first temperature, the thermoplastic resin and thermosetting resin in the second waste material are softened. Then, it is transferred to an alkaline solution and washed at least once at a second temperature to perform solid-solid separation, thereby obtaining thermosetting resin particles and thermoplastic resin sheets. The thermosetting resin granules and thermoplastic resin sheets are dried separately. The thermoplastic resin sheets and the first waste are mixed and then granulated to obtain thermoplastic resin masterbatch.

[0006] In some embodiments, the pretreatment method includes: classifying, pre-separating, pre-cleaning, and pre-crushing the waste filling materials for the wind turbine blades.

[0007] In some embodiments, the classification step includes: classifying the waste filling auxiliary materials of the wind turbine blades into thermoplastic resins, thermoplastic resins coupled with thermosetting resins, and metal materials according to the composition of the materials; the pre-separation method includes at least one of manual separation, color sorting, and flotation; the pre-cleaning method includes: immersing the waste filling auxiliary materials of the wind turbine blades in a pre-cleaning solution to remove impurities.

[0008] In some embodiments, the pre-cleaning solution includes at least one of alkaline cleaning solution, acidic cleaning solution, neutral cleaning solution, bio-enzyme cleaning solution, and solvent-based cleaning solution.

[0009] In some embodiments, the immersion of the second waste in an organic solvent is performed under ultrasonic conditions.

[0010] In some embodiments, the pH value of the alkaline solution is 7 to 12.

[0011] In some embodiments, the alkaline solution includes at least one of sodium bicarbonate, sodium carbonate, potassium bicarbonate, potassium carbonate, ammonia, and silicone.

[0012] In some embodiments, the first temperature is 0°C to 50°C, and the second temperature is 20°C to 60°C.

[0013] In some embodiments, the organic solvent is a polar organic solvent.

[0014] In some embodiments, the dielectric constant of the polar organic solvent is not less than 15.

[0015] In some embodiments, the polar organic solvent includes at least one of acetone, toluene, isopropanol, and methylene chloride.

[0016] In some embodiments, the number of times the rubbing is performed is 1 to 5 times.

[0017] In some embodiments, the modified material includes at least one of fibrous materials, mineral materials, and nanomaterials.

[0018] In some embodiments, the amount of fiber material added is 1% to 50% of the mass of thermoplastic resin, the amount of mineral material added is 1% to 50% of the mass of thermoplastic resin, and the amount of nanomaterial added is 0.01% to 20% of the mass of thermoplastic resin.

[0019] In some embodiments, the fiber material includes at least one of chopped fibers, continuous long fibers, and fiber mats.

[0020] In some embodiments, the fiber material includes one or more of glass fiber, carbon fiber, aramid fiber, basalt fiber, ceramic fiber, and bio-fiber.

[0021] In some embodiments, the mineral material includes one or more of talc, mica, silicate, kaolin, calcium carbonate, calcium sulfate, and glass microspheres.

[0022] In some embodiments, the nanomaterials include one or more of nanoclay, carbon nanotubes, graphene, nanosilica, nanoalumina, and nanocellulose.

[0023] In some embodiments, the melt extrusion granulation method includes: melting, extrusion, cooling, pelletizing, sieving, and drying.

[0024] In some embodiments, the injection molding method is characterized by a molding temperature of 110°C to 300°C, a molding pressure of 0.1 MPa to 200 MPa, a molding speed of 0.05 m / s to 50 m / s, and a cooling time of 5 s to 1800 s.

[0025] According to some embodiments of this application, another aspect of this application provides a wind turbine blade, wherein a portion of the production material of the wind turbine blade is made of a reinforcing material obtained by any one of the methods described in the above embodiments.

[0026] Compared with the prior art, this application has the following beneficial effects: 1. The materials after recycling and processing waste filling auxiliary materials for wind turbine blades have been modified and enhanced, realizing the mutual mixing and utilization of various waste materials, which greatly improves the material utilization rate and applicability. It solves the problem that the poor mechanical properties of recycled materials lead to limited application scenarios, realizes closed-loop recycling (that is, the recycled materials can be used in the production of wind turbine blades), improves the environmental and ecosystem-friendly nature of blade manufacturing, and achieves zero-carbon production. 2. The modified and reinforced plastic products can be widely used in blade auxiliary material injection, web bonding, mold closing, post-processing, material stacking, screw sleeve protection, cable fixing and other scenarios, which improves the environmental protection and economy of wind turbine blade production. 3. The addition of relevant modified reinforcing materials can be done directly during injection molding or through stepwise granulation modification. There are no strict requirements on the processing steps, the equipment is highly adaptable, and the technology is easy to implement. Detailed Implementation

[0027] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0028] According to some embodiments of this application, one aspect of this application provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, comprising the following steps: Thermoplastic resin masterbatch is recovered from waste injection materials for wind turbine blades; The thermoplastic resin masterbatch is dried and then blended with the modified material to obtain a mixture. The mixture is melt-extruded and / or injection molded to obtain a reinforced material.

[0029] In some embodiments, the method for recycling the thermoplastic resin masterbatch includes: The waste injection auxiliary materials of wind turbine blades are pre-treated to separate the first waste material containing only thermoplastic resin and the second waste material containing thermoplastic resin coupled with thermosetting resin. The second waste material is soaked in an organic solvent. At a first temperature, the thermoplastic resin and thermosetting resin in the second waste material are softened. Then, it is transferred to an alkaline solution and washed at least once at a second temperature to perform solid-solid separation, thereby obtaining thermosetting resin particles and thermoplastic resin sheets. The thermosetting resin granules and thermoplastic resin sheets are dried separately. The thermoplastic resin sheets and the first waste are mixed and then granulated to obtain thermoplastic resin masterbatch.

[0030] In some embodiments, the pretreatment method includes: classifying, pre-separating, pre-cleaning, and pre-crushing the waste filling materials for the wind turbine blades.

[0031] In some embodiments, the classification step includes: classifying the waste filling auxiliary materials of the wind turbine blades into thermoplastic resins, thermoplastic resins coupled with thermosetting resins, and metal materials according to the composition of the materials; the pre-separation method includes at least one of manual separation, color sorting, and flotation; the pre-cleaning method includes: immersing the waste filling auxiliary materials of the wind turbine blades in a pre-cleaning solution to remove impurities.

[0032] In some embodiments, the pre-cleaning solution includes at least one of alkaline cleaning solution, acidic cleaning solution, neutral cleaning solution, bio-enzyme cleaning solution, and solvent-based cleaning solution.

[0033] In some embodiments, the immersion of the second waste in an organic solvent is performed under ultrasonic conditions.

[0034] In some embodiments, the pH value of the alkaline solution is 7 to 12.

[0035] In some embodiments, the alkaline solution includes at least one of sodium bicarbonate, sodium carbonate, potassium bicarbonate, potassium carbonate, ammonia, and silicone.

[0036] In some embodiments, the first temperature is 0°C to 50°C, and the second temperature is 20°C to 60°C.

[0037] In some embodiments, the organic solvent is a polar organic solvent.

[0038] In some embodiments, the dielectric constant of the polar organic solvent is not less than 15.

[0039] In some embodiments, the polar organic solvent includes at least one of acetone, toluene, isopropanol, and methylene chloride.

[0040] In some embodiments, the number of times the rubbing is performed is 1 to 5 times.

[0041] In some embodiments, the modified material includes at least one of fibrous materials, mineral materials, and nanomaterials.

[0042] In some embodiments, the amount of fiber material added is 1% to 50% of the mass of thermoplastic resin, the amount of mineral material added is 1% to 50% of the mass of thermoplastic resin, and the amount of nanomaterial added is 0.01% to 20% of the mass of thermoplastic resin.

[0043] In some embodiments, the fiber material includes at least one of chopped fibers, continuous long fibers, and fiber mats.

[0044] In some embodiments, the fiber material includes one or more of glass fiber, carbon fiber, aramid fiber, basalt fiber, ceramic fiber, and bio-fiber.

[0045] In some embodiments, the mineral material includes one or more of talc, mica, silicate, kaolin, calcium carbonate, calcium sulfate, and glass microspheres.

[0046] In some embodiments, the nanomaterials include one or more of nanoclay, carbon nanotubes, graphene, nanosilica, nanoalumina, and nanocellulose.

[0047] In some embodiments, the melt extrusion granulation method includes: melting, extrusion, cooling, pelletizing, sieving, and drying.

[0048] In some embodiments, the injection molding method is characterized by a molding temperature of 110°C to 300°C, a molding pressure of 0.1 MPa to 200 MPa, a molding speed of 0.05 m / s to 50 m / s, and a cooling time of 5 s to 1800 s.

[0049] According to some embodiments of this application, another aspect of this application provides a wind turbine blade, wherein a portion of the production material of the wind turbine blade is made of a reinforcing material obtained by any one of the methods described in the above embodiments.

[0050] Example 1 This embodiment provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, specifically including the following steps: S1. Waste filling materials for wind turbine blades are classified into thermoplastic resins (such as vacuum bags), thermoplastic resins coupled with thermosetting resins (such as release cloths and flow guides), and metal materials (such as steel wire reinforced fillers and pipe fasteners) according to the type of materials. Among them, metal materials are recycled separately. The thermoplastic resins and thermoplastic resins coupled with thermosetting resins are separated by color sorting to obtain the first waste containing only thermoplastic resins and the second waste containing only thermoplastic resins coupled with thermosetting resins. The second waste is crushed into small pieces smaller than 5cm×5cm×2mm and then soaked together with the first waste in a sodium bicarbonate solution with a pH of 8 to remove dust, oil and other impurities. S2. After separating the second waste and the first waste again by flotation or color sorting, the waste is transferred to acetone and soaked at room temperature for 15 hours to soften the thermoplastic resin and thermosetting resin in the second waste. Then, it is transferred to a sodium carbonate solution with a pH of 9 and washed three times at room temperature to perform solid-solid separation, thereby obtaining thermosetting resin particles and thermoplastic resin sheets. S3. After drying the thermoplastic resin sheet, it is mixed with the first waste material and then granulated by melt extrusion. The thermoplastic resin masterbatch is obtained by melting, extrusion, cooling, pelletizing, sieving, and secondary drying. This masterbatch is denoted as Sample 1. S4. Sample 1 and reinforcing fibers are melt-extruded and granulated again to obtain the reinforcing material, denoted as Sample 2. The specific operation is as follows: Sample 1 is dried at 120℃~140℃ for 4h~6h, and then fed into a twin-screw extruder (the length-to-diameter ratio of the screw is not less than 40:1) through the feeding port. Short-cut glass fibers are fed into the twin-screw extruder from the fiber feeding zone at a dosage of 30% of the mass of Sample 1. The temperatures of the feeding zone, melting zone, fiber feeding zone, mixing and vacuum exhaust zone, and discharge zone distributed sequentially from the feeding port to the die head are controlled to be 240℃~260℃, 260℃~280℃, 260℃~270℃, 260℃~270℃, and 240℃~260℃, respectively. The screw speed is 250rpm~400rpm, the discharge port diameter is 2mm~4mm, and the cooling temperature is 20℃~40℃.

[0051] Example 2 This embodiment provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, specifically including the following steps: S1. Sample 1 is blended with talc to obtain a mixture, wherein the amount of talc is 20% of the mass of the thermoplastic masterbatch; S2. The mixture is melt-extruded and granulated to obtain the reinforced material, which is designated as Sample 3. The specific operation is as follows: After drying at 120℃~140℃ for 4h~6h, it is fed into a twin-screw extruder (length-to-diameter ratio not less than 30:1). The temperatures of the feeding zone, melting zone, mixing zone, and homogenizing extrusion zone, which are distributed sequentially from the feeding port to the die head, are controlled to be 220℃~240℃, 250℃~270℃, 250℃~260℃, and 220℃~250℃, respectively. The screw speed is not less than 200rpm~400rpm, the discharge port diameter is 2mm~4mm, and the cooling temperature is 20℃~40℃.

[0052] Example 3 This embodiment provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, specifically including the following steps: S1. Sample 1 is blended with carbon nanotubes to obtain a mixture, wherein the amount of carbon nanotubes is 5.0% of the mass of Sample 1; S2. The mixture is melt-extruded and granulated. Following the method in Example 2, the mixture is melted, extruded, cooled, granulated, sieved and dried to obtain the reinforcing material, which is denoted as Sample 4.

[0053] Mechanical properties of samples 1 to 4 were compared, including tensile, bending and compression tests. The relevant test data are shown in Table 1. The strength of the doped and modified material is significantly improved compared with the unmodified material, and it has better performance.

[0054] Example 4 This embodiment provides a method for modifying and reinforcing recycled materials from waste filling auxiliary materials for wind turbine blades, specifically including the following steps: S1. Collect waste fiberglass cloth (such as waste from the production of wind turbine blades), place it in a crusher and cut it into short fiberglass with a length not exceeding 60mm. S2. After blending sample 1 with the chopped glass fiber obtained in step S1, a mixture is obtained, wherein the amount of chopped glass fiber is 30% to 50% of the mass of the thermoplastic masterbatch; S3. Inject the mixture into injection molded parts. Control the molding temperature during the injection molding process to 120℃, the molding pressure to 100MPa~200MPa, the molding speed to 1m / s, and the cooling time to 60s. These injection molded parts can be used for products such as limit blocks, flow guides, release cloths, eddy current generators, threaded sleeve protection sleeves, rain covers, plastic trays, wire protection parts, and cable ties in scenarios such as blade auxiliary material injection, web bonding, mold closing, post-processing, material stacking, screw sleeve protection, and cable fixing.

[0055] Table 1. Mechanical properties of the inorganic reinforcing materials obtained in Examples 1-3 before and after modification.

[0056] In Table 1, the test methods for tensile strength and tensile fracture strain refer to GB / T6343; the test methods for unnotched impact strength and notched impact strength refer to GB / T1043.1; and the test method for bending stress refers to GB / T9341.

[0057] Comparative Example 1: The only difference between this comparative example and Example 1 is that the amount of chopped glass fiber used is 15% of the mass of the thermoplastic masterbatch, and the material obtained is Sample 5.

[0058] Comparative Example 2: The only difference between this comparative example and Example 2 is that the amount of talc used is 10% of the mass of the thermoplastic masterbatch, and the material obtained is Sample 6. Comparative Example 3: The only difference between this comparative example and Example 3 is that the amount of carbon nanotubes used is 2.0% of the mass of the thermoplastic masterbatch, and the material obtained is Sample 7.

[0059] The mechanical properties of samples 5 to 7 prepared in Comparative Examples 1, 2, and 3 are compared and tested in Table 2. Table 2. Mechanical properties of inorganic reinforced materials before and after modification obtained from Comparative Examples 1-3

[0060] The specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A modified reinforcement processing method of wind power blade waste infusion auxiliary material recycled material, characterized in that, The method comprises the following steps: recovery of thermoplastic resin masterbatch from wind power blade waste infusion auxiliary materials; drying the thermoplastic resin masterbatch, and blending with modified materials to obtain a mixture; melt extrusion granulation and / or injection molding of the mixture to obtain a reinforced material.

2. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 1, characterized in that, The recovery method of the thermoplastic resin masterbatch comprises: pretreatment of the wind power blade waste infusion auxiliary materials to separate first waste containing only thermoplastic resin and second waste containing thermoplastic resin coupled with thermosetting resin; soaking the second waste in an organic solvent, softening the thermoplastic resin and thermosetting resin in the second waste at a first temperature, and then transferring into an alkaline solution to perform solid-solid separation by rubbing and washing at least once at a second temperature to obtain thermosetting resin particles and thermoplastic resin sheets; drying the thermosetting resin particles and the thermoplastic resin sheets respectively, mixing the thermoplastic resin sheets with the first waste, and then granulating to obtain the thermoplastic resin masterbatch.

3. The method of claim 2, wherein the method further comprises the step of: The pretreatment method comprises classification, pre-separation, pre-cleaning and pre-crushing of the wind power blade waste infusion auxiliary materials. ​ 4. The modified reinforced processing method of wind power blade waste infusion auxiliary material recycled material according to claim 3, characterized in that, The classification step comprises classification of the wind power blade waste infusion auxiliary materials into thermoplastic resin, thermoplastic resin coupled with thermosetting resin and metal materials according to the composition of the materials; the pre-separation method comprises at least one of manual separation, color selection and flotation; and the pre-cleaning method comprises soaking the wind power blade waste infusion auxiliary materials in a pre-cleaning solution to remove impurities.

5. The modified reinforced processing method of wind power blade waste infusion auxiliary material recycling material according to claim 4, characterized in that, The pre-cleaning solution comprises at least one of alkaline cleaning solution, acidic cleaning solution, neutral cleaning solution, biological enzyme cleaning solution and solvent cleaning solution.

6. The modified reinforced processing method of wind power blade waste infusion auxiliary material recycled material according to claim 2, characterized in that, The soaking of the second waste in the organic solvent is performed under ultrasonic conditions.

7. The method of claim 2, wherein the method further comprises the step of: The pH value of the alkaline solution is 7-12. ​ 8. The modified reinforced processing method of wind power blade waste infusion auxiliary material recycled material according to claim 7, characterized in that, The alkaline solution comprises at least one of sodium bicarbonate, sodium carbonate, potassium bicarbonate, potassium carbonate, ammonia water and silicone.

9. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 2, characterized in that, The first temperature is 0-50°C, and the second temperature is 20-60°C.

10. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 2, characterized in that, The organic solvent is a polar organic solvent.

11. The modified reinforcement processing method of wind power blade waste infusion reinforcement material recycling material according to claim 10, characterized in that, The dielectric constant of the polar organic solvent is not less than 15.

12. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 2, characterized in that, The number of rubbing and washing is 1-5 times.

13. The process for modifying and reinforcing the windmill blade waste infusion matrix scrap material according to claim 1, wherein, The modified material comprises at least one of fiber material, mineral material and nano material.

14. The method of claim 13, wherein the wind power blade waste injection aid material recycling material modification enhancement process is characterized by, The amount of the fiber material is 1-50% of the mass of the thermoplastic resin, the amount of the mineral material is 1-50% of the mass of the thermoplastic resin, and the amount of the nano material is 0.01-20% of the mass of the thermoplastic resin.

15. The method according to claim 13 or 14, wherein the waste wind turbine blade infusion material is a wind turbine blade waste infusion material. The fiber material comprises at least one of chopped fiber, continuous long fiber and fiber mat, the length of the chopped fiber is not more than 60 mm, and the length of the continuous long fiber is greater than 60 mm.

16. The modified reinforced processing method of wind power blade waste infusion auxiliary material recycled material according to claim 15, characterized in that, The fiber material comprises one or more of glass fiber, carbon fiber, aramid fiber, basalt fiber, ceramic fiber and biofiber.

17. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 13, characterized in that, The mineral material comprises one or more of talc, mica, silicate, kaolin, calcium carbonate, calcium sulfate and glass microbeads.

18. The method for modifying and reinforcing recycled materials from waste injection auxiliary materials for wind turbine blades according to claim 13, characterized in that, The nano material comprises one or more of nano clay, carbon nanotube, graphene, nano silicon dioxide, nano aluminum oxide and nano cellulose.

19. The method of claim 1, wherein the method is characterized by: The method for melt-extrusion granulation comprises melting, extrusion, cooling, cutting, screening and drying.

20. The method of claim 1, wherein the method is characterized by: In the method for injection molding, the molding temperature is 110-300 DEG C, the molding pressure is 0.1-200 MPa, the molding speed is 0.05-50 m / s, and the cooling time is 5-1800 s.

21. A wind turbine blade, characterised in that The part of the fan blade is made of the reinforced material obtained by the method according to any one of claims 1-20.

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