Methods and apparatus for re-purposing decomissioned wind turbine blades

Abstract

An overhead signage structure includes a first vertical post and a second vertical post laterally-spaced from the first vertical post. Each post has a vertically oriented central axis, a lower end fixably coupled to the ground, and an upper end distal the ground. In addition, the signage structure includes a horizontal beam comprising a first decommissioned wind turbine blade. The beam has a horizontally oriented central axis, a first end, and a second end opposite the first end. The first end of the beam is fixably coupled to the upper end of the first vertical post and the second end of the beam is fixably coupled to the upper end of the second vertical post. Further, the signage structure includes one or more signs fixably coupled to the beam.

Description

METHODS AND APPARATUS FOR RE-PURPOSING DECOMISSIONED WIND TURBINE BLADESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. provisional patent application Serial No. 63 / 585,832 filed September 27, 2023, and entitled “Structural Repurposing of Decommissioned Wind Turbine Blade (DWTBs) as Highway Overhead Sign Structure (OSSs)," which is hereby incorporated herein by reference in its entirety for all purposes.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.BACKGROUND

[0003] The disclosure relates generally to methods and apparatus for repurposing of decommissioned wind turbine blades. More particularly, the disclosure relates to methods and apparatus for utilizing decommissioned wind turbine blades to support signage.

[0004] Wind power has become a significant source of green energy in the past decade and is expected to grow. As of June 2023, the total land-based wind generating capacity in the U.S. reached approximately 138 gigawatts, contributing 10% to the nation's electricity demand. The U.S. Department of Energy predicts wind power will supply about 20% of the U.S.'s electricity demands by 2030 (~ 224 gigawatts) and about 35% by 2050 (~ 404 gigawatts). With the rapid growth of wind power, it is expected that thousands of wind turbines will reach the end of their useful lives, typically about 20 years, in the coming years. At the end of the life of a wind turbine, it is typically decommissioned and dismantled. Notably, 6% to 14% of the mass of a wind turbine including, for example, the mass of the blades, nacelle cover, and rotor cover comprises composite materials such as fiber-reinforced polymer (FRP) materials. Consequently, it is estimated that about 16.8 million tons of FRP materials from decommissioned wind turbines will need to be disposed of or recycled by 2030 and about 39.8 million tons by 2050. By 2050, it is estimated that US landfills will receive over 350,000 tons of decommissioned wind turbine blades annually.BRIEF SUMMARY OF THE DISCLOSURE

[0005] Embodimetns of structures employing decommissioned wind turbine blades are disclosed herein. In one embodiment, an overhead signage structure comprises a first vertical post and a second vertical post laterally-spaced from the first vertical post. Each post has a vertically oriented central axis, a lower end fixably coupled to the ground, and an upper end distal the ground. In addition, the signage structure omprises a horizontal beam comprising a first decommissioned wind turbine blade. The beam has a horizontally oriented central axis, a first end, and a second end opposite the first end. The first end of the beam is fixably coupled to the upper end of the first vertical post and the second end of the beam is fixably coupled to the upper end of the second vertical post. Further, the signage structure omprises one or more signs fixably coupled to the beam.

[0006] Embodiments of methods for repurposing decommissioned wind turbine blades into structures are disclosed herein. In one embodiment, a method for constructing an overhead signage structure comprises (a) obtaining a first decommissioned wind turbine blade having a central axis, a first end, and a second end opposite the first end. In addition, the method comprises (b) raising the first decommissioned wind turbine blade over a road after (a). Further, the method comprises (c) after (a) and (b), coupling the first end of the first decommissioned wind turbine blade to a first vertical post and coupling the second end of the first decommissioned wind turbine blade to a second vertical post with the first decommissioned wind turbine blade raised over the road and with the central axis oriented horizontally. The method also comprises (d) mounting a road sign to the first decommissioned wind turbine blade.

[0007] Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designingother structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a detailed description of various exemplary embodiments, reference will now be made to the accompanying drawings in which:

[0009] FIG. 1 is a perspective view of an embodiment of a structure in accordance with the principles described herein;

[0010] FIG. 2 is a perspective view of one of the base brackets of the structure of FIG. 1 ;

[0011] FIG. 3 is an enlarged, partial perspective view of an embodiment of coupling between two decommissioned turbine blades for use in overhead signage structures;

[0012] FIG. 4 is an enlarged, partial perspective view of an embodiment of coupling between one decommissioned turbine blade and the ground for use in overhead signage structures;

[0013] FIG. 5 is a perspective view of an embodiment of an overhead signage structure in accordance with the principles described herein;

[0014] FIG. 6 is a perspective view of an embodiment of an overhead signage structure in accordance with the principles described herein;

[0015] FIG. 7 is a perspective view of an embodiment of an overhead signage structure in accordance with the principles described herein;

[0016] FIG. 8 is a schematic illustration of an embodiment of a method in accordance with the principles described herein for constructing the structure of FIG. 1 , FIG. 5, FIG. 6 or FIG. 7;

[0017] FIG. 9 is a perspective view of an embodiment of a signage structure in accordance with the principles described herein;

[0018] FIG. 10 is a perspective view of an embodiment of a signage structure in accordance with the principles described herein;

[0019] FIG. 11 is a perspective view of an embodiment of a shade structure in accordance with the principles described herein; and

[0020] FIG. 12 is a perspective view of an embodiment of a solar power structure in accordance with the principles described herein.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0022] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

[0023] Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11 , 0.12, 0.13, etc.).

[0024] In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to... .” As used herein, the phrases “consist(s) of” and “consisting of” are used to refer to exclusive components of a composition, meaning only those expressly recited components are included in the composition; whereas the phrases “consist(s) essentially of’ and “consisting essentially of” are used to refer to the primary components of a composition, meaning that only small or trace amounts of components other than the expressly recited components (e.g., impurities, byproducts, etc. ) may be included in the composition. For example, a composition consisting of X and Y refers to a composition that only includes X and Y,and thus, does not include any other components ; and a composition consisting essentially of X and Y refers to a composition that primarily comprises X and Y, but may include small or trace amounts of components other than X and Y. In embodiments described herein, any such small or trace amounts of components other than those expressly recited following the phrase “consist (s) essentially of” or “consisting essentially of” preferably represent less than 5.0 wt% of the composition, more preferably less than 4.0 wt% of the composition, even more preferably less than 3.0 wt% of the composition, and still more preferably less than 1.0 wt% of the composition. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. Use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim.

[0025] The term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct engagement between the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a particular axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to a particular axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. As used herein, the terms “approximately,” “about,” “substantially,” and the like mean within 10% (i.e., plus or minus 10%) of the recited value. Thus, for example, a recited angle of “about 80 degrees” refers to an angle ranging from 72 degrees to 88 degrees.

[0026] As previously described, the quantity of FRP materials from decommissioned wind turbine blades is expected to be substantial and continue to grow in the coming years. As a result, disposal of decommissioned wind turbine blades is expected to pose significant challenges, which may lead to environmental concerns and inefficient resource utilization. Unfortunately, recycling decommissioned wind turbine blades presents challenges due to their composition, which includes about 80% to 90%composite materials (e.g., FRP materials). In particular, recycling such composite materials requires shredding the blades and then attempting to separate fibers from the matrix, which can be a time and energy intensive process. Consequently, as the decommissioning of wind turbines continues to increase, finding alternative uses for wind turbine blades is a pressing concern and growing need. Accordingly, embodiments described herein are directed to the reuse of decommissioned wind turbine blades as structural members or elements, which offers the potential to minimize waste, reduce use of landfills, reduce carbon emissions, and reduced recycling energy usage, while promoting sustainable practices in the construction, transportation, and energy sectors. More specifically, and as will be described in more detail below, embodiments described herein are directed to methods and apparatus for repurposing decommissioned wind turbine blades (in whole or part) as support structures for overhead signage, billboards, and solar panels.

[0027] Referring now to FIG. 1 , an embodiment of a structure 10 including a plurality of repurposed, decommissioned wind turbine blades 50 is shown. In this embodiment, structure 10 is an overhead signage structure including a pair of laterally-spaced vertical support posts 20, a horizontal signage support beam 30 extending between posts 20, and a plurality of signs 40 coupled to support beam 30. Each vertical support post 20 has a vertically oriented central or longitudinal axis 25, a first or lower end 20a fixably secured to the ground 60, and a second or upper end 20b distal the ground 60 and coupled to the support beam 30. Support beam 30 has a horizontally oriented central or longitudinal axis 35, a first end 30a fixably coupled to the upper end 20b of one support post 20 and a second end 30b fixably coupled to the upper end 20b of the other support post 20. Each sign 40 is a rigid board fixably coupled to support beam 30 between ends 30a, 30b.

[0028] In this embodiment, structure 10 is used to present information to vehicles (and people therein) traveling along a road or highway 61 comprising a plurality of laterally adjacent lanes 62. Thus, highway 61 is positioned between vertical posts 20 and below support beam 30 and signs 40 mounted thereto. Support beam 30 spans all of the lanes 62 of highway 61 , and supports signs 40 overhead of highway 61. Although highway 61 shown in FIG. 1 includes a plurality of laterally adjacent lanes 62, in other embodiments, the road or highway (e.g., highway 61) may include only a single lane (e.g., one lane 62). Thus, in general, embodiments of overheadsignage structures disclosed herein (e.g., structure 10) can be used in connection with roads having one or more lanes.

[0029] In this embodiment, each support post 20 and support beam 30 is formed by a single decommissioned wind turbine blade 50. In other words, the single decommissioned wind turbine blade 50 of each post 20 extends continuously from lower end 20a to upper end 20b, and the single decommissioned wind turbine blade 50 of beam 30 extends continuously from end 30a to end 30b. In general, each decommissioned wind turbine blade 50 can cut to a predetermined, desired length (measured axially between the corresponding ends 20a, 20b, 30a, 30b) to form the corresponding support post 20 or support beam 30. Most decommissioned wind turbine blades (e.g., each blade 40) have a length ranging from 40 to 60 meters (~ 131 to 196 feet), and thus, each post 20 and support beam 30 can have a length of up to 60 meters (~ 196 feet) and be defined by a single decommissioned wind turbine blade 50. Typically, each lane 62 of highway 61 has a width of 12 feet (~ 3.7 meters). Accordingly, one support beam 30 defined by a single decommissioned wind turbine blade 50 can span over ten lanes 62 and up to a maximum of about sixteen lanes 62. Although each support post 20 and beam 30 is made of a single decommissioned wind turbine blade 50 in this embodiment of system 10, as will be described in more detail below, in other embodiments, fewer than all the posts (e.g., posts 20) and beam (e.g., beam 30) may be made of decommissioned wind turbine blades 50.

[0030] In general, decommissioned wind turbine blades 50 have twisted airfoil shapes. Prior to being cut at the desired locations and to the desired length for use as posts 20 and beam 30, each decommissioned wind turbine blade 50 has a width that generally increases moving from each of its ends toward a middle portion. In the embodiment of structure 10 shown in FIG. 1 , blades 50 employed for posts 20 are cut, oriented, and positioned such that their widths generally increase moving axially (relative to axes 25) from lower end 20a to upper ends 20b; and blades 50 employed for beam 30 is cut, oriented, and positioned such that its widths generally increase moving axially (relative to axes 35) from each end 30a, 30b toward an axial location of maximum width between ends 30a, 30b.

[0031] As posts 20 and beam 30 are made of decommissioned wind turbine blades 50, the couplings between upper ends 20b of posts 20 and ends 30a, 30b of beam30, and the couplings between lower ends 20a of posts 20 and the ground 60 are tailored to the geometry and unique contours of the outer surfaces of blades 50. In particular, lower end 20a of each post 20 is fixably secured to the ground with a coupling 70, and upper end 20b of each post 20 is fixably coupled to a corresponding end 30a, 30b of beam 30 with a connector 80.

[0032] Referring now to FIG. 2, one coupling 70 is shown. In this embodiment, coupling 70 is a rigid, U-shaped bracket having a central or longitudinal axis 75, a first end 70a, and a second end 70b. In addition, coupling 70 includes a base 71 and a blade connection flange 76 extending perpendicularly from base 71 . Base 71 and flange 76 both extending axially (relative to axis 75) from first end 70a to second end 70b. In this embodiment, base 71 is a generally flat, elongated U-shaped plate having an upper planar surface or face 71a, a lower planar surface or face 71b oriented parallel to upper surface 71a, a concave inner lateral side 72a extending between surfaces 71a, 71b, a convex outer lateral side 72b extending between surfaces 71a, 71b, and a plurality of axially-spaced holes 74 extending from upper side 71 a to lower side 71 b and laterally positioned between sides 72a, 72b.

[0033] Referring still to FIG. 2, connection flange 76 extends upwardly from inner lateral side 72a and is oriented perpendicular to upper surface 71 a. Connection flange 76 is generally elongated, curved U-shaped plate having an outer convex surface 76a oriented perpendicular to upper surface 71a of base 71 , an inner concave surface 76b oriented parallel to surface 76a, a lower lateral side 77a extending between surfaces 76a, 76b and fixably attached or integral with inner lateral side 72a of base 71 , an upper lateral side 77b extending between surfaces 76a, 76b and distal base 71 , and a plurality of axially-spaced holes 78 extending from outer surface 76a to inner surface 76b and laterally positioned between sides 77a, 77b.

[0034] Referring again to FIG. 1 , lower end 20a of each post 20 is secured to the ground 60 with one coupling 70. Attachment of one coupling 70 to the ground 60 and the lower end 20a of the corresponding post 20 will be described it being understood both couplings 70 are attached in the same manner. In particular, coupling 70 is positioned about lower end 20a with lower surface 71b of base 71 seated against a planar upper end of a rigid footing or piling proximal or protruding from the ground 60 and inner concave surface 76b of connection flange 76 slidinglyengaging the outer surface of post 20. As previously described, the decommissioned wind turbine blade 50 defining post 20 has a twisted airfoil shape, and thus, inner concave surface 76b of connection flange 76 is generally shaped to slidingly engage the twist airfoil shape of the decommissioned wind turbine blade 50. Base 71 is fixably attached to the ground 60 via rigid bolts that extend from the footing or piling through aligned holes 74 and nuts that are threaded onto such bolts to compress base 71 against the planar upper end of the footing or piling; and connection flange 76 is fixably attached to post 20 via bolts that extend through holes 78 and aligned holes in lower end 20a, and nuts that are threaded onto such bolts to compress connection flange 76 against the outer surface of post 20.

[0035] Referring still to FIG. 1 , as previously described, upper end 20b of each post 20 is fixably coupled to a corresponding end 30a, 30b of beam 30 with a connector 80. Each connector 80 is the same, and thus, one connector 80 will be described it being understood the other connector 80 is the same. In this embodiment, connector 80 has a lower end 80a, an upper end 80b, a receptacle or recess 81 extending vertically from lower end 80a, and a through passage 82 extending horizontally through upper end 80b. Passage 82 is oriented perpendicular to a projection of receptacle 81. More specifically, passage 82 has a central axis coaxially aligned with and / or parallel to horizontal central axis 35 of beam 30, and recess 81 has a central axis coaxially aligned with and / or parallel to vertical central axis 25 of the corresponding post 20.

[0036] Upper end 20b of each beam 20 is seated and secured within recess 81 of the corresponding connector 80, and each end 30a, 30b of beam 30 is seated and secured within passage 82 of the corresponding connector 80. In this embodiment, upper end 20b of each beam 20 is secured within recess 81 of the corresponding connector 80 via bolts that pass through the connector 80 and upper end 20b, and each end 30a, 30b of beam 30 is secured within passage 82 of the corresponding connector 80 via bolts that pass through the connector 80 and end 30a, 30b.

[0037] Although posts 20 and beam 30 are fixably coupled with connectors 80 in the embodiment of structure 10 shown in FIG. 1 , in other embodiments, posts 20 and beam 30 may be fixably coupled with other connectors, couplings, or devices. For example, referring briefly to FIG. 3, an alternative coupling between one exemplary post 20 and beam 30 is shown. Although the coupling is only shown between oneexemplary post 20 and beam 30, it should be appreciated that the coupling shown in FIG. 3 could also be used to fixaby couple the other post 20 to beam 30. In this embodiment, upper end 20b of post 20 is fixably coupled to end 30a of beam 30 with a plurality of rigid L-shaped brackets 90 and one coupling 70 as previously described. Each L-shaped bracket 90 has a generally linear central or longitudinal axis 95, a first end 90a, and a second end 90b. In addition, each bracket 90 includes a base 91 and a connection flange 92 extending perpendicularly from base 91 . Base 91 and flange 92 both extending axially (relative to axis 95) from first end 90a to second end 90b. In this embodiment, base 91 is a generally flat plate including a plurality of axially-spaced holes 93 extending therethrough, and connection flange 92 is a generally flat plate including a plurality of axially-spaced holes 94 extending therethrough. Base 91 or connection flange 92 of each bracket 90 is bolted to post 20 via holes 93, 94, and the other of base 91 or connection flange 92 of each bracket 90 is bolted to beam 30 via holes 93, 94. Coupling 70 is disposed around the lower edge of end 30a of beam 30 with base 71 bolted to upper end 20b of post 20 via holes 74 and connection flange 76 bolted to end 30a of beam 30 via holes 78.

[0038] Although posts 20 are fixably coupled to the ground 60 with couplings 70 in the embodiment of structure 10 shown in FIG. 1 , in other embodiments, posts 20 may be fixably coupled to the ground 60 with other connectors, couplings, or devices. For example, referring briefly to FIG. 4, an alternative coupling between one exemplary post 20 and the ground 60 is shown. Although the coupling is only shown between one exemplary post 20 and the ground 60, it should be appreciated that the coupling shown in FIG. 4 could also be used to fixaby couple the other post 20 to the ground. In this embodiment, lower end 20a of post 20 is fixably coupled to a foundation or piling on the ground 60 with a plurality of rigid L-shaped brackets 90 as previously described. Base 91 or connection flange 92 of each bracket 90 is bolted to post 20 via holes 93, 94, and the other of base 91 or connection flange 92 of each bracket 90 is bolted to the foundation or piling on the ground 60 via holes 93, 94.

[0039] In the embodiment of structure 10 described above and shown in FIG. 1 , both post 20 and beam 30 are made of decommissioned wind turbine blades 50. However, in other embodiments, one or both of the vertical support posts (e.g., post(s) 20) may not be made of decommissioned wind turbine blade(s) (e.g., blades to50). For example, referring now to FIG. 5, an embodiment of an overhead signage structure 100 including a plurality of repurposed, decommissioned wind turbine blades 50 is shown. Similar to structure 10 previously described, in this embodiment, structure 100 is an overhead highway sign, however, in this embodiment, one of the posts (e.g., one post 20) is not made of a decommissioned wind turbine blade 50. More specifically, in this embodiment, structure 100 includes a vertical support post 20, a vertical support post 120 laterally spaced from post 20 (on opposite sides of highway 61), a horizontal signage support beam 30 extending between posts 20, 120, and a plurality of signs 40 coupled to support beam 30. Post 20, beam 30, and signs 40 are each as previously described. However, vertical post 120 is not a decommissioned wind turbine blade 50, but rather, is a conventional support post made of concrete. In particular, post 120 has a vertically oriented central or longitudinal axis 125, a first or lower end 120a fixably secured to the ground 60, and a second or upper end 120b distal the ground 60 and coupled to end 30b of support beam 30. Lower end 120a can be secured to the ground 60 by any means known in the art. Upper end 120b of post 120 includes a recess or receptacle 130 having a central axis coaxially aligned with and / or parallel to horizontal central axis 35 of beam 30. End 30b of beam 30 is seated and secured within recess 130 of post 120.

[0040] As another example, referring now to FIG. 6, an embodiment of an overhead signage structure 200 including a repurposed, decommissioned wind turbine blade 50 is shown. Similar to structures 10, 100 previously described, in this embodiment, structure 200 is an overhead highway sign, however, in this embodiment, neither post (e.g., neither post 20) is made of a decommissioned wind turbine blade 50. More specifically, in this embodiment, structure 200 includes a pair of vertical support posts 120, a horizontal signage support beam 30 extending between posts 120, and a plurality of signs 40 coupled to support beam 30. Post 120, beam 30, and signs 40 are each as previously described.

[0041] In the embodiment of structure 200 shown in FIGS. 4 and 5, posts 120 are made of concrete. However, in other embodiments, different conventional posts may be used in place of posts 20. For example, in FIG. 7, an embodiment of an overhead signage structure 300 including a repurposed, decommissioned wind turbine blade 50 is shown. Similar to structures 10, 100, 200 previously described, inthis embodiment, structure 300 is an overhead highway sign. Neither post (e.g., neither post 20) is made of a decommissioned wind turbine blade 50, but rather, comprises a conventional steel post. More specifically, in this embodiment, structure 300 includes a pair of laterally-spaced vertical support posts 320 (on opposite sides of highway 61), a horizontal signage support beam 30 extending between posts 320, and a sign 40 coupled to support beam 30. Beam 30 and signs 40 are each as previously described. Each post 320 is a conventional steel post having a vertically oriented central or longitudinal axis 325, a first or lower end 320a fixably secured to the ground 60, and a second or upper end 320b distal the ground and coupled to a corresponding end 30a, 30b of support beam 30. Lower end 320a can be secured to the ground 60 by any means known in the art. Upper end 320b of each post 320 is coupled to a corresponding end 30a, 30b of beam 30 via a plurality of rigid L-shaped brackets 90 and one coupling 70, each as previously described.

[0042] Referring now to FIG. 8, an embodiment of a method 400 for constructing structures 10, 100, 200, 300 previously described is shown. Although method 400 is described in the context of structures 10, 100, 200, 300, it can also be used to construct other structures with decommissioned wind turbine blade(s) 50. Beginning in block 401 , method 400 includes obtaining one or more decommissioned wind turbine blades 50. In general, the number of blades 50 acquired in block 401 will depend on the number of blades 50 needed for the particular structure being built. For example, structure 10 includes three blades 50, whereas structure 200 includes only one blade 50. Moving now to block 402, each blade 50 obtained in block 401 is cut to the desired length depending on the particular application or use. For example, blade 50 used to form beam 30 is cut to the desired length to span highway 61 , and any blade(s) 50 used for form posts 20 are cut the desired length to hold beam 30 at the desired height above highway 61. Next, in block 403, a pair of vertical posts 20, 120, 320 are installed on opposite sides of the road or highway 62. Moving now to block 404, one decommissioned wind turbine blade 50 obtained in block 401 and cut in block 402 for use as beam 30 is raised above the highway 61 , and in block 405, ends 30a, 30b of the raised decommissioned wind turbine blade 50 are fixably coupled to upper ends 20b, 120b, 320b of the pair of posts 20, 120,320. Moving now to block 406, one or more signs 40 are fixably coupled to beam 30 to form overhead sign structure 10, 100, 200, 300.

[0043] In the embodiment of structure 10, 100, 200, 300 described above, signs 40 are supported and positioned over and above lanes 62 of a road 61 . However, in other embodiments, decommissioned wind turbine blades 50 can be used to support signs 40 in other locations (e.g., on side of road 61 , along walkways or sidewalks, etc.). For example, referring now to FIG. 9, an embodiment of a signage structure 500 including a repurposed, decommissioned wind turbine blades 50 is shown. In this embodiment, structure 500 includes a vertical support post 20 and a plurality of signs 40 coupled to opposite sides of upper end 20b of support post 20, thereby forming a billboard that can be positioned along a road (e.g., road 61), walkway, path, sidewalk, or other suitable location for being viewed by people. Support post 20 and signs 40 are both as previously described. In addition, lower end 20a of post 20 can be fixably attached to the ground 60 in a manner as previously described or by other suitable means. Referring briefly to FIG. 10, an embodiment of another signage structure 600 including a plurality of repurposed, decommissioned wind turbine blades 50 is shown. Structure 600 is the same as structure 500 previously described with the exception that structure 600 includes a plurality of laterally-spaced vertical support post 20 to support signs 40. Thus, in this embodiment, the plurality of signs 40 are coupled to opposite sides of upper ends 20b of multiple support posts 20, thereby forming a billboard that can be positioned along a road (e.g., road 61), walkway, path, sidewalk, or other suitable location for being viewed by people.

[0044] As previously described, decommissioned wind turbine blades 50 can repurposed for use as structural supports for signs 40 in various locations (e.g., overhead highway signage, billboards, etc.). However, in still further embodiments, decommissioned wind turbine blades 50 can also be repurposed for other types of structural supports. For example, referring now to FIG. 11 , decommissioned wind turbine blades 50 are repurposed for use as structural supports for a shade structure 700. In this embodiment, structure 700 includes a pair of laterally-spaced vertical support posts 20 as previously described and a shade canopy or roof 730 coupled to upper ends 20b of posts 20. Roof 730 has a horizontally oriented central or longitudinal axis 735, a first end 730a fixably coupled to upper end 20b of one post 20, and a second end 730b fixably coupled to upper end 20b of the other post 20. Thus, roof 730 generally spans the horizontal distance between laterally-spaced posts 20. Lower ends 20a of posts 20 are fixably coupled to the ground 60 andupper ends 20a are fixably coupled to roof 730. Thus, posts 20 support roof 730 above the ground 60. In general, posts 20 can be coupled to the ground 60 and roof 730 in the same manners as previously described or by other suitable means.

[0045] As yet another example, referring now to FIG. 12, decommissioned wind turbine blades 50 are repurposed for use as structural supports for a solar power structure 800. In this embodiment, structure 800 includes a pair of laterally-spaced vertical support posts 20 as previously described, a roof 830 coupled to upper ends 20b of posts 20, and a plurality of solar cells 840 mounted to the upper side of roof 830. Roof 830 has a horizontally oriented central or longitudinal axis 835, a first end 830a, and a second end 830b. In addition, roof 830 has an upper side 831 extending horizontally between ends 830a, 830b and facing upwardly, and a lower side 832 extending horizontally between ends 830a, 830b and facing downwardly toward the ground 60. Solar cells 840 are mounted to upper side 831 , and thus, face the sun and sky. Lower side 832 of roof 830 is fixaby coupled to upper ends 20b of posts 20. Thus, roof 830 generally spans the horizontal distance each pair of laterally-adjacent posts 20. Lower ends 20a of posts 20 are fixably coupled to the ground 60 and upper ends 20a are fixably coupled to roof 830. Thus, posts 20 support roof 830 and solar cells 840 mounted thereto above the ground 60. In general, posts 20 can be coupled to the ground 60 and roof 830 in the same manners as previously described or by other suitable means.ln the manner described, embodiments of structures 10, 100, 200, 300, 500, 600,700, 800 disclosed herein employ decommissioned wind turbine blades 50. Such reuse of decommissioned wind turbine blades 50 for structural purposes eliminates and / or reduces the need to undesirably dispose of blades 50 in landfills or employ energy intensive recycling processes. In addition, it should be appreciated that such reuse of blades 50 as described herein requires no reprocessing of blades 50 (or the composite materials forming blades 50) and retains the structural integrity of blades 50.

[0046] While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure.For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1 ), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

[0047] Each and every claim is incorporated into the specification as an aspect of the present disclosure. Thus, the claims are a further description and are an addition to the aspects of the present invention. The discussion of a reference herein is not an admission that it is prior art to the presently disclosed subject matter, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural or other details supplementary to those set forth herein.

Claims

CLAIMSWhat is claimed is:1 . An overhead signage structure, comprising: a first vertical post and a second vertical post laterally-spaced from the first vertical post, wherein each post has a vertically oriented central axis, a lower end fixably coupled to the ground, and an upper end distal the ground; a horizontal beam comprising a first decommissioned wind turbine blade, wherein the beam has a horizontally oriented central axis, a first end, and a second end opposite the first end, wherein the first end of the beam is fixably coupled to the upper end of the first vertical post and the second end of the beam is fixably coupled to the upper end of the second vertical post; and one or more signs fixably coupled to the beam.

2. The structure of claim 1 , wherein the first vertical post and the second vertical post are positioned on opposite sides of a road or highway.

3. The structure of claim 2, wherein the beam has a length measured axially from the first end to the second end that ranges from 40 to 60 m.

4. The structure of claim 1 , wherein the first post comprises a second decommissioned wind turbine blade.

5. The structure of claim 4, wherein the second post comprises a third decommissioned wind turbine blade.

6. The structure of claim 4, wherein the first end of the beam is fixably coupled to the upper end of the first post with a connector having a lower end, an upper end, a receptacle extending vertically from the lower end of the connector, and a passage extending horizontally into the upper end of the connector;wherein the first end of the beam is seated in the passage and the upper end of the first post is seated in the receptacle.

7. The structure of claim 4, wherein the second post is a concrete or steel post.

8. The structure of claim 7, wherein the second post is a concrete post having a receptacle in the upper end of the second post, wherein the second end of the beam is seated in the receptacle.

9. The structure of claim 4, wherein the first end of the beam is fixably coupled to the upper end of the first post with a plurality of L-shaped brackets.

10. A method for constructing an overhead signage structure, the method comprising:(a) obtaining a first decommissioned wind turbine blade having a central axis, a first end, and a second end opposite the first end;(b) raising the first decommissioned wind turbine blade over a road after (a); and(c) after (a) and (b), coupling the first end of the first decommissioned wind turbine blade to a first vertical post and coupling the second end of the first decommissioned wind turbine blade to a second vertical post with the first decommissioned wind turbine blade raised over the road and with the central axis oriented horizontally; and(d) mounting a road sign to the first decommissioned wind turbine blade.

11. The method of claim 10, further comprising cutting the first decommissioned wind turbine blade to a predetermined length to span a road or highway before (b).

12. The method of claim 10, further comprising: obtaining a second decommissioned wind turbine blade having a central axis, a first end, and a second end opposite the first end; fixably coupling the first end of the second decommissioned wind turbine blade to the ground with the central axis of the second decommissioned windturbine blade in a vertical orientation to form the first vertical post before (b) and (c).

13. The method of claim 12, further comprising: obtaining a third decommissioned wind turbine blade having a central axis, a first end, and a second end opposite the first end; fixably coupling the first end of the third decommissioned wind turbine blade to the ground with the central axis of the third decommissioned wind turbine blade in a vertical orientation to form the second vertical post before (b) and (c).

14. The method of claim 12, further comprising cutting the second decommissioned wind turbine blade to a predetermined length before (b) and (c).

15. The method of claim 10, wherein (c) comprises seating the first end of the first decommissioned wind turbine blade in a receptacle in the second end of the first vertical post.

16. The method of claim 12, further comprising coupling the first end of the first decommissioned wind turbine blade to the second end of the first vertical post with a plurality of L-shaped brackets.

17. The method of claim 12, further comprising: fixably securing the second end of the first vertical post in a receptacle extending vertically from a lower end of a connector; fixably securing the first end of the first decommissioned wind turbine blade in a passage extending horizontally into an upper end of the connector.

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