BR-122025027939-A2 - Structural hull, structural grid for a marine vessel, deck for a marine vessel, marine vessel, wind turbine blade, ski or ski pole, ballistic-resistant panel, method for disassembling the structural hull.

BR122025027939A2BR 122025027939 A2BR122025027939 A2BR 122025027939A2BR-122025027939-A2

Abstract

The present invention provides a structural shell comprising a basalt fiber reinforced material, wherein the basalt fiber reinforced material comprises a polymeric material, the polymeric material being capable of thermally cracking at least partially at a temperature of 200 to 600 °C.

Inventors

HENDRIK JOHANNES WATS

Assignees

COEUS LIMITED

Dates

Publication Date: 20260317
Application Date: 20211026
Priority Date: 20201111

Claims (20)

1. Structural shell characterized by comprising a basalt fiber reinforced material, wherein the basalt fiber reinforced material comprises a polymeric material, the polymeric material being capable of thermally cracking at least partially at a temperature of 200 to 600 °C.
2. Structural shell, according to claim 1, characterized in that the polymeric material is a thermoplastic material, and/or in that the polymeric material comprises a polymethacrylate, and/or in that the polymeric material comprises a poly(methyl methacrylate), and/or in that the polymeric material is capable of melting at least partially at a temperature of 150 to 300 °C, preferably 200 to 250 °C, and/or in that the polymeric material is capable of melting at least partially at a lower temperature than it is capable of thermally cracking at least partially, and/or in that the polymeric material is capable of thermally cracking at least partially at a temperature of 300 to 500 °C, preferably 350 to 400 °C, and/or in that the thermally cracked polymeric material is at least partially liquid at 20 °C, and/or in that the weight ratio of basalt fibers to material The polymeric ratio is 80:20 to 40:60, preferably 75:25 to 50:50, more preferably 70:30 to 55:45, most preferably around 60:40.
3. Structural shell, according to claim 1 or 2, characterized in that the basalt fibers are dispersed in the polymeric material in a regular arrangement, preferably in which the basalt fiber-reinforced material comprises a plurality of substantially parallel basalt fiber layers, wherein the mean direction of the substantially parallel basalt fibers is different in adjacent layers, preferably in which the mean direction of the substantially parallel basalt fibers in each layer is about 45° or about 90° relative to the mean direction of the substantially parallel basalt fibers in adjacent layers.
4. Structural shell, according to claim 3, characterized in that the substantially parallel basalt fiber layers are arranged quadriaxially, preferably with relative basalt fiber directions of -45°, 90°, 0 to 90° and 0°, triaxially, preferably with relative basalt fiber directions of -45°, 90° and 45°, biaxially, preferably with relative basalt fiber directions of 0° and 90°, or unidirectionally.
5. Structural shell, according to any one of claims 1 to 4, characterized in that the basalt fiber-reinforced material has a thickness of 0.5 to 3.0 mm, preferably 1.0 to 2.0 mm.
6. Structural shell, according to any one of claims 1 to 5, characterized in that it further comprises a polymer core, preferably wherein the polymer core comprises a polyester, more preferably wherein the polyester comprises PET, and even more preferably wherein the PET comprises a PET foam.
7. Structural shell, according to claim 6, characterized in that the polymer core has a melting temperature of 200 to 300 °C, preferably 230 to 270 °C.
8. Structural shell, according to any one of claims 1 to 7, characterized in that it further comprises a gelcoat, preferably wherein the gelcoat comprises unsaturated polyester resins and/or vinyl esters and/or the gelcoat comprises a pigment.
9. Structural shell, according to any one of claims 1 to 8, characterized in that the structural shell exhibits a flexural strength of 600 to 800 MPa before aging.
10. Hull for a sea vessel, characterized in that it comprises the structural hull, as defined in any one of claims 1 to 9.
11. Structural grid for a maritime vessel, characterized by comprising the structural hull, as defined in any one of claims 1 to 9.
12. Deck for a sea vessel, characterized in that it comprises the structural hull as defined in any one of claims 1 to 9, preferably the structural hull as defined in claim 6 or 7.
13. Sea vessel, characterized in that it comprises at least one hull, as defined in claim 10, and/or at least one structural grid, as defined in claim 11, and/or at least one deck, as defined in claim 12.
14. Wind turbine blade, characterized by comprising the structural casing, as defined in any one of claims 1 to 9.
15. Ski or ski pole, characterized by comprising the structural shell, as defined in any one of claims 1 to 9.
16. Ballistic-resistant panel, characterized by comprising a structural shell, as defined in any one of claims 1 to 9, wherein the weight ratio of polymeric material to basalt fibers is preferably 0.35 to 0.45, more preferably 0.39 to 0.44.
17. Method for disassembling the structural shell, as defined in any one of claims 1 to 9, the hull, as defined in claim 10, the deck, as defined in claim 12, the structural grid, as defined in claim 11, the marine vessel, as defined in claim 13, the wind turbine blade, as defined in claim 14, the ski or ski pole, as defined in claim 15, or the ballistic-resistant panel, as defined in claim 16, the method characterized in that it comprises: providing the structural shell, the hull, the structural grid, the deck, the marine vessel, the wind turbine blade, the ski or ski pole, or the ballistic-resistant panel; heating the structural shell, the hull, the structural grid, the deck, the marine vessel, the wind turbine blade, the ski or ski pole, or the ballistic-resistant panel to a temperature of 200 to 600 °C to thermally crack at least partially the polymeric material; to separate the thermally cracked polymeric material, at least partially, from the basalt fibers; and to recover the basalt fibers and/or the thermally cracked polymeric material, at least partially.
18. Method according to claim 17, characterized in that the heating is carried out in an inert atmosphere, preferably in the substantial absence of oxygen, and/or in that the heating is carried out at a temperature of 250 to 500 °C, preferably 300 to 500 °C, more preferably 350 to 400 °C, and/or in that the heating is carried out at a pressure of at least 10 bar, and/or in that the structural shell comprises a polymer core and the method further comprises recovering the polymer core, preferably in that before heating to a temperature of 200 to 600 °C, the method further comprises: heating the structural shell, hull, structural grid, deck, marine vessel, wind turbine blade, ski or ski pole, or ballistic-resistant panel to a temperature of 150 to 300 °C to at least partially melt the polymeric material; To separate the polymer core from the molten polymer material at least partially; and to recover the polymer core.
19. A method according to claim 17 or 18, characterized in that the structural shell comprises a gelcoat and the method further comprises at least partially mechanically removing the gelcoat before heating and/or removing the gelcoat by burning the gelcoat.
20. Method for disassembling the structural shell, as defined in any one of claims 1 to 9, the hull, as defined in claim 10, the deck, as defined in claim 12, the structural grid, as defined in claim 11, the marine vessel, as defined in claim 13, the wind turbine blade, as defined in claim 14, the ski or ski pole, as defined in claim 15, or the ballistic-resistant panel, as defined in claim 16, the method characterized in that it comprises: providing the structural shell, the hull, the deck, the structural grid, the marine vessel, the wind turbine blade, the ski or ski pole, or the ballistic-resistant panel; contacting the structural shell, the hull, the deck, the structural grid, the marine vessel, the wind turbine blade, the ski or ski pole, or the ballistic-resistant panel with a solvent to at least partially dissolve the polymeric material; and recovering the basalt fibers and/or the polymeric material.

Description

[001]The present invention relates to a recyclable structural shell for a hull, structural grid and/or deck for a marine vessel or a wind turbine blade and the like, a method of manufacturing a structural shell and a method of disassembling a structural shell. [002]Yacht hulls are typically made of fiber-reinforced resins, typically fiberglass and/or carbon fiber. These fiber-reinforced resins are strong, lightweight, and easy to mold into the shape of, for example, a deck, hull, or bulkhead. Despite the yacht's eco-friendly image, most of the yacht industry is in a status quo regarding sustainability. The two biggest threats are: (i) the use of toxic resins and fiberglass, and (ii) the lack of a real end-of-life solution for the boat's hull. [003]Although the most environmentally friendly solutions with sustainable materials point in the right direction, at the end of their useful life they only allow for disposal (downcycling), where the final product inevitably ends up in landfills. One reason for this is that the glass and/or carbon fibers used, which possess desirable physical and mechanical properties, allow a strong bond to be formed with the resin because they are porous and absorb some of the resin into the glass and/or carbon fibers. While this provides a strong and lightweight composite that can be used in boat hulls and similar structures, it means that currently, glass and/or carbon fibers are essentially “single-use” and cannot be recycled at the end of their useful life. Furthermore, it is common to use glass and/or carbon fibers to reinforce thermoset plastics for such applications. Thus, at the end of the useful life of the boat hull or similar structures, there are few disposal options besides landfill, particularly for impregnated glass and/or carbon fibers. Disposal of some of the material may be possible. [004]New “green” composites have been developed using flax (hemp), for example. However, these fibers also tend to absorb the resins used in the composites, which means that separation of the material at the end of its useful life is not possible and the materials can only be recycled. [005]Basalt fibers have been investigated as a “green” fiber alternative for applications such as yachting, but generally only using vinyl ester, polyester, or epoxy (green) resins. These resins are all thermosetting plastics, meaning that the resins change from liquid to rigid during the production process but cannot return to a liquid state. Basalt fibers, therefore, cannot be easily recovered and reused and/or recycled. Thus, much of the composite is likely to become “single-use” and end up in landfills. [006]KR 20190079109 A discloses a method for manufacturing a composite for a boat comprising basalt fibers and a boat manufactured using the same. However, the composite is made using a resin including a polyester and a curing agent including methyl ketone peroxide, thus providing a strong thermosetting plastic. As described above, the basalt fibers cannot be easily recovered and the composite can generally only be reduced at the end of its service life, at best. Recycling of the composite is not described. [007]CN 109370186 A refers to a method for producing a low-temperature resistant and environmentally friendly glass fiber reinforced plastic septic tank. CN 111098528 A refers to a system for producing a fully impregnated pre-impregnated thermoplastic. US 2019/330432 A refers to a two-component hybrid matrix system made of polyurethanes and polymethacrylates for the production of short fiber reinforced semi-finished products. US 2020/047427 A refers to a process for manufacturing thermoplastic polymer composite parts and an object obtained by said process. WO 2020/088173 A1 refers to a porous composite material capable of generating an electric arc in a microwave field, a method for preparing it and its use. JPH 11335929 A refers to a highly electroconductive carbon fiber and its production. JP 2003012857 A refers to a treatment method for a residual fiber-reinforced plastic material and a treatment apparatus. [008]Consequently, there is a need to provide a structural shell that can be substantially recycled at the end of its service life, particularly when used in marine vessels, but also outside the maritime sector. In particular, there is a need to provide a structural shell comprising a fiber-reinforced resin, wherein both the fibers and the resin can be recovered and recycled or recycled without significant deterioration in their physical and mechanical properties, preferably with substantially no deterioration of their physical and/or mechanical properties. [009]Another objective of the present disclosure is to provide such a substantially recyclable structural shell, wherein the structural shell has high flexural strength per unit area. [010]The present invention seeks to address at least some of the problems associated with the prior art or at least provide a commercially acceptable alterna