A method and system for recycling waste plastics into construction products using thermomesh technology

Abstract

The present invention relates to a system and method for efficiently recycling waste plastics into durable construction materials using advanced thermomesh technology Specifically, the present invention introduces a Waste Plastic Product Machine (WPPM) that integrates a mesh container, heating mechanism, molding unit, and cooling system to process various types of waste plastics. The system features an AI control unit that leverages machine learning models to optimize the recycling process by adjusting operational parameters in real-time based on data from a comprehensive sensor network. Furthermore, the network includes temperature, pressure, composition, flow, and other sensors to ensure precise control and high-quality output. Additionally, the system includes a material analysis unit and a product quality prediction unit to evaluate and ensure the consistency of the final products. The method encompasses collecting waste plastics, processing them through the WPPM, and using advanced analytics to continuously refine the recycling.

Description

A METHOD AND SYSTEM FOR RECYCLING WASTE PLASTICS INTO CONSTRUCTION PRODUCTS USING THERMOMESH TECHNOLOGYTECHNICAL FIELD

[0001] The present invention relates to the field of environmental engineering and materials science, specifically to technologies for recycling waste plastics. More particularly, it pertains to a method and system for converting waste plastic materials into construction products such as bricks, paver blocks, and road dividers using advanced Thermomesh technology. The present invention integrates plastic processing techniques to produce durable, eco-friendly construction materials while addressing the challenges of plastic waste management. The potential to open new markets for recycled plastic products, fostering economic growth through innovative product lines derived from waste plastic.BACKGROUND

[0002] Plastic pollution is a major environmental challenge, with millions of tons of plastic waste generated globally each year. Effective recycling methods are essential to mitigating the environmental impact of plastic waste. Traditional recycling systems often struggle with the complexities of mixed waste plastics, including different polymers and contamination. This underscores the need for solutions capable of efficiently recycling plastics into valuable, durable products for construction and infrastructure use.

[0003] Current plastic recycling methods include mechanical recycling, chemical recycling, and incineration. Mechanical recycling relies on precise sorting and shredding, which is costly and results in material degradation. Chemical recycling can handle various plastics but is complex, energy-intensive, and economically unfeasible on a large scale. Incineration reduces waste volume but generates greenhouse gases and pollutants. These methods face issues such as contamination, high energy consumption, and economic inefficiencies, highlighting the limitations of existing technologies.

[0004] The limitations of these conventional methods highlight the need for a new approach to plastic recycling. Mechanical recycling’s dependence on segregation, chemical recycling’s high costs and energy demands, and the environmental risks of incineration all point to significant gaps. Additionally, the economic viability of current methods is often questionable, particularly for low-value plastics. There is a clear need for a system that can efficiently process mixed plastic waste, maintain material integrity, and be cost-effective and environmentally friendly.

[0005] Addressing these challenges requires a system that recycles mixed waste plastics into durable construction materials without extensive segregation. Integrating advanced technologies such as artificial intelligence (Al) and machine learning can optimize the recycling process, ensuring consistent and efficient transformation of waste plastics into high-quality products. Such an approach would improve energy efficiency, enhance product quality, and minimize environmental impact, offering a scalable and economically viable solution to the global plastic waste problem.

[0006] Thus, there is a pressing need for a system and method that efficiently processes mixed waste plastics with minimal segregation, while maintaining high product quality and reducing environmental impact. The ideal solution would leverage advanced technologies like Al and machine learning to optimize the recycling process, ensuring that the conversion of waste plastics into durable construction materials is both sustainable and economically feasible. Such an approach addresses the limitations of current methods and provides a practical solution to the plastic waste crisis.

[0007] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through the comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.SUMMARY

[0008] In an embodiment, a system for recycling waste plastics into durable construction materials is disclosed. In one example, the system features a Waste Plastic Product Machine (WPPM) that integrates a mesh container, heating mechanism, molding unit, and cooling system. The WPPM is equipped with a processor and a memory that is communicatively coupled. In one embodiment, the memory stores processor instructions that, when executed, enable the processor to receive and analyze data from a network of sensors embedded within the WPPM. These sensors monitor various stages of the recycling process, including temperature, pressure, and flow conditions. The memory further contains instructions for optimizing the heating process of the plastics by adjusting temperature and timing based on real-time sensor data and the composition of the mixed plastics. Additionally, the processor uses machine learning techniques to predict the quality of the finalproducts, such as bricks and paver blocks. The processor dynamically controls operational parameters, such as heating intensity, molding pressure, and cooling rate, to ensure high-quality and durable construction materials. Such an integrated approach allows for efficient recycling and consistent product quality by adapting to real-time conditions and optimizing the process continuously.

[0009] In an embodiment, a method for recycling waste plastics into durable construction materials is disclosed. In one example, the method involves loading mixed waste plastics into a Waste Plastic Product Machine (WPPM), which includes a mesh container, heating mechanism, molding unit, and cooling system. Further, the method includes heating the plastics within the mesh container to achieve a semi-liquid state, and then molding the heated plastics into desired shapes, such as bricks or paver blocks. Real-time data from a network of sensors embedded in the WPPM, which monitor parameters such as temperature, pressure, and flow, is collected and analyzed. The method further involves using a machine learning model to adjust the heating, molding, and cooling parameters based on the sensor data and the composition of the plastics. Predictive analysis techniques are employed to forecast the quality of the final products. Operational parameters, including heating intensity, molding pressure, and cooling rate, are dynamically adjusted to ensure the production of high-quality construction materials. It ensures efficient recycling and high durability of the end products by continuously optimizing the process based on real-time conditions.BRIEF DESCRIPTION OF DRAWINGS

[0010] The accompanying drawings illustrate the various embodiments of systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Further, the elements may not be drawn to scale.

[0011] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate and not to limit the scope in any manner, wherein similar designations denote similar elements, and in which:

[0012] FIG. 1 is a block diagram that illustrates a system environment in which various embodiments of the method and the system may be implemented.

[0013] FIG. 2 is a block diagram that illustrates the configuration of the Waste Plastic Product Machine (WPPM), in accordance with an embodiment of present disclosure.

[0014] FIG. 3 is a flowchart that illustrates a method for recycling waste plastics into construction materials, in accordance with an embodiment of present disclosure.DETAILED DESCRIPTION

[0015] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.

[0016] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.

[0017] The present disclosure addresses the limitations of conventional plastic recycling methods by introducing an advanced system for recycling waste plastics into durable construction materials, such as bricks and paver blocks. The system utilizes a Waste Plastic Product Machine (WPPM) that integrates Thermomesh technology with artificial intelligence (Al) and machine learning to optimize the recycling process. The system eliminates the need for extensive segregation of plastics, enabling the processing of mixed waste plastics efficiently. The WPPM's Al-driven capabilities monitor and adjust operational parameters in real-time, ensuring consistent quality and minimizing energy consumption. Additionally, the system uses predictive analysis to enhance the quality of thefinal products and dynamically controls key aspects of the recycling process, such as heating and molding, to produce high-quality, eco-friendly construction materials, thereby overcoming the inefficiencies and environmental drawbacks of traditional recycling methods. Thermomesh Technology is an innovative recycling system that heats waste plastics in a mesh container to a semiliquid state, allowing various types of plastics to combine and be molded into durable products.

[0018] The primary objective of the present disclosure is to provide an efficient and sustainable system for recycling waste plastics into durable construction materials, thereby addressing the environmental and economic challenges associated with plastic pollution. To achieve this, the present disclosure aims to integrate advanced Thermomesh technology with artificial intelligence (Al) and machine learning to optimize the recycling process and ensure the consistent production of high-quality products. Plastic products made by thermomesh technology are known as thermomesh products. The system's objective is to eliminate the need for extensive segregation of plastics, allowing for the efficient processing of mixed waste plastics without compromising material integrity. Additionally, the present disclosure seeks to reduce energy consumption and operational costs by employing Al-driven predictive analysis and real-time adjustments, ultimately contributing to a more eco-friendly and economically viable recycling solution.

[0019] The present invention introduces an advanced system and method for recycling waste plastics into durable construction materials, such as bricks and paver blocks, using a Waste Plastic Product Machine (WPPM) integrated with Thermomesh technology. The system leverages artificial intelligence (Al) and machine learning to optimize the recycling process by analyzing the composition of mixed waste plastics and dynamically adjusting key operational parameters, such as heating and molding conditions. Robotic system support the Thermomesh technology. By eliminating the need for extensive plastic segregation, the invention efficiently processes various types of plastics, ensuring consistent quality while minimizing energy consumption and operational costs. The result is a sustainable and economically viable solution that produces high-quality, eco- friendly construction materials, effectively addressing the limitations of conventional plastic recycling methods.

[0020] FIG. 1 is a block diagram that illustrates a system environment 100 in which various embodiments of the method and system for recycling waste plastics may be implemented. The system environment 100 typically includes a Waste Plastic Product Machine (WPPM) 102, an Al control unit 104, a sensor network 106, and a molding unit 108. The WPPM 102, the Al control unit104, and the molding unit 108 are communicatively coupled with each other via the sensor network 106, which monitors and controls the recycling process. The drawing provides an overview of the entire system, showing the main components of the WPPM, including the mesh container, heating mechanism, Al control unit, and molding unit. The layout demonstrates how these components are interconnected and function together within the system. Labels are used to identify each key part of the system for clarity.

[0021] The Waste Plastic Product Machine (WPPM) 102 is designed to efficiently recycle mixed waste plastics into durable construction materials such as bricks and paver blocks. The WPPM 102 incorporates several key elements, including one or more mesh containers for holding and uniformly heating the waste plastics, a heating mechanism controlled by an Al system, and a molding unit where the semi-liquid plastics are shaped into final products. The Al-driven control unit continuously monitors the processing conditions, such as temperature and plastic composition, through a network of strategically placed sensors, allowing for real-time adjustments to optimize the recycling process. Such integration of advanced technology ensures that the WPPM 102 can process various types of plastics without the need for extensive segregation, producing high-quality, eco-friendly construction materials while minimizing energy consumption and operational costs. Waste Plastic Product Machine handles various volumes of plastic waste, suitable for small to large operations without compromising quality.

[0022] The Al control unit 104 is a component of the system, designed to optimize and manage the entire recycling process within the Waste Plastic Product Machine (WPPM) 102. The unit is equipped with advanced artificial intelligence and machine learning models that analyze real-time data from a network of sensors strategically placed throughout the WPPM. The Al control unit continuously monitors key parameters such as the type, composition, and temperature of the waste plastics being processed. Based on the data, it dynamically adjusts the heating mechanism, molding pressure, and other operational parameters to ensure that the plastics reach the optimal malleable state for molding into durable construction materials. Additionally, the Al control unit 104 employs predictive analysis to anticipate potential issues in the process, such as material inconsistencies or energy inefficiencies, and proactively makes adjustments to prevent these problems. The said intelligent control system enhances the efficiency, consistency, and quality of the recycling process, reducing the need for manual intervention and significantly improving the overall performance of the WPPM.

[0023] The sensor network 106 is a component of the system, providing real-time monitoring and data collection essential for the efficient operation of the Waste Plastic Product Machine (WPPM) 102. It consists of a variety of sensors strategically placed throughout the WPPM, including within the mesh container, heating mechanism, and molding unit. These sensors continuously gather data on key parameters such as temperature, plastic composition, pressure, and material flow. The sensor network 106 communicates this data to the Al control unit 104, which analyzes the information to optimize the recycling process. By providing precise, up-to-the-second feedback, the sensor network ensures that the Al control unit can make real-time adjustments to the system, maintaining optimal conditions for processing the waste plastics. Such results in consistent quality in the final construction materials produced, while also improving the energy efficiency and reliability of the entire recycling operation. The sensor network 106 enables the intelligent, adaptive functionality of the system, ensuring that each stage of the recycling process is finely tuned and responsive to changing conditions.

[0024] The molding unit 108 is a component of the Waste Plastic Product Machine (WPPM) 102, responsible for shaping processed waste plastics into durable construction materials, such as bricks, paver blocks, road dividers, railway sleepers, etc. Any type of shape can be given to processed semiliquid plastic; there is no limitation to any particular sector. After the plastics are heated and brought to a malleable state by the heating mechanism, the Al control unit 104 directs the transfer of these semi-liquid plastics into the molding unit. The unit contains customizable molds designed to form the plastics into specific shapes and sizes required for various construction applications. The molding unit 108 operates under precisely controlled conditions, with parameters such as molding pressure, cooling rate, and timing being dynamically adjusted by the Al control unit based on realtime data from the sensor network 106. It ensures that the final products are consistent in quality, with enhanced strength and durability. The molding unit’s ability to accommodate different mold designs also allows for versatility in the types of construction materials produced, making it an essential part of the system’s capability to efficiently recycle waste plastics into valuable, eco- friendly products. Thus, a new principle emerges, termed the "Reproduct Principle," where once molded, plastics attain a permanent shape, ensuring durability and eliminating the need for further recycling.

[0025] FIG. 2 is a block diagram that illustrates the configuration of the Waste Plastic Product Machine (WPPM) 102 for the system and method of recycling waste plastics into construction materials, in accordance with an embodiment of the present disclosure. FIG. 2 is explained inconjunction with elements from FIG. 1. Here, the WPPM 102 preferably includes a processor 202, a memory 204, a transceiver 206, an input / output unit 208, a temperature sensor 210, a composition sensor 212, a pressure sensor 214, a flow sensor 216, a quality detection unit 218, a material feed sensor 220, a heating sensor 222, a molding pressure sensor 224, a cooling rate sensor 226, a mold configuration unit 228, an Al control unit 230, a sensor data reception unit 232, a material analysis unit 234, a process optimization unit 236, a product quality prediction unit 238, and a dynamic control unit 240. The processor 202 is further preferably communicatively coupled to the memory 204, the transceiver 206, the input / output unit 208, the temperature sensor 210, the composition sensor 212, the pressure sensor 214, the flow sensor 216, the quality detection unit 218, the material feed sensor 220, the heating sensor 222, the molding pressure sensor 224, the cooling rate sensor 226, the mold configuration unit 228, the Al control unit 230, the sensor data reception unit 232, the material analysis unit 234, the process optimization unit 236, the product quality prediction unit 238, and the dynamic control unit 240, while the transceiver 206 is preferably communicatively coupled to the sensor network 106.

[0026] Processor 202 in the Waste Plastic Product Machine (WPPM) 102 is the central processing unit responsible for coordinating and executing the various functions of the system. It acts as the brain of the WPPM, processing data received from the sensor network 106 and other connected components. The processor 202 is programmed with advanced algorithms and is communicatively coupled with the memory 204, Al control unit 230, and other critical units, such as the sensor data reception unit 232 and the process optimization unit 236. Its primary role is to analyze real-time data related to the composition, temperature, pressure, and flow of the waste plastics being processed. Based on this data, processor 202 dynamically adjusts the operational parameters of the WPPM, including heating intensity, molding pressure, and cooling rates, to optimize the recycling process and ensure the production of high-quality construction materials. Additionally, the processor 202 integrates inputs from the product quality prediction unit 238 and the dynamic control unit 240, enabling it to anticipate potential issues and make proactive adjustments to maintain consistent product quality and system efficiency.

[0027] The Memory 204 in the Waste Plastic Product Machine (WPPM) 102 acts as the storage and retrieval hub for all the data and instructions required for the system’s operation. It is communicatively coupled to the processor 202 and stores the algorithms, machine learning models, and control instructions that the processor uses to manage the recycling process. Memory 204 holds real-time data collected by the sensor network 106, including temperature, composition, pressure,and flow information, as well as historical data that the Al control unit 230 uses for predictive analysis and process optimization. Additionally, memory 204 stores the configurations for various mold designs and the parameters for dynamic control of the system, such as heating profiles and molding pressures. It allows the WPPM to quickly adapt to different types of waste plastics and ensure consistent production quality. Memory 204 also plays a crucial role in storing the outcomes of the quality control processes and adjustments made during operation, enabling continuous learning and improvement of the recycling process over time.

[0028] The transceiver 206 in the Waste Plastic Product Machine (WPPM) 102 is a communication component that facilitates the exchange of data between the WPPM and other connected systems or networks, including the sensor network 106 and external control units. It enables real-time data transmission to and from the processor 202, allowing the system to receive sensor inputs and send control commands efficiently. The transceiver 206 ensures that the processor can continuously communicate with the Al control unit 230, the dynamic control unit 240, and other essential components, enabling synchronized operations and timely adjustments to the recycling process. The said component also plays a vital role in remote monitoring and control, allowing operators to access and manage the WPPM from external devices or networks. By maintaining a robust and reliable communication link, the transceiver 206 supports the seamless integration of the WPPM into larger waste management systems or smart manufacturing environments, ensuring that all processes are optimally coordinated and responsive to real-time data inputs.

[0029] The input / output unit 208 in the Waste Plastic Product Machine (WPPM) 102 acts as the primary interface for data exchange between the machine and its operators, as well as between the internal components of the system. It is responsible for receiving input commands from operators, such as setting operational parameters, selecting mold configurations, or initiating specific recycling processes. It also facilitates the output of data, such as real-time system status, processing metrics, and quality control results, to external displays or control panels, enabling operators to monitor and adjust the system as needed. The input / output unit 208 is communicatively linked to the processor 202, allowing it to convey operator inputs directly to the system for execution, while simultaneously transmitting critical feedback and alerts to the operators. The unit may include various interfaces, such as touchscreens, buttons, or remote access capabilities, making it a versatile and user-friendly component that enhances the overall functionality and control of the WPPM. By providing a reliable means for interaction and data flow, the input / output unit 208 plays a crucial role in ensuring thatthe system operates efficiently and responds promptly to both operator commands and real-time processing conditions.

[0030] The temperature sensor 210 in the Waste Plastic Product Machine (WPPM) 102 is a vital component that continuously monitors the temperature within the system, particularly within the mesh container where the waste plastics are processed. The sensor provides real-time data to the processor 202, allowing the system to maintain precise control over the heating mechanism. The accurate temperature readings from the sensor 210 are essential for ensuring that the waste plastics reach the optimal transitional phase between solid and liquid states without fully liquefying, which is essential for preserving the material's integrity and ensuring high-quality final products. The temperature sensor 210 is strategically positioned within the WPPM to detect any fluctuations in temperature, enabling the Al control unit 230 to make immediate adjustments to the heating parameters if necessary. It ensures a consistent and efficient recycling process, preventing overheating or underheating that could compromise the quality of the molded construction materials. By providing reliable and precise temperature data, the temperature sensor 210 plays a key role in the successful operation of the WPPM, contributing to the production of durable and environmentally friendly construction products.

[0031] The composition sensor 212 in the Waste Plastic Product Machine (WPPM) 102 is designed to analyze the chemical and material composition of the waste plastics being processed. The sensor provides data on the types of plastics present, their purity levels, and any potential contaminants. The real-time information gathered by the composition sensor 212 is transmitted to the processor 202, which uses it to optimize the recycling process. By understanding the exact composition of the waste plastics, the Al control unit 230 can adjust the processing parameters, such as temperature, pressure, and molding conditions, to ensure that the plastics are treated in a way that maximizes their structural integrity and suitability for conversion into high-quality construction materials. The composition sensor 212 is particularly important in handling mixed plastic streams, as it allows the WPPM to dynamically adapt to variations in material composition without the need for extensive pre-sorting. Such capability enhances the efficiency and effectiveness of the recycling process, ensuring that the final products meet stringent quality standards while minimizing waste and energy consumption.

[0032] The pressure sensor 214 in the Waste Plastic Product Machine (WPPM) 102 is responsible for monitoring the pressure levels within the system, particularly during the molding and heatingphases of the recycling process. The sensor provides real-time data on the internal pressures exerted on the waste plastics as they are heated to a malleable state and then shaped into construction materials like garden products, road products, household products, railway products, agricultural products, space project products, etc. The information from the pressure sensor 214 is continuously relayed to the processor 202, which, in conjunction with the Al control unit 230, adjusts the pressure applied during the molding process to ensure optimal material density and structural integrity. Maintaining the correct pressure is essential for preventing defects such as air pockets or inconsistencies in the final product. The pressure sensor 214 enables precise control over these conditions, allowing the system to produce high-quality, durable construction materials consistently. By ensuring that the appropriate pressure is applied at each stage, the sensor provides an important role in the overall efficiency and effectiveness of the WPPM, contributing to the production of reliable and environmentally sustainable products.

[0033] The flow sensor 216 in the Waste Plastic Product Machine (WPPM) 102 is a component that monitors the flow rate and movement of plastic materials as they transition through various stages of the recycling process. Positioned strategically within the system, the sensortracks the flow of plastics from the heating chamber, where they are brought to a malleable state, to the molding unit, where they are shaped into construction products like bricks and paver blocks. The flow sensor 216 provides real-time data to processor 202, allowing the Al control unit 230 to regulate the speed and consistency of material flow, ensuring that the plastics are evenly distributed and properly prepared for molding. By maintaining optimal flow conditions, the sensor helps prevent issues such as blockages, uneven filling of molds, or inconsistent product quality. The flow sensor 216 is essential for ensuring that the recycled plastic materials are processed smoothly and efficiently, contributing to the overall reliability and productivity of the WPPM. Its accurate monitoring capabilities enable the system to produce high-quality, uniform construction materials while minimizing waste and operational disruptions.

[0034] The quality detection unit 218 in the Waste Plastic Product Machine (WPPM) 102 is designed to ensure the consistent production of high-quality construction materials from recycled plastics. The unit operates by analyzing the final products, such as bricks and paver blocks, for defects or inconsistencies that could compromise their structural integrity or aesthetic appearance. Using data from various sensors, including those monitoring temperature, pressure, and flow, the quality detection unit 218 assesses key parameters such as material density, surface finish, and dimensional accuracy. It is integrated with the Al control unit 230, which uses the insights providedby the quality detection unit to make real-time adjustments to the recycling process, such as modifying heating profiles or adjusting molding pressures, to correct any detected issues. If the unit identifies products that do not meet predefined quality standards, it can trigger corrective actions or alert operators for further inspection. The proactive approach to quality control ensures that only materials meeting the highest standards are produced, reducing waste and enhancing the overall reliability and efficiency of the WPPM. By continuously monitoring and maintaining product quality, the quality detection unit 218 plays a role in the system’s ability to deliver durable, eco- friendly construction materials. Construction plastic products are high strength, enhanced insulation, low volume, and no harmful by-products, suitable for diverse industries.

[0035] The material feed sensor 220 in the Waste Plastic Product Machine (WPPM) 102 is a component that monitors the input of waste plastics into the system, ensuring that the materials are fed into the processing stages at the correct rate and in the appropriate quantities. The sensor is strategically positioned at the entry point of the WPPM, where it detects the type, volume, and consistency of the incoming plastic feedstock. The real-time data collected by the material feed sensor 220 is transmitted to the processor 202, which, in coordination with the Al control unit 230, adjusts the feed rate to match the system’s processing capacity and the specific requirements of the recycling process. By regulating the flow of materials into the heating and molding stages, the sensor helps maintain optimal conditions within the WPPM, preventing issues such as overloading, underfeeding, or inconsistent material flow that could affect the quality of the final products. The material feed sensor 220 is essential for ensuring the smooth operation of the recycling process, enabling the system to handle varying types and amounts of waste plastics efficiently while minimizing waste and ensuring the production of high-quality construction materials.

[0036] The heating sensor 222 in the Waste Plastic Product Machine (WPPM) 102 is responsible for monitoring the temperature within the heating chamber where waste plastics are processed. The sensor provides real-time data on the precise temperature levels as the plastics are heated to a malleable state, which is essential for achieving the optimal conditions needed for efficient recycling. The heating sensor 222 is directly linked to the processor 202, enabling the Al control unit 230 to continuously adjust the heating mechanism based on the sensor’s readings. It ensures that the temperature remains within the ideal range, preventing the plastics from either underheating, which could result in incomplete processing, or overheating, which could degrade the material and compromise the quality of the final product. Also, fire preventive measures are maintained During the process of the plastic. By maintaining consistent and accurate heating conditions, the heatingsensor 222 plays a vital role in the WPPM’s ability to produce high-quality, durable construction materials from recycled plastics. Its precise monitoring helps optimize the energy efficiency of the system while ensuring that the recycling process is both reliable and effective.

[0037] The molding pressure sensor 224 in the Waste Plastic Product Machine (WPPM) 102 is a component that ensures precise control over the pressure applied during the molding process, where the heated, malleable plastics are shaped into construction materials like bricks, paver blocks, mile stone, railway sleepers, etc. In this system, mold can be interchangeable so according to the user requirement product materials will be customized. The sensor continuously monitors the pressure levels within the molds, providing real-time data to the processor 202. The Al control unit 230 uses this data to dynamically adjust the molding pressure to the optimal level required for each specific batch of material, ensuring that the final products achieve the desired density, strength, and dimensional accuracy. The molding pressure sensor 224 is crucial for preventing defects such as voids, warping, or insufficient compaction, which can occur if the pressure is too low or too high. By maintaining the correct pressure throughout the molding process, the sensor helps to produce uniform, high-quality construction materials that meet stringent performance standards. Additionally, the sensor contributes to the overall efficiency and reliability of the WPPM by enabling the system to respond quickly to any fluctuations in pressure, ensuring consistent product quality and minimizing waste.

[0038] The cooling rate sensor 226 in the Waste Plastic Product Machine (WPPM) 102 monitors and regulates the rate at which the molded plastic products are cooled after being shaped. Proper cooling is essential for ensuring that the construction materials, such as bricks and paver blocks, solidify with the desired structural integrity and dimensional stability. The cooling rate sensor 226 provides real-time data on the temperature decline within the molds, which is relayed to the processor 202. The Al control unit 230 utilizes this data to dynamically adjust the cooling process, ensuring that the materials cool at an optimal rate to avoid issues like internal stress, cracking, or warping. By precisely controlling the cooling rate, the sensor helps maintain the high quality and durability of the final products. The cooling rate sensor 226 is integral to the overall efficiency of the WPPM, enabling the system to produce consistently reliable and robust construction materials while minimizing energy consumption and reducing the risk of defects during the cooling phase.

[0039] The mold configuration unit 228 in the Waste Plastic Product Machine (WPPM) 102 allows for the customization and adjustment of molds used in shaping recycled plastic into variousconstruction materials, such as bricks, paver blocks, road dividers, railway sleepers, and other structural components. The unit is designed to manage different mold configurations, enabling the WPPM to produce a wide range of product sizes and shapes to meet specific construction needs. The mold configuration unit 228 is integrated with the processor 202 and the Al control unit 230, which allows it to automatically adjust the mold settings based on the type of plastic being processed, the desired product specifications, and real-time data from the sensor network 106. Such flexibility ensures that the molds are precisely aligned and configured for each batch, optimizing the molding process for consistency and quality. The unit also enables quick changes between different mold designs, enhancing the system’s versatility and efficiency in producing diverse products. By managing the configuration of the molds, mold configuration unit 228 ensures that the final products are accurately formed, structurally sound, and meet the required standards for use in construction applications.

[0040] The Al control unit 230 in the Waste Plastic Product Machine (WPPM) 102 is the intelligent core of the system, responsible for optimizing and managing the entire recycling process. The advanced unit leverages artificial intelligence and machine learning models to analyze real-time data from the sensor network 106, which monitors key parameters such as temperature, pressure, material composition, and flow within the WPPM. The Al control unit 230 dynamically adjusts the processing conditions, including heating, molding pressure, and cooling rates, to ensure that the waste plastics are efficiently converted into high-quality construction materials. It also predicts potential issues, such as material inconsistencies or process inefficiencies, and proactively makes adjustments to prevent defects in the final products. Additionally, the Al control unit 230 plays a role in learning from past processing cycles, continuously improving the system's performance over time. By integrating this Al-driven control, the WPPM achieves a high level of automation, consistency, and precision, ensuring that the recycling process is both efficient and capable of producing durable, eco-friendly construction materials.

[0041] The sensor data reception unit 232 in the Waste Plastic Product Machine (WPPM) 102 acts as the central hub for collecting and processing real-time data from the various sensors integrated throughout the system. This unit is responsible for receiving inputs from temperature sensors, pressure sensors, composition sensors, flow sensors, and other critical monitoring devices. Once the data is received, the sensor data reception unit 232 organizes and transmits this information to the processor 202 and the Al control unit 230 for analysis. By consolidating data from all sensor inputs, this unit enables the Al control unit to make informed decisions and adjustments to the recyclingprocess, such as modifying heating levels, adjusting molding pressures, or optimizing cooling rates. The sensor data reception unit 232 ensures that the system operates with precise, up-to-date information, which is crucial for maintaining the consistency, quality, and efficiency of the WPPM. Its role in facilitating seamless communication between the sensors and the control systems is fundamental to the machine's ability to produce high-quality construction materials from waste plastics.

[0042] The material analysis unit 234 in the Waste Plastic Product Machine (WPPM) 102 is a specialized component designed to evaluate the properties and composition of the waste plastics as they are processed. The said unit analyzes data collected from the composition sensor 212, including the types of plastics present, their chemical makeup, and any impurities or contaminants. The material analysis unit 234 processes this information and provides detailed insights to processor 202 and the Al control unit 230, enabling them to optimize the recycling process based on the specific characteristics of the input materials. By accurately identifying the composition of the plastics, the material analysis unit 234 helps tailor the heating, molding, and cooling parameters to ensure that the final products are of high quality and meet the desired specifications. It plays an important role in adapting the WPPM’s operations to varying types of waste plastics, ensuring consistent performance and the production of durable, eco-friendly construction materials. Its ability to provide precise material characterization is key to maximizing the efficiency and effectiveness of the entire recycling process.

[0043] The process optimization unit 236 in the Waste Plastic Product Machine (WPPM) 102 is a component that ensures the recycling process is continuously refined and optimized for maximum efficiency and product quality. The unit works in conjunction with the Al control unit 230 and other system components to analyze real-time data from the sensor network 106, including temperature, pressure, flow rates, and material composition. Using this data, the process optimization unit 236 identifies areas where the recycling process can be improved, such as adjusting heating profiles, optimizing molding pressure, or fine-tuning the cooling rate. It also monitors the overall performance of the WPPM, making dynamic adjustments to enhance throughput, reduce energy consumption, and minimize waste. The Process Optimization Unit 236 plays a role in ensuring that the WPPM operates at peak performance, consistently producing high-quality, durable construction materials from waste plastics. Its continuous monitoring and adjustment capabilities allow the system to adapt to varying input materials and processing conditions, ensuring that the recycling process remains efficient, reliable, and sustainable.

[0044] The product quality prediction unit 238 in the Waste Plastic Product Machine (WPPM) 102 is an advanced component dedicated to forecasting the quality of the final construction materials produced from recycled plastics. The unit utilizes data from various sensors, including temperature, pressure, and material composition sensors, along with historical processing data to predict the quality of the output. By employing machine learning modules and statistical models, product quality prediction unit 238 assesses factors such as strength, durability, and dimensional accuracy of the molded products before they are fully finished. The predictive capability allows the system to anticipate potential defects or inconsistencies in the final products, enabling preemptive adjustments to the processing parameters to address any issues. The product quality prediction unit 238 ensures that the WPPM consistently delivers high-quality construction materials by providing valuable insights into the expected performance of the products, thereby enhancing overall reliability and customer satisfaction.

[0045] The Dynamic Control Unit (240) is a component of the Waste Plastic Product Machine (WPPM) 102, designed to enable real-time adaptability of the recycling process. It works closely with the processor (202) to analyze data received from various sensors, such as the temperature sensor (210), pressure sensor (214), and cooling rate sensor (226), and make instantaneous adjustments to the operational parameters. The unit dynamically controls variables such as heating intensity, material flow, molding pressure, and cooling rates to ensure optimal process efficiency and consistent product quality. By responding promptly to fluctuations in material properties or environmental conditions, the Dynamic Control Unit (240) enhances the overall system's reliability and productivity. Additionally, it integrates feedback from the Product Quality Prediction Unit (238) and the Al Control Unit (230) to fine-tune its adjustments, enabling the WPPM to handle different types of waste plastics and achieve high-quality outputs tailored to specific construction material requirements. Such capability makes the Dynamic Control Unit (240) indispensable for maintaining a seamless, adaptive, and efficient recycling workflow.

[0046] FIG. 2 illustrates a detailed block diagram of the Waste Plastic Product Machine (WPPM) 102, highlighting its various integrated components and their interactions within the system. The diagram showcases the central role of the Al control unit 230, which is connected to key components such as the processor 202, memory 204, and transceiver 206. It also depicts specialized units including the sensor data reception unit 232, material analysis unit 234, process optimization unit 236, and product quality prediction unit 238. Each component is linked to the processor 202, which coordinates the overall operation of the WPPM based on real-time data from a network of sensors.The diagram emphasizes how these elements work together to monitor and adjust the recycling process, ensuring efficient and high-quality production of construction materials. The layout demonstrates the interconnectivity and functional integration of the system’s components, illustrating how data flows between the sensors, analysis units, and control mechanisms to optimize the recycling process.

[0047] The present disclosure addresses the limitations of conventional plastic recycling systems, which often struggle with inefficiencies in processing mixed and contaminated plastics and producing consistent, high-quality output. Further, the present system comprises advanced Al control and sensor technologies to automate and optimize the entire recycling process. The system features a Waste Plastic Product Machine (WPPM) that integrates real-time data analysis, process optimization, and predictive quality control to ensure precise and efficient conversion of waste plastics into durable construction materials. By utilizing components such as a sensor network, material analysis unit, and process optimization unit, the system overcomes the limitations of traditional methods, improving overall performance, reducing manual labor, and enhancing the quality and reliability of the recycled products. Such an approach not only addresses existing challenges but also advances the capabilities of plastic recycling technology.

[0048] In an exemplary operation, a system to efficiently convert waste plastics into high-quality construction materials is employed. The system comprises a Waste Plastic Product Machine (WPPM) equipped with advanced components, including a mesh container for processing mixed plastics and a heating mechanism for reaching optimal temperatures. The system also comprises an Al control unit that dynamically adjusts processing parameters based on real-time sensor data. In an embodiment, the Al control unit integrates data from a sensor network to optimize heating, molding, and cooling processes. In another embodiment, the system features a material analysis unit that characterizes the plastic composition, guiding the Al control unit in making precise adjustments. Furthermore, in an embodiment, a product quality prediction unit forecasts the final product's attributes to preemptively address potential defects. It ensures that the recycling process is efficient, automated, and capable of producing consistent and durable construction materials from various types of waste plastics.

[0049] In an embodiment, the processor is configured to receive and process real-time data from a network of sensors, enabling precise control over the recycling process by analyzing variables such as temperature, pressure, and material composition. In another embodiment, the processor isconfigured to run advanced machine learning models to optimize the heating, molding, and cooling parameters based on the data received, ensuring high-quality output. Additionally, in an embodiment, the processor is configured to integrate with the Al control unit to dynamically adjust processing conditions and predict potential issues in the recycling cycle. Furthermore, in an embodiment, the processor is configured to interface with the product quality prediction unit, providing actionable insights to prevent defects and enhance the consistency and durability of the final construction materials. The multi-faceted configuration allows the processor to effectively manage and refine the entire recycling process for optimal performance and product quality.

[0050] In another embodiment of the present invention, the system is equipped with an advanced feedback loop that enables continuous process refinement. In this configuration, the processor is linked to a real-time monitoring system that tracks not only the immediate operational parameters but also historical data trends. The processor utilizes this feedback to fine-tune the Al control unit's algorithms, adjusting the recycling parameters such as heating rates and molding pressures based on both current conditions and historical performance data. It further incorporates an automated maintenance module that predicts and schedules preventative maintenance based on usage patterns and sensor data, minimizing downtime and extending equipment lifespan. By integrating real-time feedback with predictive maintenance and continuous optimization, this embodiment enhances the overall efficiency and reliability of the waste plastic recycling process, ensuring consistent production of high-quality construction materials.

[0051] In another embodiment of the present invention, the system incorporates a modular design for the Waste Plastic Product Machine (WPPM), allowing for flexible and scalable operations. The configuration includes interchangeable modules for different stages of the recycling process, such as heating, molding, and cooling, which can be easily swapped or upgraded based on specific requirements or material types. In this embodiment, the processor coordinates with these modular components to adapt the system's functionality in real-time, optimizing the process for varying input materials and production volumes. Additionally, the system features a user-friendly interface that allows operators to customize settings and monitor performance through a centralized control panel. Such a modular approach provides versatility and adaptability, enabling the system to efficiently handle diverse recycling tasks and scale operations according to demand, thereby enhancing its overall utility and effectiveness in converting waste plastics into valuable construction materials.

[0052] In an embodiment, a practical scenario to illustrate the working of the present disclosure is disclosed. In one example, imagine a recycling facility equipped with the Waste Plastic Product Machine (WPPM) as described. In this facility, a diverse range of waste plastics, including packaging materials, municipal plastic waste, and industrial scraps, are collected and fed into the system. The Al control unit, utilizing real-time data from an array of sensors, monitors the composition and condition of the input materials as they are processed. The processor adjusts the heating and molding parameters to suit the specific types of plastics being handled, ensuring optimal conditions for conversion. Meanwhile, the material analysis unit evaluates the properties of the plastics, and the process optimization unit fine-tunes the operations based on ongoing feedback. The product quality prediction unit forecasts the characteristics of the final output, allowing for preemptive adjustments to address any potential issues. The presented integrated approach ensures that the system efficiently transforms waste plastics into high-quality construction materials, such as bricks and paver blocks, demonstrating the effectiveness and versatility of the present disclosure in a real-world setting. A vehicle-mounted WPPM for on-site recycling on land and water environments.

[0053] FIG. 3 illustrates a method for converting waste plastics into high-quality construction materials using the Waste Plastic Product Machine (WPPM). The process begins at Start step 302 and progresses to step 304, where waste plastics are collected and loaded into the WPPM. In step 306, the system’s sensors assess the material composition and condition, providing real-time data to the Al control unit. Step 308 involves the Al control unit adjusting the heating parameters based on this data to achieve the optimal processing temperature, during the plastic is converted into a semi-liquid form within a mesh container using Thermomesh Technology. In step 310, the semiliquid plastic is transferred to the molding unit, where it is shaped into the desired construction products. Step 312 follows with the cooling phase, solidifying the molded items to the required structural properties. In step 314, the product quality prediction unit evaluates the attributes of the final products against predetermined standards. Finally, step 316 involves making necessary process adjustments based on the quality predictions to ensure that the final products meet the required specifications. The method concludes at the end of step 318, completing the recycling process and preparing the system for the next batch.

[0054] The present disclosure offers several technical advantages over conventional plastic recycling systems. Its integration of multiple sensors, including temperature, pressure, composition, and flow sensors, enables real-time monitoring and precise control of the recycling process. Theenhanced sensor network allows for accurate adjustments to heating, molding, and cooling parameters, ensuring optimal conditions and high-quality output. Additionally, the use of an advanced Al control unit and machine learning modules enables dynamic process optimization based on real-time data, improving efficiency and reducing manual intervention. The incorporation of a material analysis unit and product quality prediction unit further enhances the system's ability to produce consistent and durable construction materials. Further, the modular design of the system allows for scalability and adaptability to different types of waste plastics and production requirements. Overall, these technical advancements collectively enhance the system's performance, reliability, and versatility compared to traditional recycling methods.

[0055] The present disclosure provides a solution to a significant technical problem in the field of waste plastic recycling by addressing the inefficiencies and limitations of conventional methods. The present disclosure offers specific technical features and functionalities, such as an advanced sensor network that includes temperature, pressure, composition, and flow sensors, which work in unison to monitor and control the recycling process with high precision. Additionally, the integration of an Al control unit and machine learning modules enables real-time optimization of heating, molding, and cooling parameters, ensuring optimal processing conditions and high-quality output. The system also includes a material analysis unit for the accurate characterization of plastic inputs and a product quality prediction unit to forecast and ensure the consistency of the final products. These features collectively enable efficient, adaptable, and scalable recycling operations, effectively transforming diverse waste plastics into durable construction materials while overcoming the challenges faced by traditional recycling systems.

[0056] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems. A computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general-purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions.

[0057] A person with ordinary skills in the art will appreciate that the systems, modules, and submodules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above-disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.

[0058] Those skilled in the art will appreciate that any of the aforementioned steps and / or system modules may be suitably replaced, reordered, or removed, and additional steps and / or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software or a combination thereof.

[0059] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.

Claims

We Claim:

1. A system for recycling waste plastics into construction materials, the system comprising: a Waste Plastic Product Machine (WPPM) including: a mesh container for holding and processing waste plastics; a heating mechanism utilizing Thermomesh Technology to bring the waste plastics to a semi-liquid state within the mesh container; a molding unit configured to shape the semi-liquid waste plastics into construction products; a cooling system to solidify the molded products; and an Al control unit configured to: receive data from a sensor network monitoring temperature, pressure, and flow parameters; and adjust the heating, molding, and cooling parameters based on real-time data.

2. The system of claim 1, wherein the Al control unit further comprising Machine learning modules that dynamically adjust process parameters based on sensor data, including adjustments for heating, molding, and cooling to optimize product quality and energy efficiency.

3. The system of claim 1, further comprising a sensor network integrated into the WPPM, including: temperature sensors to monitor the heating and cooling stages; pressure sensors to ensure consistent molding conditions; and flow sensors to regulate the material feed and flow rates within the system.

4. The system of claim 1, further comprising: a material analysis unit to evaluate the composition and quality of the input plastics, and a product quality prediction unit to forecast the attributes of the final products based on real-time data and historical performance.

5. The system of claim 1, wherein the WPPM is modular, allows for: interchangeable components that can process different types of plastics and cater to varying production requirements, including specialized molds for producing various construction products like plastic bricks or plastic paver blocks.

6. A method for recycling waste plastics into construction materials, the method comprising: collecting and loading waste plastics into the WPPM; heating the waste plastics within one or more mesh containers using Thermomesh Technology to achieve a semi-liquid state; molding the semi-liquid plastics into construction products;Cooling the molded products to solidify them; and analyzing real-time data from sensors to adjust process parameters using an Al control unit.

7. The method of claim 6, further comprising utilizing machine learning modules within the Al control unit to refine and adjust heating, molding, and cooling parameters dynamically, ensuring consistent product quality.

8. The method of claim 6, further comprising: evaluating the composition of the input materials using a material analysis unit, and predicting the quality of the final products using a product quality prediction unit.

9. The method of claim 6, further comprising: customizing system settings and monitoring WPPM performance via a user interface, allowing operators to make real-time adjustments.

10. The method of claim 6, wherein the WPPM is modular, comprising interchangeable components that allow for the processing of different types of plastics and the production of various construction materials, with the ability to reconfigure the system for specific applications or standards.

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