Pre-compressed Bioplastic Composite Elements for Structural Use
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Solution Overview
Problem
Existing methods for producing composite building materials fail to maintain internal stresses in pre-compressed elements, leading to loss of mechanical characteristics when fibrous organic materials are wetted, and none utilize exclusively compostable materials.
Innovation Solution
A method involving the use of compostable dry fibrous organic materials and bioplastic materials, where the materials are subjected to compression and tension to create pre-compressed elements with a permanent state of co-action, using a mould and high-frequency electromagnetic radiation for processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fibrous organic materials are wetted during compression, then the materials become more pliable and easier to compress, but the materials lose their elastic return characteristics and mechanical strength
Solution Approach 1:
The patent changes the physical state parameter of the binding material from liquid/wet to solid/dry. By using dry fibrous organic materials and solid-state bioplastic binding materials, the system avoids the plasticization effect of moisture while still achieving compression through the solid-state melting process during heating
Solution Approach 2:
The patent utilizes phase transition of the bioplastic binding material from solid to liquid state during heating, allowing compression and shaping without wetting the fibrous materials. The bioplastic melts at elevated temperature to bind the fibers, then solidifies upon cooling to maintain structural integrity and mechanical strength
2Strength
If conventional adhesives and binders are used to bind fibrous materials, then the mechanical strength and structural integrity are improved, but the environmental sustainability is reduced due to non-compostable materials
Solution Approach 1:
The patent applies homogeneity by using exclusively compostable materials throughout the entire composite structure. Both the fibrous organic materials and the bioplastic binding materials are selected to be biodegradable and compostable, ensuring uniform environmental sustainability across all components of the composite element
Solution Approach 2:
The patent creates a composite material system combining natural fibrous organic materials with bioplastic binding materials. This composite approach maintains structural integrity through the synergistic combination of fiber reinforcement and bioplastic matrix, while both components are designed to be environmentally sustainable and compostable
3Strength
If high compression forces are applied to fibrous materials, then the density and structural strength are improved, but the thermal insulation properties deteriorate due to reduced air pockets
Solution Approach 1:
The patent applies local quality by creating non-uniform compression distribution within the composite element. The bioplastic binding material strategically locates compressed zones where structural strength is needed while preserving air pockets and lower density regions where thermal insulation is required, achieving spatial differentiation of material properties
Solution Approach 2:
The composite structure combines densely compressed fibrous regions for structural strength with air-filled cavities and less compressed zones for thermal insulation. The bioplastic binding material holds this heterogeneous structure together, allowing coexistence of high-density and low-density regions within the same element
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces elements with improved mechanical load-bearing capacity, thermal insulation, and high environmental sustainability, as they are biodegradable and compostable, maintaining internal stresses and reducing deformations during use.
Implementation Method 1
heating, for example with the use of generators of high-frequency electromagnetic radiation (microwaves)
Implementation Method 2
generators of high-frequency electromagnetic radiation (microwaves)
Implementation Method 3
the fibrous organic material and the casing being configured for maintaining a permanent state of co-action with the fibrous organic material permanently compressed and the casing made of bioplastic material permanently tensioned
Data Source
Figure 1~2
Figure 3~4b
Figure 5~5a
AI summary
A method for the production of pre-compressed elements made of composite material, such as blocks, panels, prefabricated walls, beams, and slabs for structural or non-structural use in the building sector, comprising the following steps: providing an amount of a dry fibrous organic material (7); providing a first outer casing made of a heat-meltable bioplastic material (2) for containing the fibrous material for the formation of a composite material; providing a plurality of inner casings containing portions of said fibrous material; compressing the composite material comprising the fibrous material (7) and the outer and inner casings of plastic material; heating the composite material; and cooling the composite material.