Blast Resistant Wall Panels Using Recycled Rubber Mats
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Solution Overview
Problem
Commercially available anti-blast wall products are excessively expensive due to materials and assembly costs, necessitating a more cost-effective solution for impact and blast resistance.
Innovation Solution
A method involving prefabricated parts comprising rubber mats and a central core, where the external surfaces of the core are prepared with a sealer, bonding agent primer, and top coat, and the rubber mats are pressed onto the core under constant pressure to form a blast and ballistic resistance wall, utilizing recycled materials for sustainability and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If commercially available anti-blast wall products are used, then blast and ballistic resistance is achieved, but the cost becomes excessively high due to materials and assembly
Solution Approach 1:
The wall system is divided into modular prefabricated parts including a central core, external rubber mats, and internal rubber mats that can be manufactured separately and assembled together. This segmentation allows for more efficient manufacturing of individual components and simplifies the overall assembly process, reducing both material waste and assembly costs while maintaining blast and ballistic resistance performance
Solution Approach 2:
The invention uses composite material construction combining a central core with rubber mats on both external and internal surfaces. This composite structure provides superior blast and ballistic resistance compared to traditional homogeneous materials, while the use of rubber materials specifically reduces costs compared to conventional anti-blast wall products. The composite design also enables the wall to provide multiple functions including thermal insulation and noise reduction
2Strength
If traditional multi-layer anti-blast walls are constructed, then impact resistance is improved, but assembly complexity and time increase
Solution Approach 1:
The wall components including the central core and rubber mats are prefabricated in advance with bonding agents and sealers pre-applied to the surfaces. This preliminary preparation eliminates the need for complex on-site assembly procedures, reducing assembly time and complexity while maintaining the multi-layer structure necessary for impact resistance. The prefabricated nature of the components allows for quality control during manufacturing rather than during assembly
Solution Approach 2:
Multiple functions are merged into a single integrated wall assembly. The central core with external and internal rubber mats provides simultaneously blast resistance, ballistic resistance, thermal insulation, and noise reduction. This merging of functions into one unified prefabricated unit simplifies assembly compared to traditional multi-layer walls that require separate installation of each layer and function
3Ease of manufacture
If recycled materials are used in the wall construction, then environmental impact is reduced and cost is lowered, but material durability and performance may be compromised
Solution Approach 1:
The rubber mats are formulated with specific physical and chemical parameters optimized for blast and ballistic resistance. By controlling the rubber compound composition, thickness, and physical properties during manufacturing, the patent ensures that recycled rubber materials achieve the necessary durability and performance standards. The bonding agents and sealers are also formulated with specific parameters to ensure long-term adhesion and weathering resistance
Solution Approach 2:
The use of composite materials combines recycled rubber with bonding agents, sealers, and potentially other reinforcing materials to create a multi-component system that maintains or enhances the durability of recycled materials. The central core material is also selected to complement the recycled rubber components, creating an overall composite structure that achieves the required performance standards while utilizing recycled materials for cost and sustainability benefits
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 solution provides a cost-effective, sustainable blast and ballistic resistance wall that offers multipurpose resistance to blasts, ballistic impacts, noise, and thermal insulation, with the ability to withstand extreme impacts without replacement, while simplifying installation and reducing environmental impact through the use of recycled materials.
Implementation Method 1
applying a bonding agent primer and a top coat to the one or more external surfaces of the central core
Implementation Method 2
pressing the one or more rubber mats to the one or more external surfaces of the central core
Implementation Method 3
one or more rubber mats and a central core... forms a blast and ballistic resistance wall
Implementation Method 4
thermal insulation non-metallic wall panels... multipurpose resistance to blasts, ballistic impacts, noise, and thermal insulation
Implementation Method 5
multipurpose resistance to blasts, ballistic impacts, noise, and thermal insulation
Data Source
AI summary
A method includes providing a plurality of prefabricated parts for assembly, where the plurality of prefabricated parts comprises one or more rubber mats and a central core. The method also includes preparing one or more external surfaces of the central core, applying a sealer to the one or more external surfaces of the central core, applying a bonding agent primer and a top coat to the one or more external surfaces of the central core, and pressing the one or more rubber mats to the one or more external surfaces of the central core. The method further includes applying a constant pressure to the one or more rubber mats and the central core, where a combination of the one or more rubber mats and the central core forms a blast and ballistic resistance wall.