Lattice Plastic Brick Structure for Compact Thermal Insulation
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Solution Overview
Problem
Existing building materials, such as concrete and traditional insulation materials, are inefficient in thermal insulation and require thick envelopes to achieve desired efficiency, leading to high energy consumption and carbon footprint, while lacking lightweight, high-performance alternatives.
Innovation Solution
A lattice-based plastic brick with two solid plates and sandwiched lattice unit cells, manufactured via 3D printing, utilizing recycled plastics, offering relative densities from 5% to 80% and designed with various topologies, providing high thermal insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional insulation materials (mineral wool, EPS, polyurethane) are used, then thermal insulation is provided, but thermal conductivity increases substantially with moisture uptake and thick envelopes are required
Solution Approach 1:
The patent employs a lattice structure with controlled porosity (relative density 5-80%) created through additive manufacturing. This porous configuration traps air within the lattice cells, providing thermal insulation while maintaining a compact thickness. The porous structure reduces the quantity of material needed compared to solid insulation materials, directly addressing the contradiction between insulation performance and envelope thickness.
Solution Approach 2:
The invention uses composite construction combining polymer materials with lattice geometry. The polymer matrix provides structural integrity while the lattice configuration provides thermal insulation. This composite approach enables the brick to achieve both mechanical strength and thermal insulation performance in a compact form, reducing the required envelope thickness while maintaining insulation effectiveness.
2Loss of energy
If thicker insulation is used to achieve required thermal efficiency, then energy savings increase, but initial cost and material quantity increase
Solution Approach 1:
The lattice structure's porous configuration creates multiple air pockets that impede heat transfer, providing high insulation performance per unit thickness. This allows achieving required thermal efficiency with less material quantity, reducing both initial material costs and embodied energy while maintaining effective energy savings throughout the building's lifecycle.
Solution Approach 2:
The patent optimizes the relative density parameter of the lattice structure (ranging from 5-80%) to balance insulation performance with material usage. By adjusting this parameter, the design achieves maximum thermal efficiency with minimum material quantity, optimizing the trade-off between initial material cost and long-term energy savings.
3Strength
If lattice structures are used for structural applications, then mechanical properties are improved, but thermal insulation performance is not optimized
Solution Approach 1:
The patent applies different lattice configurations in different regions of the brick to optimize both mechanical and thermal properties. The lattice structure provides structural strength where needed while maintaining porosity for thermal insulation. This localized optimization allows the same component to fulfill both structural and insulation functions, resolving the contradiction between mechanical performance and thermal efficiency.
Solution Approach 2:
The lattice-based plastic brick is designed to perform multiple functions simultaneously: structural load-bearing through the lattice framework and thermal insulation through the trapped air within lattice cells. This multi-functional design eliminates the need for separate structural and insulation layers, resolving the contradiction between mechanical strength and thermal insulation performance.
4Weight of moving object
If polymer materials are used to reduce embodied energy and weight, then lightweight characteristics are achieved, but structural strength may be compromised
Solution Approach 1:
The lattice structure creates a lightweight polymer material by introducing void spaces within the brick volume. The polymer matrix maintains structural integrity while the porous configuration reduces overall density and weight. This porous construction enables polymer materials to achieve both lightweight characteristics and adequate structural strength for building applications.
Solution Approach 2:
The invention uses composite construction combining polymer materials with lattice geometry to achieve optimal strength-to-weight ratio. The polymer provides lightweight characteristics while the lattice configuration provides structural rigidity. This composite approach allows the material to be significantly lighter than traditional concrete while maintaining sufficient structural strength through the geometric reinforcement of the lattice structure.
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 plastic brick reduces operational and embodied energy, enhances thermal insulation, and lowers carbon footprint by using lightweight, recyclable materials with improved mechanical properties.
Implementation Method 1
the utilise of polymer-based lattice structure with enclosed air cavities manufactured via additive manufacturing is yet to be used as a building envelope
Data Source
AI summary
The present invention of the polymer bricks that are considered highly efficient in terms of mechanical properties, providing thermal insulation in buildings and reducing the operating energy of the building and the energy embodied in the manufacturing stages compared to concrete bricks (blocks) or ready-made concrete. The lattice-based plastic brick includes at least two solid plates and a plurality of lattice unit cells. The two solid plates include an inner layer and an outer layer. The lattice unit cells are sandwiched between the at least two solid plates in a predefined manner. The lattice unit cells is designed using topologies comprising triangle, diamond, hexagonal/honeycomb, cubic, polygonal, star, gyroid, and a combination thereof. The lattice unit cells includes struts of predefined thickness and length.