Mobile Drywall Processor On-Site Crushing
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Solution Overview
Problem
The handling and transportation of scrap drywall in construction projects are inefficient due to its irregular shapes, leading to high costs and environmental concerns from contamination during transportation to recycling facilities.
Innovation Solution
A mobile drywall processor is introduced that can be used on-site to crush scrap drywall into smaller pieces, reducing bulk volume and allowing for more efficient transportation and recycling, featuring a feeder, crusher, and removable container designed to fit through doorways and elevators, with hammers driven by an electric motor to process the drywall into smaller, more manageable sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scrap drywall is transported from the construction site to offsite crushers or processing plants, then the drywall can be processed for recycling or disposal, but the transportation time and cost increase significantly, and the probability of contamination increases
Solution Approach 1:
The patent applies preliminary action by installing a mobile crusher at the construction site to process drywall immediately after it becomes scrap, before transportation is needed. This preliminary processing eliminates the need for lengthy transportation to offsite facilities, reducing both transportation time and contamination risk while maintaining recycling quality.
2Ease of manufacture
If scrap drywall is processed offsite at large industrial crushers, then processing can be performed, but transportation costs and labor costs increase due to multiple stops and significant transportation time
Solution Approach 1:
The patent applies local quality by bringing the processing capability directly to the construction site through a mobile crusher, rather than transporting material to a centralized facility. This localizes the processing function where it is needed, eliminating transportation costs and energy loss while maintaining full processing capability.
3Ease of operation
If irregularly shaped scrap drywall pieces are transported in containers or trucks, then the drywall can be moved to disposal or recycling facilities, but large voids between pieces reduce transportation efficiency
Solution Approach 1:
The patent applies parameter changes by altering the physical state and dimensions of the drywall material through crushing. The mobile crusher reduces the bulk volume of scrap drywall by breaking it into smaller, more compact pieces, which eliminates voids and significantly improves transportation efficiency by maximizing container utilization.
4Productivity
If a mobile drywall processor is used at the worksite, then bulk volume of drywall is reduced for efficient handling and transportation, but the device must be transportable through doorways and elevators
Solution Approach 1:
The patent applies segmentation by dividing the processing system into modular, transportable components that can be assembled at the construction site. The mobile crusher is designed as a compact, self-contained unit that can be broken down or configured to fit through standard doorways and elevators, maintaining high processing efficiency while satisfying portability constraints.
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
This solution significantly reduces transportation costs and labor, minimizes environmental impact by processing drywall at the source, and enhances recycling efficiency by consolidating material into smaller volumes for easier handling and processing, potentially reducing the volume by up to 50% and improving the cleanliness of recycled drywall.
Implementation Method 1
one or more hammers fixedly coupled to the drive shaft such that the hammers rotate with the drive shaft when driven by the electric motors, the one or more hammers positioned such that, during at least a portion of the rotation of the drive shaft, the one or more hammers pass below an outlet of the feed chute so as that the one or more hammers contact the pieces of scrap drywall received at the feed chute to break the pieces of scrap drywall into smaller pieces
Data Source
AI summary
Methods and systems for processing and recycling drywall are described herein. A mobile dry wall processor may be used at a construction site to process or crush scrap or waste drywall to reduce the size of dry wall pieces before transporting the drywall off the construction site. The mobile drywall processor may include a container to capture the processed drywall. The container and the mobile drywall processor may be configured in size and shape for easy transportation to and from construction sites, including building interiors. Processed drywall is transported to be recycled or to a landfill. The processed or crushed drywall may have a higher density, reducing shipping and transportation costs.