Recycled PET Panels for Modular Construction
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Solution Overview
Problem
Conventional construction materials are expensive, time-consuming to assemble, difficult and costly to ship, and not environmentally friendly, while also being susceptible to damage from the elements.
Innovation Solution
The use of recycled PET plastic construction panels, which are lightweight, environmentally friendly, and impervious to elements, providing support for structures and allowing for modular construction methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional construction materials (wood, aluminum) are used, then structural support is provided, but the materials are expensive, time-consuming to assemble, difficult to ship, and susceptible to damage from elements
Solution Approach 1:
The construction system is divided into modular panels that can be pre-assembled in factories and then quickly shipped to the final site for rapid assembly. Each panel is a self-contained module with standardized connection points, enabling fast installation without complex on-site construction processes.
Solution Approach 2:
Structural panels are pre-assembled and pre-treated in factory conditions before shipment. This includes pre-attaching structural elements, applying protective coatings, and preparing connection interfaces, which eliminates time-consuming on-site preparation and assembly steps.
2Strength
If conventional construction materials are used, then structural support is provided, but shipping costs and difficulty increase
Solution Approach 1:
The structure is segmented into standardized panels of optimized dimensions that maximize shipping efficiency. These modular units can be stacked and secured efficiently during transport, reducing shipping costs and logistical complexity compared to traditional bulk material delivery.
Solution Approach 2:
The structural panels are designed with optimized thickness and material density parameters that maintain structural integrity while reducing overall weight. This allows the panels to be strong enough for structural support yet light enough for cost-effective and easy shipping.
3Strength
If conventional construction materials (wood, aluminum) are used, then structural support is provided, but environmental friendliness deteriorates
Solution Approach 1:
The panels are designed for full recyclability at end of life. The thermoplastic material can be melted down and reprocessed into new panels or other products, creating a closed-loop system that eliminates waste and reduces the need for virgin material extraction, unlike traditional wood or aluminum construction materials.
Solution Approach 2:
The material composition parameters are specifically selected to enable recyclability. The thermoplastic polymer matrix and reinforcement fibers are chosen to be compatible with established recycling processes, allowing the structural panels to be recovered and reused without degrading performance.
4Strength
If conventional construction materials are used, then structural support is provided, but resistance to elemental damage deteriorates
Solution Approach 1:
The material composition parameters are specifically engineered to resist elemental damage. The thermoplastic matrix and fiber reinforcement are selected for their inherent resistance to rot, insect attack, and moisture degradation, providing superior durability compared to traditional wood or aluminum materials that require additional protective treatments.
Data Source
AI summary
A system and method for building and assembling parts of or entire modular structures such as dwelling units, marine structures or watercraft from recycled PET material panels. Each assembly is made from panels of recycled PET material having a core and a rigid skin on both faces of the panel. The panels are joined together with splines of the same type of panel material. The splines may be glued and or fastened in place. The panels provide the necessary rigidity and insulative qualities for construction and watercraft manufacture and may be painted. The panels are impervious to environmental elements as well as to insects.