Recycled Plastic Wall Elements with H-Profile Beams
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Solution Overview
Problem
Existing building solutions lack efficiency and cost-effectiveness for rapid construction of temporary or permanent buildings, particularly in situations like refugee camps or disaster recovery, and they do not effectively utilize plastic waste as a sustainable building material.
Innovation Solution
A wall-building element system utilizing recycled or waste plastic materials for both the load-bearing core and thermally insulating layers, combined with H-profiled beams for load transfer, allowing for quick assembly of buildings with decent and reliable standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials and modular building systems are used, then buildings can be constructed with decent and reliable standards, but construction time is extended and costs increase
Solution Approach 1:
The building system is divided into modular wall-building elements that can be independently manufactured and assembled. Each element is a self-contained module with standardized dimensions and connection interfaces, enabling rapid assembly without compromising structural integrity or insulation performance
Solution Approach 2:
Wall-building elements are pre-manufactured with integrated insulation layers and connection features before delivery to the construction site. The H-profiled beams are pre-cut and prepared with connection elements, allowing for immediate assembly upon arrival, significantly reducing on-site construction time while maintaining reliable building standards
2Strength
If conventional building materials are used, then structural strength and stability are achieved, but construction costs increase
Solution Approach 1:
The patent changes the material parameter from conventional materials to recycled plastic materials, specifically using HDPE and other plastic waste streams. These materials maintain sufficient structural strength for wall applications while being abundant, low-cost, and requiring minimal processing. The extrusion process creates consistent structural properties at low manufacturing cost
Solution Approach 2:
The wall-building elements combine different plastic materials with complementary properties: structural cores provide strength and rigidity, while insulation layers provide thermal performance. This composite approach using recycled plastics achieves both structural requirements and cost-effectiveness
3Ease of manufacture
If plastic waste material is used as raw material, then construction costs decrease and environmental sustainability improves, but material strength and structural reliability may be compromised
Solution Approach 1:
The extrusion process parameters are optimized to create consistent structural properties in recycled plastic materials. By controlling temperature, pressure, and cooling rates during extrusion, the patent achieves uniform density and structural integrity in the wall-building elements, ensuring sufficient strength despite using recycled materials
Solution Approach 2:
The patent uses composite construction with distinct structural cores and insulation layers made from recycled plastics. The structural cores are designed with specific wall thicknesses and reinforcement features to achieve required strength, while the insulation layers provide thermal performance. This differentiated composite approach ensures both strength and cost-effectiveness
4Use of energy by stationary object
If thermal insulation layers are made from foamed recycled plastic material, then thermal insulation performance improves and material costs decrease, but the layers become more vulnerable to overload
Solution Approach 1:
The wall element is segmented into distinct functional zones: strong structural cores for load bearing and softer insulation layers for thermal performance. This segmentation allows each layer to be optimized for its specific function without compromise
Solution Approach 2:
The H-profiled beams act as intermediaries that bridge between wall elements and distribute loads through the insulation layers. These beams prevent direct point loads from transferring to the vulnerable insulation material, spreading forces evenly across the insulation surface and preventing overload while maintaining thermal performance
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 system enables rapid and cost-effective construction of buildings on any flat surface, utilizing plastic waste as a sustainable resource, while maintaining stability and durability, even in adverse weather conditions.
Implementation Method 1
form-stable layers of thermally insulating materials preferably made of foamed recycled or waste plastic material
Data Source
AI summary
Wall-building element system comprising sole elements, basic wall-building elements adapted to be assembled to a wall, and beams adapted to be fitted between each horizontal layer of the basic wall-building elements. The basic wall-building elements are prefabricated with a central, load bearing core member and form-stable layers of thermal insulation on both sides thereof. The core member and the thermal insulation layers are mutually adapted in a tongue-and-groove system while the beams are made in an “H”-profile corresponding thereto. The core member typically consists of a plate-shaped main body provided with laterally extending, vertically oriented ribs.