Aerated plastic! higher R value lighter strongR

hey ladies and gents, its getting cold af up here in Canadaland! My minds always going towards cheap // good // building products. Although Im new to upcycling plastics.

Whats your opinion on:

Somehow injecting air bubbles / pockets into the plastic to use less plastic, make it stronger and increase its Rvalue (insulation)? Use this method for lego blocks for building the walls of a house or the wall cavities of a house. Or for geodomes.

Another Idea would be to make a machine that was comparable to the spray foam gun for spray insulation, except using plastic. Air bubbles are also a must with this.

Any ideas on how to get the air pockets into the plastic?

A comparable technology may be aircrete, which uses bubbles mixed into a concrete mixture to provide higher insulation, strength, lightness, and to use less concrete.

cheers boyz n gals.

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Hi,
we at Cabinz have been exprimenting along a similar line, so far without success.  We need a design for a lattice of plastic (possibly aireated ) that can be folded , inserted into a bottle through the small opening, then expanded/ folded. out to support  the inside of the bottle wall from a vacuum. while the cap is replaced & air pumped  out.

I just discovered a good method for removing the air with a vacuum chamber & rubber patch
here Will Food GO BAD in a Vacuum Chamber? - YouTube

We have been working on an air filled eco brick inside reused plastic panels covered with fire proof mgo boards . We’ve also been trying to develop a way (unsucessfully so far) of supporting a Pet bottle internally or externally wihile having the air sucked out , as a vacuum is a much beter insualter than air

Making an Insulated Eco Brick by Filling Empty Plastic Bottles with Rolled Cardboard or Plastic & Evacuating Air (VIB))
http://www.cabinznet.blogspot.com/2018/09/making-better-insulated-eco-brick-by.html

Could you get polystyrene chips which contain mostly air into the plastic ?

However, the heating process may melt them . or pressure crush them