Digital Template Insulation Panels for Building Retrofit
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Solution Overview
Problem
Existing methods for retrofitting insulation to buildings, especially walls and flat roofs, are difficult, expensive, and disruptive to occupants, with internal insulation requiring on-site cutting and external insulation facing access and planning restrictions, while cavity wall fill methods are insufficient for future energy-saving standards.
Innovation Solution
A method involving scanning a building's internal surface to create a digital template, cutting a laminated board with a thermally insulating material and decorative plasterboard into pre-fabricated panels using a computer-controlled cutting device, allowing for remote preparation and installation without on-site disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If internal insulation is installed using traditional methods, then insulation performance is improved, but the process becomes disruptive and time-consuming due to on-site cutting and installation
Solution Approach 1:
The patent applies preliminary action by pre-cutting insulation panels to exact dimensions using digital templates generated from 3D laser scans of the building interior. The panels are manufactured off-site with precise fitment before installation, eliminating time-consuming on-site cutting and fitting operations while maintaining effective insulation coverage.
Solution Approach 2:
The patent uses digital copying by creating a digital 3D model of the building's internal surfaces through laser scanning. This digital replica is then used to generate cutting templates for the insulation panels, ensuring precise reproduction of complex geometries without manual measurement and cutting on-site.
2Loss of energy
If internal insulation is installed using traditional methods, then insulation performance is improved, but the process becomes messy and disruptive due to on-site cutting operations
Solution Approach 1:
The patent extracts the cutting operation from the installation site by manufacturing insulation panels with precise cutouts off-site using computer-controlled equipment. The panels arrive pre-cut to match the building's geometry, removing dust-generating cutting operations from the occupied space and eliminating mess associated with on-site material preparation.
Solution Approach 2:
The patent performs preliminary cutting and preparation of insulation panels before they reach the installation site. All cutting operations are completed in advance using digital templates, so that when panels are installed on-site, no cutting or messy operations are required in the occupied building.
3Loss of energy
If external insulation is used to meet future energy-saving standards, then insulation performance is improved, but the cost increases due to scaffolding and access requirements
Solution Approach 1:
The patent inverts the traditional approach by installing insulation from the inside rather than the outside of the building. This eliminates the need for scaffolding and external access equipment, reducing installation costs while achieving the same thermal insulation performance through internally-mounted panels with decorative plasterboard facing.
4Ease of manufacture
If cavity wall fill is used for insulation, then installation simplicity is improved, but the insulation performance becomes insufficient for future energy-saving standards
Solution Approach 1:
The patent uses composite materials by combining rigid insulation boards with decorative plasterboard layers to create multi-functional panels. The insulation boards provide the necessary thermal performance to meet future energy-saving standards, while the plasterboard facing provides a finished appearance and structural integrity, achieving both performance and aesthetic requirements.
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 method reduces labor costs and noise, enables insulation to be installed while occupants are present, and meets future energy-saving standards by providing efficient thermal insulation with reduced dust and disruption.
Implementation Method 1
a layer of thermally insulating material for reducing heat loss therethrough
Data Source
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AI summary
A method of insulating a building (1) by cladding internal surfaces (10) of the external walls of the building. The method includes the steps of digitally scanning (11) the surfaces to produce a digital representation (4), producing a template from the digital representation (4), cutting a sheet (41) of material in accordance with the template to produce panels (140a...), which panels (140a...) are then installed on the internal surfaces (10). The scanning step is carried out using a digital scanner (3) to produce a digital representation (4) of the shape and/or size of the surface. The digital representation (4) is then manipulated to produce the digital template, which template represents selected areas of the surface (10) to be insulated. The cutting step is carried out using a cutting device (5) programmed in accordance with the digital template to produce the panels (140a...). The panels (140a...) include a thermally insulating material for reducing heat loss through the panel (140a...).