Robotic Underfloor Insulation Spraying for Suspended Floor Cavities
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Solution Overview
Problem
Current methods for insulating building cavities, especially underfloor cavities in older buildings, are labor-intensive, disruptive to occupants, and require significant human input, leading to inefficient and inconsistent results, along with logistical and cost challenges.
Innovation Solution
A robotic vehicle equipped with a spray nozzle and sensors is designed to autonomously spray thermally insulating material onto internal surfaces, including underfloor cavities, allowing for controlled depth application and removal of excess material, reducing labor and disruption while improving consistency and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual spraying of insulation material is used, then insulation can be applied to building cavities, but the process is labor-intensive and disruptive to occupants
Solution Approach 1:
The robotic vehicle autonomously navigates and sprays insulation material without human operators inside the cavity. The system serves itself by using onboard sensors to map the environment, plan its path, and control the spray nozzle, eliminating the need for human workers to physically enter and manually apply insulation in disruptive conditions.
Solution Approach 2:
The patent replaces manual mechanical spraying operations with an automated robotic system. The robotic vehicle uses computer-controlled spray nozzles, automated navigation, and sensor-based positioning to substitute human labor, thereby improving productivity while reducing occupant disruption since the robot can work more efficiently and cleanly than manual workers.
2Manufacturing precision
If insulation boards are cut to fit interior walls and floor voids, then insulation can be installed, but the process is labor-intensive and requires moving occupants out
Solution Approach 1:
The robotic system changes the state of insulation application from pre-cut rigid boards to sprayable material that can be deposited in any shape or size. By changing the material delivery method from solid panels to aerosol spray, the system achieves both precise fit (through controlled deposition) and high productivity (through continuous application without cutting or fitting operations).
Solution Approach 2:
The robotic vehicle divides the insulation application process into discrete spray deposits that can be precisely controlled in position, size, and density. Instead of moving large insulation boards around and fitting them together, the system segments the insulation into many small spray deposits that are applied sequentially, achieving both precision and speed.
3Quantity of substance
If foam insulation is applied to exterior walls, then insulation coverage is achieved, but scaffolding and multiple workers are required
Solution Approach 1:
The robotic vehicle approaches the insulation problem from a different dimension by working from inside the building cavity rather than from the exterior. This internal approach eliminates the need for external scaffolding structures, as the robot can access and spray insulation on all interior surfaces of the cavity from within the building space itself.
Solution Approach 2:
The robotic vehicle acts as an intermediary between the insulation material and the building cavity surfaces. Instead of requiring human workers to manually apply insulation or use complex scaffolding systems, the robot serves as the mediating device that delivers the insulation material precisely to all required surfaces, simplifying the overall system complexity.
4Reliability
If traditional insulation methods are used, then insulation can be applied, but material waste and logistical challenges occur
Solution Approach 1:
The robotic vehicle uses sensor feedback to monitor the insulation application process in real-time. Sensors detect the presence of surfaces, measure spray deposit thickness, and provide feedback to the control system to adjust spraying parameters. This closed-loop control ensures consistent insulation application while minimizing material waste by only depositing where needed and monitoring coverage accuracy.
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 robotic system significantly reduces labor costs and disruption, achieves consistent insulation results, and eliminates the need for scaffolding, enhancing the speed and quality of insulation processes while minimizing material requirements and site access issues.
Implementation Method 1
a spray nozzle to spray the thermally insulating material
Implementation Method 2
allow the thermally insulating material to solidify whereby to form a covering
Implementation Method 3
a first sensor configured to identify the position of the internal surface to be sprayed
Implementation Method 4
a second sensor configured to monitor the thickness of the covering applied to the surface
Data Source
Figure 1A~3
Figure 4~5
Figure 6~7
AI summary
The present invention provides a robotic vehicle (101, 151, 301, 501) configured to spray thermally insulating material (311) onto an internal surface of a building, and allow the thermally insulating material to solidify whereby to form a covering (313) of the internal surface. The internal surface is the underside of the floor (204, 304, 410) of the building in an underfloor cavity (202, 302, 408) and the floor is a suspended floor. The robotic vehicle (101, 151, 301, 501) comprises a spray nozzle (104, 154, 312, 508) to spray the thermally insulating material. The robotic vehicle (101, 151, 301, 501) also comprises a hose coupling the spray nozzle to a source of the thermally insulating material located outside the underfloor cavity. The robotic vehicle (101, 151, 301, 501) also comprises a propulsion system (102, 152, 327, 502) configured to move the robotic vehicle (101, 151, 301, 501) relative to the internal surface. The robotic vehicle (101, 151, 301, 501) also comprises a sensor configured to identify the position of the internal surface to be sprayed. The robotic vehicle (101, 151, 301, 501) is configured to be introduced into the cavity and remotely operated to move the robotic vehicle relative to the internal surface by the propulsion system to spray the thermally insulating material onto the internal surface.