Method and system for fabricating thermal insulation for retrofit applications

• US 10,307,962 B2
• Filed: 02/02/2015
• Issued: 06/04/2019
• Est. Priority Date: 02/02/2014
• Status: Active Grant

• Current Assignee: Worcester Polytechnic Institute
• Original Assignee: Worcester Polytechnic Institute
• Inventors: Dessel, Steven Van
• Primary Examiner(s): Travers, Matthew P
• Application Number:
  US14/611,335
• Publication Number:
  US 20160001508A1
• Time in Patent Office: 1,583 Days
• Field of Search: 523091, 523094, 523097, 523098, 523099, 5230913, 5230914, 5230916, 5250601
• CPC Class Codes: B29C 39/123 Making multilayered articles
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29L 2031/10 Building elements, e.g. bricks, blocks, tiles, panels, posts, beams frameless domes B29L2025/00, doors B29L2031/724
• CPC Class Codes: B29L 2031/776 Walls, e.g. building panels
• CPC Class Codes: E04F 13/0875 having a basic insulating layer and at least one covering layer
• CPC Class Codes: E04F 13/16 of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• CPC Class Codes: G06F 2119/08 Thermal analysis or thermal optimisation
• CPC Class Codes: G06F 30/13 Architectural design, e.g. computer-aided architectural design [CAAD] related to design of buildings, bridges, landscapes, production plants or roads
• CPC Class Codes: H04N 1/00827 Arrangements for reading an image from an unusual original, e.g. 3-dimensional objects

Abstract

A three-dimensional (3D) laser-based scan of a façade of a structure is conducted. Based on data of the 3D laser-based scan, a 3D computer model of the façade is generated. Then, a design of insulation to be installed on the façade is determined based on the generated 3D computer model. According to the determined design, insulation is fabricated via an automated fabrication process.

Claims

1. A method, comprising:

conducting a three-dimensional (3D) laser-based scan of a faç

ade of a structure;

generating a 3D computer model of the faç

ade based on data of the 3D laser-based scan;

generating a plurality of insulation design alternatives based on the generated 3D computer model;

determining one design of the plurality of insulation design alternatives to be installed on the faç

ade based on one or more criteria selected from a group consisting of;

energy efficiency, appearance, and a machinery limitation; and

fabricating insulation via an automated fabrication process according to the determined design, wherein the automated fabrication process comprises;

forming casting cavities in a substrate,

creating casting barriers in the substrate operable to contain a first resin-based substance having a first viscosity,

casting the first resin-based substance in the formed casting cavities,

processing the casted first resin-based substance to form an insulation panel, and

depositing a second resin-based substance having a second viscosity higher than the first viscosity on the processed and casted first resin-based substance so as to create an additional feature on the insulation panel in accordance with the determined design.

2. The method according to claim 1, further comprising:

installing the fabricated insulation on the faç

ade.

3. The method according to claim 1, further comprising:

programming a computer numerical control (CNC) manufacturing tool according to the determined design; and

fabricating the insulation using the CNC manufacturing tool.

4. The method according to claim 3, further comprising:

translating the determined design into a format suitable for the programming of the CNC manufacturing tool.

5. The method according to claim 1, further comprising:

programming a computer aided design (CAD) tool according to the data of the 3D laser-based scan; and

generating the 3D computer model using the CAD tool.

6. The method according to claim 1, wherein the generated 3D computer model is a Building Information Model (BIM).

7. The method according to claim 1, further comprising:

modifying an aspect of the generated 3D computer model to affect a performance of the insulation.

8. The method according to claim 1, further comprising:

estimating a cost of the determined design; and

modifying the determined design based on the estimated cost.

9. The method according to claim 1, further comprising:

accessing a database of stored insulation design data; and

determining the design further based on the stored insulation design data.

10. The method according to claim 1, wherein the automated fabrication process further comprises:

depositing a finishing coat on a surface of the insulation panel, and

forming a foam gasket in the insulation panel to seal an edge of the insulation panel.

11. The method according to claim 1, wherein the fabricating of the insulation comprises:

adding a secondary functionality component to the insulation.

12. A system, comprising:

a 3D laser-based scanning device that conducts a 3D laser-based scan of a faç

ade of a structure;

a model generating controller that generates a 3D computer model of the faç

ade based on data of the 3D laser-based scan;

a design controller that generates a plurality of insulation design alternatives based on the generated 3D computer model, and determines one design of the plurality of insulation design alternatives to be installed on the faç

ade based on one or more criteria selected from a group consisting of;

energy efficiency, appearance, and a machinery limitation; and

an automated fabrication tool that fabricates insulation via an automated fabrication process according to the determined design, wherein the automated fabrication process comprises;

forming casting cavities in a substrate,

creating casting barriers in the substrate operable to contain a first resin-based substance having a first viscosity,

casting the first resin-based substance in the formed casting cavities,

processing the casted first resin-based substance to form an insulation panel, and

depositing a second resin-based substance having a second viscosity higher than the first viscosity on the processed and casted first resin-based substance so as to create an additional feature on the insulation panel in accordance with the determined design.

13. The system according to claim 12, wherein the automated fabrication tool is a computer numerical control (CNC) manufacturing tool that is programmed according to the determined design.

14. The system according to claim 13, wherein the determined design is translated into a format suitable for the CNC manufacturing tool to be programmed.

15. The system according to claim 12, wherein the model generating controller is a component of a computer aided design (CAD) tool that is programmed according to the data of the 3D laser-based scan.

16. The system according to claim 12, wherein the generated 3D computer model is a Building Information Model (BIM).