Robotically and Autonomously Installed Wall Interior Spray Foam

Invention Reference Number

202205217

Installing spray foam insulation in walls during construction is a manual process, but installers must wear safety gear to avoid exposure to chemicals, and fatigue often results that can lead to mistakes and low quality foam. This technology provides robotic automatic installation of spray foam that improves installer safety, reduces labor, and provides consistent quality.

Description

Spray foam installation is labor-intensive and requires extensive safety precautions to avoid health risks. Manual installation is often inconsistent, not providing the targeted thermal and airtightness performance or resulting in overspray that requires shaving off excess insulation. Installation requires careful attention to detail as improperly installed spray foam can leave gaps and not fully cure. The detached foam may not perform the air and water barrier functions, and the achieved R-value is significantly lower than the target. Additionally, the improperly cured foam may cause indoor air quality and health issues for the installers and occupants. This technology automates spray foam installation with the robotic application, saving on labor and increasing the quality of the installation. The robot scans the walls, finds the cavities, determines a spray path, and then automatically sprays the foam, managing thickness and proper installation. The technology could be extended by adding nozzles for sealants and paints as well. The robot can be made with off-the-shelf components and utilizes the algorithms of this technology.