GB2518807A

GB2518807A - Computer controlled system for 3D printing of building materials

Info

Publication number: GB2518807A
Application number: GB1311928.4A
Authority: GB
Inventors: Tomasz B Lipinski; Peter Rn Childs; Mathew Holloway
Original assignee: Q Bot Ltd
Current assignee: Q Bot Ltd
Priority date: 2013-07-03
Filing date: 2013-07-03
Publication date: 2015-04-08
Also published as: GB201311928D0

Abstract

The method comprises: 1) application of an expanding main additive medium; 2) subtractive refinement of the medium; and 3) final additive finish or cleaning. The application may include spraying or extruding a two part expanding foam through a nozzle onto a three dimensional (3d) surface. The foam expands rapidly when mixed and binds with the surface onto which it is prayed, to facilitated 3d printing onto walls, floors or roofs. The foam may be open cell thermally insulating material with a binder for adhesion. Also claimed is a system for applying building materials including a platform that facilitates access to different parts of a building and one or more heads which facilitate different operations. The platform may be a crane, a scissor lift which can be wheeled or tracked or a suspended platform.

Description

I

COMPUTER CONTROLLED SYSTEM FOR 3D PRINTING OF BUILDING

MATERIAL S

This invention relates to a computer controlled system for spraying building materials such as thermal insulation onto the interior or exterior surfaces of a building, shaping the material to rcmove excess and applying a finishing coat.

It is known to improve the thermal performance of buildings by insulating the walls (or, more gcncrically, thc extcrnal fabric or building cnvclopc. such as walls, floor and roof) of those buildings. This can hc currcntly achicvcd by fixing insulation boards or bats to walls or fitting these between joists and rafters. Spray insulation foam, such as Polyurethane is known, and can he sprayed onto the walls or roof structure in order to reduce Ute antount of heat that is transferred through the building fabric.

Recognising the various challenges posed by the need to insulate the walls of millions of inefficient buildings there are a number of potential solutions: Cutting insulation boards to fit interior walls, is labour intensive, never 100% effective and will usually mean moving the occupants of such a house out of their dwelling (and removing furniture, destroying carpets, floor hoards, generating waste and associated strife) whilst the insulation is applied; Application of foam to the outside walls. for example by spraying insulation manually can only hc applied in particular situations, does not offer a finished product, requires scaffolding and multiple workers to install.

Current 3D mapping of building surfaces and insulation installation processes (Whiscers, Franz Sahler Patent: EP22 13805 B 1) deal either with internal wall insulation and require multiple workers for insulation, occupant disruption and create cold bridges, or require scaffolding, additional work for applying the finish, and a significant number of workers.

It is known to use spraying techniques within the construction process to both build 3D structures and components of them (for example wall panel composites as described in JPI-1051 63769 MIYOSHI YASUO), fill in cavities with insulation (such as \V02006071 519 PAY RALPH MICHAEL), and apply finishing treatments to surfaces by spraying (for example JINGTING ZHANG CN101435221 or FAY RALPH MICHAEL CA2790710).

More specifically there are various methods for applying insulation to internal or external walls, floors and roofs by hand or machine, e.g. KEMPE STEVEN ALLAN et al W00173233, or KLEIN HANS etalDElO2ll33l.

However all of these methods have a similar set of problems the application and finishing of the insulation requires significant human input and is largely done by hand or by human operated machines. While it is known to apply insulation to the surFaces oF a building these techniques result in an uneven surface finish that requires significant finishing, and there is no way to guarantee consistent results and measure performance. Most on site fabrication techniques are limited by the speed and volume in which the building materials can he made.

However a system that allows 3D printing of an expanding insulation material to existing surfaces and structures, which includes the means to apply' the insulation automatically to suit the given 3D surface, monitor the application depth, remove excess material automatically and apply finishing treatments could significantly reduce disruption to occupants, reduce the amount of labour required and therefore the cost to insulate buildings, whilst also providing more consistent and complete results without the technical issues of current methods.

The invention provides for a manufacturing system for applying building material(s) to new and existing buildings that comprises a three stage process; expanding main additive medium; subtractive refinement: and final additive finish or cleaning.

According to the first stage a method for applying the building material on 3D surfaces by spraying or extruding a two part expanding foam through a nozzle, that when mixed expands rapidly and hinds with the surface on which it is sprayed to facilitate 3D printing onto walls, floors or roofs.

The foam may comprise or consist of a closed or open cell thermally insulating material (such as poltrethane) combined with a binder fbr adhesion, that typically expands 25 fold on impact (with full expansion achieved within 18 seconds from leaving the spraying head and structural rigidity achieved within 60 seconds).

Since the printing is based on chemical reaction as opposed to molten material the finished product has high dimensional stability and can withstand temperatures above 200 °C.

According to the secondary stage a method to remove excess material and shape the surface to create the desired 3D shape. This method may use one or ntore tools such as rotary drills, cutters, sanding, rubbing, compression, the application of a mould, water jet cuttiag, heat or other trteans to create the desired shape and surface; Accordin to the third stage of tlic invcntion a mcthod is provided for cleaning thc rcsulting surface and / or applying a finishing treatment. This flay comprise or consist of; water jet; weather proofing; surface coatings, binders, surface textures; or paint.

The final coating (such as polyurea) provides texture, colour and protection from the elements. Patterns such as stone walls, pebble dash or brick work may be applied to give the insulation a more natural appearance.

In one preferred embodiment of the invention a system is provided that comprises: a platform that facilitates access to different parts of the building; one or more head(s) that facilitates different operations which optionally may be mounted on a robotic arm a control system; According to the first aspect of the invention the use of a platform that may he selected from the following list: an access platform such as a scissor lift that may he wheeled or tracked; a crane; rails such as scaffolding that need to he installed prior to operation; a platform suspended below the building; or attached to an industrial machine such as digger replacing the current arm or tool.

The platform may he varied to suit the size and nature of the building being treated, from single story dwelling, multi story house, to tower blocks and skyscrapers.

The platform may he moveahlc, by wheels or other means, or be installed around the building to he treated, e.g. a crane or scaffolding.

In a further desirable aspect the platform may be selected from any pre existing third party access platform and an adaptable chassis with mounting points provided that can attach to said platform provided.

According to the second aspect of the invention either a single multipurpose head or multiple heads arc attached to the platform to facilitate each part of the three stage process.

The head may he mounted on the platform through chassis and a movable arm, which allows the angle of the head relative to the chassis to he varied. As such, the head may therefore he able to aim at a variety of directions relative to the chassis.. The moveable arm may he pivotable about at least two non-parallel, and preferably perpendicular axes. It may be pivotable about an axis perpendicular to the length of the chassis and/or an axis along the length of the chassis.

The head may he interchangeable to suit different operations., e.g. spraying, cutting or finishing. Alternatively or additionally, each operation may be conducted by separate machines each tailored to its speciFic job.

The source of thermal insulation or other materials such as water may hea port to which a supply pipe carrying the insulation can he Fitted. Alternatively or additionally, the source may comprise a container carried on the chassis.

The head and robot arm may comprise a receiver for receiving command signals to control at least one of its motion and its spraying activity. This maybe a wireless receiver for receiving signals wirelessly, such as a radio receiver, or may comprise a wired receiver, arranged to receive signals over a wired connection. The wired connection may form part of an umbilical cord connecting the robot to the services.

According to the third aspect of the invention a control systetn is provided that combines some or all oF the Following elements: 3D surveying and mapping of existing buildings,for example by using range finding sensors. 2D and / or 3D imaging systems; the ability to read a pre determined profile or CAD model of the building, e.g. the architects drawings;

S

the means to create and follow a set of instructions, that includes where to apply insulation, how much instTlation will he deposited and surface finishes; the means to calibrate the robot's position against the instructions by using visual markcrs or 3D spacc rnarkcrs; real time position sensin, orientation and automatic head adjustment; fccdback to thc movcablc platfonn so an opcrator can control its position manually or the platform can he positioned automatically.

monitoring and control of the thickness and coverage of the deposited material using visual and depth feedback; the means to gather data on the resulting finish, e.g. depth of finish, percentage area of the surface covered; and / or the ability to calculate energy and CO2 savings based on the improvements made; The method may comprise mapping the cavity before spraying the insulation. The step of mapping may comprise determining the positions of the surfaces to he sprayed, and may comprisc dctcrmining thc pcrinictcr of tlic surf accs, total height, obstructions, windows.

cabling, and othcr issucs, typically in ordcr to prcparc for acccss. Whilst this may he donc with the robot, the step of mapping the cavity may be carried out before the robot is introduced to the site. As such, the step of mapping may conmprise the step of introdtTcing a mapping apparatus or surveying equipment. The surveying equipment may be provided with a sensor for sensing the position of the walls to be sprayed, such as ultrasonic range finders, infra red imaging. one or more canleras.

The invention described above illovs solid wall insulation (SWI) to he directly 3D printed on existing building façades by an automated robotic device and can have the following

advantages over tlic prior art:

dramatically faster than conventional 3D printing technologies while allowing fbr high resolution precise cutting / jetting to he used where required; the 25 fold expansion of sprayed material on impact also significantly reduces the requirement for material on site, further increasing the speed and quality of construction; using this system, installation of SW1 can be undertaken by only one skilled operative in a day at 50% of the costs required for the installation of traditional SW!; the new process is user-centred, allowing for the customisation of the external appcarancc of thc house to a much greater cxtcnt than a traditional rctrofit process; and facilitates the printing of high speed/high volume large scale objects such as building facades, building components (on site) or even whole buildings that are normally constrained by the necessity of bringing prohibitively large volumes of material to site as well as slow and expensive print process.

This new process will dramatically reduce the requirentent for material and workers on site, eliminate the need for scaffolding, eliminate wet trades. minimise/eliminate building access issues and improve the speed and quality of construction. The features of the proposed invcntion cnablcs a solution that combines efficiency, automation and prccision.

There now follows, by way of example only, description of embodiments of the invention described with reference to the accompanying drawings, in which: Figure 1 shows the three stage process.

Figure 2 shows a robot arm and head mounted on a movable platform.

Figure 3 shows a third party vehicle adapted to suit the invention.

Figure 4 shows a third party vehicle adapted to suit the invention.

Figure 5 shows a platform suspended below a frame.

Figure 6 shows the stTspended platform from the side.

Figure 7 shows a platform mounted on a frame.

Figure 8 shows a vehicle that uses telescopic arms.

Figure 1 of the accompanying drawings shows the three stage process; 1) a method for applying a building material such as expanding foam on 3D surfaces; 2) a method to remove excess material and shape the surfaces; and 3) a method for applying a finishing treatment to the surface. A robot arm (4) is positioned in front of the surface to be treated (5), in the first stage a mixing nozzlc(6) is uscd to mix and spray a two part cxpanding foam and binder onto thc wall to form an insulating harricr (7). In the sccond stagc a forming head, e.g. a cutting tool (8) is used to remove excess material and add details to the foam (9), e.g. the outline of brickwork. In thc final stagc a finishing hcad (10) is uscd that applics a sealant and surface coat(l1).

Figure 2 of the accompanying drawings shows a moveable platform (1). which includes the means to raise the height via a scissors lift (2), onto which is mounted a platform (3)for the robot arm (4). The robot arm allows for fine control of the head (5) position, once the movable platform is in position.

Figure 3 of the accompanying drawings shows a vehicle (1) which has two mounting points for tools (2) & (6). Spray, cutting or finishing heads can he connected and driven from the vehicle. They may be moved in one or more planes, to extend the range of movement and pie ferahly in at I cast one axis perpendicular to the vchicl c's cxisting arms to allow for full control of the inoventent of the head. For exantple head 2) is ntounted on an ann which can pivot on an axis (3), which is perpendictTlar to the range of movement of the vehicle (4&5).

Similarly thc sccond head (6) is mounted on an arm with two axis (8&9) which arc pcrpcndicular to the vehicles own rangc of movcmcnt (9).

Figure 4 of the accompanying drawings shows a vehicle (1) which can raise the height of the head (2) which is attached to the vehicle through a platform that can rotate about axis (3). The vehicle can raise the height of the platform and move it back and forward by extending or retracting the arm. The head's axis of movement (3) is perpendicular to the vehicles arm (4 & 5) to provide additional control.

Figure 5 of the accompanying drawings shows a frame or scaffolding that is erected around the building (I) on the ground (2). A movcablc platform (3) can move along the cross beam (4) below which on wires (6) is suspended a second platform whose height can be adjusted (7). A series of heads (8) to fulfil the different functions are nmounted on the platform.

Figure 6 of the accompanying drawings shows the platform (1) shown from the side, where it is suspended from another platform (2) on wires (3) in front of the wall (4). The head (5) may he moved towards or away from the wall (6) to get the tool (7) the required distance from the wall.

Figure 7 of the accompanying drawings shows a frame (1) made up of linear sliders or bearings (2 & 3) and a horizontal slider (4) positioned in front of a wall (5). The platform (6) is able to move horizontally (7) and vertically (8) on the frame. A lead screw or threaded rod (9) is shown on ftc Iramc to allow thc platlorm to hc moved in cithcr planc. Altcrnativcly other power transmission methods may be used such as belt drives, gears and pulleys, pneumatics or hydraulics. The platform may be moved manually or automatically using motors or other power sources. One or more tools (10) can be mounted on the platform. The frame sits on a base (11) to provide stability.

Figure 8 shows a vehicle (1) which can manoeuvre into position on tracks (2). Alternatively the vehicle may be lifted into position or use wheels, actuated legs or other means to manoeuvre into position. The vehicle is shown raised above the ground (4) on stabilising legs (3). The vehicle has an arm with multiple segments that can rotate around one or more points (5, 6 & 7) using hydraulic or pneumatic actuators (8, 9 & 10). The vehicle can also rotate around it's base (11) in a plane perpendicular to the other axis.. One or more telescopic arms (12 & 13) can be used extend the arm (14 & 15) to move the head (16) into position.

Claims

CLAIMS1. A method of applying building material(s) to new and existing buildings that comprisesDapplication of an expanding niain additive medium; subtraclive refinemeni of (lie medium; and tO final additive finish or cleaning.
2. The method of claim 1, in which the application of the medium comprises spraying or extruding a two part expanding foam through a nozzle onto 3D surfaces, the two part foam expanding rapidly when mixed and binds with the surface on wlnch it is sprayed, to facilitate 3D printing onto walls, floors or roofs.
3. The method of claim 2, in which the foam comprises a closed or open cell thermally 0 insulating material (such as polyurethane) combined with a binder for adhesion.
4, The method of an preceding claim, in which the subtractive refinement comprises the r removal of excess material and the shaping of the surface of the medinm to create a desired o 3D shape.
5, The method of any preceding claim, in which the subtractive refinement comprises the use of one or more tools such as rotary drills, cutters, sanding, rubbing, compression, the application of a inould water jet cutting, heat or other means to create the desired shape and surface.
6, The method of any preceding claim, in which the final additive finish or cleaning comprises at least one of: the use of a water jet; weather proofing; surface coatings, binders, surface textures; or paint.
7. A system for the application of building materials, comprising: a platform that facilitates access to different parts of a building; one or more head(s) that facilitates different operations; and a control system arranged to cause the system to carry out the method of any preceding claim.
8. The system of claim 7, in which the platform is selected from the following list:Dan access platform such as a scissor lift that may be wheeled or tracked; a crane; rails such as scaffolding that need to be installed prior to operation; a platform suspended below the building; or attached to an industrial machine such as digger replacing the current arm or tool.
9. The system of claim 7 or claim 8, in which the platform is moveable. by wheels or other means.
10. The system of any of claims 7 to 9. in which each head is mounted on the platform through a chassis and a movable ann which allows the angle of the head relative to the chassis r to be varied.C
II. The system of any of claims 7 lo It). in which each head is interchangeable lo suil different operations.
12. The system of any of claims? to 11, in which at least one of each head and any robot arm comprise a receiver for receiving command signals to control at least one of its motion and is spraying acUvily,
13. The system of any of claims 7 to 12, in which the control system provides at least one of the following elements: 3D surveying and mapping of existing buildings. for example by using range finding sensors. 2D and / or 3D imaging systems; the ability to read a pre determined profile or CAD model of the building, e.g. the archilecCs drawings;

Hthe means to create and follow a set of instructions, that includes where to apply insulation, how much insulation will be deposited and surface finishes; the means to calibrate the robot's position against the instructions by using visual markers or 3D space markers; real lime position sensing. orientation and automatic head adjuslment; feedback to the iuoveablc platform so an operator can control its position manually or tO the platform can be positioned automatically.monitoring and control of the thickness and coverage of the deposited material using visnal and depth feedback; the means to gather data on the resulting finish, e.g. depth of finish, percentage area of the surface covered: and I or 0 the ability to calculate energy and CO2 savings based on the improvements made.
14. The sstem of any of claims 7 to 13, in which the control sstem is arranged to map r the cavity before spraying the niedinni.C
15. A sslem for the application of building materials subsianlially as described herein with reference to and as illustrated in the accompanying drawings.