Search

US-20260124705-A1 - INSULATION INSTALLATION SYSTEM AND METHOD OF INSTALLING INSULATION IN A WALL STRUCTURE FOR A MODULAR CONSTRUCTION UNIT

US20260124705A1US 20260124705 A1US20260124705 A1US 20260124705A1US-20260124705-A1

Abstract

An insulation installation system and method of installing insulation in a wall structure for a modular construction unit. The insulation installation system includes an insulation in-feed table, an insulation out-feed table, an insulation saw assembly, and an insulation unload tool. The insulation in-feed table moves a batt of insulation thereon. The insulation out-feed table receives the batt of insulation from the insulation in-feed table. The insulation saw assembly includes an insulation saw that cuts the batt of insulation into a cut insulation having a size to fit into a wall cavity of the wall structure. The insulation unload tool grabs the cut insulation from the insulation out-feed table and places the cut insulation into the wall cavity of the wall structure.

Inventors

  • MARK JOSEPH BELLISSIMO
  • Stanley Clark Beard, JR.
  • HARRISON GRANT MEADOWS
  • Benjamin Austin Tucker

Assignees

  • BUILDZ, LLC

Dates

Publication Date
20260507
Application Date
20260102

Claims (20)

  1. 1 - 30 . (canceled)
  2. 31 . An insulation installation system for installing insulation in a wall structure for a modular construction unit, the insulation installation system comprising: an insulation material having a size to fit into a wall cavity of the wall structure; and an insulation unload tool that is configured to grab the insulation material and place the insulation material into the wall cavity of the wall structure.
  3. 32 . The insulation installation system of claim 31 , wherein the size of the insulation material includes at least one of an insulation length of the insulation material that is greater than a wall cavity length of the wall cavity or an insulation width of the insulation material that is greater than a wall cavity width of the wall cavity.
  4. 33 . The insulation installation system of claim 31 , wherein the insulation unload tool includes an insulation grabbing tool comprising a static frame and a plurality of frame arms coupled to the static frame, and the plurality of frame arms are spaced laterally to grab the insulation material.
  5. 34 . The insulation installation system of claim 33 , wherein the insulation unload tool includes one or more actuators connected to the plurality of frame arms, the one or more actuators being configured to extend and retract the plurality of frame arms to grab the insulation material and place the insulation material into the wall cavity.
  6. 35 . The insulation installation system of claim 31 , wherein the insulation unload tool is configured to rotate to align with the insulation material and lower to grab the insulation material.
  7. 36 . The insulation installation system of claim 35 , wherein the insulation unload tool is configured to lift the insulation material, rotate towards the wall structure, and place the insulation material into the wall cavity.
  8. 37 . The insulation installation system of claim 31 , further comprising an insulation out-feed table that is configured to support the insulation material thereon, wherein the insulation unload tool is configured to grab the insulation material from the insulation out-feed table.
  9. 38 . The insulation installation system of claim 37 , wherein the insulation out-feed table includes one or more vertical stopper walls that stop the insulation material on the insulation out-feed table at a predetermined position, the insulation unload tool being configured to grab the insulation material from the predetermined position.
  10. 39 . The insulation installation system of claim 31 , further comprising an insulation saw that is configured to cut the insulation material into the size to fit into the wall cavity, wherein the insulation unload tool is configured to grab the insulation material after the insulation saw cuts the insulation material into the size to fit into the wall cavity.
  11. 40 . The insulation installation system of claim 31 , further comprising a wall stop assembly comprising one or more extendable wall stop devices that are configured to move to engage the wall structure to stop the wall structure at a position for receiving the insulation material in the wall cavity, wherein the insulation unload tool is configured to place the insulation material into the wall cavity when the wall structure is at the position for receiving the insulation material.
  12. 41 . A method of installing insulation in a wall structure for a modular construction unit, the method comprising: providing an insulation material having a size to fit into a wall cavity of the wall structure; grabbing, with an insulation unload tool, the insulation material; and placing, with the insulation unload tool, the insulation material into the wall cavity of the wall structure.
  13. 42 . The method of claim 41 , wherein the size of the insulation material includes at least one of an insulation length of the insulation material that is greater than a wall cavity length of the wall cavity or an insulation width of the insulation material that is greater than a wall cavity width of the wall cavity.
  14. 43 . The method of claim 41 , wherein the insulation unload tool includes an insulation grabbing tool comprising a static frame and a plurality of frame arms coupled to the static frame, and grabbing the insulation material includes grabbing, with the plurality of frame arms of the insulation unload tool, the insulation material.
  15. 44 . The method of claim 43 , further comprising extending and retracting, with one or more actuators, the plurality of frame arms to grab the insulation material and place the insulation material into the wall cavity.
  16. 45 . The method of claim 41 , further comprising: rotating the insulation unload tool to align with the insulation material; and lowering the insulation unload tool to grab the insulation material.
  17. 46 . The method of claim 45 , further comprising: lifting, with the insulation unload tool, the insulation material; rotating the insulation unload tool towards the wall structure; and placing, with the insulation unload tool, the insulation material into the wall cavity.
  18. 47 . The method of claim 41 , further comprising: supporting the insulation material on an insulation out-feed table; and grabbing, with the insulation unload tool, the insulation material from the insulation out-feed table.
  19. 48 . The method of claim 47 , further comprising: stopping, with one or more vertical stopper walls, the insulation material at a predetermined position on the insulation out-feed table; and grabbing, with the insulation unload tool, the insulation material from the predetermined position.
  20. 49 . The method of claim 41 , further comprising: cutting, with an insulation saw, the insulation material into the size to fit into the wall cavity; and grabbing, with the insulation unload tool, the insulation material after the insulation saw cuts the insulation material into the size to fit into the wall cavity.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63/622,365, filed on Jan. 18, 2024, the entire contents of which is hereby incorporated by reference in its entirety. TECHNICAL FIELD The present disclosure relates generally to construction of modular construction units. In particular, the present disclosure relates to an insulation installation system and method of installing insulation in a wall structure for a modular construction unit. BACKGROUND The production of modular, or prefabricated, buildings is a growing industry. In this type of manufacturing, sections of a building or structure, also referred to as a modular construction unit, are partially assembled at a remote location, and the sections are then delivered to the final building site, where final construction of the structure is ultimately completed by assembling the various sections together. Such modular construction units can be used for a variety of purposes, including, for example, as temporary or permanent buildings, such as residential homes, commercial offices, educational or service facilities, etc. Wall structures of the modular construction unit may require insulation installed within the wall structures for insulating the modular construction unit. SUMMARY An insulation installation system for installing insulation in a wall structure for a modular construction unit. The insulation installation system includes an insulation in-feed table that moves a batt of insulation thereon, an insulation out-feed table that receives the batt of insulation from the insulation in-feed table, an insulation saw assembly comprising an insulation saw that cuts the batt of insulation into a cut insulation having a size to fit into a wall cavity of the wall structure, and an insulation unload tool that grabs the cut insulation from the insulation out-feed table and places the cut insulation into the wall cavity of the wall structure. A method of installing insulation in a wall structure for a modular construction unit. The method includes: moving, by an insulation in-feed table, a batt of insulation thereon, receiving, by an insulation out-feed table, the batt of insulation from the insulation in-feed table, cutting, by an insulation saw of an insulation saw assembly, the batt of insulation into a cut insulation having a size to fit into a wall cavity of the wall structure, and grabbing, by an insulation unload tool, the cut insulation from the insulation out-feed table and placing the cut insulation into the wall cavity of the wall structure. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other features and advantages will be apparent from the following, more particular, description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. FIG. 1 is a perspective view of an insulation installation system for installing insulation in a wall structure for a modular construction unit, according to the present disclosure. FIG. 2 is an enlarged view of an insulation load tool of the insulation installation system, taken at detail 2 in FIG. 1, according to the present disclosure. FIG. 3A is an enlarged view of an insulation in-feed table of the insulation installation system, taken at detail 3A in FIG. 1, according to the present disclosure. FIG. 3B is a perspective view of the insulation in-feed table isolated from the insulation installation system, according to the present disclosure. FIG. 4A is an enlarged view of an insulation out-feed table of the insulation installation system, taken at detail 4A in FIG. 1, according to the present disclosure. FIG. 4B is a perspective view of the insulation out-feed table isolated from the insulation installation system, according to the present disclosure. FIG. 5 is an enlarged view of an insulation saw assembly of the insulation installation system, taken at detail 5 in FIG. 1, according to the present disclosure. FIG. 6 is an enlarged view of an insulation unload tool of the insulation installation system, taken at detail 6 in FIG. 1, according to the present disclosure. FIG. 7 is an enlarged view of an insulation scrap removal assembly of the insulation installation system, taken at detail 7 in FIG. 1, according to the present disclosure. FIG. 8 is an enlarged view of a wall stop assembly of the insulation installation system, taken at detail 8 in FIG. 1, according to the present disclosure. FIG. 9 is a flow diagram of a method of installing insulation in a wall structure for a modular construction unit, according to the present disclosure. FIG. 10 illustrates a computing device for controlling aspects of the insulation installation system, according to the present disclosure. DETAILED DESCRIPTION Various embodiments are discussed in detail below. While specific embodiments are discussed, this is don