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• Energy simulation of AIS using experimentally validated thermal resistances. • AIS evaluation at varying orientations, climate zones, and switching ratios. • Investigation of AIS switching and wall thermal conductivity/heat transfer. • Application of freeze timer to reduce the number of switches of AIS. Active insulation systems (AISs) in buildings are envelopes that integrate thermal insulation, thermal energy storage, and controls. Although different designs for AISs have been proposed in the literature, a comprehensive analysis of feasible AISs is lacking. This paper discusses the energy performance, peak demand reduction potential, and performance characteristics of an AIS that uses a concrete wall as thermal mass sandwiched between two solid-state thermal switches (STSs). These STSs change their thermal conductivity using an on/off metal switch to create or break a thermal bridge across the STS. This paper first describes the experimental setup, used to determine the ratio of thermal resistance during R-high (low thermal conductivity) and R-low (high thermal conductivity) states of the STSs. This ratio was then used in whole-building energy simulations to evaluate the performance of AIS walls across different climate zones with/without a freeze timer of 60 min. The timer was added to reduce the number of switches of STSs from one state to another, and hence the energy needed for these switches. Analysis of the switching frequency and interval of STSs, thermal conductivity of walls, impact of wall orientation, and heat transfer through the wall from the use of AIS at different climate zones/locations were performed. The simulation results show that the AIS can achieve energy savings ranging from ∼ 980 to 2,290 kWh in a single-family home with a floor area of ∼ 220 m2 compared with an IECC 2018 baseline. The energy savings was higher in dry climate zones which represent 17% of residential buildings in the United States, compared to humid or marine climate. [ABSTRACT FROM AUTHOR]

• An innovative building envelope called Empower Wall was designed and tested. • The smart wall integrates with both thermal energy storage and active insulation. • Model predictive control was implemented to optimize energy consumption and cost. • The prototype system demonstrated the ability for both energy and cost savings. Buildings are one of the largest energy consumers worldwide, using large amounts of energy during their construction and for climate control during operation. Active insulation systems (AIS) have been shown to reduce the energy needed for climate control in buildings by dynamically regulating the heat transferred between a building's interior and exterior. Infrastructure-scale additive manufacturing (AM) has the potential to reduce the resources needed for building construction. Combining these two technologies into a single building envelope would create a path towards more sustainable buildings. A test was conducted for the Federal Energy Management Program (FEMP) Energy Exchange training and trade show, in August 2021, to investigate a new building envelope design, termed the Empower Wall, that utilized an AIS and was constructed using AM. Model predictive control was implemented to manage operation of the Empower Wall in concert with the existing HVAC system. The prototype system demonstrated that the Empower Wall lowered total energy consumption and reduced the cost of energy used. [ABSTRACT FROM AUTHOR]