CN112513388A - Building panels, materials, systems and methods - Google Patents

Abstract

Provided herein are construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels. The panel includes at least one environmental sensor assembly associated with the panel core and configured to detect an environmental condition of the panel including moisture, pressure, or both and wirelessly transmit data regarding the environmental condition to a reader.

Description

Building panels, materials, systems and methods

Cross Reference to Related Applications

This application claims priority to U.S. patent application No. 16/047132, filed on 27/7/2018, the disclosure of which is incorporated herein by reference.

Technical Field

The present disclosure relates generally to the field of panels and other materials for building construction, and more particularly to panels and other construction materials having environmental sensors, methods of making such panels, and systems for their use.

Background

Indoor wallboard panels, exterior building sheathing panels, floor panels, roof panels, and other construction panels may be exposed to extreme environmental conditions, including moisture, wind, and extreme temperatures, during and after construction. Additionally, such systems may be installed improperly such that the seams between the panels are not completely sealed. Furthermore, sheathing and roofing panels installed around windows, drains, retaining walls and other openings and areas in buildings can be particularly vulnerable to environmental damage.

When moisture ingress and/or panel degradation or destruction occurs as a result of these conditions, it is generally not noticed for a period of time, usually until visually observed. Furthermore, leaks and/or degradation that may not be visible by typical inspection methods may never be detected. Thus, such damaging conditions and mold and mildew caused by water penetration may be exacerbated to the point of easy avoidance due to the lack of early detection systems for these problems.

For example, in environments exposed to freezing temperatures, water that leaks into the roof or sheathing panels may undergo multiple freeze-thaw cycles, resulting in separation of the panel core and fiberglass mat facings and associated membranes (e.g., building wraps), if present. Once separation of the mat facing has occurred, the upwardly-rising wind causes further separation of the mat facing, sometimes causing the mat facing to bulge.

Accordingly, it is desirable to provide construction panels and other construction materials with sensors for detecting environmental conditions in or on the panels/structures to monitor and prevent damage to such materials.

Disclosure of Invention

In one aspect, a building panel is provided, the building panel comprising a panel core and having a first surface and an opposing second surface; and at least one environmental sensor assembly associated with the panel core and configured to detect an environmental condition of the panel including moisture, pressure, or both, and wirelessly communicate data regarding the environmental condition to a reader, wherein the at least one environmental sensor assembly is self-supporting, passive, and includes an antenna, a processing module, and a wireless communication module.

In another aspect, a system for detecting an environmental condition at a panel is also provided, the system including at least one of the building panels and at least one reader for receiving data wirelessly transmitted from at least one environmental sensor assembly.

In yet another aspect, a method of detecting environmental conditions is provided that includes providing at least one of the building panels and wirelessly transmitting data regarding the environmental conditions from the at least one environmental sensor assembly to a reader.

In yet another aspect, a method for manufacturing a build panel is provided, including combining a panel core slurry and a panel facing material to form a panel core having a first surface and an opposing second surface, the first surface associated with the panel facing material; and disposing at least one environmental sensor assembly within the panel core slurry or between the panel core slurry and the panel facing material, wherein the at least one environmental sensor is configured to detect an environmental condition (including moisture, pressure, or both) of the panel; and wirelessly communicating data regarding the environmental condition to the reader, wherein the at least one environmental sensor assembly is self-supporting, passive, and includes an antenna, a processing module, and a wireless communication module.

Drawings

Referring now to the drawings, which are intended to be exemplary and not limiting, and wherein like elements are numbered alike. The detailed description is set forth in connection with the appended drawings showing examples of the disclosure, wherein like reference numerals are used to refer to similar or identical items. Certain embodiments of the present disclosure may include elements, components, and/or configurations other than those shown in the figures, and in certain embodiments, some of the elements, components, and/or configurations shown in the figures may not be present.

FIG. 1 is a diagrammatic, partial side view showing a portion of a manufacturing line for producing gypsum board suitable for use in manufacturing gypsum panels for use in accordance with the present disclosure;

FIG. 2 is an enlarged partial cross-sectional view of the underlying fiberglass mat used to manufacture the gypsum board, taken from the left side of FIG. 1;

FIG. 3 is a fragmentary plan view taken as indicated by line 3-3 in FIG. 2;

FIG. 4 is an enlarged cross-sectional view taken as shown on the right side of FIG. 1 and showing the underlying fiberglass mat and overlying fiberglass mat with an intervening gypsum composition used to make the board;

FIG. 5 is a fragmentary plan view taken as indicated by line 5-5 in FIG. 4;

FIG. 6 is a partial bottom view taken as indicated by line 6-6 of FIG. 4 and showing the bottom surface of the underlying pad of the plate;

FIG. 7 is a cross-sectional view of an edge portion of the completed panel, the view being taken as indicated by line 7-7 of FIG. 4;

FIG. 8 is a further enlarged, fragmentary, cross-sectional view taken as indicated at the top of FIG. 4;

FIG. 9 is a further enlarged partial sectional view taken as shown at the bottom of FIG. 4;

FIG. 10 is a perspective view, partially in section and in section, of an exemplary roof deck system incorporating panels according to the present disclosure;

FIG. 11 is an enlarged cross-sectional view taken along line 11-11 of FIG. 10;

FIG. 12 is an enlarged cross-sectional view of the circled area of FIG. 11 showing the infiltration of a first asphalt layer into the fiber upper surface of the panel according to the present disclosure;

FIG. 13 is a perspective view of another type of roofing system incorporating panels according to the present disclosure as a primary support layer;

FIG. 14 is a cross-sectional view taken along line 14-14 of FIG. 13;

FIG. 15 is a perspective view, partially in section and in section, of a composite wall structure using panels according to the present disclosure;

FIG. 16 is an enlarged view of the circled portion of FIG. 15 showing the penetration of the gypsum layer into the fiber surface of the panel;

FIG. 17 is a cross-sectional view of a build panel;

FIG. 18 is a cross-sectional view of a build panel;

FIG. 19 is a perspective view of a building sheathing system with waterproof and air barrier properties;

FIG. 20 is a plan view of the environmental sensor assembly;

FIG. 21 is a perspective view of the roof platform assembly;

FIG. 22 is a partial perspective view of the roof platform assembly;

FIG. 23 is a cross-sectional view of a construction panel or material; and

fig. 24 is a sectional view of the floor mat.

Fig. 25 is a graph showing sensor code readings and free moisture weight percent as measured in the examples.

Fig. 26 is a graph showing hand-held sensor code readings and free moisture weight percent as measured in the examples.

FIG. 27 is a graph showing a regression plot of sensor and RFID readings as measured in an embodiment.

Fig. 28 is a graph showing sensor codes for various combinations of adhesives and sensor arrangements in samples of embodiments.

Detailed Description

Building construction panels and materials, as well as methods of making and using such panels and materials, and systems for their use are disclosed herein. The panels and materials described herein may be panels for interior or exterior construction applications, such as for wall panels, exterior sheathing, roof panels and flooring, sound deadening and rain protection mats, and other construction applications. For example, the panels described herein may be exterior gypsum sheathing panels, such as those described in U.S. patent application nos. 15/014793 and 15/014922 entitled "gypsum panels, systems, and methods," which are incorporated by reference herein in their entirety. For example, the panels described herein may be fiber reinforced gypsum panels comprising cellulosic fibrous materials, such as those described in U.S. patent nos. 6893752, 8070895, 6342284, 6632550, 7244304, 7425236, 7758980, 7964034, 8142914, and 8500904, which are incorporated by reference in their entirety. For example, the panels described herein may be roof deck panels, such as those described in U.S. patent No. 5319900, which is incorporated herein by reference in its entirety. For example, the panels described herein may be isocyanurate or similar insulation type panels, such as those described in U.S. patent No. 7612120, which is incorporated herein by reference in its entirety. For example, the panels described herein may be plywood, Oriented Strand Board (OSB), or other wood-based panels known in the construction industry. For example, the build material described herein can be a polymeric rain curtain or sound deadening mat, such as those described in U.S. patent nos. 9157231 and 7861488, which are incorporated herein by reference in their entirety. For example, the panels or construction materials described herein may be gypsum and/or concrete floor underlayments, such as those described in U.S. patent No. 7651564, which is incorporated herein by reference in its entirety. In general, the present disclosure relates to various building panels and materials for interior and/or exterior building applications for commercial and/or residential applications, wherein the building panels and/or materials contain environmental sensors configured to detect one or more environmental conditions of the panels, materials or surrounding structures associated therewith.

Building panels and materials

In general, the panels and other build materials may include any suitable build or configuration known in the art. For example, the panel may be a panel comprising gypsum as a significant component of the panel core (e.g., in an amount of up to 90% or more by weight), or may be a panel comprising gypsum in combination with other components as a component of the panel core (e.g., in an amount of less than 90%). Examples of other components that may be present in the panel core include cellulose or other fibers. Further, while the present disclosure generally relates to construction panels comprising a gypsum core or layer, other panels may be substituted for gypsum panels as appropriate, such as wood-based, foam-based panels, and other material-based panels suitable for the building construction purposes described herein. That is, while various embodiments of the present disclosure are described or illustrated in connection with gypsum panels, it should be understood that the gypsum core and other panel features may be replaced by suitable components of these other panels or types of construction materials. In particular, such panels and other materials are described in the documents incorporated by reference herein. For example, these panels and mats may include any suitable panel core (e.g., one or more layers forming the structural core of the panel) and any suitable facing material or other exterior coating material, as will be described herein.

In certain embodiments, as shown in fig. 23, the construction panel 2300 comprises: a panel having a first surface 2307 and an opposing second surface 2309 (e.g., panel core 2301 formed from one or more layers of panel core material 2308, with or without facing material); and an environmental sensor component 2320 associated with panel 2300 and configured to detect an environmental condition of panel 2300 and wirelessly communicate data related to the environmental condition to a reader, an environmental sensor component 2322, an environmental sensor component 2324, wherein the environmental sensor component is self-supporting and includes an antenna, a processing module, and a wireless communication module. For example, as discussed above, the panels may be selected from gypsum panels, fiber reinforced gypsum panels, isocyanurate panels, wood based panels, or other known construction panels. For example, construction materials such as various construction mats or other structures, including but not limited to polymeric rain curtains with environmental sensor assemblies associated therewith, polymeric sound deadening mats, and polymeric roof drainage mats may also be provided. For example, such a mat may be a rolled material that is cut to a desired size. As shown in fig. 23, environmental sensor components (the various components shown as 2320, 2322, 2324) may be positioned in or on any suitable surface (internal or external) of a panel or material. For example, the environmental sensor assembly may be disposed on an outer surface or edge of the panel, or disposed within or on a surface of the panel. For example, in a panel having a facing material, a panel coating, or multiple layers forming a panel core, the environmental sensor assembly may be disposed internally, i.e., between two layers of the panel.

For example, in a gypsum panel, such as a fiber reinforced gypsum panel, the environmental sensor assembly may be disposed on an outer surface or edge of the panel, or disposed within or on a surface of the panel. For example, in a gypsum panel having a facing material, a panel coating, or multiple layers forming a panel core, the environmental sensor assembly may be disposed internally, i.e., between two layers of the panel. Accordingly, in certain embodiments, a construction panel includes a panel core and at least one environmental sensor assembly associated with the panel core. For example, in an isocyanurate panel, the environmental sensor assembly may be disposed on an exterior surface or edge of the panel, or within the panel, such as between layers of the panel, or on a surface of the panel. For example, in a wood-based panel, the environmental sensor assembly may be disposed on an exterior surface or edge of the panel, or within the panel, such as between layers of the panel, or on a surface of the panel. For example, in a polymer mat such as a sound dampening mat, a roof drain mat, or a rain curtain, the environmental sensor assembly may be disposed on an outer surface of the mat or between layers thereof.

In certain embodiments, as shown in fig. 24, a floor underlayment 2400 is provided and includes: gypsum and/or concrete underlayment 2401 (e.g., a cast-in-place or other suitable underlayment configuration formed of one or more layers of underlayment 2408 on the floor base 2430); and an environmental sensor component 2420, an environmental sensor component 2422, an environmental sensor component 2424 associated with the bedding material and configured to detect an environmental condition of the bedding and wirelessly communicate data regarding the environmental condition to the reader, wherein the environmental sensor component is self-supporting and comprises an antenna, a processing module, and a wireless communication module. For example, the backing layer may have a first surface 2407 and an opposing second surface 2409. For example, the environmental sensor component 2420, the environmental sensor component 2422, the environmental sensor component 2424 can be disposed within or on a surface of a gypsum and/or concrete mat material.

In certain embodiments, as shown in fig. 17, a panel 1000 includes a panel core 101 having a first surface and a second opposing surface, and a first facing material 104 associated with the first surface of the panel core 101. For example, the facing material may be any suitable facing material known in the art, including paper facing materials and fibrous facing materials. In certain embodiments, as shown in fig. 17, the facing material 104 is a fibrous material, such as fiberglass. Thus, while certain embodiments herein are described in connection with glass fiber mats, it should be understood that any suitable paper facing or other fiber mat material may be substituted and fall within the scope of the present disclosure.

In certain embodiments, as shown in fig. 17, a gypsum panel 1000 includes a gypsum core 101 having a first surface and a second, opposing surface, and a first facing material 104 associated with the first surface of the gypsum core 101. For example, the facing material may be any suitable facing material known in the art, including paper facing materials and fibrous facing materials. In certain embodiments, as shown in fig. 17, the facing material 104 is a fibrous material, such as fiberglass. Thus, while certain embodiments herein are described in connection with glass fiber mats, it should be understood that any suitable paper facing or other fiber mat material may be substituted and fall within the scope of the present disclosure.

In certain embodiments, the facing material is a non-woven fibrous mat formed from a fibrous material capable of forming a strong bond with the material from which the panel core is constructed by the pseudo-mechanical interlocking between the interstices of the fibrous mat and portions of the core material. Examples of fibrous materials for use in the nonwoven mat include mineral-type materials such as glass fibers, synthetic resin fibers, and mixtures or blends thereof. Both chopped and continuous strands may be used.

In certain embodiments, the facing material is a non-woven fiberglass mat. For example, the glass fibers can have an average diameter of about 1 micron to about 17 microns and an average length of about 1/16 inches to about 1 inch. For example, the glass fibers may have an average diameter of 13 microns (i.e., K-fibers) and an average length of 3/4 inches. In certain embodiments, the nonwoven glass fiber mat has a basis weight of from about 1.5 pounds to about 4.0 pounds per 100 square feet of mat. The pads may each have a thickness of about 10 mils to about 50 mils. The fibers may be bonded together by a suitable adhesive to form a unitary mat structure. For example, the binder may be a urea formaldehyde resin binder, optionally modified with a thermoplastic extender or crosslinker (such as an acrylic crosslinker) or an acrylate binder resin.

In certain embodiments, as shown in fig. 2 and 3, the facing material mats 6 and 16 comprise glass fiber filaments 30 oriented in a random pattern and bonded together with a resin binder (not shown). One embodiment of a fiberglass mat-faced gypsum board 40 is shown in fig. 4 and 7, wherein the set gypsum of the core 42 substantially penetrates the thickness of the mat 6 over a substantial portion of its area, and wherein the set gypsum of the core 42 partially penetrates the mat 16, such that the surface is substantially free of set gypsum. As shown in fig. 8, the gypsum-free surface of the pad 16 is highly textured and provides an excellent substrate for adhering overlying components thereto, as it contains numerous interstices into which the adhesive composition can flow and bond.

In certain embodiments, the panel has a thickness of about 1/4 inches to about 1 inch. For example, the panel may have a thickness of about 1/2 inches to about 5/8 inches.

In some embodiments, as shown in fig. 17, the gypsum crystals of the gypsum core 101 penetrate the remaining portion of the first glass fiber mat 104 such that voids in the first glass fiber mat 104 are substantially eliminated and the water resistance of the panel 1000 is further enhanced. For example, in one embodiment, the first glass fiber mat 104 has a continuous barrier coating 106 on a surface opposite the gypsum core 101, the continuous barrier coating 106 penetrating a portion of the first glass fiber mat 104 to define a remaining portion of the first glass fiber mat 104. That is, the gypsum crystals of the gypsum core 101 penetrate the remaining fiber portion of the first glass fiber mat 104 such that voids in the first glass fiber mat 104 are substantially eliminated. As used herein, the phrase "such that voids in the glass fiber mat are substantially eliminated" and similar phrases refer to gypsum slurry (e.g., slate coating) that fills all or nearly all of the interstitial volume of the glass fiber mat that is not filled by the coating material.

As used herein, the term "continuous barrier coating" refers to a substantially uninterrupted coating material on the surface of a fibrous mat. The continuous barrier coating on the exterior surface of the facing may be any suitable coating known in the art. For example, the coating may include a binder material and optionally a filler. For example, the coating may include a polymer or resin-based binder material and one or more inorganic fillers.

In certain embodiments, as shown in fig. 17, the gypsum core 101 comprises two or more gypsum layers 102, 108, while in other embodiments, the gypsum core comprises a single gypsum layer. For example, the gypsum core may include various gypsum layers having different compositions. In some embodiments, the first gypsum layer 102 in contact with the glass fiber mat 104 (i.e., the layer that forms the remaining fiber portion having the coating material interface and at least partially penetrating the first fiber mat) is a slate coating layer. In some embodiments, the first gypsum layer 102 is present in an amount from about 2% to about 20% by weight of the gypsum core 101. For ease of illustration, the various gypsum layers are shown as separate layers in the figures; however, it should be understood that the overlap of these materials may occur at their interface.

The layers of the gypsum core can be similar to gypsum cores used in other gypsum products, such as gypsum wallboard, drywall, gypsum board, gypsum laths, and gypsum sheathing. For example, the gypsum core can be formed by mixing water with powdered calcium sulfate anhydrous or calcium sulfate hemihydrate (also known as calcined gypsum) to form an aqueous gypsum slurry, and then allowing the slurry mixture to hydrate or set to calcium sulfate dihydrate (a relatively hard material). In certain embodiments, the gypsum core comprises about 80% by weight or more of set gypsum (i.e., fully hydrated calcium sulfate). For example, the gypsum core can comprise about 85% by weight set gypsum. In some embodiments, the gypsum core comprises about 95% by weight set gypsum. The gypsum core may also include various additives such as accelerators, retarders, foaming agents, and dispersants.

In certain embodiments, as shown in fig. 18, the gypsum panel 200 includes two facings 204, 212 associated with the gypsum core 201. Like the first facing material, the second facing material may be any suitable facing material, such as paper or a fibrous material. In certain embodiments, both facings 204, 212 are fiberglass mats. A second fiberglass mat 212 is present on the face of the gypsum core 201 opposite the first fiberglass mat 204. In some embodiments, only the first glass fiber mat 204 has a continuous barrier coating 206 on its surface. In other embodiments, both glass fiber mats 204, 212 have a coating 206, 214 on their surface opposite the gypsum core 201. In some embodiments, the gypsum core 201 includes three gypsum layers 202, 208, 210. One or both of the gypsum layers 202, 210 in contact with the fiberglass mats 204, 212 may be a slate paint layer.

As shown in fig. 17, a gypsum panel according to the present disclosure may have a continuous barrier coating 106 on and/or on the first surface 107 of the panel 1000 formed from the first facing material 104. The gypsum panel 1000 also has a second surface 109 of the panel opposite the first surface 107.

In certain embodiments, as shown in fig. 10-14 and 21-22, the panel may be a roof deck panel. For example, installing a roof deck system in the construction of a building generally involves constructing a frame to support the roof of the building; attaching to the frame corrugated sheet to provide a surface for supporting other components of the roof deck system; attaching a planar support member to the corrugated sheet; and attaching an exterior finishing material having good weathering characteristics to the planar support member. Roof deck systems comprising insulating panels sandwiched between the corrugated sheets and planar support members described above are also widely used. Such systems are designed to be insulative and weatherable. Such roof deck systems may be used to harness energy for heating and to conserve energy for air conditioning. More specifically, such roof deck systems typically comprise corrugated sheet metal that is mechanically attached, typically by screws or bolts, to appropriate structural members of the building, such as steel beams. The corrugated metal sheet supports the weight of the components overlying it, including the insulation material (when used), the planar support members and the trim material. Lightweight low density insulation panels such as expanded polystyrene, polyisocyanurate and the like are widely used in such systems, especially in colder climates. The planar support member typically comprises gypsum board and is secured in place by mechanical fasteners such as screws to form the underlying corrugated metal sheet. When insulating panels are used, they are sandwiched between the underlying corrugated metal sheet and the overlying panel of the gypsum board. Exterior trim materials such as polymer or rubber membranes or alternating layers of asphalt and roofing felt overlay the face sheet of gypsum board.

A typical roof deck system incorporating fiber mat faced gypsum board as described above is shown in fig. 10-12. In this configuration, spaced parallel trusses 50 extending between building support members (not shown) support corrugated metal platforms 52 welded or otherwise fastened to the trusses. Layers 54 and 56 of insulating sheet material (which may be, for example, polyisocyanurate) are provided on the corrugated metal platform. A layer 58 of a fibrous mat facing gypsum board panel of the type described above is secured to the corrugated platform 52 by fasteners 60 passing therethrough and through the underlying insulation 54 and 56 into the platform 52. The joints of the panel layers 58 are sealed by applying tape 62, as shown in figure 10 with respect to one of the panel joints. Overlying the gypsum layer 58 is a waterproof roofing membrane that includes alternating layers of asphalt 64 and roofing felt 66, three layers each being shown in this example. The final coating of bitumen 68 is covered with a crushed gravel top layer 70.

In the enlarged view of fig. 12, the manner in which the first asphalt layer 64 penetrates into the upwardly facing fibrous mat face of the gypsum board facing layer 58 is shown. This penetration ensures that the waterproofing membrane adheres firmly to the structural layer of the roof system.

In some embodiments, as shown in fig. 21, a roof deck system 150 incorporating a gypsum panel with an environmental sensor assembly includes a gypsum roof deck/panel as a cladding 158, a backing layer 154, or both, and a mounting 156, a roof covering or membrane 160 mounted on a steel, wood, or other roof deck 152 (shown as steel). In some embodiments, as shown in fig. 22, the roof deck system 162 incorporating gypsum board with an environmental sensor assembly is a single-layer membrane system. For example, the system may include at least one gypsum roof panel 166, 170, insulation 168, and a single layer film 172 (e.g., EPDM or thermoplastic film). Various embodiments of such roofing systems utilizing gypsum roofing panels are known in the art, and the present disclosure is intended to encompass any such suitable system configuration or design incorporating the gypsum panels disclosed herein. For example, the roofing system may comprise a suitable asphalt, EPDM, Turbo Seal, CSPE, modified asphalt, PVC, cold liquid membrane, FTPO, TPO, coal tar asphalt stack, or other stacked roofing construction, among others.

Referring to fig. 13 and 14, a cast-in-place roof deck system is shown including purlins 72 supporting spaced apart secondary purlins (bulb tees 74 in parallel spaced-apart relation). Fiber mat facing gypsum boards 76 of the type described above are supported on horizontal flanges 74a of secondary purlins 74. A reinforcing mesh screen 78 is laid over the secondary purlin and gypsum panel 76 and a layer of settable gypsum slurry 80 is poured into place over the reinforcing mesh screen. The slurry 80 is allowed to harden to form a smooth continuous platform surface 82. The adherence of the slurry to the gypsum board facing sheet 76 is ensured by penetration of the slurry onto the upwardly facing fibrous mat surface of the facing sheet. A roofing membrane comprising alternating layers of asphalt 84 and roofing felt 86 (three layers each in the example shown) is applied to the surface 82. The final asphalt layer 88 is covered with a coating of crushed rock or gravel 90.

In the case of interior decoration systems for buildings, the installation of such systems generally involves the construction of a frame to support the interior walls of the building; and attaching to the frame planar support member, the support member providing a smooth continuous surface to support interior trim materials having aesthetic and durability characteristics. Such systems are designed to be rugged and resistant to abuse during building occupancy. Fig. 15 and 16 show an example of the internal use of the fiber mat-faced panel of the present invention. In these views, the inner wall system includes spaced vertical studs 92 to which fiber mat-facing gypsum board panels 94 are attached by spaced fasteners 96 (such as screws or nails). A thin layer 98 of plaster of paris is applied to the fibrous mat surface 100 of the panel 94 and smoothed to form a smooth decorative surface, which can then be decorated in a conventional manner with paint, paper, or the like. As shown in the enlarged view of FIG. 16, the plaster of Paris 98 penetrates into the fibrous mat surface of the panel 94 to achieve a secure mechanical bond of the plaster of Paris layer to the panel. Although shown in the context of the wall of fig. 15, the panel 94 may equally suitably be used as a ceiling and may be used with wood or metal stud support systems. For some applications, it may be found desirable to adjust the water resistance of the core to obtain a satisfactory plaster of paris decoration.

In an external system, the sheathing panels may be attached to the underlying support members in any suitable manner, such as by using nails or screws. In such systems, the underlying brace members may include, for example, panels of rigid plastic or metal sheet (e.g., panels in corrugated form), purlins, and secondary purlins. A panel of insulating material may be attached to such a support member and overlie a panel of the panels attached thereto. The support members are typically attached to the frame of the building.

In certain embodiments, as shown in fig. 17 and 18, the gypsum panel includes at least one environmental sensor component 120, an environmental sensor component 122, an environmental sensor component 124 associated with the gypsum panel. Although three environmental sensor assemblies are shown in fig. 17 and 18, it should be understood that the sensor assemblies may alternatively be disposed at one, two, or all of these locations, as well as in other locations in and on the gypsum panel. Additionally, as discussed in further detail below, a plurality of environmental sensor assemblies may be provided that are substantially equally spaced from one another at similar locations along the length of the panel (e.g., every 1 foot, 2 feet, or 3 feet).

In one embodiment, the environmental sensor assembly is disposed on a first surface of the panel. In one embodiment, the environmental sensor assembly is disposed on the second surface of the panel. For example, the first surface of the panel may be the outward facing surface of the panel when installed, and the second surface of the panel may be the inward facing surface of the panel when installed. In other embodiments, the environmental sensor assembly is disposed at an outer edge of the panel. In other embodiments, the environmental sensor assembly 120, the environmental sensor assembly 122, the environmental sensor assembly 124 are disposed within the panel core or at a surface thereof. For example, the environmental sensor assembly may be positioned on or near the facing material, or in another portion of the core material of the panel core, such as in another of the slate coating or gypsum layers in a gypsum panel. For example, the sensor assembly 120 is disposed between a first surface of the panel core 101/201 and the facing material (e.g., the fiber mat 104). For example, the sensor assembly 122 is embedded in the body of the panel core 101/201. For example, the sensor assembly 124 is disposed between the first and second gypsum layers 102, 108/202 and 208 forming the panel core 101/201. In other embodiments, the environmental sensor assembly may be disposed on a surface of the facing material that receives the continuous barrier coating. Thus, the environmental sensor assembly may be disposed at any suitable location on or in the panel depending on the desired location and type of environmental condition detection and the particular application of the panel.

In certain embodiments, the environmental sensor assembly is configured to detect an environmental condition of a panel or material associated therewith and transmit data regarding the environmental condition to the reader. For example, the environmental sensor assembly is configured to detect one or more environmental conditions, such as moisture, temperature, and/or pressure.

In certain embodiments, the environmental sensor assembly is self-supporting and includes a substrate on which the antenna, processing module, and wireless communication module are disposed. As used herein, the term "self-supporting" means that the sensor assembly is operable to sense a target environmental condition as a stand-alone assembly without requiring a wired connection external to the sensor assembly. Thus, the environmental sensor assemblies disclosed herein may be advantageously incorporated into a panel or other material at various locations throughout the panel during manufacture or at a construction site without the need for additional labor or materials to wire or program the sensor. In certain embodiments, the environmental sensor assembly is a passive system. As used herein, the term "passive system" refers to a sensor assembly without a battery that uses radio energy transmitted by a reader to power the assembly. Advantageously, passive systems may be used in applications where panels, materials and/or sensor components are substantially inaccessible, making it impossible to replace components or batteries associated therewith without damaging the building or building envelope. Furthermore, since passive systems have no power source and typically no moving parts, these components can have extremely long lifetimes that are at least equal to the typical lifetime of a panel or other build material. In other embodiments, the environmental sensor assembly is an active system that includes an integrated power source (such as a battery), for example a rechargeable battery, such as a battery powered by solar energy.

In certain embodiments, the environmental sensor component is a passive ultra high frequency single chip sensor embedded system. In certain embodiments, the antenna is a resistor/inductor/capacitor (RLC) tuned circuit operable to convert environmental conditions into impedance changes, and the processing module is coupled to the antenna and operable to convert the impedance changes into sensor codes by matching the antenna impedance to the die impedance. Thus, while conventional sensors utilize changes in resistance to measure environmental variables, which results in a reduced tag read range due to power dissipated in the resistance, the ability of the sensor assembly of the present invention to use inductance or capacitance advantageously avoids read range problems.

For example, the antenna may have an antenna impedance that is operable to vary based on environmental conditions. The processing module may be coupled to the antenna and include a tuning module operable to (i) change the reactive component impedance to change a system impedance including the antenna impedance and the reactive component impedance, and (ii) generate an impedance value representative of the reactive component impedance. The wireless communication module may be coupled to the processing module and operable to communicate an impedance value representative of the reactive component impedance to the reader, the impedance value representative of data regarding the environmental condition. In some embodiments, the environmental sensor assembly further includes a memory module operable to store an impedance value representative of the reactive component impedance.

For example, the sensor assembly may be a passive Radio Frequency Identification (RFID) sensor, such as the sensor described in PCT patent application publication No. WO2015/184460, which is incorporated by reference herein in its entirety. As shown in fig. 20, the passive RFID sensor includes an antenna, a processing module, and a wireless communication module. The antenna has an antenna impedance that may vary with the environment in which the antenna is placed. The processing module is coupled to the antenna and has a tuning module that can vary a reactive component impedance coupled to the antenna in order to vary a system impedance that includes both the antenna impedance and the reactive component impedance. The tuning module then generates an impedance value representative of the reactive component impedance. The memory module may store impedance values, which may then be communicated to the RFID reader via the wireless communication module. The RFID reader may then exchange impedance values representing the reactive component of the impedance with the RFID reader so that the RFID reader or another external processing unit may process the impedance values in order to determine the environmental condition at the antenna.

Fig. 20 is a view of one embodiment of an RFID moisture or humidity sensing tag 3300. The moisture or humidity sensing tag 3300 is a passive RFID tag having a substrate 2101 on which an Integrated Circuit (IC)2100 is disposed. The IC 2100 includes a memory module 2012, a wireless communication engine 2104, and a sensor engine 2106 that includes an antenna. The IC 2100 is capable of sensing changes in the ambient surroundings proximate the IC 2100 via changes in impedance associated with the antenna. The memory module 2102 is coupled with both the wireless communication engine 2104 and the sensor engine 2106. The memory module 2102 can store information and data collected by the sensor engine 2106 and transmitted via the wireless communication engine 2104. Further, the wireless communication engine 2104 and the sensor engine 2106 may be fully programmed by wireless methods.

The sensor impedance varies as the coupling of the cross capacitor 3304 changes in response to environmental changes. In one embodiment, cross capacitor 3304 is located adjacent to film 3306 applied over cross capacitor 3304. Membrane 3306 may be water (i.e., moisture or humidity) or other fluid, such as CO, CO₂Arsenic, H₂S or other material with affinity for the toxin or gas of interest. When the membrane 3306 absorbs fluids, such as those previously described, the dielectric constant proximate the crossover capacitor 3304 changes, resulting in a change in impedance. The impedance of the crossed capacitor 3304 sensed by the processing module coupled to the sensor then produces an output, i.e., a sensor code, that represents the material absorbed within the film 3306. The data may be stored within a memory circuit of the IC 2100 or transmitted by a wireless communication module of the IC 2100 to an external reader.

Thus, in certain embodiments, when configured as a humidity sensor, the sensor assembly measures the presence of water when the surrounding environment becomes wet. When the cross capacitor changes from dry to wet, it undergoes a significant change in capacitance; the dipole antenna records the impedance change according to the amount of water on the capacitor; and the sensor IC converts the impedance change into a code indicative of the amount of water present.

Advantageously, the sensor assemblies described herein can have small dimensions, such as about 4 inches by 1 inch, and be very thin to provide nominal additional thickness when externally applied to a panel or build material.

In certain embodiments, as shown in fig. 17 and 18, the build panel includes at least one environmental sensor component 120, 122, 124 embedded or disposed within the panel (e.g., between a surface of the core and a facing material, between layers forming the panel core, or within a body of the panel core). In such embodiments, the panel may also have at least one visual indicator 121 positioned on the first exterior surface of the panel (e.g., on the surface coating 106/206), wherein each of the at least one visual indicators indicates a location of the environmental sensor assembly within the panel. That is, the visual indicator 121 may be positioned on the surface of the panel in line with one or more sensor components embedded at the panel core. The visual indicator 121 may be any suitable indicia, indentations, raised features, or the like. For example, the visual indicator may be a score or indicia. Such visual indicators may advantageously provide an indication to the builder of where such sensor assemblies are located, and thus indicate which areas of the panel should avoid drilling, nailing or otherwise penetrating the panel during installation. As mentioned herein, the sensors may be spaced at a consistent distance across the length of the panel, such as 1 foot, 2 feet, 3 feet, or other spacing. Likewise, the visual indicators 121 may be similarly spaced apart. For example, the at least one environmental sensor assembly may include a plurality of environmental sensor assemblies spaced apart from each other by a distance of about 1 foot to about 4 feet.

Method of producing a composite material

Methods of making the construction panels and materials described herein are also provided. For example, gypsum panels, fiber reinforced gypsum panels, isocyanurate panels, polymeric rain curtains, polymeric sound damping mats, polymeric roof drainage mats, wood based panels, floor underlayments, or other construction materials may be manufactured by any suitable method known in the industry. For example, as described above, the environmental sensor assembly may be associated with a panel, material, or backing layer during or after the manufacturing process. For example, the environmental sensor assembly may be embedded within the material forming the panel or other material, or may be disposed between various layers of the panel or material (e.g., layers forming the panel core, facing, and/or coating).

For example, in a gypsum panel, the environmental sensor component can be associated with the panel before or after the gypsum core is set. In certain embodiments, the environmental sensor assembly is positioned in the gypsum slurry prior to setting, e.g., at, near, or remote from the facing material. For example, the sensor assembly may be positioned within or on a surface of the panel core slurry during manufacture, or may be positioned between layers of the panel core (e.g., between slurry layers, such as between an in situ gypsum slurry layer and a slate coating gypsum slurry layer).

In other embodiments, the environmental sensor assembly is attached or affixed to an outer surface or edge of the gypsum panel. In other embodiments, the environmental sensor assembly is attached or affixed to a surface of the facing material opposite the gypsum core and is covered by, embedded in, or surrounded by a coating material. In other embodiments, the environmental sensor assembly is attached or affixed between the facing material and the gypsum core.

In some embodiments, multiple sensor assemblies are disposed along a length of material (e.g., paper backing, other film, fiberglass, or other nonwoven scrim) in a desired spaced pattern and wound on a roll. During manufacture, the rollers of the sensor assembly may be unwound (such as by spoilers) at a desired arrangement during manufacture (e.g., between slate coating and in-situ (other gypsum) slurry or between the gypsum core and facing material). In other implementations, the sensor component may be pre-applied to the interior face of the facing material (e.g., the panel core facing). In another embodiment, the integrated circuit and/or antenna of the sensor assembly may be integrated within the fibrous mat facing material to increase the size and read range of the antenna.

Alternatively, as discussed above in connection with fig. 13 and 14, the cast-in-place gypsum or concrete panel system may be used for roofing or flooring underlayment applications, where the environmental sensor assembly is applied during the cast-in-place process.

In some embodiments, the environmental sensor assembly is applied consistent with a panel manufacturing process. In other embodiments, the environmental sensor assembly is applied after the panel is manufactured, such as at a construction site or an intermediate storage device or other manufacturing/processing facility.

The present invention also provides a method of making a gypsum panel having water-resistant properties. In certain embodiments, during manufacture, the gypsum slurry may be deposited on the uncoated surface of the facing material and set to form the gypsum core of the panel. Where the facing material is a fibrous mat, the gypsum slurry can penetrate some of the remaining fibrous portion of the thickness of the mat (i.e., some portion of the mat that is not penetrated by the coating) and provide a mechanical bond to the panel. The gypsum slurry can be disposed in one or more layers of the same or different composition, including one or more slate coating layers. As used herein, the term "slate coating" refers to a gypsum slurry having a higher wet density than the remainder of the gypsum slurry forming the gypsum core. These methods can be used to produce gypsum panels having any feature or combination of features described herein. Enhanced penetration of gypsum into the fibrous mat can be accomplished by chemical modification of the gypsum slurry, by applying a penetration enhancing coating on the surface of the fibrous mat contacted by the gypsum slurry, and/or by mechanical means.

In certain embodiments, the outer surface of the fibrous mat is coated with a continuous barrier coating that penetrates a portion of the first glass fiber mat to define the remaining portion of the first glass fiber mat through which the gypsum crystals of the gypsum core penetrate such that voids in the first glass fiber mat are substantially eliminated.

In certain embodiments, the gypsum core comprises multiple layers that are sequentially applied to the glass fiber mat and allowed to set sequentially or simultaneously. In other embodiments, the gypsum core comprises a single layer. In some embodiments, a second glass fiber mat may be deposited onto the surface of the final gypsum slurry layer (or the only gypsum slurry layer) to form a double-faced mat-faced gypsum panel. For example, the first and/or second fiberglass mats may include a barrier coating on a surface thereof that penetrates a portion of the mat. The gypsum slurry or layers thereof can be deposited on the glass fiber mat by any suitable method, such as roll coating.

In some embodiments, the gypsum core comprises at least three gypsum layers, with the outermost gypsum layer of the gypsum core (i.e., the layer that forms an interface with the glass fiber mat). In certain embodiments, the two outermost layers are chemically altered to enhance permeation.

In certain embodiments, the first fibrous mat and/or the second fibrous mat has been coated when contacted with a gypsum (or other panel core) slurry. In some embodiments, the method includes applying a continuous coating to the first fiber mat and/or the second fiber mat before or after contacting with the panel core slurry. In certain embodiments, applying the barrier coating comprises spraying, band coating, curtain coating, knife coating, or direct roll coating. In some embodiments, the barrier coating is applied at from about 1 to about 9 pounds per 100ft²Is applied to each of the first fiber mat and/or the second fiber mat. For example, the barrier coating may be applied at from about 2 pounds to about 8 pounds per 100ft²Is applied to the first fiber mat and/or the second fiber mat. In other embodiments, the coated fibrous mat may be obtained in a pre-processed form.

In some embodiments, the method further comprises mechanically vibrating at least the first glass fiber mat having the first gypsum slurry deposited thereon to effect penetration of the gypsum slurry into the remaining fiber portion of the first glass fiber mat.

In certain embodiments, the panel core slurry (or layer thereof) may be deposited on the uncoated side of the horizontally oriented moving web of the pre-coated fibrous mat. The coated or uncoated fibrous mat may be deposited onto the surface of the panel core slurry opposite the first coated fibrous mat, e.g., the uncoated surface of the second coated fibrous mat contacts the panel core slurry. In some embodiments, a moving web of pre-coated or uncoated nonwoven fibrous mat may be placed on the upper free surface of the aqueous panel core slurry. Thus, the panel core material may be sandwiched between two fibrous mats, one or both of which have a barrier coating. In certain embodiments, allowing the panel core material and/or continuous barrier coating to solidify comprises curing, drying (such as in an oven or by another suitable drying mechanism), or allowing the material(s) to solidify (i.e., self-harden) at room temperature.

In certain embodiments, as shown in fig. 1-9, the dry ingredients (not shown) from which the gypsum core is formed are pre-mixed and then fed into a mixer of the type commonly referred to as a multi-lobe mixer 2. The water and other liquid components (not shown) used to make the core are metered into a multi-blade mixer 2 where they are mixed with dry ingredients to form an aqueous gypsum slurry. The slurry 4 is dispersed through one or more outlets at the bottom of the agitator 2 onto a moving sheet of fibrous mat 6. The sheet of fibre mat 6 is endless in length and is fed from a roll of mat (not shown). In certain embodiments, two opposing edge portions of the fiber mat 6 are gradually flexed upward from the average plane of the mat 6, and then turned inward at the margins to provide a covering for the edges of the resulting panel 40. In fig. 1, this progressive flexing and shaping of the edge of the pad 6 is shown for only one side edge of the pad, and conventional guide means normally used for this purpose are omitted from the drawing for clarity. Fig. 7 shows the edges of the set gypsum core 42 covered by the overlapping edge portions 6A of the mat 6. Fig. 7 also shows score marks 10 and score marks 10A of pad 6 that allow for the formation of good edges and flat surfaces. Score marks 10 and score marks 10A are made from conventional scoring wheels 12. The advantage of using a fiberglass mat is that it can be scored and edged like a conventional paper surface.

Another fibrous mat sheet 16 is fed from a roll (not shown) onto the top of the slurry 4, thereby sandwiching the slurry between the two moving fibrous mats forming the slurry. The pad 6 and the pad 16 with the slurry 4 sandwiched therebetween enter the nip between the upper and lower forming or shaping rollers 18 and 20 and are then received on the conveyor belt 22. Conventional edge guides (such as indicated at 24) shape and hold the edges of the composite until the gypsum has set sufficiently to retain its shape. Where appropriate, the sequential lengths of board are cut and further processed by exposure to heat, which accelerates drying of the board by increasing the rate of evaporation of excess water in the gypsum slurry.

Referring to fig. 7, it has been observed that the set gypsum of the core 42 is effective in forming a satisfactory bond with the mat and between the edge portion of the underlying mat 16 and the overlapping edge portion 6A of the underlying mat 6, thus making the use of a bond modifier in the slurry or edge paste unnecessary to form the aforementioned bond.

In certain embodiments, a method of manufacturing a panel includes associating a self-supporting environmental sensor assembly with the panel. For example, the environmental sensor component can be any suitable component described herein, such as those components including an antenna, a processing module, and a wireless communication module, and is configured to detect an environmental condition of the panel and wirelessly communicate data regarding the environmental condition to the reader.

In some embodiments, the method includes associating a visual indicator of the position of the sensor assembly with the panel. For example, the markings, scoring, or other methods of creating the indicator may be performed in-line, assisted by metal detection of the sensor assembly, or may be created at regular intervals corresponding to regular intervals at which known sensor assemblies are spaced. In other embodiments, the indicator may be pre-printed on the facing material or other outer surface of the panel to correspond to a known pattern of the arrangement of the sensor components.

Applications of

Systems and methods for detecting environmental conditions at a panel or other build material are also provided herein. In certain embodiments, the system comprises at least one of a construction panel, a material, or a floor underlayment as described herein and at least one reader for receiving data wirelessly transmitted from the environmental sensor assembly. In certain embodiments, a system includes at least one panel containing an environmental sensor assembly such as described herein and at least one reader for receiving data wirelessly transmitted from the environmental sensor assembly. In certain embodiments, a method of monitoring an environmental condition of a panel comprises: providing at least one panel having an environmental sensor assembly associated therewith; detecting, via an environmental sensor assembly, an environmental condition of a panel; and wirelessly transmitting data regarding the environmental condition from the environmental sensor assembly to the reader.

The reader may be any suitable wireless sensor reader known in the art. For example, the reader may be a hand-held manual reader. In other embodiments, the reader is a stationary powered reader installed at a building comprising at least one panel, material, or underlayment. For example, a stationary powered reader may be located at or near the panel, or may be located at a distance from the panel (e.g., 10 feet to 100 feet, such as 10 feet to 50 feet, such as 25 feet to 30 feet). For example, in a building containing one or more panels with mounting as roof decks, interior/exterior sheathing panels, mats, or other structural panels, electrically powered readers may be mounted at one or more sites on and/or around the building to continuously or intermittently monitor the status of the environmental sensor assembly. In certain embodiments, a building control system is provided to receive information from a reader. In some embodiments, the reader may be mounted on a drone configured to be proximate to the at least one panel to receive the data wirelessly transmitted from the environmental sensor assembly. In certain implementations, the sensed data is digitized and wirelessly communicated to an off-the-shelf reader for further processing using standard UHF 2-generation protocol READ commands.

In certain embodiments, the system further comprises a processing unit, and the reader is configured to transmit data regarding the environmental condition to the processing unit, and the processing unit is operable to determine at least one condition state at the environmental sensor assembly from the data. For example, the reader may be configured to communicate the impedance value representative of the reactive component impedance to the processing unit such that the processing unit is operable to determine the at least one condition state at the environmental sensor component from the impedance value representative of the reactive component impedance.

In some embodiments, the system includes an integration service that allows for the programming of sensors without the need for complex IT infrastructure and middleware. For example, the integration service may provide for the deposit of all sensor tag related data (e.g., sensor range and calibration data), the deposit of measurement data related to sensor tag panels, and a decision flow engine securely accessed by authorized web services and applications, such as to send a notification to a service technician via SMS/email if the panels of the sensor tags exceed a preset level (e.g., a preset humidity level).

In certain embodiments, raw data is collected from these sensors via a reader for processing by a data processing unit, where calculations are made to determine humidity or temperature measurements. Further, referring to fig. 20, the wireless communication engine 2104 and the sensor engine 2106 may be fully programmed by wireless methods. The passive RFID sensor of fig. 20 may be deployed as a smart sensor array (e.g., multiple sensor components mounted on one or more panels at a single location) to collect data that may be sent back to the central processing unit. Another embodiment provides an environment sensing method for an RF system, the method comprising the steps of: calibrating the RF sensor by generating a first calibration value indicative of the absence of the detectable amount of the substance and a second calibration value indicative of the presence of the detectable amount of the substance; installing a sensor in a structure; exposing the structure to the substance; interrogating the sensor to retrieve the sensed value; and detecting the presence of the substance in the structure as a function of the sensed values relative to the first and second calibration values.

As shown in fig. 19, a building may include a sheathing system including at least two panels 300 and a seaming component 320 configured to provide a seam at an interface between at least two of the panels 300. As described herein, environmental sensor components can be disposed on or in one or more interior wall panels, exterior jackets, or ceiling panels, with the location of such components externally indicated by visual indicators 350, 352. In particular, such panels with environmental sensor assemblies may be used in sheathing or roofing systems where improved water resistance is desired, such that water penetration may be detected quickly and efficiently.

In certain embodiments, the seaming component in such systems comprises tape or a bonding material. For example, the seaming component may be a tape comprising a solvent acrylic adhesive, a tape having a polyethylene top layer with a butyl rubber adhesive, a tape having an aluminum foil top layer with a butyl rubber adhesive, a tape having a polyethylene top layer with a rubber asphalt adhesive, or a tape having an aluminum foil top layer with a rubber asphalt adhesive. For example, the seaming component may be a bonding material such as synthetic limestone, cement paste, synthetic acrylic, sand filled acrylic, solvent based butylene, polysulfide, polyurethane, silicone, silyl modified polymer, water based latex, EVA latex, or acrylic latex. Thus, the panels may be fitted with tape, liquid polymer or other suitable material to effectively treat potential water and air intrusion areas such as seams, door/window openings, penetrations, roof/wall interfaces and wall/foundation interfaces. Thus, when used in combination with suitable seaming components, the building sheathing panels may create an effective waterproof and/or air barrier envelope.

Thus, in certain embodiments, the building construction panels, materials, and underlayments described herein are configured to detect moisture, temperature, or pressure on a roof, on other external building components, on external building components covered with other covering films, within a roof or wall, and within a building envelope. The system is configured to detect environmental conditions that may lead to degradation of the rooftop system or other building components. Thus, the systems described herein may advantageously provide early detection of moisture intrusion before damaging the roof, floor, walls, or other areas of the building system.

Instead of manually inspecting roofs and/or other panels as is conventional, the use of a reader as described herein will reduce or eliminate the labor associated with inspection. The reader may be hand-held or may be attached to a drone that transfers the reader from tag to tag (i.e., sensor assembly to sensor assembly). Alternatively, the reader is a rooftop or other location mounted electrically powered reader (such as those used in highway and DOT applications) that reads the tags and relays the information to the intelligent building control system over the internet or similar system. In addition to exterior sheathing and roofing applications, panels and sensors may also be used in the interior of buildings to identify moisture intrusion anywhere within the building, including mold and mildew resistant foundation applications behind shower and tile floors and/or on or behind exterior sheathing.

In certain embodiments, the methods and systems for detecting environmental conditions further include identifying the building panel or portion of the building panel on which the condition was detected, such as by the visual indicators discussed herein. The method may further comprise repairing the construction panel or the portion of the panel identified as damaged. For example, such systems and methods may enable building owners to make real-time determinations when their roofs, walls, floors, etc. are damaged in a manner that may affect energy efficiency, water intrusion, or other performance characteristics. For example, typical moisture intrusion problems may take up to a year or more to detect, which may require replacement of a large number of building panels. In contrast, once a portion of the panel is affected, the disclosed system will identify moisture intrusion issues. Thus, these systems allow only a portion of a panel or a single panel to be repaired or replaced. Similarly, temperature issues that can lead to degradation of the panel core material can also be detected in real time.

In addition, the panel of the present invention eliminates the need for wired sensors and sensors containing microcontrollers, where the amount of labor involved in programming and installation is very high. In these wired implementations, a technician with microcontroller/PLC programming knowledge would have to program the system to operate. The present system will be plug-and-play in nature and any programming can be done prior to panel installation in the form of a GUI (graphical user interface) that will integrate with existing facility management software. In systems with stationary readers, such as commercial buildings, the readers advantageously can be connected to the building network and kept together by the building engineer with other facility systems (e.g., HVAC, fire, lighting, occupancy control).

Examples

Building panels and representative samples with the environmental sensor assemblies were fabricated and subjected to various performance tests.

First, a sample build panel is prepared in which the environmental sensor assemblies are located at various locations within the panel, including within or on a surface of the panel core (e.g., between the panel core and the facing material) and on an outer surface of the panel. These panel samples were exposed to typical panel handling and installation conditions and coated with exemplary coating materials such as solvent-based and water-based adhesives and hot asphalt. It has been observed that sensor assemblies located on the surface of the panel are more susceptible to damage from handling. In addition, the binder and asphalt are observed to cause damage to the sensor assembly, which prevents accurate readings of conditions such as temperature and moisture. In contrast, sensor assemblies located in or on the surface of the panel core (inside the entire panel) do not suffer from these problems.

These panels are then tested to determine if any differences in the accuracy of the detection of the moisture condition of the panels by the sensor assemblies are present in the sensor assemblies located in or on the surface of the panel core (i.e., in the panel) versus on the outer surface of the panel. Specifically, water droplets are placed directly on the sensor assembly disposed on the outer surface of the panel and the panel is tested for percent free moisture readings at both the outer and inner panel sensors. Generally, the surface sensor reads a "very wet" condition, although the moisture saturation of the panel itself is not changed. Embedding the sensor assembly in the panel core correlated well with the percent free moisture and the laboratory moisture meter. That is, falsely high readings are obtained from localized surface wetting in the sensor assembly located on the outer panel surface, while the embedded sensor assembly more closely replicates the true moisture content of the panel.

Next, the sample panel with the internally embedded RFID sensor was completely immersed in water for approximately 6 hours. Both the internal sensor assembly and the laboratory moisture meter read the panel moisture content readings every 5 minutes to determine the relative accuracy of the embedded sensor assembly. The results of this test are shown in fig. 27, which is a regression plot of the laboratory sensor (labeled "sensor" in the figure) and the embedded RFID readings. Coefficient of correlation (R)²) The content was 72.6%. Can be used forAs can be seen, the embedded RFIC sensor assembly is significantly prone to laboratory moisture meter readings.

Next, four combined sample panels with sensor assembly arrangements and panel surface adhesive exposure were tested. Condition 1 includes a sensor assembly positioned on an exterior surface of the panel in direct contact with the solvent-based adhesive. Condition 2 includes a sensor assembly positioned on the outer surface of the panel in direct contact with the water-based adhesive. Condition 3 includes the sensor assembly at the opposite surface of the sample panel (to represent the sensor assembly within the core or otherwise spaced from the outer surface exposed to the adhesive), where the opposite surface is exposed to the solvent-based adhesive. Condition 4 relates to the sensor assembly at the opposing surface, wherein the outer surface is exposed to the water-based adhesive. After curing the adhesive for one week, a moisture reading of the RFID sensor assembly is taken. Fig. 28 is a graph showing the sensor codes detected in these samples. Sensor codes of about 30 or higher are "dry" with decreasing codes indicating higher and higher moisture content. It can be seen that sensor assemblies positioned in direct contact with solvent-based adhesives show significant read changes, possibly due to interference from the chemistry of the adhesive. The sensor assembly representing the internally disposed sensor assembly and exposed to the solvent-based adhesive performed best. Accordingly, construction panels of the present disclosure that require an exterior film or other exterior coating or covering may utilize solvent-based adhesives to apply such films, coatings or coverings. Sensor assemblies exposed to water-based adhesives perform better than assemblies in direct contact with solvent-based adhesives, where the sensor assemblies in direct contact with water-based adhesives perform slightly worse than "internal" sensor assemblies.

Next, the sample panel including the RFID sensor assembly was tested for accuracy of sensor readings (measured using a handheld reader and a fixed sensor reader) relative to laboratory moisture meter readings. Specifically, 30 samples were heated in an oven to remove all free moisture. The samples were then removed from the oven and their dry weight recorded. RFID sensor code readings for water content were obtained using a NORDIC ID Merlin 1 hand-held 1 watt RFID tag reader and a FEIG ELECTRONICS fixed tag reader (reader ID MAX.U1002-FCC and Antenna ID ISC.ANT.U600/270-FCC Antenna UHF). A laboratory moisture meter was also used to take moisture readings and record the moisture readings for comparison. The sample was immersed in water for 5 hours and then removed. Swatches were patted dry using paper towels. The samples were re-weighed and the sensor code read and recorded using Nordic and FEIG systems, along with the moisture meter reading. The immersion, patting and code reading were repeated at intervals of 24 hours, 48 hours and 120 hours. Fig. 25 is a graph showing fixed reader code readings and free moisture weight percent (as measured by a moisture meter). Fig. 26 is a graph showing a handheld reader code reading and a free moisture weight percent (as measured by a moisture meter). Generally, a free moisture content of 0-2% is considered a dry panel, a free moisture content of 2% -6% is considered a wet panel, and a free moisture content of 6% or higher is considered a wet panel. As can be seen from the results, the fixed reader gave more consistent results with the laboratory tester, indicating on average the correct moisture status at each level (dry, wet).

Thus, it has been demonstrated that an environmental sensor assembly can be associated with a building panel (e.g., embedded in or associated with a panel core) to provide a useful reading of environmental conditions, such as moisture, at the panel. It was found that a sensor assembly disposed within the core showed improved performance and accuracy.

While the disclosure has been described in connection with various embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims (20)

1. A construction panel comprising:

a panel having a first outer surface and an opposing second outer surface, the panel comprising a panel core and having a first surface and an opposing second surface;

at least one environmental sensor assembly associated with the panel core and configured to detect an environmental condition of the panel including moisture, pressure, or both, and wirelessly communicate data regarding the environmental condition to a reader; and

at least one visual indicator positioned on the first outer surface of the panel, each of the at least one visual indicators indicating a location of each of the at least one environmental sensor assemblies,

wherein the at least one environmental sensor assembly is self-supporting, passive, and includes an antenna, a processing module, and a wireless communication module, and

wherein the at least one environmental sensor component is embedded within a body of the panel core, disposed between layers forming the panel core, or disposed between the first surface of the panel core and a panel facing material.

2. The construction panel of claim 1, wherein the panel core comprises a gypsum panel core.

3. The construction panel according to claim 2, wherein:

the gypsum panel core comprises a first gypsum layer and a second gypsum layer, the first gypsum layer comprises a slate coating layer, and

the at least one environmental sensor assembly is disposed between the first gypsum layer and the second gypsum layer.

4. The construction panel according to claim 3, wherein the first gypsum layer is present in an amount of from about 2% to about 20% by weight of the gypsum panel core.

5. The construction panel according to claim 1, wherein:

the panel further comprises the panel facing material comprising a fiberglass facing mat, and

the at least one environmental sensor assembly is disposed between the first surface of the panel core and the fiberglass facing mat.

6. The building panel as described in claim 1 wherein the at least one visual indicator comprises a score or a mark.

7. The construction panel according to claim 1, wherein the at least one environmental sensor assembly comprises a plurality of environmental sensor assemblies spaced apart from each other by a distance of about 1 foot to about 4 feet.

8. The panel of claim 1, wherein the at least one environmental sensor component comprises a passive radio frequency identification sensor.

9. A system for detecting an environmental condition at a panel, the system comprising:

at least one of the building panels according to any one of claims 1 to 9; and

at least one reader for receiving data wirelessly transmitted from the at least one environmental sensor assembly.

10. The system of claim 9, further comprising a processing unit, wherein the reader is configured to transmit the data regarding the environmental condition to the processing unit, and the processing unit is operable to determine at least one condition state at the at least one environmental sensor assembly from the data.

11. The system of claim 9, wherein the at least one reader comprises a hand-held manual reader or a stationary powered reader positioned at or near the at least one building panel.

12. A method of detecting an environmental condition, the method comprising:

providing at least one of the building panels according to any one of claims 1 to 9; and

wirelessly transmitting data regarding the environmental condition from the at least one environmental sensor component to a reader.

13. The method of claim 12, further comprising:

communicating the data regarding the environmental condition to a processing unit; and

determining, at the processing unit, at least one condition state at the at least one environmental sensor assembly.

14. The method of claim 12, wherein the environmental condition comprises moisture.

15. The method of claim 14, further comprising repairing the building panel or a portion of the building panel where a moisture condition is detected.

16. The method of claim 15, further comprising identifying the portion of the building panel where the moisture condition is detected by positioning at least one visual indicator disposed on an outer surface of the panel, each of the at least one visual indicators indicating a location of an environmental sensor assembly within the building panel.

17. A method of manufacturing a building panel, comprising:

combining a panel core slurry and a panel facing material to form a panel core of a build panel, the build panel having a first outer surface and an opposing second outer surface, the panel core comprising a first surface and an opposing second surface, the first surface associated with the panel facing material;

disposing at least one environmental sensor component within the panel core slurry or between the panel core slurry and the panel facing material; and

associating at least one visual indicator with the first outer surface of the building panel such that each of the at least one visual indicators indicates a location of each of the at least one environmental sensor assemblies,

wherein the at least one environmental sensor assembly is configured to detect an environmental condition of the panel including moisture, pressure, or both, and wirelessly transmit data regarding the environmental condition to a reader,

wherein the at least one environmental sensor assembly is self-supporting, passive, and includes an antenna, a processing module, and a wireless communication module.

18. The method of claim 17, wherein associating the at least one visual indicator with the first exterior surface of the building panel comprises marking or scoring the first exterior surface of the building panel.

19. The method of claim 17, wherein associating the at least one visual indicator with the first outer surface of the building panel is performed according to the steps of: the method includes combining the panel core slurry and a panel facing material to form a panel core from which the panel is constructed, and disposing at least one environmental sensor component within the panel core slurry or between the panel core slurry and the panel facing material.

20. The method of claim 17, wherein associating the at least one visual indicator with the first exterior surface of the building panel comprises metal detection of the at least one environmental sensor assembly.

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