ES2927029T3 - Building panel with sensor assembly - Google Patents

Abstract

Building panels and other materials, methods for their manufacture, and systems and methods for controlling environmental conditions with such panels are provided in this document. The panels include at least one environmental sensor assembly associated with a panel core and configured to sense an environmental condition of the panel comprising humidity, pressure, or both, and wirelessly communicate data about the environmental condition to a reader. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Building panel with sensor assembly

Countryside

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

Background

Drywall panels, exterior building cladding, flooring, decking and other construction panels can be exposed to extreme environmental conditions including humidity, wind and extreme temperatures during and after construction. Also, such systems can be installed incorrectly, so that the joints between the panels are not completely sealed. In addition, veneer and cover panels installed around windows, scuppers, parapets, and other openings and areas of the building can be particularly vulnerable to environmental damage.

When moisture intrusion and/or panel degradation or destruction occurs due to these conditions, it often goes undetected for a period of time, usually until visually observed. Additionally, leaks and/or degradation that may not be visible through typical inspection methods may never be detected. Therefore, such damaging conditions, as well as mold and mildew resulting from water infiltration, can escalate to easily avoidable levels due to a lack of early detection systems for these problems.

For example, in environments exposed to sub-zero temperatures, water seeping into a decking or clad panel can undergo multiple freeze-thaw cycles, thereby causing separation of the panel's core and scrim cladding. fiberglass and associated membrane (eg, building envelope), if present. Once separation of the mesh liner has occurred, wind uplift causes further separation of the mesh liner, sometimes resulting in ballooning of the mesh liner.

US 2018/002916 A1 discloses a building panel comprising: a panel having a first surface and a second opposing surface; and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate environmental condition data to a reader, wherein the environmental sensor assembly is self-supporting and comprises an antenna, a processing and a wireless communication module, wherein the environmental sensor assembly is configured to detect a panel environmental condition selected from a group consisting of humidity, temperature, and pressure.

Accordingly, it would be desirable to provide building panels and other building materials that have sensors to detect environmental conditions in or on the panel/structure, to monitor and prevent damage to such materials.

Resume

In one aspect, building panels are provided according to claim 1.

In another aspect, systems for sensing an environmental condition in a panel are also provided, including at least one of the building panels and at least one reader for receiving wirelessly communicated data from the at least one environmental sensor assembly.

In yet another aspect, methods for sensing an environmental condition are provided, including providing at least one of the building panels and wirelessly communicating environmental condition data from the at least one environmental sensor assembly to a reader.

In yet another aspect, methods of manufacturing a building panel are provided, including combining a panel core grout and a panel facing material to form a panel core having a first surface and an opposing second surface, being associated with the first skin surface of the panel, and disposing at least one environmental sensor assembly within the panel core grout or between the panel core grout and the panel skin material, wherein the at least one environmental sensor configured to detect an environmental condition of the panel including humidity, pressure, or both, and wirelessly communicate environmental condition data 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.

Brief description of the drawings

Referring now to the drawings, which are intended to be exemplary and not limiting, and in which similar elements are numbered in the same manner. The detailed description is established with reference to the accompanying drawings which illustrate examples of the disclosure, in which the use of the same reference numerals indicates similar or identical elements. Certain embodiments of this disclosure may include elements, components, and/or configurations other than those illustrated in the drawings, and some of the elements, components, and/or configurations illustrated in the drawings may not be present in certain embodiments.

Figure 1 is a schematic, partial side elevational view illustrating portions of a manufacturing line for producing gypsum board of a type suitable for use in the manufacture of ready-to-use gypsum boards in accordance with the present disclosure;

Figure 2 is an enlarged partial sectional view, taken as indicated to the left of Figure 1, of an underlying fiberglass scrim used in the manufacture of gypsum board;

Figure 3 is a partial plan view taken as indicated by the line 3--3 in Figure 2;

Figure 4 is a sectional view on an enlarged scale taken as indicated to the right in Figure 1 and illustrating both the underlying and overlying fiberglass scrims, with an intermediate gypsum composition, used in the manufacture of the board;

Figure 5 is a partial plan view taken as indicated by the line 5--5 in Figure 4;

Figure 6 is a partial bottom view taken as indicated by the line 6--6 in Figure 4 and illustrating the lower surface of the underlying mesh of the board;

Figure 7 is a cross-sectional view of an edge portion of the complete board, this view being taken as indicated by the line 7--7 in Figure 4;

Figure 8 is another partial sectional view on an enlarged scale taken as indicated towards the top of Figure 4;

Figure 9 is another partial sectional view on an enlarged scale taken as indicated towards the bottom of Figure 4;

Figure 10 is a partially broken away, sectional perspective view of an exemplary flat roof system incorporating a panel in accordance with the present disclosure;

Figure 11 is a sectional view on an enlarged scale taken along the line 11--11 of Figure 10; Figure 12 is a greatly enlarged sectional view of the circled area of Figure 11 showing the penetration of the first asphalt layer into the fibrous top surface of the panel in accordance with the disclosure;

Figure 13 is a perspective view of another type of roof system that incorporates the panel according to the disclosure as the main support layer;

Figure 14 is a sectional view taken along line 14--14 of Figure 13;

Figure 15 is a partially broken away, sectional perspective view of a composite wall structure employing the panel in accordance with the disclosure;

Figure 16 is a greatly enlarged view of the encircled portion of Figure 15 showing the penetration of the render layer into the fibrous surface of the panel;

Figure 17 is a cross-sectional view of a building panel;

Figure 18 is a cross-sectional view of a building panel;

Figure 19 is a perspective view of a building cladding system having air barrier and water resistant properties;

Figure 20 is a plan view of an environmental sensor assembly;

Figure 21 is a perspective view of a flat roof assembly;

Figure 22 is a partial perspective view of a flat roof assembly;

Figure 23 is a cross-sectional view of a building material or panel; Y

Figure 24 is a cross-sectional view of a subfloor for flooring.

Figure 25 is a graph showing sensor code reading versus percent free moisture, by weight, measured in the Examples.

Figure 26 is a graph showing the portable sensor code reading versus percent free moisture, by weight, measured in the Examples.

Figure 27 is a graph showing a regression curve of the sensor against the RFID readings, as measured in the Examples.

Figure 28 is a graph showing the sensor codes for various combinations of adhesives and sensor locations on the Example samples.

Detailed description

Disclosed herein are building construction panels and materials, as well as methods for making and using such panels and materials, and systems for their use. The panels and materials described herein may be panels for internal or external construction applications such as wallboard, external veneers, ceiling and flooring boards, rain and sound attenuation sheeting, and other wall applications. building. For example, the panels described herein may be external gypsum veneer panels, such as those described in US Patent Application Nos. 15/014,793 and 15/014,922, entitled "Gypsum Panels, Systems, and Methods." ". For example, the panels described herein can be fiber-reinforced gypsum boards containing cellulosic fibrous material, such as those described in US Patent Nos. 6,893,752, 8,070,895, 6,342,284, 6,632,550, 7,244,304, 7,425,236, 7,758,980. , 7,964,034, 8,142,914, and 8,500,904.For example, the panels described herein may be flat roof panels, such as those described in US Patent No. 5,319,900. For example, the panels described herein may be isocyanurate panels or similar insulating type, such as those described in US Patent No. 7,612,120. For example, the panels described herein may be made of plywood, oriented strand board (OSB) or other wood-based panels known in the construction industries. For example, the materials of construction described herein may be polymeric rainscreens or sound attenuating sheets, such as those described in US Patent Nos. 9,157,231 and 7,861,488. For example, the panels or construction materials described herein can be gypsum and/or concrete flooring subfloors, such as those described in US Patent No. 7,651,564. In general, this disclosure is directed to various building materials and panels for internal and/or external building applications, for commercial and/or residential applications, wherein the building materials and/or panels contain environmental sensors configured to detect a or more environmental conditions of the surrounding panel, material, or structure with which it is associated.

Panels and building materials

Generally, the panels and other construction materials may include any suitable construction or configuration known in the industry. For example, the panels may be panels that contain gypsum as a significant component of the panel core (eg, in amounts up to 90 percent, by weight, or more) or they may be panels that contain gypsum as a component of the panel core. in combination with other components (for example, in amounts less than 90 percent). Examples of other components that may be present in the panel core include cellulose or other fibers.

In addition, while the present disclosure is generally directed to building boards that include a gypsum core or skin, other boards may suitably substitute for gypsum board, such as wood-based, foam-based, and other boards. materials that are suitable for the purposes of building construction described herein. That is, while various embodiments of the present disclosure are described or illustrated with reference to gypsum board, it is to be understood that the gypsum core and other features of the board could be replaced with suitable components of these other types of boards or building materials. In particular, such panels and other materials are described in the documents mentioned in the previous paragraphs. For example, these panels and sheets may include any suitable panel core (for example, one or more layers that form the structural core of the panel) together with any suitable skin material or other outer skin material, as will be described herein. .

In certain embodiments, such as that shown in Figure 23, a building panel 2300 includes a panel (for example, a panel core 2301 formed from one or more layers of a panel core material 2308, with or without skin material). ) having a first surface 2307 and an opposing second surface 2309, and an environmental sensor assembly 2320, 2322, 2324 associated with panel 2300 and configured to sense an environmental condition of panel 2300 and wirelessly communicate environmental condition data to a reader, where the environmental sensor assembly is self-supporting and comprises an antenna, a processing module and a wireless communication module. For example, as discussed above, the board may be selected from gypsum board, fiber reinforced gypsum board, isocyanurate board, wood-based board, or other known construction boards. For example, a building material may also be provided, such as various building sheets or other structures including, but not limited to, a polymeric rainscreen, a polymeric sound attenuation sheet and a polymeric cover drain sheet, which have an environmental sensor assembly associated therewith. For example, such sheets may be roll materials that are cut to size. As shown in Figure 23, the environmental sensor assembly (several illustrated assemblies, shown as 2320, 2322, 2324) can be placed in or on any suitable surface (internal or external) of the panel or material. For example, the environmental sensor assembly may be disposed on an outer surface or edge of the panel or within or on a surface of the panel. For example, in panels that have a skin material, a panel skin, or multiple layers that form the core of the panel, the environmental sensor assembly may be disposed internally, ie, between two layers of the panel.

For example, in a gypsum board, such as a fiber-reinforced gypsum board, the environmental sensor assembly may be disposed on an external surface or edge of the panel or within or on a surface of the panel. For example, in gypsum boards that have a face material, a board skin, or multiple layers that form the core of the board, the environmental sensor assembly may be disposed internally, ie, between two layers of the board. Thus, according to the invention, a building panel includes a panel core and at least one environmental sensor assembly associated with the panel core. For example, in isocyanurate panels, the environmental sensor assembly may be disposed on an external surface or edge of the panel or within, such as between several layers or on a surface of the panel. For example, in wood-based panels, the environmental sensor assembly may be arranged on an external surface or edge of the panel or within, such as between several layers or on a surface of the panel. For example, in a polymeric sheet, such as a sound attenuating sheet, a roof drainage sheet, or a rain screen, the environmental sensor assembly can be disposed on an external surface or between various layers of the sheet.

In certain embodiments, as shown in Figure 24, a flooring underlayment 2400 is provided, and includes a gypsum and/or concrete underlayment material 2401 (eg, a pour-in-place or other suitable underlayment material configuration formed by one or more layers of subfloor material 2408 over a floor substrate 2430) and an environmental sensor assembly 2420, 2422, 2424 associated with the subfloor material and configured to sense an environmental condition of the subfloor and wirelessly communicate data about the subfloor. environmental condition to a reader, wherein the environmental sensor assembly is self-supporting and comprises an antenna, a processing module, and a wireless communication module. For example, the subfloor may have a first surface 2407 and an opposing second surface 2409. For example, the environmental sensor assembly 2420, 2422, 2424 may be disposed within or on a surface of the gypsum and/or concrete subfloor material.

In certain embodiments, as shown in Figure 17, a panel 1000 includes a panel core 101 having a first surface and an opposing second surface, and a first skin material 104 associated with the first surface of panel core 101. For example, the lining material can be any suitable lining material known in the art, including paper and fibrous lining materials. In certain embodiments, as shown in Figure 17, the lining material 104 is a fibrous material, such as fiberglass. Therefore, although certain embodiments herein are described with reference to fiberglass scrim, it is to be understood that any suitable paper or other fibrous scrim material liner may be substituted and fall within the scope of the disclosure.

In certain embodiments, as shown in Figure 17, a gypsum board 1000 includes a gypsum core 101 having a first surface and an opposing second surface, and a first facing material 104 associated with the first surface of the gypsum core. 101. For example, the liner material can be any suitable liner material known in the art, including paper and fibrous liner materials. In certain embodiments, as shown in Figure 17, the lining material 104 is a fibrous material, such as fiberglass. Therefore, although certain embodiments herein are described with reference to fiberglass scrim, it is to be understood that any suitable paper or other fibrous scrim material liner may be substituted and fall within the scope of the disclosure.

In certain embodiments, the facing material is a nonwoven fibrous web formed from fiber material that is capable of forming a strong bond with the core material of a building panel through a mechanical interlock between the interstices of the lining. fibrous mesh and portions of the core material. Examples of fiber materials for use in nonwoven webs include mineral-type materials such as glass fibers, synthetic resin fibers, and mixtures or combinations thereof. Both chopped strands and continuous strands can be used.

In certain embodiments, the facing material is a non-woven fiberglass scrim. For example, the glass fibers may have an average diameter of about 1 to about 17 microns and an average length of about 1.59 mm (1/16 inch) to about 25.4 mm (1 inch). For example, glass fibers may have an average diameter of 13 microns (ie, K fibers) and an average length of 19.05 mm (% inch). In certain embodiments, the nonwoven fiberglass mats have a basis weight of from about 0.68 kg (1.5 pounds) to about 1,814 kg (4.0 pounds) per 9.29 m2 (100 square feet). ) of the mesh. Each of the scrims may have a thickness from about 10 mm (mils) to about 50 mm (mils). The fibers can be bonded together to form a unitary mesh structure by means of a suitable adhesive. For example, the adhesive can be a urea-formaldehyde resin adhesive, optionally modified with a thermoplastic extender or crosslinker, such as an acrylic crosslinker or acrylate adhesive resin.

In certain embodiments, as shown in Figures 2 and 3, scrims of coating material 6 and 16 contain fiberglass filaments 30 oriented in a random pattern and bonded together with a resin binder (not shown). One embodiment of fiberglass scrim faced gypsum board 40 is shown in Figures 4 and 7, in which the set gypsum of core 42 penetrates substantially through the thickness of scrim 6 over substantial area portions thereof and in which the set gypsum of the core 42 partially penetrates the mesh 16, thus leaving the surface substantially free of set gypsum. The gypsum-free surface of mesh 16, as seen in Figure 8, is highly textured and provides an excellent substrate for adhering an overlay component to as it contains many interstices into which a material can flow and bond. adhesive composition.

In certain embodiments, the panels have a thickness of from about 0.0762 µm to about 0.3048 µm (/ inch to about 1 inch). For example, the panels may have a thickness of from about 0.1524 µm to about 0.1905 µm (from / inch to about 5/8 inch).

In some embodiments, as shown in Figure 17, the gypsum crystals of the gypsum core 101 penetrate a remaining portion of the first fiberglass mat 104 such that voids in the first fiberglass mat 104 are substantially eliminated and the water resistance of panel 1000 is further improved. For example, in one embodiment, the first fiberglass 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 fiberglass mat. 104, to define the remaining portion of the first glass fiber mat 104. That is, the gypsum crystals of the gypsum core 101 penetrate a remaining fibrous portion of the first glass fiber mat 104 in such a way that the voids in the first fiberglass mesh 104 they are substantially eliminated. As used herein, the phrase "such that voids in the fiberglass mat are substantially eliminated" and similar phrases refer to the gypsum slurry (eg, a slate layer) that fills all or nearly all of the interstitial volume of the fiberglass mat that is not filled with the coating material.

As used herein, the term "continuous barrier coating" refers to a coating material that is substantially uninterrupted over the surface of the fibrous web. The continuous barrier coating on the outer surface of the liner can be any suitable coating known in the art. For example, the coating can include a binder material and, optionally, a filler. For example, the coating may include a resin or polymer-based binder material together with one or more inorganic fillers.

In certain embodiments, as shown in Figure 17, the gypsum core 101 includes two or more layers of gypsum 102, 108, while in other embodiments the gypsum core includes a single layer of gypsum. For example, the gypsum core may include several layers of gypsum having different compositions. In some embodiments, the first layer of plaster 102 that is in contact with the fiberglass mat 104 (i.e., the layer that forms a contact surface with the coating material and penetrates at least partially into the remaining fibrous portion of the first fibrous mat) is a layer of slate. In some embodiments, the first plaster layer 102 is present in an amount of from about 2 percent to about 20 percent, by weight, of the plaster core 101. The various plaster layers are shown as separate layers in the figures. for ease of illustration; however, it should be understood that overlapping of these materials must occur at their contact surfaces.

Gypsum core layers can be similar to gypsum cores used in other gypsum products, such as gypsum wallboard, gypsum wallboard, gypsum board, gypsum lath, and gypsum veneer. 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 slurry of gypsum, and then allowing the slurry mixture to hydrate. or set in calcium sulfate dihydrate, a relatively hard material. In certain embodiments, the gypsum core includes about 80 weight percent or more set gypsum (ie, fully hydrated calcium sulfate). For example, the gypsum core may include about 85 weight percent set gypsum. In some embodiments, the gypsum core includes about 95 weight percent set gypsum. The gypsum core may also include a variety of additives, such as accelerators, set retarders, foaming agents, and dispersing agents.

In certain embodiments, as shown in Figure 18, a gypsum board 200 includes two skins 204, 212 that are associated with the gypsum core 201. As with the first skin material, the second skin material can be any suitable covering material, such as paper or fibrous materials. In certain embodiments, both skins 204, 212 are fiberglass scrims. The second fiberglass mat 212 is present on a face of the gypsum core 201 opposite the first fiberglass mat 204. In some embodiments, only the first fiberglass mat 204 has a continuous barrier coating 206 on a surface thereof. In other embodiments, both fiberglass scrims 204, 212 have a coating 206, 214 on a surface thereof opposite gypsum core 201. In some embodiments, gypsum core 201 includes three layers of gypsum 202, 208, 210. One or both of the layers 202, 210 that are in contact with the fiberglass mats 204, 212 may be a slate cover layer.

As shown in Figure 17, gypsum panels according to the present disclosure may have a first surface 107 of the panel 1000 formed by the first facing material 104 and/or a continuous barrier coating 106 thereon. Gypsum board 1000 also has a second panel surface 109 opposite the first surface 107.

In certain embodiments, as shown in Figures 10-14 and 21-22, the panel may be a flat top panel. For example, installing a flat roof system in building construction typically involves constructing a frame to support a building's roof; attaching corrugated sheets to the frame to provide a surface for supporting the other components of the flat roof system; attach flat support elements to the corrugated sheets; and affixing to the planar support members an exterior finish material having good weather resistance properties. Flat roof systems including insulation panels sandwiched between the aforementioned corrugated sheets and flat support members are also widely used. Such systems are designed to be insulating in nature and weather resistant. Such flat roof systems can be used to advantage to conserve energy used for heating and to conserve energy used for air conditioning. More specifically, such flat roof systems typically include corrugated metal sheets that are mechanically attached, typically by screws or bolts, to appropriate structural members of the building, such as steel beams. Corrugated sheet metal supports the weight of the components that rest on it, including insulation material (when used), flat support members, and trim material. Insulating panels of low density and light weight, such as expanded polystyrene, polyisocyanurate and the like, are widely used in such systems, especially in colder climates. Flat support members typically include drywall and are held in place by mechanical fasteners, such as screws, to the underlying corrugated sheet metal. When insulation boards are used, they are sandwiched between the underlying corrugated sheet metal and the overlaying drywall. An exterior finish material, such as a rubber or polymeric membrane or alternating layers of asphalt and roofing felt, overlies the drywall panels.

A typical flat roof system system incorporating gypsum board faced with fibrous scrims as described above is shown in Figures 10 through 12. In this construction, the parallel spaced trusses 50 extending between the support members of the building (not shown) support a corrugated metal support plate 52 that is welded or otherwise attached to the trusses. Layers 54 and 56 of insulating sheet material, which can be, for example, polyisocyanurate, are arranged on the corrugated metal support plate. A layer 58 of fibrous scrim faced gypsum board panels of the type described above is attached to the corrugated backer board 52 by means of through fasteners 60 through the underlying insulation layers 54 and 56 to the backer board. 52. The joints of the panel layer 58 are sealed by applying tape 62, as shown in Figure 10 with respect to one of the panel joints. Supported over the gypsum layer 58 is a waterproof roofing membrane including alternating layers of asphalt 64 and roofing felt 66, three layers of each being shown in the present example. A final asphalt coating 68 is covered with a finishing layer of crushed gravel 70.

In the enlarged view of Figure 12, the manner in which the first layer of asphalt 64 penetrates the upward facing side of the fibrous mat of the layer of gypsum board panels 58 is illustrated. secure adhesion of the waterproof membrane to the structural layers of the roof system.

In some embodiments, as shown in FIG. 21, the flat roof system 150 incorporating the gypsum panels having the environmental sensor assembly includes a gypsum roofing board/panel, as top skin 158, bottom skin 154, or both, as well as insulation 156, and sheathing. deck or membrane 160, mounted on a steel, wood or other support plate 152 (shown as steel). In some embodiments, as shown in Figure 22, the flat roof system 162 incorporating the gypsum boards having the environmental sensor assembly is a single layer membrane system. For example, the system may include at least a gypsum deck panel 166, 170, insulation 168, and a single layer membrane 172 (eg, EPDM or thermoplastic membrane). Various embodiments of such roofing systems using gypsum roofing panels are known in the art and the present disclosure is intended to cover any suitable system configurations or designs incorporating the gypsum panels described herein. For example, the roofing system may incorporate suitable asphalt, EPDM, Turbo Seal, CSPE, modified bitumen, PVC, cold liquid membranes, FTPO, TPO, coal aggregate pitch, or other composite roofing constructions, among others.

Referring to Figures 13 and 14, a poured-in-place flat roof system is shown including purlins 72 supporting spaced secondary purlins (bulbhead T-sections 74 in parallel spaced relationship). Fibrous scrim faced gypsum board panels 76 of the type described above are supported by horizontal flanges 74a of secondary purlins 74. A reinforcing mesh 78 is placed over the secondary purlins and gypsum board panels 76 and a slurry coat of hardening gypsum 80 is poured over the reinforcing mesh. The grout 80 is allowed to harden to form a smooth and continuous deck surface 82 . Adhesion of the grout to the gypsum board panel 76 is ensured by penetration of the grout into the upward facing fibrous mesh surface of the panels. A roofing membrane including alternating layers of asphalt 84 and roofing felt 86, three layers each in the illustrated example, is applied to the surface 82. A final layer of asphalt 88 is covered with a layer of crushed rock or gravel. 90.

With regard to interior trim systems for use in a building, the installation of such a system generally involves the construction of a frame to support the interior walls of a building; and attaching to the frame flat support members that provide a smooth continuous surface for supporting an interior trim material having aesthetic and durability properties. Such systems are designed to be strong and durable and to withstand abuse during building occupancy. An example of interior use of this panel with fiber mesh siding is illustrated in Figures 15 and 16. In these views, an interior wall system includes spaced upright studs 92 to which fiber mesh gypsum board panels 94 are attached by spaced fasteners 96 such as screws or nails. A thin layer 98 of plaster is applied to the fibrous mesh surface 100 of panel 94 and smoothed to form a smooth finished surface which can then be decorated with paint, paper or the like in a conventional manner. As shown in the enlarged view of Figure 16, the plaster 98 penetrates the fibrous mesh surface of the panel 94 to effect a secure mechanical bond of the plaster layer to the panel. Although shown in the context of a wall in Figure 15, panel 94 can equally well be used as a ceiling panel and can be used with a wood or metal joist support system. For some applications, it may be found that adjustments to the water resistant properties of the core are necessary to obtain a satisfactory plaster finish.

In exterior systems, veneer panels can be attached to an underlying support element in any suitable way, for example by using nails or screws. In such systems, the underlying support element may include, for example, rigid plastic panels or metal sheets, eg in corrugated form, purlins and secondary purlins. Panels of insulating material can be attached to said support members and to underlying panels of said panels, which are attached thereto. The support member is normally attached to the building structure.

In accordance with the invention, as shown in Figures 17 and 18, the gypsum board includes at least one environmental sensor assembly 120, 122, 124 associated with the gypsum board. Although three environmental sensor assemblies are shown in Figures 17 and 18, it is to be understood that a sensor assembly may alternatively be provided at one, two, or all of those locations, as well as other locations within and on the drywall. Additionally, as discussed in more detail below, a plurality of ambient sensor arrays can be provided, roughly equidistant from one another at similar positions along the length of a panel (for example, every 0.3048, 0.6096 , 0.9144 m or every 1.2 or 3 feet).

In one embodiment, the environmental sensor assembly is disposed on the 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 panel surface may be the outward facing panel surface during installation, while the second panel surface may be the inward facing panel surface during installation. In other examples, the environmental sensor assembly is disposed at an outer edge of the panel. According to the invention, the environmental sensor assembly 120, 122, 124 is arranged within or on a surface of the panel core. For example, the environmental sensor assembly can be placed on or adjacent to the siding material or another portion of the core material of the panel core, such as in the slate layer or another of the gypsum layers in a gypsum board. For example, the sensor assembly 120 is disposed between the first surface of the panel core 101/201 and the facing material (eg, the fibrous scrim 104). For example, sensor assembly 122 is embedded in panel core body 101/201. For example, sensor assembly 124 is disposed between first and second layers of plaster 102 and 108/202 and 208 that form the core of panel 101/201. In other examples, the environmental sensor assembly may be disposed on the surface of the coating material receiving a continuous barrier coating. Therefore, the environmental sensor assembly can be arranged in any suitable position on or within the panel, depending on the desired location and type of detection of environmental conditions and the particular application of the panel.

In accordance with the invention, the environmental sensor assembly is configured to detect an environmental condition of the panel or material with which it is associated and to communicate data relating to the environmental condition to a reader. According to the invention, the environmental sensor assembly is configured to detect one or more environmental conditions comprising humidity, temperature and/or pressure.

According to the invention, the environmental sensor assembly is self-supporting and includes a substrate on which an antenna, a processing module and a wireless communication module are arranged. As used herein, the term "self-supporting" refers to a sensor assembly that can function to sense target environmental conditions as an independent assembly, without the need for an external wired connection to the sensor assembly. As such, the environmental sensor assemblies described herein can be advantageously incorporated into panels or other materials in a variety of positions throughout the panel during manufacturing or on a construction site, without the need for additional labor or materials for wiring. or program the sensors. According to the invention, the environmental sensor assembly is a passive system. As used herein, the term "passive system" refers to the sensor assembly that does not have a battery and instead uses radio energy transmitted by a reader to power the assembly. Advantageously, passive systems can be used in applications where panels, materials, and/or sensor assemblies are essentially inaccessible, making replacement of the assembly or an associated battery impossible without damaging the building or building envelope. Also, because passive systems have no power supply and often have no moving parts, these assemblies can have an extremely long life that is at least equal to the typical life of panels or other building materials. . 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 one powered by solar energy.

In certain embodiments, the environmental sensor assembly is a passive ultra-high frequency single-chip sensor embedded system. In certain embodiments, the antenna is a resistor/inductor/capacitor (RLC) tuned circuit that can function to convert the environmental condition into an impedance change, and the processing module is coupled to the antenna and can function to translate the change. impedance into a sensor code by matching the antenna impedance to the input impedance. Therefore, while traditional sensors take advantage of changes in resistance to measure environmental variables, resulting in reduced tag read range due to power dissipated in the resistance, the capability of present sensor assemblies to use inductance or capacitance beneficially avoids problems with read range.

For example, the antenna may have an operable antenna impedance to vary as a function of environmental conditions. The processing module may be coupled to the antenna and include a tuning module operable to (i) vary the impedance of a reactive component to change a system impedance that includes the antenna impedance and the reactive component impedance, and ( ii) producing an impedance value representative of the impedance of the reactive component. The wireless communication module may be coupled to the processing module and operated to communicate the impedance value representative of the impedance of the reactive component to the reader, which represents the data on the environmental condition. In some embodiments, the environmental sensor assembly also includes a memory module that functions to store the impedance value representative of the impedance of the reactive component.

For example, the sensor assembly may be a passive radio frequency identification (RFID) sensor, such as the sensor described in PCT Application Publication No. WO2015/184460. As shown in Figure 20, this passive RFID sensor includes an antenna, a processing module, and a wireless communication module. The antenna has an antenna impedance that can 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 the impedance of a reactive component coupled to the antenna to change a system impedance that includes both the antenna impedance and the reactive component impedance. The tuning module then produces an impedance value representative of the impedance of the reactive component. A memory module can store the impedance value which can then be communicated to an RFID reader via the wireless communication module. The RFID reader can then exchange the impedance value representative of the reactive impedance components with the RFID reader in such a way that the RFID reader, or another external processing unit, can process the impedance value to determine environmental conditions. on the antenna.

Figure 20 is a view of one embodiment of a RFID moisture or condensation detection tag 3300. The moisture or condensation detection tag 3300 is a passive RFID tag having a substrate 2101, on which an integrated circuit ( IC) 2100. IC 2100 includes a memory module 2012, a wireless communication engine 2104, and a sensor engine 2106, including an antenna. The IC 2100 is capable of detecting a change in the environmental perimeters close to the IC 2100 through impedance changes associated with the antenna. The 2102 memory module is coupled with both the 2104 wireless communication engine and the 2106 sensor engine. The 2102 memory module is capable of storing information and data collected by the 2106 sensor engine and communicated through the communication engine. wireless 2104. In addition, the wireless communication engine 2104 and the sensor engine 2106 can be fully programmable through wireless methods.

Sensor impedance varies as the 3304 interdigitated capacitor coupling responds to environmental changes. In one embodiment, interdigitated capacitor 3304 is located near a film 3306 applied over interdigitated capacitor 3304. Film 3306 may be a material that has an affinity for water (i.e., moisture or condensation) or other fluids, such as CO, CO ² , Arsenic, H ² S or other known toxins or gases of concern. When the film 3306 absorbs a fluid such as those described above, the dielectric constant near the interdigitated capacitor 3304 changes causing a change in impedance. The impedance of the interdigitated capacitor 3304 detected by the processing module coupled to the sensor then produces an output, a sensor code, representative of the material absorbed within the film 3306. This data may be stored within a memory circuit of the IC 2100 or transmitted to an external reader via the wireless communication module of the IC 2100.

Therefore, in certain embodiments, when configured as a humidity sensor, the sensor assembly measures the presence of water when the surrounding environment becomes humid. The interdigitated capacitor experiences a significant change in capacitance, when it changes from dry to wet; the dipole antenna registers an impedance change depending on the amount of water in the capacitor; and the sensor IC converts this into a code indicating the amount of water present.

Advantageously, the sensor assemblies described herein can be small in size, such as about 10.16 cm by 2.54 cm (4 inches by 1 inch), and be very thin to provide additional nominal thickness when applied externally. to the panel or construction material.

According to the invention, as shown in Figures 17 and 18, the building panel contains at least one environmental sensor assembly 120, 122, 124, which is embedded or disposed within the panel (for example, between the core surface and the cladding material, between the layers that form the core of the panel or within the body of the core panel). In said embodiments, and according to the invention, the panel also has at least one visual indicator 121 placed on the first external surface of the panel (for example, on the surface covering 106/206), with each of the at minus one visual indicator indicating a location of an environmental sensor assembly within the panel. That is, the visual indicator 121 can be placed on the surface of the panel in line with one or more sensor assemblies embedded in the core of the panel. The visual indicator 121 can be any marking, indentation, raised element, etc. suitable. For example, the visual indicator may be a notch or a mark. Such visual indicators can beneficially provide builders with an indication of where such sensor arrays are located and therefore which areas of a panel should be avoided in order to drill, nail or otherwise penetrate the panel during installation. As mentioned herein, the sensors may be spaced at a constant distance along the panel, such as 0.3048m, 0.6096m, 0.9144m or 1ft, 2ft, 3ft, or others. spacings. Also, the visual indicators 121 may be similarly spaced. For example, the at least one environmental sensor assembly may include a plurality of environmental sensor assemblies spaced apart from about 0.3048 m to 1.2192 m or 1 foot to about 4 feet apart.

methods

Methods of construction materials and panel fabrication described herein are also provided. For example, gypsum board, fiber-reinforced gypsum board, isocyanurate board, polymeric rainscreen, polymeric sound attenuating sheet, polymeric roof drainage sheet, wood-based panel , flooring underlayment or other construction material may be made by any suitable means known in these industries. For example, as described above, the environmental sensor assembly can be associated with the panel, material, or subfloor during or after the manufacturing process. For example, the environmental sensor assembly may be embedded within a panel-forming material or other material, or it may be arranged between multiple layers (for example, layers that form the core of a panel, the skin, and/or the skin of the panel). panel) of the panel or material.

For example, in a gypsum board, the environmental sensor assembly can be associated with the board before or after the gypsum core has set. In certain embodiments, the environmental sensor assembly is placed in the gypsum slurry, eg, at, near, or away from the investment material, prior to setting. For example, the sensor assembly can be placed within or on a surface of the panel core grout during manufacture, or it can be placed between layers of the panel core (for example, between layers of grout, such as between layers of the panel). slurry of bottom plaster and layer of slate).

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

In some embodiments, a plurality of sensor assemblies are arranged along a length of material (for example, a paper backing, other membrane, fiberglass, or other nonwoven scrim) in the desired spacing pattern and rolled in a roll During manufacturing, the roll of sensor assemblies can be unrolled (for example, by means of a flap) at the desired location during manufacturing (for example, between the slate layer grouts and the bottom grouts (other plaster) or between the gypsum core and the investment material). In other embodiments, the sensor assemblies may be pre-applied to the interior face (eg, panel core skin) of the skin material. In another embodiment, the integrated circuit and/or sensor assembly antenna may be embedded within a fibrous mesh cladding material to increase the size of the antennas and the read range.

Alternatively, as discussed above with reference to Figures 13 and 14, a poured-in-place concrete or gypsum panel system can be used for deck or floor subfloor applications, where the environmental sensor assembly is applied during the process. of discharge in situ.

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

Methods for making gypsum boards having water resistant properties are also provided. In certain embodiments, during fabrication, a slurry of gypsum may be deposited on the uncoated surface of the facing material and set to form a gypsum core of the panel. When the facing material is a fibrous mesh, the gypsum slurry can penetrate some remaining fibrous portion of the thickness of the mesh (i.e., some portion of the mesh not yet penetrated by the coating) and provide a mechanical bond for the panel. The gypsum grout can be provided in one or more layers, with the same or different compositions, including one or more layers of slate coating. As used herein, the term "slate coating" refers to a gypsum slurry that has a higher wet density than the remainder of the gypsum slurry that forms the gypsum core. These methods can be used to produce gypsum board having any of the characteristics or combinations of characteristics described herein. Improved penetration of plaster into the fibrous mesh can be achieved by chemical modification of the plaster slurry, by applying a coating that improves penetration on the surface of the fibrous mesh in contact with the plaster 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 fiberglass mat, to define the remaining portion of the first fiberglass mat that is penetrated. the gypsum crystals from the gypsum core, such that voids in the first fiberglass mat are substantially eliminated.

In certain embodiments, the gypsum core includes multiple layers that are sequentially applied to the fiberglass mat and allowed to set sequentially or simultaneously. In other embodiments, the gypsum core includes a single layer. In some embodiments, a second fiberglass mat may be deposited on one surface of the final slurry coat (or the only gypsum slurry coat), to form a double-mat faced gypsum board. For example, the first and/or second fiberglass scrim may include a barrier coating on its surface that penetrates a portion of the scrim. The gypsum slurry or multiple layers thereof may be deposited onto the fiberglass scrim by any suitable means, such as roller coating.

In some embodiments, the gypsum core includes at least three gypsum layers, with the outermost gypsum layers of the gypsum core (ie, the layers that form a contact surface with the fiberglass mats). In certain embodiments, both outermost layers are chemically altered to improve penetration.

In certain embodiments, the first and/or second fibrous mats are already coated upon contact with the gypsum slurry (or other panel core). In some embodiments, the methods include applying the continuous coating to the first and/or second fibrous mats, either before or after contacting the mats with the panel core grout. In certain embodiments, the application of the barrier coating includes spray coating, tape coating, curtain coating, knife coating, or direct roll coating. In some embodiments, the barrier coating is applied to each of the first and/or second fibrous mats in an amount of from about 453.6 g (1 pound) to about 4.08 kg (9 pounds), per 9, 29 m2 (100 square feet). For example, the barrier coating can be applied to the first and/or second fibrous web in an amount of about 907.2 g (2 pounds) to about 3.63 kg (8 pounds) per 9.29 m2 (100 square feet). In other embodiments, the coated fibrous meshes can be obtained in a pre-fabricated form.

In some embodiments, the method also includes mechanically vibrating at least the first fiberglass mat having the first gypsum slurry deposited to effect penetration of the gypsum slurry into the remaining fibrous portion of the first fiberglass mat. .

In certain embodiments, the panel core grout (or layers thereof) may be deposited on the uncoated side of a horizontally oriented moving band of pre-coated fibrous scrim. A second coated or uncoated fibrous mat may be deposited on the surface of the panel core grout opposite the first coated fibrous mat, for example, an uncoated surface of the second coated fibrous mat contacts the core grout panel. In some embodiments, a movable web of a precoated or uncoated nonwoven fibrous scrim may be placed on the top free surface of the slurry of the panel core. Therefore, the core material of the panel can be sandwiched between two fibrous scrims, one or both of which have a barrier coating. In certain embodiments, allowing the panel core material and/or continuous barrier coating to set includes curing, drying, such as in an oven or by other suitable drying mechanism, or allowing the material(s) to set at room temperature. (ie self harden).

In certain embodiments, as shown in Figures 1 to 9, the dry ingredients (not shown) from which the gypsum core is formed are pre-mixed and then fed to a mixer of the type commonly known as a pin mixer. 2. The water and other liquid constituents (not shown) used in making the core are metered into the pin mixer 2 where they are combined with the dry ingredients to form an aqueous gypsum slurry. The slurry 4 is dispersed through one or more outlets at the bottom of the mixer 2 onto a moving sheet of fibrous mesh 6. The fibrous mesh sheet 6 has an indefinite length and is fed from a roll (not shown) of mesh. . In certain embodiments, the two opposing edge portions of the fibrous mesh 6 are progressively flexed upward from the median plane of the mesh 6 and then turned inward at the margins to cover the edges of the resulting board 40. In Figure 1 , this progressive bending and shaping of the edges of the mesh 6 is shown for only one lateral edge of the mesh and the conventional guide devices normally used for this purpose are omitted from the figure for the sake of clarity. Figure 7 shows an edge of the set gypsum core 42 covered by the overlapping edge portion 6A of the mesh 6. Figure 7 also shows the score notches 10 and 10A of the mesh 6, the score notches allowing the formation of good edges and flat surfaces. Scoring slits 10 and 10A are made with a conventional scoring wheel 12. One advantage of using fiberglass scrim is that it can be scored and edged like conventional paper liner.

Another fibrous scrim sheet 16 is fed from a roll (not shown) over the top of the slurry 4, thus sandwiching the slurry between the two moving fibrous scrims that form the slurry. Meshes 6 and 16 with slurry 4 sandwiched between them enter the nip between the upper and lower forming rolls 18 and 20, and thereafter they are received on a conveyor belt 22. Conventional edge-guiding devices, as indicated at 24, shape and hold the edges of the composite until the plaster has set sufficiently to retain its way. In due course, sequential lengths of the board are cut and further processed by exposure to heat, which speeds up the drying of the board by increasing the rate of evaporation of excess water in the gypsum slurry.

Referring to Figure 7, it has been found that the set gypsum of the core 42 is effective in forming satisfactory bonds with the plates and between the edge portions of the upper plate 16 and the overlapping edge portion 6A of the underlying plate 6, so it is unnecessary to use a grout bond improver or edging paste to form the aforementioned joints.

In accordance with the invention, the method of manufacturing the panel includes associating a self-supporting environmental sensor assembly with the panel. For example, the environmental sensor assembly can be any suitable assembly described herein, such as those that include an antenna, a processing module, and a wireless communication module, and configured to sense an environmental condition of the panel and communicate wirelessly. wireless data about the environmental condition to a reader

In accordance with the invention, the methods include associating a visual indicator of the location of the sensor assembly with the panel. For example, marking, scoring, or other methods of creating the indicator can be done in-line, with the help of metal detection from sensor assemblies, or can be created at regular intervals corresponding to the regular intervals at which the sensor assemblies were known to have been spaced apart. In other embodiments, the indicators may be pre-printed into the liner material or other external surface of the panel to correspond to a known pattern of placement of the sensor assemblies.

Applications

Also provided herein are systems and methods for detecting an environmental condition in a panel or other construction material. In certain embodiments, a system includes at least one of the building panels, flooring materials or subfloors described herein along with at least one reader for receiving wirelessly communicated data from the environmental sensor assembly. In certain embodiments, a system includes at least one panel containing an environmental sensor assembly, as described herein, and at least one reader for receiving wirelessly communicated data from the environmental sensor assembly. In certain embodiments, a method of monitoring an environmental condition of a panel includes providing at least one panel having an associated environmental sensor assembly, sensing an environmental condition of the panel via the environmental sensor assembly, and wirelessly communicating data about the environmental condition from the environmental sensor assembly to a reader.

The reader can be any suitable wireless sensor reader known in the art. For example, the reader may be a portable handheld reader. In other embodiments, the reader is a stationary powered reader mounted on a building containing at least one panel, material, or subfloor. For example, a stationary powered reader can be located on or adjacent to the panels, or it can be located some distance away (for example, 3 to 30.48 m (10 to 100 ft), such as 3 to 15.24 m ( 10 to 50 ft), as 25 to 30 ft (7.62 to 9.14 m)) of panels. For example, in a building that contains one or more panels that have environmental sensor assemblies installed as a flat roof, interior/exterior veneer panels, mesh, or other structural panels, a powered reader may be mounted in one or more locations on and/or or around the building to continuously or intermittently monitor the status of the environmental sensor assemblies. In certain embodiments, a building control system is provided for receiving information from readers. In some embodiments, a reader may be mounted on a drone that is configured to approach the at least one panel to receive wirelessly communicated data from the environmental sensor assembly. In certain embodiments, the detection data is digitized and communicated wirelessly to commercially available readers using a standard UHF Gen 2 protocol READ command for further processing.

In certain embodiments, the system also includes a processing unit and the reader is configured to communicate environmental condition data to the processing unit, and the processing unit may function to determine at least one condition status in the set. of the environmental sensor from the data. For example, the reader can be configured to communicate the impedance value representative of the impedance of the reactive component to the processing unit, such that the processing unit can operate to determine at least one state of the condition in the sensor assembly. from the impedance value representative of the impedance of the reactive component.

In certain embodiments, the system includes an integration service that allows programming of the sensors without requiring complex IT infrastructure and middleware. For example, the integration service can provide a repository of all sensor tag related data, such as sensor range and calibration data, which can be securely accessed by authorized web services and applications, a repository measurement data related to sensor-tagged panels and a decision flow engine, for example, so that if a sensor-tagged panel exceeds a preset level (for example, a preset humidity level), a notification is sent by SMS/email to a service technician.

In certain embodiments, raw data is collected from these sensors via the reader for processing to be performed by a data processing unit where calculation is performed to determine a humidity or temperature measurement. Also, referring to Fig. 20, the wireless communication engine 2104 and the sensor engine 2106 can be fully programmed through wireless methods. The passive RFID sensors of Figure 20 can be implemented as an intelligent sensor array (eg, multiple sensor arrays in one or multiple panels installed at a single site) to collect data that can be sent back to a central processing unit. Another embodiment provides an environmental detection method for use in an RF system that includes the steps of: calibrating an RF sensor by developing a first calibration value indicative of the absence of a detectable amount of a substance and a second calibration value indicative of the presence of the detectable amount of the substance, installing the sensor in a structure, exposing the structure to the substance, interrogating the sensor to retrieve a sensed value, and detecting the presence of the substance in the structure based on the sensed value relative to with the first and second calibration values.

As shown in Figure 19, a building may include a cladding system that includes at least two panels 300 and a gasket component 320 configured to provide a gasket at a contact surface between at least two of the panels 300. The assemblies Environmental sensor panels may be provided in one or more boards for internal walls, external veneer or cover panels, as described herein, with the location of such assemblies indicated externally by visual indicators 350, 352. In particular, such panels having Environmental sensor assemblies can be useful in cladding or decking systems where it is desired to improve water resistance so that water infiltration can be detected quickly and efficiently.

In certain embodiments, the gasket component in such systems includes tape or a bonding material. For example, the bonding component can be a tape that includes solvent acrylic adhesives, a tape that has a polyethylene top layer with butyl rubber adhesive, a tape that has an aluminum foil top layer with butyl rubber adhesive, a tape having an EPDM top layer with butyl rubber adhesive, a tape having a polyethylene top layer with rubberized asphalt adhesive, or a tape having an aluminum foil top layer with rubberized asphalt adhesive. For example, the joint component can be a bonding material such as synthetic stucco plasters, cement mortars, synthetic acrylics, sand-filled acrylics, solventborne acrylics, solventborne butyls, polysulfides, polyurethanes, silicones, polymers, etc. modified with silyl, water-based latex, EVA latex, or acrylic latex. Therefore, the panels described above can be installed with either a tape, liquid polymer, or other suitable material to effectively treat areas of potential water and air intrusion, such as joints, door/window openings, penetrations, junctions. roof/wall, and wall/foundation junctions. As such, building veneer panels, when used in combination with a suitable joint component, can create an effective waterproof envelope and/or air barrier.

Therefore, in certain embodiments, the building construction panels, materials, and subfloors described herein are configured to sense moisture, temperature, or pressure on decks, on other exterior building components, on building components building exteriors covered with a membrane of another coating, inside roofs or walls, and inside the building envelope. The system is configured to detect environmental conditions that could lead to deterioration of roof systems or other building components. Therefore, the systems described herein can advantageously provide early detection of moisture intrusion before it damages the deck, floor, walls, or other regions of the building system.

Instead of traditional manual inspections of ceilings and/or other panels, the use of the readers described in this specification will reduce or eliminate the work associated with inspections. The readers could be portable or could be attached to a drone that would carry a reader from tag to tag (ie, from sensor array to sensor array). Alternatively, the reader would be a powered reader, such as those used in highway and DOT applications, mounted on a deck or other location that reads the tags and transmits the information via the Internet or a system similar to a vehicle control system. smart buildings. In addition to exterior and cladding applications, the panels and sensors could also be used inside the building, to identify moisture intrusion into any part of the building, including mold and mildew resistant basement applications, behind the shower and the tiled cloth and/or on or behind the exterior cladding.

In certain embodiments, methods and systems for detecting environmental conditions further include identifying a building panel or part of a building panel in which the condition is detected, such as through the visual indicators discussed herein. The methods may further include repairing the building panel or the portion of the panel identified as damaged. For example, such systems and methods can allow the owner of a building to determine in real time when his roof, walls, floors, etc. are damaged in a way that may affect energy efficiency, water intrusion, or other performance characteristics. For example, a typical moisture intrusion problem can take up to a year or more to detect, likely requiring the replacement of a significant number of building panels. Rather, the described systems would identify a moisture intrusion problem as soon as a portion of a panel is affected. As such, these systems allow only a section of a panel or a single panel to be repaired or replaced. Similarly, temperature issues, which can lead to degradation of panel core materials, can also be detected in real time.

In addition, the present panels eliminate the need for wired sensors and sensors containing a microcontroller, where the labor involved in programming and installation is very high. In these hardwired embodiments, a technician with knowledge of microcontroller/PLC programming would have to program the system to work. The current system will be virtually plug-and-play, 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 that have stationary readers, such as commercial buildings, the reader may advantageously be connected to the building network and maintained by a building engineer along with other facility systems (for example, HVAC, fire suppression, lighting, occupancy control).

examples

Representative building panels and samples having the described environmental sensor assemblies were fabricated and subjected to various performance tests.

First, sample building panels were prepared with environmental sensor assemblies located at various positions within the panel, including within or on a surface of the panel core (for example, between the panel core and a facing material) and on a external surface of the panel. These panel samples were exposed to typical panel handling and installation conditions, as well as coated with exemplary coating materials such as solvent-based and water-based adhesives and hot asphalt. Sensor assemblies located on the surface of the panels were found to be much more susceptible to damage from handling. In addition, the adhesives and asphalt were found to cause damage to sensor assemblies that prevented accurate readings of conditions such as temperature and humidity. In contrast, sensor assemblies located within or on a panel core surface (internal to the panel as a whole) did not suffer from these problems.

These panels were then tested to determine if there was any difference in the accuracy of the sensor assembly's detection of the panel's moisture condition over sensor assemblies located within or on a surface of the panel core (i.e. , inside the panel) versus on the outer surface of the board. Specifically, drops of water were placed directly on the sensor assembly disposed on the external surface of the panel and both the external sensor and the internal sensor of the panel were tested for the percentage free moisture reading of the panel. In general, surface sensors read as a "very wet" condition, even though the moisture saturation of the panel itself does not change. Embedding the sensor assembly in the core of the panel correlated well with percent free moisture and laboratory moisture meters. That is, falsely high readings were obtained from localized surface wetting on sensor assemblies located on the surface of the outer panel, while embedded sensor assemblies more closely replicated the actual moisture content of the panel.

The sample panels having internally embedded RFID sensors were then completely submerged in water for approximately 6 hours. Panel moisture content readings were taken every 5 minutes with both the internal sensor and a laboratory moisture meter to determine the relative accuracy of the embedded sensor assemblies. The results of this test are shown in Figure 27, which is a regression curve of the laboratory sensor (labeled "sensor" on the graph) versus the embedded RFID readings. The correlation coefficient (R2) was 72.6%. As can be seen, the embedded RFIC sensor arrays showed a significantly similar trend to the laboratory moisture meter readings.

Sample panels were then tested with four combinations of sensor assembly location and panel surface adhesive exposure. Condition 1 included a sensor assembly placed on the outer surface of the panel in direct contact with a solvent-based adhesive. Condition 2 included a sensor assembly placed on the external surface of the panel in direct contact with a water-based adhesive. Condition 3 included a sensor assembly on the opposite surface of the sample panel (to represent a sensor assembly within the core or otherwise detached from the external surface exposed to adhesive) with the opposite surface exposed to solvent-based adhesive. Condition 4 involved an opposite surface sensor mount with the outer surface exposed to the water-based adhesive. Moisture readings from the RFID sensor assemblies were taken after the adhesives had been allowed to cure for one week. Figure 28 is a graph showing the sensor codes detected in these samples. A sensor code of approximately 30 or above is "dry", with lower codes representing increasingly higher moisture content. As can be seen, sensor assemblies placed in direct contact with the solvent-based adhesive showed significant reading variation, possibly due to interference with the adhesive's chemistry. The sensor assembly representing the sensor assembly arranged internally and exposed to the solvent-based adhesive performed best. Therefore, building panels of the present disclosure that require an external membrane or other external coating or covering may use a solvent-based adhesive to apply said membrane, coating or covering. The sensor arrays exposed to the water-based adhesive performed better than the array in direct contact with the solvent-based adhesive, with the sensor array in direct contact with the water-based adhesive performing slightly worse than the "internal" sensor array. .

Sample panels containing RFID sensor assemblies (measured with a handheld reader and a fixed sensor reader) were then tested for accuracy relative to the reading of an RFID meter. laboratory humidity. 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 was documented. RFID sensor code readings for moisture content were taken using the NORDIC ID Merlin 1 1-watt portable RFID tag reader and the FEIG ELECTRONICS fixed tag reader (ID MAX.U1002-FCC Reader and ID ISC.ANT Antenna .U600/270-FCC Antenna UHF). Moisture readings were also taken using a laboratory moisture meter and documented for comparison. The samples were immersed in water for 5 hours and then removed. The samples were dried with paper towels. Samples were reweighed and sensor codes read and documented using the Nordic and FEIG systems along with moisture meter readings. Immersion, drying, and code readings were repeated at 24, 48, and 120 hour intervals. Figure 25 is a graph showing the fixed reader code reading versus percent free moisture (as measured by the moisture meter), by weight. Figure 26 is a graph showing the handheld reader code reading versus percent free moisture (as measured by the moisture meter), by weight. Generally, a free moisture content of 0-2% was considered a dry panel, a free moisture content of 2-6% was considered a wet panel, and a free moisture content of 6% or more was considered a wet panel. As can be seen from the results, the fixed reader gave more consistent results with the laboratory meter, indicating on average the correct moisture condition at each level (dry, humid, wet).

Therefore, it has been shown that environmental sensor assemblies can be associated with a building panel (eg, embedded in or associated with the core of a panel) to provide useful readings on environmental conditions, such as humidity, in the environment. panel. Sensor assemblies provided within the core were found to show better performance and accuracy.

While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the invention is not limited to such disclosed embodiments. Rather, the invention may be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not disclosed herein, but which are within the scope of the invention defined by the appended claims. Furthermore, 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 should not be limited by the above description, but is limited only by the scope of the appended claims.

Claims (15)

1. A building panel (2300), comprising: a panel (300, 1000) having a first outer surface and an opposite second outer surface, the panel (1000) comprising a panel core (101, 201, 2301) and the panel core having a first surface (107, 2307). , 2407) and a second opposite surface (109, 2309, 2409); at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) associated with the panel core (101,201,2301) and configured to detect an environmental condition of the panel (300, 1000 ) comprising humidity, pressure, or both, and wirelessly communicating data about environmental conditions to a reader; wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is self-supporting, passive, and comprises an antenna, a processing module, and a wireless communication module, wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is embedded within a panel core body (101, 201, 2301), disposed between layers (54, 56, 58, 102, 108, 202, 208, 210) that form the core of the panel (101,201,2301), or arranged between the first surface of the core of the panel (101, 201, 2301) and a material of panel cladding, and wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) preferably comprises a passive radio frequency identification sensor, characterized in that The building panel further comprises at least one visual indicator (121, 350, 352) positioned on the first external surface of the panel (300, 1000), each of the at least one visual indicators (121, 350, 352) indicating ) a location of each of the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424), wherein the at least one visual indicator (121, 350, 352) preferably comprises a slit or mark. The building panel (2300) of claim 1, wherein the panel core (101,201,2301) comprises a gypsum board core. The building panel (2300) of claim 2, wherein: the gypsum board core comprises a first gypsum layer (102, 108) and a second gypsum layer (202, 208), the first gypsum layer (102, 108) comprising a slate coating layer, and The at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is arranged between the first (102, 108) and the second plaster layers (202, 208), in particular , wherein the first layer of gypsum (102, 108) is present in an amount of about 2 percent to about 20 percent, by weight, of the gypsum board core. The building panel (2300) of claim 1, wherein: the panel (300, 1000) further comprises the panel facing material, which comprises a fiberglass facing scrim, and the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is arranged between the first surface (107, 2307, 2407) of the panel core (101,201,2301) and fiberglass lining mesh. The building panel (2300) of claim 1, wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) comprises a plurality of sensor assemblies. environmental (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) separated from each other at a distance of approximately 0.3048 m to 1.292 m. 6. A system for detecting an environmental condition in a panel (300, 1000), comprising: at least one of the building panels (2300) of any of claims 1 to 5; Y at least one reader for receiving wirelessly communicated data from the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424), wherein the at least one reader preferably comprises a stationary powered reader placed on or near at least one building panel (2300) or a portable handheld reader. The system of claim 6, further comprising a processing unit, wherein the reader is configured to communicate environmental condition data to the processing unit, and the processing unit is operable to determine at least one status. condition on the at least one environmental sensor set (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) from the data. 8. A method for detecting an environmental condition, comprising: providing at least one of the building panels (2300) of any one of claims 1 to 5; Y wirelessly communicating environmental condition data, such as humidity, from at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) to a reader. The method of claim 8, further comprising: communicate environmental condition data to a processing unit; Y determining, in the processing unit, at least one condition state in at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424). The method of claim 8, further comprising repairing the building panel (2300) or a portion of the building panel (2300) in which a wet condition is detected. The method of claim 10, further comprising identifying the portion of the building panel (2300) where the moisture condition is detected by locating at least one visual indicator (121, 350, 352) positioned on an external surface of the panel (2300), each of at least one visual indicator (121, 350, 352) indicating the location of an environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) inside the building panel (2300) . 12. A method for manufacturing a building panel (2300), comprising: combining a panel core grout and a panel cladding material to form a panel core (101, 201, 2301) of a building panel (2300) having a first external surface and an opposed second external surface, comprising the panel core (101, 201, 2301) a first surface (107, 2307, 2407) and an opposing second surface (109, 2309, 2409), the first surface (107, 2307, 2407) being associated with the skin material panel; dispose at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) within the panel core grout or between the panel core grout and the panel facing material ; Y associating at least one visual indicator (121,350, 352) with the first external surface of the building panel (2300), such that each of the at least one visual indicator (121, 350, 352) indicates a location of each of the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424), wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is configured to detect an environmental condition of the panel (300, 1000) comprising humidity, pressure, or both. , and wirelessly communicate environmental condition data to a reader, wherein the at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) is self-supporting, passive, and comprises an antenna, a processing module, and a wireless communication module. The method of claim 12, wherein associating the at least one visual indicator (121,350, 352) with the first external surface of the building panel (2300) comprises scoring the first external surface of the building panel (2300). . The method of claim 12, wherein associating the at least one visual indicator (121,350,352) with the first outer surface of the building panel (2300) is performed in line with the steps of blending the panel core grout. and a panel skin material for forming a panel core (101, 201, 2301) of a building panel (2300) and arranging at least one environmental sensor assembly (120, 122, 124, 2320, 2322, 2324, 2420, 2422, 2424) within the panel core grout or between the panel core grout and the panel facing material. The method of claim 12, wherein associating the at least one visual indicator (121,350, 352) with the first external surface of the building panel (2300) comprises metal detecting the at least one environmental sensor assembly (120). , 122, 124, 2320, 2322, 2324, 2420, 2422, 2424).