Construction Panels With Integrated Environmental Sensor Assemblies

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Solution Overview

Problem

Building construction panels and materials are often exposed to extreme environmental conditions, leading to moisture intrusion and degradation issues that go unnoticed until significant damage occurs, due to the lack of early detection systems.

Innovation Solution

Integration of self-supporting environmental sensor assemblies within or on the panels, comprising an antenna, processing module, and wireless communication module, to detect moisture, pressure, or both, and wirelessly communicate data to a reader, enabling early detection of potential damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional construction panels without sensors are used, then the device complexity is low and manufacturing cost is reduced, but the ability to detect environmental conditions and prevent damage is insufficient

Engineering Contradiction:

Improvedamage detection capabilityVSAvoidpanel structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor assembly is integrated directly into the construction panel, merging the structural function of the panel with the detection function of the sensor. This allows the panel to simultaneously serve as both building material and monitoring device, improving reliability without proportionally increasing overall system complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The construction panel is designed to perform multiple functions: structural support, environmental sensing (moisture, temperature, pressure), and wireless communication. This multi-functionality allows a single component to address multiple needs, improving damage detection capability while managing complexity through functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of information

If sensor assemblies are integrated into panels, then real-time monitoring of environmental conditions is enabled, but the manufacturing process and installation complexity increase

Engineering Contradiction:

Improveenvironmental condition detectionVSAvoidpanel manufacturing ease

Core Design Contradiction:

Loss of informationVSEase of manufacture

Solution Approach 1:

The sensor assembly is pre-integrated into the panel during manufacturing, with the sensor positioned in optimal locations for detecting environmental conditions. This preliminary integration ensures that detection capabilities are built-in from the start, enabling real-time monitoring without requiring complex post-installation setup

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor assembly is designed to be self-contained and self-configuring, with automatic calibration and wireless communication capabilities that eliminate the need for complex manual configuration during installation. This self-service approach reduces installation complexity while maintaining comprehensive environmental condition detection

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10400452B2Construction panels, materials, systems, and methods

Publication Date: 2019.09.03 GEORGIA PACIFIC GYPSUM LLC

AI summary

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include at least one environmental sensor assembly associated with a panel core and configured to detect an environmental condition of the panel comprising moisture, pressure, or both, and wirelessly communicate data on the environmental condition to a reader.