Sensor-Integrated Insulated Panels for Structural Feedback and Lighting

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Solution Overview

Problem

Current building envelope methodologies lack integrated components for feedback and functionality beyond thermal insulation, necessitating improved insulated panels with sensors and light devices for structural monitoring and lighting.

Innovation Solution

Incorporation of sensors (pressure, temperature, humidity, etc.) and light devices within insulated panels, along with panel hubs for communication and energy transfer, enabling feedback and lighting integration, and utilizing AI/ML for optimized operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If sensors and light devices are integrated into insulated panels, then functionality and feedback capability are improved, but device complexity increases

Engineering Contradiction:
ImprovefunctionalityVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates sensors, light devices, and communication modules directly into the insulated panel structure, combining multiple functions (thermal insulation, sensing, lighting, communication) into a single unified component. This merging approach improves versatility while managing complexity through integration rather than separate components.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The insulated panels are designed to perform multiple functions simultaneously: thermal insulation, structural support, sensor housing, light emission, and wireless communication. This multi-functionality approach allows a single component to replace multiple separate systems, improving adaptability while the integrated design helps manage the inherent complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Loss of information

If panel hub communication system is implemented, then feedback capability is improved, but device complexity increases

Engineering Contradiction:
Improvefeedback capabilityVSAvoiddevice complexity
Core Design Contradiction:
Loss of informationVSDevice complexity

Solution Approach 1:

The panel hub system implements feedback loops where sensors continuously monitor environmental conditions (temperature, humidity, structural integrity) and communicate data through the hub network to building management systems. This enables real-time monitoring and automated responses, improving feedback capability while the standardized hub protocol helps manage communication complexity.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The panel hub acts as an intermediary device that mediates communication between sensors, light devices, and central building management systems. This intermediary layer simplifies the communication architecture by providing a standardized interface and protocol, reducing the complexity of direct point-to-point connections while enhancing feedback capability.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If AI/ML analysis is utilized for optimization, then operational efficiency is improved, but loss of time for data processing increases

Engineering Contradiction:
Improveoperational efficiencyVSAvoiddata processing time
Core Design Contradiction:
ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary data processing and analysis using AI/ML algorithms to predict future conditions and optimize operations in advance. By analyzing historical and real-time sensor data beforehand, the system can proactively adjust building operations (lighting, HVAC, security) to optimize efficiency before conditions change, reducing real-time processing delays.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The AI/ML analysis operates continuously in the background, constantly processing sensor data and optimizing building operations without interrupting normal functions. This continuous analysis allows the system to maintain optimal performance over time while distributing processing load, thereby improving operational efficiency without significant time loss.

Inventive Principle:
Principle #20Continuity of useful action

Data Source

PatentUS20250237054A1Insulated panels with sensors and light devices, insulated panel network systems, and methods of manufacturing the insulated panels and utilizing the insulated panel network systems
Publication Date: 2025.07.24 NUCOR INSULATED PANEL GROUP LLC
  • US20250237054A1 patent drawing
  • US20250237054A1 patent drawing
  • US20250237054A1 patent drawing

AI summary

Insulated panels with sensors (e.g., pressure, temperature, humidity, gas, wind, or the like) allow for feedback regarding the structure and/or the conditions around the structure in order to allow for identifying potential issues and taking actions with respect to such potential issues. The insulated panels with light devices allow for incorporation of lighting within the insulated panels to provide exterior and/or interior lighting of the structure. The sensors and/or light devices of the insulated panels may communicate with each other through the use of panel hubs that allow signals (e.g., wired, wireless, or the like) to be transferred between insulated panels and/or with a primary hub using an insulated panel network system for monitoring and operating components of the structure. Improved manufacturing processes are provided that allow for manufacturing the insulated panels with sensors, light devices, and/or the panel hubs, and electrical connections therebetween.