RFID-BASED MOISTURE-SENSING AND LEAK-DETECTION FOR BUILDING STRUCTURES AND METHODS OF USE

Abstract

The inventive disclosures pertain to an improved moisture-sensing insulation panel for use in building structures that features enhanced leak-detection and analytical capabilities. The improved system features RFID-enabled moisture-sensing elements contained in a moisture-sensing membrane, and can measure impedance changes across the moisture-sensing membrane. In some variations, the system is designed to detect and measure moisture leakage and structural loading by way of biplanar capacitance measurements. RFID tags for moisture sensors are read by drones or robots and wirelessly transmitted to the Cloud/Internet for remote data analytics.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the priority benefit of U.S. Patent Application No. 63/000,606, filed on Mar. 27, 2020, for “RFID-Based Moisture-Sensing and Leak Detection for Building Structures and Methods of Use.” In addition, this patent application hereby incorporates by reference U.S. Patent Application No. 63/000,606. For claim-construction purposes, if there are any irreconcilable differences between the disclosures in the present patent application and U.S. Patent Application No. 63/000,606, then the disclosures of the present patent application shall govern.

BACKGROUND

The mechanical integrity of a building structure can be severely compromised by water infiltration, and the health of building occupants may be negatively impacted by the long-term persistence of moisture within occupied spaces due to the accumulation of mold, mildew, etc. Passive methods of leakage and moisture protection inherently carry risk because any evidence of dampness or wetness within a building structure almost always is detected only after the damage has already been done.

Exterior insulation and finish systems (EIFS) are a general class of non-load-bearing building-cladding systems that provides exterior walls with an insulated, water-resistant, finished surface in an integrated composite material system. EIFS first gained use in North America during the 1960s and grew in popularity because of the energy crisis of the 1970s, but water-infiltration problems in early EIFS resulted in costly litigation. This led to the development of drainable EIFS with a drainage plane located behind the insulation layer to prevent the build-up of excessive moisture within the system. Drainable EIFS is superior to traditional stucco and face-sealed EIFS in terms of mitigating the moisture that infiltrates the exterior cladding of a building.

FIG. 1A depicts an isometric rendering of a typical current-art EIFS installation (adapted from a drawing available on https://www.brickface.com/opt-eifs-siding/) as viewed from the exterior side, where the underlying wall is represented by wooden framing members and gypsum panel; however, the framing may be steel or other structural material and the paneling may instead be a poured-concrete or preformed masonry wall (i.e., cinder blocks and mortar). The moisture-barrier membrane in such current-art systems may be both waterproof and vapor-permeable, or may be waterproof and non-vapor permeable, depending on the climate where the structure is located. In commercial EIFS, the membrane is typically fluid-applied. Examples of some of the systems available on the market include DriVit Backstop®NT™ and BASF Senershield-VB®. At the lower edge of the panel in a typical commercial exterior insulation & finish system (EFIS) is flashing and a drainage track to carry away excess water. The basecoat strips are applied over the barrier membrane with a notched trowel, and this serves as an adhesive onto which the expanded polystyrene (EPS) or extruded polystyrene (XPS) insulating panel is installed. The notched trowel forms drainage channels in the basecoat, creating a drainage plane through which excess water can flow by gravity so that moisture does not build up within the EIFS installation. Alternately, to create the drainage plane, the facing surface of the EPS or XPS insulating panels may have vertically-oriented channels pre-cut into the foam material, which is a feature normally provided by the foam-panel manufacturers. The basecoat is coated over a strengthening mesh, and, in turn, this is covered with the final finishing coat to create a relatively lightweight, yet strong, exterior finish for the building. The installed configuration of EIFS depends on the construction specifications as well as the manufacturer and system that is used.

Excess moisture build-up within the EIFS system can lead to the formation of mold and fungus that could result in a so-called ‘sick building’ creating a health hazard to the occupants. Drainable EIFS solves the moisture-retention issues when the manufacturer's installation instructions and guidelines are followed, but the effectiveness of the drainage plane is still largely dependent upon the skill and competence of the installers, and if done improperly, the EIFS installation may be compromised. In the current art, as represented by commercially-available EIFS systems, once installed, there is no way to check whether the EIFS drainage plane is functioning correctly. This is a glaring weakness in current-art EIFS systems.

Moisture may build-up within the cladding and structure materials if the function of the EIFS drainage plane is compromised either by poor installation practices that clogs the drainage channels with excessive adhesives, or by foreign material that clogs the drainage channels, or by excessive water infiltration through the EIFS cladding that can occur from poor workmanship and/or materials. This is especially true along joints formed by decks and roofing, and at fenestrations from windows and doors. Since the introduction of drainable EIFS, the risk of a compromised installation has been shifted away from the manufacturer and towards the installation contractors.

Installation contractors, the installation methods used by those installation contractors, and the materials used for EIFS are imperfect. Therefore, it must be assumed that water will enter every EIFS installation at some point:

• • It is impossible to install sealants perfectly 100% of the time for all joints.
  • The use of an incorrect diameter of backer rod can cause improper gapping.
  • Surface contamination cannot always be removed correctly, leading to poor adhesion.
  • Over the passage of time, cracks may appear in the EIFS installation from thermal and mechanical cycling of the structure.
  • Water may enter the drainage plane at imperfections, such as between the EIFS and lamina, at the window frames, through balcony elements, at railings, at doors, at service penetrations, and from the roofing system.

Excess moisture that builds-up within the cladding and the underlying structure may damage the underlying structure and cause material deterioration from mold, decay, loss of strength, dimensional instability and corrosion. Excessive moisture may lead to:

• • Mold growth on gypsum board and fiberglass cavity insulation materials; and/or
  • A loss of cohesive strength in gypsum boards and oriented strand board (OSB) sheathing; and/or
  • The corrosion of metal studs leading to a discoloration of material surfaces; and/or
  • Dimensional instability from the loss of cohesive and adhesive properties of sealant-lamina interfaces, leading to cracks, gaps, and other openings.

Currently, there is no way to easily monitor the drainage plane of an EIFS installation without physically drilling into the cladding to make measurements using a hand-held moisture-measurement instrument. The effectiveness of this method is quite limited because it can only spot-check a few locations within an installation. Typically, this type of measurement is made initially during the inspection of new EIFS installations, or forensically, after moisture damage to the structure has already occurred. The reality of this limitation is reflected by the existence of specific EIFS insurance (see “Why You Should Opt for EIFS Siding,” available at https://www.eima.com/eifs-insurance) that may be purchased by EIFS contractors to cover the potential liability arising from EIFS installations.

In U.S. Pat. No. 7,768,412 to Vokey, a moisture-monitoring system for buildings is described that uses externally-switched moisture-detecting sensors, and a method for isolating the location of a leak and calculating the severity of the water infiltration is also described. However, the Vokey system is discretely applied with a plurality of individual wiring connections to a building structure and is therefore non-intrinsic to the building envelope, necessitating additional effort to install and verify the system's integrity. Furthermore, the Vokey system requires that an external computerized Supervisory Control and Data Acquisition (SCADA) system be installed within the monitored structure to switch the sensors and determine the location and severity of any detected leakage.

What is needed is an improved EFIS that integrates a moisture-sensing device into the insulation panel and uses self-powered, passive wireless RFID technology to read data that represents the state of moisture within the EIFS drainage plane.

BRIEF SUMMARY

The inventive disclosures contained herein are designed to address limitations associated with the buildup of excessive moisture within the EIFS drainage plane. Moisture-sensing elements are integrated directly into the proximal (inward-facing) surface of the insulation board material, and the electronic-nature of the detection technology may allow the improved insulation panel to become ‘smart’ and respond to the presence of water and/or moisture within the drainage plane of the EIFS installation.

In embodiments, the configuration of the improved EFIS installation exists as a stand-alone intrinsic moisture-sensing panel, optimized to accommodate the EIFS installation environment, requiring little to no differences in the installation protocols presently used by the contracting construction trades. A method is also revealed for how the data may be wirelessly and securely acquired from the EIFS insulating panel using passive RFID that requires no internal power source, and then transmitted to a cloud-based application that may be used to perform predictive analytics. The improved moisture-sensing EIFS panel and data acquisition and processing method provides the following advantages:

• • Having an integrated sensing apparatus with the insulating panel provides an EIFS installation with intrinsic moisture-monitoring capability without the need for installing discrete sensors and the associated externally-wired power and measurement connections;
  • Exploiting the inherent capabilities of low-cost and miniaturized RFID technology allows the EIFS insulation panel itself to become a moisture-sensing device that functions as a so-called edge device in the IoT (Internet of Things);
  • Moving the computational process to a cloud-based application eliminates the need to install and connect a complex computerized SCADA system within the monitored structures to switch between sensors to read and process the data;
  • The RFID-based IoT edge-device for the cloud-based application provides both the moisture-sensing and leakage-location method, and allows trends to be exploited by predictive analytics that can be used to bring a potentially compromised EIFS installation to the attention of stakeholders;
  • Machine-learning AI (Artificial Intelligence) can be employed within the cloud-based application to continuously improve predictive performance by learning to recognize data patterns that lead to trouble, and this predictive capability will improve as the volume of data continues to grow across multiple installations; and
  • The simplified and reduced-cost system provides building owners with the benefits of a low-cost continuously or semi-continuously monitored moisture-sensing system within the exterior cladding of their building, and the peace-of-mind that goes with it.

The moisture-sensing elements is an improvement over the configuration revealed by U.S. Pat. No. 5,648,724 to Yankielun et al. (“Yankielun”) for “Metallic time-domain reflectometry roof moisture sensor,” which prescribes that a transmission-line sensor be embedded within a medium having a dielectric constant that changes in the presence of water. However, the moisture-sensing elements in the present inventive disclosures have been adapted for integration within an insulation board to provide an EIFS insulation panel with stand-alone intrinsic moisture sensing capability.

In an embodiment, the sensing device is a composite membrane in the form of a strip of metalized polymer material placed within a recessed channel on the proximal surface of the insulation panel onto which a moisture-wicking layer has been placed, with another metalized polymer strip placed over the proximal surface of the wicking layer, where the wicking layer between the metalized strips forms a dielectric. The electrical impedance between the two parallel metalized areas of this composite membrane is then used to sense the presence of moisture by measuring the biplanar capacitance, the electrical resistance, or both the biplanar capacitance and electrical resistance. The stack of layers are bonded together through friction-welding or by an adhesive process.

In another embodiment, the layer of wicking material is first placed within a recessed channel on the proximal surface of the insulation panel, and a polymer layer that has two parallel metalized areas is then placed over the proximal surface of the first wicking layer, and over the polymer layer with the two metalized areas, a second wicking layer is placed. The electrical impedance between the two parallel metalized areas of this composite membrane is then used to sense the presence of moisture by measuring the coplanar capacitance, the electrical resistance, or both the coplanar capacitance and electrical resistance.

In other embodiments, there are additional strips of composite membrane in an additional channel or channels with different geometric orientations placed on the proximal surface of the insulation panel. In still another embodiment, the entire plane of the proximal surface of the insulating board is covered by a layer of the composite moisture-sensing membrane.

In most applications, passive ultra-high frequency (UHF) Radio Frequency Identification (RFID) sensor tags are used to excite the capacitive or resistive sensing elements within the composite moisture-sensing membrane to measure the presence of moisture.

In other embodiments, a plurality of discrete passive UHF RFID tags based on resistive/inductive/capacitive (RLC) impedance of the RFID sensor antenna are integrated within the insulating panels. Tags based on RLC impedance make use of specially-designed RFID sensor chips or simply use standard retail RFID chips that are adapted to the dielectric constant of the material that they are installed into. These RLC impedance-based sensor tags do not require direct contact with water to sense the presence of moisture below the membrane. Because of the sensitivity of RLC impedance-based RFID sensor tags to the materials they are installed into, a baseline calibration is needed to calibrate the dry condition of the sensor tags.

In many embodiments, the discrete or panel-integrated RFID sensor tags are used to provide data to determine whether moisture is present within an EIFS drainage plane, and the unique digital code associated with each RFID tag allows the panel where the moisture is detected to be identified, thereby allowing the location of the moisture within an EIFS installation to be determined. This information is wirelessly transferred to an RFID reader and from the reader, in some variations, the data is uploaded directly to a cloud-based application, while in other variations, the data is sent to the internet via a wireless router and then on to the cloud-based application. The cloud-based application is capable of determining and displaying data trends, as well as to perform predictive-analytics using applied statistics and machine-learning-based AI.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1A depicts an isometric-cutaway view of a current-art EIFS installation fragment.

FIG. 1B depicts an isometric-cutaway view of one embodiment of an improved EIFS installation fragment.

FIG. 1C depicts the FIG. 1B embodiment of an improved EIFS installation fragment that is opened to fully reveal the interior drainage-plane moisture-sensing apparatus.

FIG. 1D depicts another embodiment of an improved EIFS installation fragment that is opened to fully reveal the interior drainage-plane moisture-sensing apparatus.

FIG. 2A depicts one embodiment of an isometric-cutaway view of an improved moisture-sensing membrane configured to measure biplanar capacitance.

FIG. 2B depicts a cross-sectional view of the FIG. 2A embodiment of the improved moisture-sensing membrane.

FIG. 2C depicts an alternate embodiment of an isometric-cutaway view of an improved moisture-sensing membrane configured to measure biplanar capacitance.

FIG. 2D a cross-sectional view of the FIG. 2C alternate embodiment of the improved moisture-sensing membrane.

FIG. 3A depicts one embodiment of the proximal surface of an improved EIFS panel.

FIG. 3B depicts an alternate embodiment of the proximal surface of an improved EIFS panel.

FIG. 3C depicts an embodiment of an improved EIFS panel's proximal or distal surface, depending on whether it is part of a horizontal or vertical installation.

FIG. 3D depicts an alternate embodiment of an improved EIFS panel's proximal or distal surface, depending on whether it is part of a horizontal or vertical installation.

FIG. 3E depicts the distal surface of the FIG. 3A embodiment of an improved EIFS panel.

FIG. 4A depicts one embodiment of an electrical block-diagram of a composite moisture-sensing membrane that uses biplanar capacitance.

FIG. 4B depicts an embodiment of an electrical block-diagram of a composite moisture-sensing membrane that uses coplanar capacitance and/or parallel resistance.

FIG. 4C depicts an embodiment of an electrical schematic diagram for a biplanar-capacitance measurement.

FIG. 4D depicts an embodiment of an electrical schematic diagram for a coplanar-capacitance and/or parallel-resistance measurement.

FIG. 4E depicts an electrical schematic diagram of a simple RC filter.

FIG. 4F depicts examples of electrical signals for several RC measurements.

FIG. 5 depicts an installation that employs several embodiments of methods of wireless readout and data delivery to a cloud-based application.

FIG. 6A depicts one embodiment of a flow diagram of a method for mapping the topography of a “smart” EIFS installation.

FIG. 6B depicts one embodiment of a flow diagram of a method for verifying a “smart” EIFS installation.

These drawings are intended to provide notional configurations and are therefore not drawn to scale.

DETAILED DESCRIPTION

I. Overview

The inventive disclosures contained herein are designed to address the limitations of current-art EIFS installations, and primarily focus upon an improved insulation panel with an integrated moisture-sensing channel, thereby providing state-of-the-art EIFS installations with intrinsic moisture-sensing capability for the drainage plane. Generally, one or more moisture-sensing elements are integrated directly into the proximal (inward-facing) surface of insulation-board material, and the electronic-nature of the detection technology allows the improved insulation panel to become ‘smart’ and respond to the presence of water and/or moisture within the drainage plane of the EIFS installation using capacitive and/or resistive sensing methods.

In one embodiment, the capacitive-sensing device is a composite membrane in the form of a strip of metalized polymer material placed within a recessed channel on the proximal surface of an insulation panel onto which a hydrophilic moisture-wicking layer is placed, with another metalized polymer strip placed over the proximal surface of the wicking layer, wherein the wicking layer between the metalized strips forms a capacitive dielectric. Because water has a much higher dielectric constant than the wicking-layer material, when such moisture is present within the insulation panel, the capacitance of the sensing device is increased by an order-of-magnitude or more, enabling the detection of the moisture through electronic means. The change in biplanar capacitance of this composite membrane can then be used to sense the presence of moisture. Typically, the stack of layers is bonded together through friction-welding or by an adhesive process with low mobility of the adhesive into the wicking layer.

In another embodiment, the layer of wicking material is first placed within a recessed channel on the proximal surface of the insulation panel, and a polymer layer that has two parallel metalized areas is then placed over the proximal surface of the first wicking layer, and over the polymer layer with the two metalized areas, a second wicking layer is placed. The electrical impedance between the two parallel metalized areas of this composite membrane can then be used to sense the presence of moisture by measuring the change in coplanar capacitance, or the change in electrical resistance, or both the change in coplanar capacitance and the change in electrical resistance.

In other embodiments, there are additional strips of composite membrane in an additional moisture-detection channel or channels with different geometric orientations that are placed on the proximal surface of the insulation panel. The orientation of the moisture-detection channels is selected to take advantage of the downward movement of moisture by gravity within the EIFS drainage plane.

In yet another embodiment, the proximal surface of the improved panel has pre-formed drainage channels and one or more moisture-detection channels with different geometric orientations that are placed on the proximal surface of this insulation panel. As before, the orientation of the moisture-detection channels is selected to take advantage of the downward movement of moisture by gravity within the EIFS drainage plane. In variations, the entire plane of the proximal surface of the insulating board is covered by a layer of the composite moisture-sensing membrane.

In an embodiment, the base membrane of the composite moisture-sensing membrane is formed from high-density polyethylene (HDPE) onto which a metalized layer formed by a vacuum metal deposition (VMD) process is created. The wicking layer can be comprised of a thin membrane of polypropylene/polyethylene (PP/PE), or of a layer of untreated tightly-woven untreated nylon fabric, or of any other hydrophilic porous membrane or moisture-wicking fabric material. In typical variations, the metalized layers over the wicking layer are formed through the VMD process of metal onto a thin carrier membrane that is made of a polymer material such as biaxially oriented polyethylene terephthalate (BoPET) film.

In other embodiments, the proximal surface of the composite moisture-sensing membrane may be covered by a semi-permeable Nafion™ perfluorosulfonic acid (PFSA) membrane that may allow the amount of base coat material present in the EIFS drainage plane to be better detected by the composite moisture-sensing membrane.

The stack of layers may be bonded together through a friction-welding process or with an adhesive that exhibits low mobility into the wicking layer during the curing process.

In other embodiments, a plurality of discrete passive ultra-high frequency (UHF) RFID (Radio Frequency Identification) tags based on resistive/inductive/capacitive (RLC) impedance of the RFID-sensor antenna is integrated within the insulating panels. RFID tags based on RLC impedance make use of specially-designed RFID-sensor chips or simply use standard retail RFID chips that are adapted to the dielectric constant of the material they are installed into. These RLC impedance-based sensor tags do not require direct contact with water in order to sense the presence of moisture below the membrane. Because of the sensitivity of RLC impedance-based RFID-sensor tags to the materials they are installed into, a baseline calibration is needed to calibrate the dry condition of the sensor tags.

Passive UHF RFID tags are used to excite the capacitive or resistive sensing elements within the composite moisture-sensing membrane to measure the presence of moisture. In some embodiments, since the insulation panels are not restricted by area, the RFID dipole antennas can be made much larger than normally seen with UHF tags, thereby extending reading ranges.

The capacitance or resistive sensor integrated into the insulation panel are used to provide the RFID tag with data to determine whether moisture is present within an EIFS drainage plane, and the unique digital code associated with each RFID tag allows the panel in which the moisture is found to be identified, thereby allowing the location of the moisture within an EIFS installation to be determined. This information can be wirelessly transferred to and from an RFID reader. In some embodiments, the data is uploaded directly to a cloud-based application, while in other embodiments, the data is sent to the Internet via a wireless router and then on to the cloud-based application.

The initial installation of the improved moisture-sensing installation panels within an EIFS installation typically requires that the installation topography (moisture-reading, RFID-tag ID, and physical location) to be mapped, and this is accomplished using an RFID reader in association with a surveyor-quality differential Global Positioning System (GPS) Global Navigation Satellite System (GNSS) device. In some variations, the installation topography is mapped manually using a hand-held RFID reader and differential GPS device, while in other variations, the installation topography is mapped using either a flying drone equipped with a high-resolution camera or video feed to carry the RFID reader. In all cases, at the time of installation, data related to the installation (such as the GPS coordinates of the RFID tag, the structure the tag is installed upon, and the identity of the installing contractor) is written to the RFID tag's non-volatile memory and protected by an encryption password using the RFID reader. Finally, the cloud-based application can display data trends and performing predictive-analytics using applied statistics and machine-learning-based Artificial Intelligence (AI).

II. Terminology

The terms and phrases as indicated in quotes (“ ”) in this Section are intended to have the meaning ascribed to them in this Terminology Section applied to them throughout this document, including the claims, unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.

The term “or”, as used in this specification, drawings, and any appended claims, is not meant to be exclusive; rather, the term is inclusive, meaning “either or both”.

References in the specification to “one embodiment”, “an embodiment”, “a preferred embodiment”, “an alternative embodiment”, “other embodiments”, “another embodiment”, “a variation”, “one variation”, and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment”, “in one variation”, and/or similar phrases in various places in the specification are not necessarily all meant to refer to the same embodiment.

The term “couple” or “coupled”, as used in this specification, drawings, and any appended claims, refers to either an indirect or a direct connection between the identified elements, components, or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.

The term “removable”, “removably coupled”, “readily removable”, “readily detachable”, “detachably coupled”, and similar terms, as used in this specification, drawings, and any appended claims, refer to structures that can be uncoupled from an adjoining structure with relative ease (i.e., non-destructively and without a complicated or time-consuming process) and that can also be readily reattached or coupled to the previously adjoining structure.

The terms “transverse” and “longitudinal” as used in this specification, drawings, and any appended claims, respectively refer to the short or widthwise dimension of a membrane, and the long or lengthwise dimension of a membrane. The transverse direction (TD), when used with a membrane or panel, refers to the direction across the short dimension. The longitudinal direction (LD), when used with a membrane or panel, refers to the direction along the long dimension. The LD also refers to the so-called “machine” direction (MD), which is the direction a roll is processed (unrolled and/or rolled) during the manufacturing process.

As used in this specification, drawings, and any appended claims, directional and/or relational terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front, lateral, proximal, and distal are relative to each other, are dependent on the specific orientation of an applicable element or article, are used accordingly to aid in the description of the various embodiments, and are not necessarily intended to be construed as limiting in this specification, drawings, and any appended claims.

Similarly, as used in this specification, drawings, and any appended claims, the terms “over” and “under”, are relative terms. For example, the improved moisture-sensing membrane strip is positioned “over” the proximal surface side of the insulation panel because the proximal surface side is designated as the surface nearest to the structural substrate.

The terms “discrete” and “integrated” are used to associate the relationship of the moisture-sensing elements with their installation panels. “Discrete” implies that the sensing elements act as stand-alone sensors within a panel installation, while “integrated” implies that the sensing elements are part of the installation panel and therefore act in conjunction with the installation panel.

As applicable, the terms “about” or “generally” or “approximately”, as used herein unless otherwise indicated, means a margin of +/−20%. Also, as applicable, the term “substantially” as used herein unless otherwise indicated means a margin of +/−10%. The terms “nominal” and “nominally” are used to indicate dimensions within a margin of +/−5%. The terms “reference” or “reference value” refer to non-critical dimensions or characteristics. The terms “typical” or “typically” refer to methods, compositions, or dimensions used in current-art and/or commercially available applications (including when current-art and/or commercially available applications are incorporated in the improved applications described herein). It is to be appreciated that not all uses of the above terms are quantifiable such that the referenced ranges can be applied.

III. An Improved EFIS with Intrinsic Moisture-Sensing Capabilities

This Section III is directed to an improved EFIS with intrinsic moisture-sensing capabilities for use in building structures, such as vertical wall cladding structures that are disposed above ground. Refer to FIGS. 1B though 6B.

Mechanical Configuration of the Improved Moisture-Sensing EFIS Panel

Refer to FIGS. 1B, 1C, and 1D. FIG. 1B depicts an isometric-cutaway view of one embodiment of the improved moisture-sensing insulation panel 1 as part of an EIFS installation as viewed from the exterior side, wherein the underlying wall is represented by wooden framing members 7 and gypsum panel 6; however, in variations the framing 7 can also be steel or other structural material and the paneling 6 can instead be a poured-concrete or preformed-masonry wall (i.e., cinder blocks and mortar). The moisture-barrier membrane 4 can be both waterproof and vapor-permeable, or both waterproof and non-vapor-permeable, depending on the climate where the structure is located. In commercial EIFS, the membrane 4 is typically fluid-applied. At the lower edge of the structural panel 6 is flashing 12 and a drainage track 11 to facilitate the drainage of excess water. The basecoat strips 5 are applied over the barrier membrane 4 with a notched trowel and this serves as an adhesive onto which the expanded polystyrene (EPS) or extruded polystyrene (XPS) improved insulating panel 1 is installed. The improved insulating panel 1 is depicted as a partially removed fragment to more clearly show the drainage plane formed between the distal surface of barrier membrane 4 and the proximal surface of the improved insulating panel 1. The notched trowel forms drainage channels in the basecoat, creating a drainage plane through which excess water may flow by gravity so that moisture does not build up within the EIFS installation.

Over the distal surface of the installed improved insulating panel 1, basecoat 9 is coated over a strengthening mesh 8, and this is in turn covered with the final finishing coat 10 to create a relatively lightweight-yet-strong exterior finish for the building. The basecoat 9, strengthening mesh 8, and final finishing coat 10 are depicted partially removed to reveal keep-away-zones 3 that, in variations, are stenciled into the distal surface of improved insulating panel 1 that indicate where the moisture-sensing channels 2 are located on the proximal side of improved insulating panel 1. Keep-away-zones 3 provide indications to installing contractors where mechanical fasteners should not be driven through improved insulating panel 1 in order to avoid damaging the moisture-sensing-channel 2 elements.

The embodiment of the improved moisture-sensing insulation panel 1 depicted in FIG. 1B is isometrically depicted in FIG. 1C as rotated away (A) from the underlying wall 6 and framing members 7 to reveal the proximal surface of the improved moisture-sensing insulation panel 1 that normally faces the EIFS drainage plane. Moisture-sensing channels 2 are typically, nut no necessarily, arranged in an X-pattern extending between the corners on the proximal surface of improved insulation panel 1. Improved insulating panel 1 has thickness t_A. Thickness t_A can vary depending on the space restrictions of the installation and the insulating R-value desired and can range between one and 13 inches. As an example, the R-value of 1-inch-thick EPS is 3.85.

Another embodiment of the improved moisture-sensing insulation panel 1A is isometrically depicted in FIG. 1D as part of an EIFS installation as depicted in FIGS. 1B and 1C as rotated away (B) from the underlying wall 6 and framing members 7 to reveal the proximal surface of the improved moisture-sensing insulation panel 1A that normally faces the EIFS drainage plane. However, improved moisture-sensing insulation panel 1A has pre-formed or pre-cut vertical drainage channels 13 on the proximal surface 14 of improved moisture-sensing insulation panel 1A. The pre-formed or pre-cut vertical drainage channels 13 are depicted notionally, and is should be understood that any number and many configurations of pre-formed or pre-cut vertical drainage channels 13 are possible. As before, moisture-sensing channels 2 are typically, but not necessarily, arranged in an X-pattern extending between the corners on the proximal surface of improved insulation panel 1A, and it is expected that the moisture-sensing channels intersect some or all pre-formed or pre-cut vertical drainage channels 13.

Mechanical Configurations of the EIFS Panel Composite Moisture-Sensing Membrane

Refer now to FIGS. 2A through 2D for details of the composite moisture-sensing membranes, as well as FIGS. 3A through 3E for embodiments of the composite moisture-sensing membranes within improved moisture-sensing insulation panel 1. (It should be noted note that only improved panel 1 is depicted for clarity, but these various embodiments can also apply to improved moisture-sensing insulation panel 1A.

FIG. 2A depicts an isometric view of the detail of a section moisture-sensing channel 2 with width d1 and depth t_B that resides on the proximal surface of improved moisture-sensing insulation panel 1 or 1A. A base membrane 16 with thickness t_C can be composed of high-density polyethylene (HDPE). Typically, width d1 is approximately 1 to 2 inches and depth t_B is approximately 25 to 50 mils; however, these dimensions can vary depending on the application and configuration of moisture-sensing channel 2. A metalized coating 17 on the proximal surface of base membrane 16 is created using a VMD process. The preferred specification for the metalized coating 17 is >99.9% pure aluminum with an optical depth of >125 Angstroms, although other metals and optical depths can be used. Additionally, metalized coating 17 can be created by a sputter-deposition process (often performed with indium tin-oxide, but other metals could be used). In other embodiments, metalized layer 17 is directly applied to the floor of moisture-sensing channel 2 material using VMD, allowing the base membrane 16 to be eliminated. In all cases, the metalized coating 17 should exhibit a surface resistivity <10 ohms/square when measured in accordance with ASTM D257.

Wicking layer 18 of thickness t_D can be formed from a hydrophilic layer of PE/PP with a thickness t_D of approximately 10 to 20 mils; however, this dimension can vary depending on the application and configuration of moisture-sensing channel 2. Alternatively, wicking layer 18 can be composed of untreated (i.e., there are no water-repellant chemical additives) nylon 70-denier fabric with a taffeta weave, or other finely woven pattern, with a thickness t_D of approximately 13 mils. The untreated nylon exhibits hydrophilic wicking behavior with moisture. Notably, untreated nylon fabric is often used as a liner for sports equipment or clothing to wick perspiration away from an athlete's skin. It should be recognized for those skilled in the art that the wicking layer 18 can be composed of any porous hydrophilic material with appropriate dimensional, chemical, and thermal properties that can facilitate its function as a dielectric material that varies with water content and conforms to the intended environmental and installation applications. Wicking layer 18 is attached to the metalized coating 17 using any low volatile organic compound (VOC) adhesive with low mobility into wicking layer 18 during the curing process. A sensing membrane 19 of width x1 is attached to the proximal surface of wicking layer 18 using any low VOC adhesive with low mobility into wicking layer 18. Sensing membrane 19 has a sandwiched metalized layer 20 formed by a VMD with the same characteristics as metalized layer 17. The covering layers over sandwiched metalized layer 20 of sensing membrane 19 are typically composed of BoPET film, where overall thickness t_E of sensing membrane 19 may be approximately 8 mils or less. For capacitance measurements, the edges of the sandwiched metalized layer 20 must be completely sealed by the covering layers of sensing membrane 19 so that metalized layer 20 may not electrically contact the water in the wicking layer 18. Gaps of distance d2 are left between the outer edges of sensing membrane 19 and the walls of moisture-sensing channel 2 to allow water or moisture within the EIFS drainage plane to contact wicking layer 18. Gap width d2 may be approximately 100 to 200 mils, depending on the configuration of the moisture-sensing channel 2 and the sensing membrane 19. The covering layers of sensing membrane 19 may be composed of any polymer or fluoropolymer material with mechanical and chemical properties conforming to the intended environmental and installation applications. A covering layer of semi-permeable membrane 21 may be placed over the proximal surface of the composite moisture-sensing membrane (detection device) residing within moisture-sensing channel 2 and may be composed of PFSA with thickness t_F, where t_F may be vary between approximately 100 and 300 microns (about 4 to 12 mils). The PFSA material of covering semi-permeable membrane 21 is also used as membrane in proton exchange membrane (PEM) fuel cells, which allows water and ions to pass but no other larger molecules, and therefore this property of semi-permeability may be useful to help the detection device within moisture-sensing channel 2 sense the presence of basecoat material 5 in contact with the proximal surface covering semi-permeable membrane 21. The amount of contacting basecoat material 5 may provide an indication about the quality of the drainage plane configuration, because excess basecoat material 5 may clog the EIFS drainage plane, while excessively sparse basecoat material 5 may result in poor adhesion with the improved moisture-sensing insulating panel 1 or 1A. Typical uptake of water through the PFSA layer is 38% and typically occurs over a 1-hour period as measured by ASTM D570. Temperature will affect the uptake rate, where the rate increases with increasing temperature. Uptake rate may be improved by introducing small perforations (around several microns in diameter) into the semi-permeable membrane 21, in which case, a conventional polymer membrane material such as BoPET may be possible to use instead of PFSA. It must be noted that because the EIFS drainage plane (depending on climate and installation) may experience dramatic cyclic swings in moisture content; therefore, it is critical that the moisture detecting element be resistant to ionic contamination that can introduce electrically-conductive residues to the moisture-sensing element wicking layer 18, and thereby impart a resistance change to the sensing element, even after the moisture within the EIFS drainage plane subsides and becomes completely dry. The semi-permeable membrane covering layer 21 is intended to provide this resistance to ionic contamination.

The composite moisture-sensing membrane that forms the detection device within moisture-sensing channel 2 may therefore be composed of a plurality of adhesively-attached layers and materials as described previously, with an overall thickness of t_C+t_D+t_E+t_F or approximately 25 to 45 mils, depending on the configuration. The strength of the adhesive bonds between layers should be sufficient to allow the improved moisture-sensing insulating panels 1 or 1A to be stored, transported and moved into place on the jobsite during installation. The bonding adhesives should be chemically compatible with the materials of the various layers and should be capable of withstanding the environmental conditions of the EIFS installation (ambient temperature extremes and moisture). Alternatively, a mechanical friction-welding process may be used to bond the various layers together instead of adhesive or may be used in combination with adhesives to bond the various layers together. The bond strength of the various layers of the sensing device within moisture-sensing channel 2 should be sufficient to allow the panel to be cut-to-size in the field during installation without tearing or delaminating the various layers from the underlying insulating materials. A removable paper or silicone release liner (not depicted) may be adhered to the proximal surface of the improved moisture-sensing insulating panels 1 or 1A to serve as protection for the detection device within the moisture-sensing channels 2 until the release liner is removed prior to installation. It may also be beneficial to introduce a factory-applied mastic sealant to the longitudinal edges of the sensing elements at location 16, or in the field when cuts are made, to protect the sensing element longitudinal ends from ionic contamination.

FIG. 2B depicts a cross-sectional view of the detail of a section of moisture-sensing channel 2 depicted in FIG. 2A along the longitudinal direction in the area where an electronic device 22 external to the sensing device residing in moisture-sensing channel 2 may be placed. Here the electronic device takes the form of a wireless RFID tag 22 and is depicted installed within cavity 26 below moisture-sensing channel 2 opposite to the drainage plane. Wireless RFID tag 22 may be electrically connected 25A to the sandwiched metalized layer 20 of sensing membrane 19 and is also may be electrically connected 25B to metalized layer 17. A backing plug 23 composed of panel 1/1A insulating material may be installed into cavity 26 over wireless RFID tag 22 as a method for reducing the open volume above RFID tag 22 to minimize areas that may trap moisture. A factory-applied mastic sealant may also be applied to fill any potential water-trapping cavities. Metalized coating 24 may be place on the surface of backing plug 23 that faces wireless RFID tag 22 as a method for increasing the reading range. Although not shown, a chemically-compatible elastomeric adhesive potting compound may also be placed over RFID tag 22 under backing plug 23 to further reduce open volume and may serve as additional protection for RFID tag 22. The antenna configuration of the wireless RFID tag 22 may be optimized to extend the reading range.

FIG. 2C depicts an isometric view of the detail of a section moisture-sensing channel 2A with width d1 and depth t_B that resides on the proximal surface of improved moisture-sensing insulation panel 1 or 1A. Width d1 may be approximately 1 to 2 inches and depth t_B may be approximately 25 to 50 mils, but these dimensions may vary depending on the application and configuration of moisture-sensing channel 2A. As with the FIG. 2A embodiment, wicking layer 18 of thickness t_C may be formed from a hydrophilic layer of PE/PP with a thickness t_C of approximately 10 to 20 mils but this dimension may vary depending on the application and configuration of moisture-sensing channel 2A, or wicking layer 18 may be composed of untreated (i.e. there are no water-repellant chemical additives) nylon 70 denier fabric with a taffeta weave, or other finely woven pattern, and with a thickness t_C of approximately 13 mils; the untreated nylon may exhibit hydrophilic wicking behavior with moisture. Two longitudinally parallel sensing membranes 19A and 19B both of width x2 separated by gap d3 may be bonded to the proximal surface of wicking layer 18 using any low VOC adhesive with low mobility into wicking layer 18. Sensing membranes 19A and 19B may each have a sandwiched metalized layer 20 formed by a VMD with the same characteristics as metalized layer 17 described in the FIG. 1A embodiment. The covering layers over sandwiched metalized layer 20 of sensing membranes 19A and 19B may be composed of BoPET film, where overall thickness t_E of sensing membranes 19A, 19B are approximately 8 mils or less.

For capacitance measurements, the edges of the sandwiched metalized layer 20 must be completely sealed so that metalized layer 20 does not electrically contact the water in the wicking layer 18, 18A. For resistance measurements, the edges of the sandwiched metalized layer 20 can be left partially exposed, or either one of the upper or lower covering layers of sensing membranes 19A, 19B can be eliminated. Another wicking layer 18A, also of thickness t_D, can be bonded over sensing membranes 19A, 19B using any low-VOC adhesive with low mobility into wicking layer 18A. The covering layers of sensing membranes 19A, 19B are composed of any polymer or fluoropolymer material with mechanical and chemical properties conforming to the intended environmental and installation applications. Gaps of distance d2 are left between the outer edges of sensing membranes 19A, 19B and the walls of moisture-sensing channel 2A. Gap width d2 is approximately 100 to 200 mils, depending on the configuration of the moisture-sensing channel 2A and the sensing membrane 19, and separation gap d3 is 50 to 100 mils, depending on the electrical characteristics desired (i.e., lowering the dimension of gap d3 will increase coplanar capacitance, but if gap d3 is too narrow, the resistance sensitivity might become too great to be effective). As with the FIG. 2A embodiment, a covering layer of semi-permeable membrane 21 is placed over the proximal surface of the composite moisture-sensing membrane (detection device) residing within moisture-sensing channel 2A and is composed of PFSA with thickness t_F, where t_F can be vary between approximately 100 and 300 microns (about 4 to 12 mils). The covering semi-permeable membrane 21 is useful to help the detection device within moisture-sensing channel 2A sense the presence of basecoat material 5 in contact with the proximal surface covering semi-permeable membrane 21.

The amount of contacting basecoat material 5 provides an indication about the quality of the drainage plane configuration, because excess basecoat material 5 can clog the EIFS drainage plane, while excessively sparse basecoat material 5 can result in poor adhesion with the improved moisture-sensing insulating panel 1, 1A. Typical uptake of water through the PFSA layer is 38% and typically occurs over a one-hour period as measured by ASTM D570. Temperature affect the uptake rate, where the rate increases with increasing temperature. Uptake rate can be improved by introducing small perforations (around several microns in diameter) into the semi-permeable membrane 21, in which case a conventional polymer membrane material such as BoPET is possible to use instead of PFSA. It must be noted that because the EIFS drainage plane (depending on climate and installation) can experience dramatic cyclic swings in moisture content, it is critical that the moisture-detecting element be resistant to ionic contamination that can introduce electrically-conductive residues to the moisture-sensing element wicking layers 18, 18A, and thereby impart a resistance change to the sensing element, even after the moisture within the EIFS drainage plane subsides and becomes completely dry. The semi-permeable membrane covering layer 21 is intended to provide this resistance to ionic contamination.

The composite moisture-sensing membrane that forms the detection device within moisture-sensing channel 2A can, therefore, be composed of a plurality of adhesively-attached layers and materials as described previously, with an overall thickness of 2t_D+t_E+t_F, or approximately 30 to 50 mils, depending on the configuration. The strength of the adhesive bonds between layers should be sufficient to allow the improved moisture-sensing insulating panels 1, 1A to be stored, transported, and moved into place on the jobsite during installation. The bonding adhesives should be chemically compatible with the materials of the various layers and should be capable of withstanding the environmental conditions of the EIFS installation (ambient temperature extremes and moisture). Alternatively, a mechanical friction-welding process can be used to bond the various layers together instead of adhesive or can be used in combination with adhesives to bond the various layers together. The bond strength of the various layers of the sensing device within moisture-sensing channel 2A should be sufficient to allow the panel to be cut-to-size in the field during installation without tearing or delaminating the various layers from the underlying insulating materials. A removable paper or silicone release liner (not depicted) is adhered to the proximal surface of the improved moisture-sensing insulating panels 1, 1A to serve as protection for the detection device within the moisture-sensing channels 2A until the release liner is removed prior to installation. It may also be beneficial to introduce a factory-applied mastic sealant to the longitudinal edges of the sensing elements, or to introduce a mastic sealant in the field when cuts are made, in order to protect the sensing-element longitudinal ends from ionic contamination.

FIG. 2D depicts a cross-sectional view of the detail of a section of moisture-sensing channel 2A depicted in FIG. 2C along the longitudinal direction in the area where an electronic device 22 external to the sensing device residing in moisture-sensing channel 2A can be placed. Here the electronic device takes the form of a wireless RFID tag 22 and is depicted installed within cavity 26 below moisture-sensing channel 2A opposite to the drainage plane. Wireless RFID tag 22 is electrically connected 25A to the sandwiched metalized layer 20 of sensing membrane 19A and is also electrically connected 25B to the sandwiched metalized layer 20 of sensing membrane 19B. A backing plug 23 composed of panel 1/1A insulating material is installed into cavity 26 over wireless RFID tag 22 as a method for reducing the open volume above RFID tag 22 in order to minimize areas that might trap moisture. A factory-applied mastic sealant is also applied to fill any potential water-trapping cavities. Although not shown, a chemically-compatible elastomeric adhesive potting compound can also be placed over RFID tag 22 under backing plug 23 to further reduce the open volume and serves as additional protection for RFID tag 22. The metalized coating 24 is placed on the surface of backing plug 23 that faces wireless RFID tag 22 as a method for increasing the reading range. The antenna configuration of the wireless RFID tag 22 can be optimized to extend the reading range.

The wireless RFID tags 22 depicted in the embodiments of FIGS. 2B and 2D may be electrically connected 25A, 25B using an electrically conductive adhesive such as, for example, Permabond® 820, with an electrical conductivity of >1×10E7 (m/ohm), a dielectric strength of 25 kV/mm, and a service temperature range of −55° C. to +200° C. (−65° F. to +390° F.). Considerations for the environmental conditions that the wireless RFID tags 22 could be subjected to in EIFS applications have been made. For example, the electronic chips within wireless RFID tags 22 can have an automotive-grade-temperature operating range between −40° C. and +125° C. (−40° F. and +257° F.) and can have a non-operating-temperature range between −65° C. and +150° C. (−85° F. and +302° F.). In some variations, wireless RFID tags 22 are hermetically sealed within a hydrophobic polymer or fluoropolymer covering to ensure that the devices may operate for decades without degradation.

Any moisture present in the drainage plane contacts the detection device within the moisture-sensing channels 2, 2A and is drawn into wicking layer 18A and/or wicking layer 18 through gaps d2 and/or separation gap d3. The porous material of the wicking layers 18, 18A have a relative permittivity (i.e., dielectric constant) of approximately 1.5 to 2.4 for polymer materials (polyethylene 2.2 to 2.4; see, e.g., http://www.clippercontrols.com/pages/Dielectric-Constant-Values.html#P) and approximately 3 to 5 for nylon (nylon 4.0 to 5.0, or nylon resin 3.0 to 5.0; see, e.g., http://www.clippercontrols.com/pages/Dielectric-Constant-Values.html#N), while water has a relative permittivity of 80.2 at 68° F. (20° C.); therefore, between the dry and wet states of wicking layers 18, 18A, both the biplanar capacitance between sandwiched metalized layer 20 of sensing membrane 19 and metalized coating 17, and the coplanar capacitance between adjacent sandwiched metalized layers 20 of sensing membranes 19A, 19B, may change by a factor of 20 to 50 (greater than one order of magnitude), allowing an external electronic measurement device to readily detect the presence of any water absorbed into wicking layers 18, 18A within the detection device residing in moisture-sensing channels 2, 2A. Electrical resistance between sensing membranes 19A and 19B configured for resistance measurements is altered by the presence of water within wicking layers 18, 18A. The advantage of a resistance-based measurement is that a simpler electronic measurement method can be performed by wireless RFID tag 22; however, but the disadvantage of relying one a resistance-based measurement is the need to eliminate the covering semi-permeable membrane 21 in order to allow electrically-conductive ionic compounds within the moisture to be carried into the wicking layers 18, 18A, which also serves to make the resistance measurement inoperative if these electrically-conductive ionic compounds remain as residue within wicking layers 18, 18A when the moisture evaporates. The resistance-based measurement can also be insensitive to the presence of base coat 5 that can be in contact with the sensing device within moisture-sensing channel 2A. It should be noted that capacitive-based measurements may not be sensitive to electrically-conductive ionic compounds that remain as residue within wicking layers 18, 18A.

FIG. 3A depicts a proximal surface view of the improved moisture-sensing insulating panel 1 with moisture-sensing channel 2/2A with width d1 arranged in an X-pattern, extending from corner to corner of the improved moisture-sensing insulating panel 1, with panel dimensions of w1 in width and w2 in height. A typical dimension can be w1=4 feet and w2=2 feet, and for purposes of the discussions remaining herein, the dimensions w1=4 feet and w2=2 feet shall be retained to provide a reference for any further cited examples. However, it should be understood that there will be much variation in these dimensions depending on the EIFS installation configuration. The wireless RFID tag 22 installation below moisture-sensing channel 2/2A as described for FIGS. 2B and 2D is depicted by the dashed rectangle in the center of the drawings. The X-shaped moisture-sensing channel 2/2A arranged diagonally is a preferred embodiment and can provide full horizontal coverage for water draining downwards within the drainage plane under the force of gravity, even with improved moisture-sensing insulating panel 1 installed vertically and arranged with either with the w1 width or the w2 height aligned along the direction drainage, and even when the panel 1 is altered by cutting during installation.

FIG. 3B depicts a proximal surface view of the improved moisture-sensing insulating panel 1 with moisture-sensing channel 2/2A with width d1 arranged in a diagonal-pattern, extending from the lower left corner to the upper right corner of the improved moisture-sensing insulating panel 1, with panel dimensions of w1 in width and w2 in height. The wireless RFID tag 22 installation below moisture-sensing channel 2/2A as described for FIGS. 2B and 2D is depicted by the dashed rectangle in the middle of the drawing. The single moisture-sensing channel 2/2A arranged diagonally provides full horizontal coverage for water draining downwards within the drainage plane under the force of gravity, even with improved moisture-sensing insulating panel 1 installed vertically and arranged with either with the w1 width or the w2 height aligned along the direction drainage, and even when the panel 1 is altered by cutting during installation.

FIG. 3C depicts both a distal surface and a proximal surface view of the improved moisture-sensing insulating panel 1 with moisture-sensing channel 2/2A, with width d1 arranged along the longitudinal axis of the insulating panel 1, extending from the left edge to the right edge of the insulating panel 1, and with panel dimensions of w1 in width and w2 in height. For horizontal distal surface installations of the FIG. 3C improved moisture-sensing insulating panel 1, the sensing elements reside on the insulating panel 1 surface facing away from the substrate, and the single moisture-sensing channel 2/2A arranged horizontally is augmented by a plurality of small channels 36 cut into the surface of the insulating panel 1. The plurality of small channels 36 are intended to facilitate the transport of water from the transverse edges of insulating panel 1 to the moisture-sensing channel 2/2A by means of capillary action. Additionally, wicking material 18 can be placed into each of the plurality of small channels 36 to facilitate the transport of water from the transverse edges of insulating panel 1 to the moisture-sensing channel 2/2A by means of wicking action, which enhances water transport at the cost on increasing the complexity of the improved moisture-sensing insulating panel 1. To eliminate RF interference from the electrically-conducting elements within the moisture-sensing channel 2/2A, wireless RFID tag 22 is installed above the moisture-sensing channel 2/2A in this configuration and is depicted as a dashed rectangle. This application can be installed under the horizontal waterproofing membranes used for decking, balconies, and roofing installations. Furthermore, the distal surface configuration of the FIG. 3C improved moisture-sensing insulating panel 1, when used under single-ply roofing, does not compromise the attachment strength of fully-adhered (i.e., adhesively attached) membrane installations.

For vertical proximal surface EIFS installations of the FIG. 3C improved moisture-sensing insulating panel 1, the single moisture-sensing channel with width d1 is arranged along the longitudinal axis of the insulating panel 1, extending from the left edge to the right edge of the insulating panel 1, with panel dimensions of w1 in width and w2 in height. This configuration is most effective at sensing water draining downwards within the drainage plane under the force of gravity when the improved moisture-sensing insulating panel 1 is installed with the w1 width or the w2 height aligned perpendicular to the direction drainage. The wireless RFID tag 22 installation below moisture-sensing channel 2/2A as described for FIGS. 2B and 2D is depicted by the dashed rectangle at the center of the drawing.

FIG. 3D depicts both a distal surface and a proximal surface view of the improved moisture-sensing insulating panel 1, with moisture-sensing plane 2C extending across the entire distal or proximal surface of improved moisture-sensing insulating panel 1, and with panel dimensions of w1 in width and w2 in height. For horizontal distal surface installations of the FIG. 3D improved moisture-sensing insulating panel 1, the moisture-sensing plane 2C resides on the insulating panel 1 surface facing away from the substrate. A covering layer of semi-permeable membrane 21 (depicted as a fragment) is placed over moisture-sensing plane 2C. To eliminate RF interference from the electrically-conducting elements within the moisture-sensing channel 2/2A, wireless RFID tag 22 is installed above the moisture-sensing channel 2/2A in this configuration and is depicted as a dashed rectangle at the center of the drawing. This application can be installed under the horizontal waterproofing membranes used for decking, balconies, and roofing installations.

For vertical proximal surface EIFS installations of the FIG. 3D improved moisture-sensing insulating panel 1, the moisture-sensing plane 2C extends across the entire proximal surface of improved moisture-sensing insulating panel 1, with panel dimensions of w1 in width and w2 in height. The wireless RFID tag 22 installation below moisture-sensing plane 2C is depicted by the dashed rectangle at the center of the drawing. The single moisture-sensing plane 2C arranged horizontally provides high sensitivity for detecting any moisture within the EIFS drainage plane adjacent to the moisture-sensing plane 2C.

FIG. 3E depicts a distal surface view of the FIG. 3A embodiment of improved moisture-sensing insulating panel 1. Keep-away zones 3 are stenciled onto the distal surface of improved moisture-sensing insulating panel 1 to designate where contractors should not drive mechanical fasteners through the panel 1. The keep-away zones 3 have widths D1′ that are approximately 20% greater than moisture-sensing channel 2/2A to help ensure that fasteners are not inadvertently driven through the moisture-sensing channels 2/2A. A plurality of bar code 27 patterns are ink-stamped or printed onto the distal surface of improved moisture-sensing insulating panel 1. The bar code 27 patterns represent the unique digital ID of the wireless RFID tag 22 installed into the associated improved moisture-sensing insulating panel 1, which can imply that the ink-stamping or printing process is a factory operation. The unique digital ID of the installed wireless RFID tag 22 is captured by an RFID reader during the assembly process and the corresponding bar code 27 patterns that encode the unique digital ID are then ink-stamped or printed onto the distal surface of improved moisture-sensing insulating panel 1 as depicted. The unique digital ID of the installed wireless RFID tag 22 encoded as a visible bar code 27 facilitates the installation topography of the EIFS panels that can be recorded/mapped concurrently during the installation process.

The factory-integrated nature of the improved moisture-sensing insulating panels 1, 1A of various configurations are ideally suited for prefabricated EIFS panels, where the EFIS panels are custom-fabricated for an installation within a factory setting. These completed EFIS panels are then transported to the jobsite and installed, saving time, and reducing the installation variation and compromised quality that often arises during a direct installation by a contractor at a jobsite. A commercial example of a prefabricated EIFS panels is the Dryvit Tech21® prefabricated panel program (see, e.g., http://www.dryvit.com/our-solutions/panelization/).

Electrical Configurations of the EIFS Panel Composite Moisture-Sensing Membrane

Now refer to FIGS. 4A, 4B, 4C, 4D, and 4E. FIG. 4A depicts an electrical block-diagram for the FIG. 2A embodiment of the composite moisture-sensing membrane (detection device) residing within moisture-sensing channel 2. Dashed line 22 denotes the components within the wireless RFID tag 22. Sensing area 19/20 with width x1 is shown arranged along the longitudinal axis of the detection device residing within moisture-sensing channel 2. The sensing area 19/20 has a corresponding external capacitance-measurement device Va representing wireless RFID tag 22 and is connected via electrical interface wiring 25A and 25B. The signal ground denotes the electrical node that is common to the external capacitance-measurement device Va to which all measurement currents return to the source. Biplanar capacitance exists between each sensing area 19/20 and the metalized coating 17 of base membrane 16 across the thickness and across the opposite surfaces of wicking layer 18.

FIG. 4B depicts an electrical block-diagram for the FIG. 2C embodiment of the composite moisture-sensing membrane (detection device) residing within moisture-sensing channel 2A. Dashed line 22 denotes the components within the wireless RFID tag 22. Sensing areas 19A and 19B, each having width x2 and separated by distance d3, are shown arranged along the longitudinal axis of the detection device residing within moisture-sensing channel 2A. The sensing areas 19A and 19B have a corresponding external capacitance-measurement device Vb representing wireless RFID tag 22 and are connected via electrical interface wiring 25A and 25B. The signal ground denotes the electrical node that is common to the external capacitance-measurement device Vb to which all measurement currents return to the source. Coplanar capacitance exists between sensing areas 19A and 19B across the coplanar distance d3 of wicking layers 18 and 18A.

Biplanar capacitance yields a large change in capacitance when wicking layer 18 absorbs moisture. Coplanar capacitance yields a smaller magnitude of capacitance, but still may experience a large relative change in capacitance when wicking layers 18 and 18A absorb moisture.

FIG. 4C depicts an electrical schematic diagram of the FIG. 4A block diagram with biplanar capacitance C_biplanar. Protection device TVSa protects the wireless RFID tag 22 from electro-static discharges (ESD). Impedance Zatest represents a test load present within the wireless RFID tag 22 that allows self-testing and diagnostic checks of the detection device residing within moisture-sensing channel 2. Resistance Ra represents a measurement load necessary to create the RC time constants between Ra and C_biplanar, while time-varying current i_a(t) flows through Ra and C_biplanar, and the time-varying voltage V_a(t) measurement determines if the capacitance value of C_biplanar has changed. The values selected for Ra correspond to the expected levels of C_biplanar capacitance and the expected change in capacitance between the dry and wet conditions of wicking layer 18 of the detection device residing within moisture-sensing channel 2, as described for FIG. 4E. Electrical-interface wiring 25A and 25B represent the connecting wires to the detection device capacitance C_biplanar. The signal ground denotes the electrical node common to the external measurement devices Va.

Biplanar capacitance C_bp in Farads is defined as shown in Equation [1] below:

$\begin{array}{cc}{C}_{\mathrm{bp}}=\frac{{\varepsilon }_0{\varepsilon }_r\mathrm{wl}}{t}& \mathrm{Equation}\left[1\right]\end{array}$

Where:

• • x1=l;
  • w1′=w(diagonal length of panel 1); and
  • t_D=t(wicking layer 18 thickness)

TABLE 1
Biplanar Capacitance Values With Moisture-Sensing
Membrane Parameters
							Capacitance
×1	w1′						Increase dry
(inches)	(inches)	tD (mils)	εr dry	εr wet	Cbp (Farads) dry	Cbp (Farads) wet	to wet
1.8	54	10	2	60	4.37 × 10E−9	1.31 × 10E−7	×30
1.8	54	20	2	60	2.18 × 10E−9	6.55 × 10E−8	×30

For the calculations in Table 1, the percent fill of wicking layer 18 was set to 25%, which yielded an ε_r wet value of 60 with ε_r water=80.2. The difference in biplanar capacitance is approximately 30 times between a completely dry wicking layer 18 and a fully saturated wet wicking layer 18. This large change in biplanar capacitance between dry and wet conditions provides very good electrical-measurement sensitivity for detecting the presence of moisture in wicking layer 18.

FIG. 4D depicts an electrical schematic diagram of the FIG. 4B block diagram with coplanar capacitance C_coplanar. Protection device TVSb protects the wireless RFID tag 22 from electro-static discharges (ESD). Impedance Zbtest represents a test load present within the wireless RFID tag 22 that allows the wireless RFID tag 22 to perform self-testing and diagnostic checks of the detection device residing within moisture-sensing channel 2A. Resistance Rb represents a measurement load necessary to create the RC time constants between Rb and C_coplanar, while time-varying current i_b(t) flows through Rb and C_coplanar, and the time-varying voltage V_b(t) measurement determines if the capacitance value of C_coplanar has changed. The values selected for Rb correspond to the expected levels of C_coplanar capacitance and the expected change in capacitance between the dry and wet conditions of wicking layers 18 and 18A of the detection device residing within moisture-sensing channel 2A, as described for FIG. 2C. Electrical-interface wiring 25A and 25B represent the connecting wires to the detection-device capacitance C_coplanar. Resistance Rwater represents the resistance within wicking layers 18 and 18A from water. The signal ground denotes the electrical node common to the external measurement devices Vb.

Coplanar capacitance C_ep in Farads is defined as shown in Equation [2] (see also, Clayton R. Paul, “Analysis of Multiconductor Transmission Lines,” 2nd Ed., 2008):

$\begin{array}{cc}{C}_{\mathrm{cp}}\left(s\right)=\{\begin{array}{cc}\frac{{\varepsilon }_{r}l\ln \left(-\frac{2}{4\sqrt{\frac{d^2}{{\left(d+2w\right)}^2}-1}}\left(4\sqrt{1-\frac{d^2}{{\left(d+2w\right)}^2}}+1\right)\right)}{377\pi v_o},& \mathrm{for}0<\frac{d}{d+2w}\le \frac{1}{\sqrt{2}}\\ \frac{{\varepsilon }_{r}l}{120v_o\ln \left(-\frac{2}{\sqrt{\frac{d}{d+2w}-1}}\left(\sqrt{\frac{d}{d+2w}}+1\right)\right)},& \mathrm{for}\frac{1}{\sqrt{2}}<\frac{d}{d+2w}\le 1\end{array}& \mathrm{Equation}\left[2\right]\end{array}$

Where:

• • permittivity ε=ε₀ε_r;
  • permeability μ=μ₀;
  • d₃=d (separation between sensing elements 19A and 19B);
  • w1′=l (diagonal length of panel 1); and
  • x2=w. All distance dimensions are in meters.

TABLE 2
Coplanar Capacitance Values With Moisture-Sensing
Membrane Parameters
							Capacitance
×2	w1′	d3					increase dry
(inches)	(inches)	(inches)	εr dry	εr wet	Cbp (Farads) dry	Cbp (Farads) wet	to wet
0.9	54	0.05	2	60	7.72 × 10E−11	2.32 × 10E−9	×30
0.9	54	0.10	2	60	6.69 × 10E−11	2.01 × 10E−9	×30

For the calculations in Table 2, the percent fill of wicking layers 18 and 18A was set to 25%, which yielded an ε_r wet value of 60 with ε_r water=80.2. A symmetrical wicking layer above and below sensing areas 19A and 19B was assumed. The difference in coplanar capacitance is approximately 30 times between completely dry wicking layers 18 and 18A and fully saturated wet wicking layers 18 and 18A. Although the coplanar capacitance levels are around two orders-of-magnitude less than the equivalent biplanar capacitance values shown in Table 1, the large change in coplanar capacitance between dry and wet conditions still provides very good electrical-measurement sensitivity for detecting the presence of moisture in wicking layers 18 and 18A.

FIG. 4E depicts the schematic for a generic low-pass RC filter, where Vdrive represents a drive voltage from a wireless RFID tag (various embodiments), R represents resistance, C represents capacitance, and Vcap represents the measurement of the voltage applied by Vdrive through resistance R across capacitance C. The dashed boundary Panel represents what is contained within the detection device residing within moisture-sensing channels 2 and 2A. The Signal Ground represents the common voltage node where the electrical current from Vdrive returns. Resistance R may be a fixed value (resistors Ra or Rb, as shown in FIGS. 4C and 4D) within wireless RFID tag 22, while capacitance C may be the biplanar or coplanar capacitance within the detection device residing within moisture-sensing channel 2 and 2A (see FIGS. 4C and 4D) that can vary with moisture content, as described in Tables 1 and 2. The electrical RC time constant τ is altered by changes to the capacitance value C within the detection device residing within moisture-sensing channel 2 and 2A.

Capacitator voltage Vcap while charging and discharging is defined as shown in Equation [3] below:

$\begin{array}{cc}{V}_{\mathrm{cap}}\left(t\right)=\{\begin{array}{cc}\mathrm{Charging},& V_{\mathrm{drive}}\left(1-e^{-t{/}_{\tau }}\right)\\ \mathrm{Discharging},& V_{\mathrm{drive}}\left(e^{-t{/}_{\tau }}\right)\end{array}& \mathrm{Equation}\left[3\right]\end{array}$

• • Where: τ=RC

FIG. 4F depicts the waveforms at Vcap in volts for various states of wicking layer 18, 18A in the detection devices residing within moisture-sensing channels 2, 2A, where capacitance change occurs when wicking layer 18, 18A absorbs moisture, which results in a change in the biplanar capacitance between the sensing areas 19/20 and the metalized coating 17 or results in changes in the coplanar capacitance between adjacent sensing areas 19A and 19B. A square wave is applied by Vdrive between 0V and 3V, with period=t3−t1, V_{drive_high}=t2−t1, and V_{drive_low}=t3−t2. The square-wave period and R are set be selected to produce the maximum difference in average voltage between the DRY and WET conditions of wicking layer 18/18A, as represented by Vaverage3 and Vaverage1, respectively, as determined by the range of RC time constants, where C represents the improved moisture-sensing membrane capacitance as determined by the difference between τ₃ and τ₁, again respectively.

IV. An Improved Method of Building-Structure Installation and Leak-Detection

This Section IV is directed to an improved method of installing an improved moisture-sensing insulation panel for use in a building structure, and an improved method of detecting and locating post-installation leaks in the building structure. Refer to FIGS. 1B though 6B.

Installations and Methods of Use of the Improved Moisture-Sensing EIFS Panel

Referring to FIG. 5, which depicts an installation with several embodiments of methods of wireless readout and data delivery to the cloud-application, the two improved moisture-sensing panels 1 are intended to represent a notional installation process of an EIFS wall cladding. The location of wireless RFID tags 22 within the improved moisture-sensing panels 1 are denoted by the dashed quadrangles 22.

Typically, the wireless and passive RFID tags 22 use transceiver components that do not require an internal power supply such as a battery and are instead powered from the energy of the reading signal. The RFID tags 22 allows user data to be both read and written to a memory location within each RFID tag 22. In variations, the RFID tag 22 has the capability to encrypt the information stored within its memory locations to prevent the unauthorized deletion, overwriting, or any other malicious or unintentional modification of the RFID tag 22 data and information. Additionally, blockchain cryptographic hash can be used, which ensures that the collection, storage, and readout of the data is secure by design, thereby enabling trust that the data has not been tampered with.

In most embodiments, the RFID tag 22 has the capability to be read passively from a distance greater than 10 feet. In one embodiment, the RFID tag 22 is an Electronic Product Code (EPC) Class 3 Gen 2 Version 2 ISO 18000-6C-Compliant RFID tag and is be Pb-Free, Halogen Free/BFR Free, and RoHS-compliant for environmental responsibility. EPC tags operate in the ISM (Industrial Scientific and Medical) UHF 902-928 MHz band for passive remote sensing and require no installed batteries or power sources, and instead scavenge power only from the radio-frequency (RF) energy of the reading devices and then communicate back to the reader during this time using backscatter. An EPC Class 3 tag has read-write capability with onboard sensors capable of recording external parameters. An EPC Generation 2 tag has four banks of non-volatile memory (Reserved Memory, EPC Memory, Tag Identification—or TID Memory, and User Memory). Finally, Version 2 of the EPC Gen 2 standard includes built-in 128-bit data encryption that allows a proprietary reading protocol to be established (i.e., the tags described herein can only communicate with RFID readers that are equipped with the proper decryption protocols).

In most embodiments, the RFID tags 22 Class 3 sensory capability includes temperature and several additional sensor interfaces that can be configured for the sensory application, such as measuring capacitance, currents, or voltage levels. An example of an EPC Class 3 sensory tag chip that can be used is the AMS SL900A, with an on-board ±0.5° C. temperature measurement sensor that can read across a −40° C. to +125° C. range, and with interfaces for up to two additional sensors external to the chip. The SL900A chip includes a driver voltage and references capacitor location to measure capacitive-based sensors. The reference capacitor used for the SL900A chip would take the place of the load resistors Ra and Rb depicted in FIGS. 4C and 4D. For high-rate production, a custom-designed Application-Specific Integrated Circuit (ASIC) may be more cost effective, because the ASIC EPC sensory-tag chip may be optimized for a specific application, with only the circuitry required to perform the functions needed.

Generic longevity specifications for Gen-2 chips are 40 to 50 years of data retention and 100,000 write cycles. Gen-2 tags can have a read range of over 16 meters or 52 feet when using the full 4-Watt Effective Isotropic Radiated Power (EIRP) legally allowed on the readers by the FCC and other global regulators. Range can be effectively extended for UHF Gen-2 tags by increasing the size of the dipole antenna array. Typically, to save space, Gen-2 tags are restricted to a size that approximates a credit card, or approximately 4 inches in length, which equates to a ¼-wavelength dipole antenna. The wavelength of a 1 GHz signal is approximately 12 inches. It should be noted that 1 GHz is near the UHF 902-928 MHz band or the 0.902-0.928 GHz wavelength. Because the size restriction might not be as important for EIFS applications, the wireless RFID tags 22 can have full-wavelength dipole antennas, and four times (or more) the effective antenna array area over ¼-wavelength dipole antennas. This theoretically doubles the reading range to around 100 feet, because the RFID readers 29, 32, and 33 act as point sources, where the reader's radiated power decreases as an inverse-square of the distance between the reader and the tag. Reading range can also be increased by placing a reflective-metalized-conductive layer immediately under the installed wireless RFID tags 22, as described for metalized coating 24 in FIGS. 2B and 2C, and this reflective-metalized-conductive layer function can also be served by metalized coatings 17, 20 present within the detection devices residing within moisture-sensing channels 2, 2A.

The actual reading distances may be dependent upon insulation panel 1 thicknesses and cladding materials 8, 9, and 10; the reading angles; and the presence of any line-of-site obstructions, including water, snow, and ice. Furthermore, there is an upper limit to how large a wireless RFID tag 22 antenna can become due to parasitic-impedance losses from stray capacitance and inductance that can negatively impact the ability of the RFID chip to drive the antenna signal. Therefore, each EIFS installation requires a different approach to obtain complete reading coverage across the entire area of the building structure.

FIG. 5 also depicts several embodiments of methods to extract moisture-sensing data from the EIFS installation through wireless RFID tags 22. A flying remotely-controlled drone 28 carries RFID reader 29 and a high-definition camera or video-recording device 30. Drone 28 RFID reader 29 is used to read 29B wireless RFID tag 22 in order to obtain both the tag digital identification (ID) number and tag data that can include moisture content and temperature measurements. The distance for taking readings 29B is dictated by the power of the RFID reader 29, which can be limited below full EIRP due to the limited battery power in drone 28. The limited reading range may not present a problem for drone 28 based wireless RFID tag 22 readings because the drone 28 can fly to any area of the installation. A drone 28 based wireless RFID tag 22 reading method 29B is considered to be semi-continuous monitoring, with the frequency of monitoring set by the time interval between drone 28 based surveys.

In variations, a handheld RFID reader 32 that also has a differential GPS device 31 can be used to obtain wireless RFID tag 22 information, as described above, for the drone 28 survey method. Again, as with the drone 28 method 29B, a handheld RFID reader 32 can be limited below full EIRP due to the limited battery power in the handheld RFID reader 32. A handheld-based wireless RFID tag 22 is considered as semi-continuous monitoring, with the frequency of monitoring set by the time interval between handheld-based surveys.

A permanent fixed RFID reader or readers 33 can also be used to obtain wireless RFID tag 22 information, as described previously for the drone 28 method 29B. Distance d4 between fixed RFID readers 33 is established based on the reading range of the fixed RFID readers 33. Unlike portable RFID readers 29 and 32, which may have limited power, a fixed RFID reader 33 can be powered locally from structure power, or from a battery pack that is recharged continuously with outside solar cells or other source; therefore, the full EIRP is available, which allows for the maximum possible passive wireless RFID tags 22 reading range and a continuous monitoring of data within the EIFS installation. The quantity of fixed RFID readers 33 needed to provide full reading coverage is dependent on the practical RFID reading range, the dimensions of the structure with the EIFS installation, the available reading angles, and whether any obstacles are present such as trees and other buildings.

Data can be uploaded directly to a cloud-based application 34 by the drone 28, handheld reader 32, and fixed reader 22 using an onboard 4G or 5G wireless cell connection, or the data can be relayed to another point where it may be uploaded to the cloud-based application 34. In many embodiments, the cloud-based application 34 can perform analysis on the data to generate trend charts and statistical process-control charts, and to perform predictive analytics using applied statistics and Artificial Intelligence (AI)-based machine-learning algorithms. The AI algorithms can be used to predict whether an EIFS installation could soon suffer build-up of excessive moisture so that preventative measures can be timely taken before damage to the underlying structure occurs. The cloud-based application 34 can also augment the database with weather conditions encountered by each EIFS installation in order to help correlate the data obtained from the wireless RFID sensors with actual weather conditions encountered so that prediction capabilities are enhanced. The information from the cloud-application 34 can be available through a wireless application running on a smart phone 35 or through another remote computing device such as a tablet or computer. Furthermore, the cloud-based application 34 uses aggregate data from all EIFS installations uploading data in order to improve the leak-prediction capabilities of the AI-based algorithms.

FIG. 5A also depicts an embodiment for a method that can be used to perform a topographical mapping of an EIFS installation. Handheld RFID reader 32 is equipped with a metalized directional-reading shield 32A to limit the off-axis detection of wireless RFID tags 22.

When handheld RFID reader 32 detects a wireless RFID tag 22 immediately under improved moisture-sensing insulating panel 1, or even within a fully-clad EIFS installation, differential GPS device 31 records the location with high precision. This precision is typically within 25 cm horizontally and 50 cm vertically using an internal antenna. An example of a surveyor-quality differential GPS GNSS handheld device that can be used is the Trimble Geo 7X Handheld (see https://geospatial.trimble.com/products-and-solutions/geo-7x) with an external fixed antenna reference. The unique digital ID, temperature, and capacitance readings from wireless RFID tag 22 as captured by RFID reader 32, and precise location information from differential GPS device 31, including photos or video records, can then be either stored in the memory of differential GPS device 31, or the data can be relayed to a local computer-storage device, or the data can be uploaded to the cloud application 34. When all wireless RFID tag 22 within the EIFS installation have been located, read, and mapped (tag's unique digital ID associated with precision differential GPS location), the topographical mapping of the EIFS installation will have been completed. This topographical mapping operation may only need to be performed once immediately after installation of the EIFS. The data from each wireless RFID tag 22 allows the initial improved moisture-sensing insulation panel 1/1A readings of the EIFS installation to be normalized by referencing all future readings to this baseline (also referred to as a calibration tare). Any future improved moisture-sensing insulation panel 1/1A readings that depart from the baseline will be obvious when tracked over time. An initial-installation verification can then be performed by ensuring that no improved moisture-sensing insulation panels 1/1A depart statistically from the initial baseline. Any wireless RFID tags 22 readings with departures from the baseline that are statistically significant, are flagged as “Out-of-Family” (OOF) and warrant further investigation. OOF readings upon initial-installation verification can be caused by improperly installed insulation panels from either too much or too little basecoat 5 used to bond the improved moisture-sensing insulation panels 1/1A to the barrier membrane 4.

The handheld topographical mapping of an EIFS installation can be used for smaller structures of <10 kSQF. As an example, assuming improved moisture-sensing insulation panels 1/1A of 2×4 feet (or 8-SQF each), 10 kSQF implies around 1000 moisture-sensing insulation panels 1/1A panels, assuming that 25% of the surface area would be doors, windows, and other openings in the building structure. Therefore, it may be more-effective to perform the installation verification jointly with the installation process, or an installation verification immediately after each section of EIFS has been completed. It is also be possible to mount the RFID reader 32 with directional reading shield 32A, differential GPS device 31, and cameras or video-recording devices on a vehicle and drive slowly around the perimeter of a building structure. However, this methodology would only be effective for structures that are no more than two stories in height because of the range limitations of the RFID readers. The directional nature of the initial topographical mapping survey requires that each wireless RFID tag 22 location be precisely known. For topographical mapping surveys by vehicle, it may be possible to use the photographic or video-recording data to rebuild/map the location of each wireless RFID tag 22 visually, but again the directional reading shield 32A would be required to ensure that only one tag is being read at a time. As a result, the practicality of vehicle-based topographical mapping may be limited.

In many embodiments, it is also possible to perform the topographical mapping with a drone 28 using the RFID reader 29 and high-definition camera or video-recording device 30, along with the plurality of bar codes 27 stamped or printed onto the distal side of improved moisture-sensing insulation panels 1/1A. Because each bar code 27 encodes the unique digital ID of the wireless RFID chip 22 contained within the improved moisture-sensing insulation panels 1/1A, the drone-based observation is able to relate its data from each wireless RFID tag 22 reading and correlate this data with the unique digital ID to the bar code 27. This can be accomplished by reading dozens or even hundreds of wireless RFID tags 22 simultaneously within the field of view of the high-definition camera or video-recording device 30. In some cases, it is possible to use the photographic or video-recording data to rebuild/map the location of each wireless RFID tag 22 visually within the cloud application 34 without the need for a differential GPS 31 device. The unique digital ID, temperature, and capacitance readings from wireless RFID tag 22, as captured by RFID reader 32, and precise location information from photos or video records, can be relayed to a local computer-storage device, or the data can be uploaded to the cloud application 34. When all wireless RFID tag 22 within the EIFS installation have been located, read, and mapped (tag's unique digital ID associated with precision differential GPS location), the topographical mapping of the EIFS installation will have been completed.

Because topographical mapping by drone 28 relies on being able to image the plurality of bar codes 27 stamped or printed onto the distal side of improved moisture-sensing insulation panels 1/1A, it is necessary to perform the installation verification while the EIFS installation process is occurring. In this scenario, drone 28 with RFID reader 29 and high-definition camera or video-recording device 30, periodically sweep by the installation contractors as they are placing improved moisture-sensing insulation panels 1/1A in order to obtain wireless RFID tag 22 readings while the plurality of bar codes 27 are visible, prior to the application of the strengthening mesh 8, basecoat 9, and finishing coat 10. Finally, it is possible to print or apply the bar code 27 with a material such as conductive ink or polymers that have a different infrared signature from the base material of improved moisture-sensing insulation panels 1/1A, and/or the bar code 27 can be printed onto raised or recessed areas that have a physical pattern identical with the bar code 27 pattern. In this case, it is possible to obtain the infrared image of the plurality of bar codes 27 through strengthening mesh 8, basecoat 9 and finishing coat 10. The following restrictions would apply for the infrared method described here: (1) The high definition camera or video recording device 30 used for drone 28 with RFID reader 29 must have infrared wavelength capability; (2) The metalized bar code 27 placed on the distal side of improved moisture-sensing insulation panels 1/1A, have to be made as large as possible to improve its infrared detectability; and (3) The metalized bar code 27 placed on the distal side of improved moisture-sensing insulation panels 1/1A have to be placed so as not to interfere with the antenna of wireless RFID tags 22 while the tags are being read.

Finally, some observations and notes must be made for the number of improved moisture-sensing insulation panels 1/1A required for an EIFS installation. Assuming 8-SQF per moisture-sensing insulation panels 1/1A and 25% of a structure's vertical wall area is devoted to doors, windows, and other openings, as well as one wireless RFID tag 22 per improved moisture-sensing insulation panels 1/1A, the number of wireless RFID tags 22 required for a large EIFS installation may become excessive (e.g., approximately 10,000 tags for a 100 kSQF structure). In view of this, the following can be considered to mitigate this situation:

• • The size of the improved moisture-sensing insulation panels 1/1A can be increased (this is especially true for prefabricated EIFS panels) to also increase the coverage area of each panel; and/or
  • Improved moisture-sensing insulation panels 1/1A can be placed in lower densities on center sections of wall (i.e., only every other panel would be an improved moisture-sensing insulation panels 1/1A and arranged in a checkerboard pattern) and only concentrated in higher densities along known trouble areas such as rooflines, windows, and other joints; and/or
  • State-of-the art UHF Gen-2 RFID readers can simultaneously read nearly 1000 tags per second, which implies a drone 28 survey may read as much as 10 kSQF area of installed EIFS paneling per second. This may be limited in practice due to the building geometry and readings angles coupled with the maximum reading range as dictated by the RFID reader 29 EIRP available from the drone 28 battery pack. Notably, a vehicle-borne survey would not have the same power restrictions as the drone 28, so full EIRP might be available and with it a maximum RFID reading range. Therefore, it does not appear that the ability to obtain RFID readings from an EIFS-clad structure is a limiting factor for maximum wireless RFID tag 22 count.

Referring to the method flowchart of FIG. 6A, the installation-topography-mapping method consists of three basic functions/steps: (1) Readout data all RFID sensor tags; (2) Associate the location of each RFID sensor tag with the physical location of that tag within the installation; and (3) Normalize the dry readings of all the RFID sensor tags by using a calibration tare. The installation-topography-mapping method is necessary to identify the physical location of every RFID sensor tag within the EIFS installation and establish the dry baseline reading of the system. The installation-topography-mapping process begins 101 after the “smart” EIFS with intrinsic moisture-sensing capability has been installed on a structure. The following algorithm is performed each time an RFID data readout 102 is made:

• • IF the associated panel or membrane transponder (TID) barcode is visible 104,
  • THEN (YES) associate the visible TID barcode 27 marking and with the actual RFID data readout TID;
  • ELSE (NO) 103 use an alternate tag location method.

The alternate tag location method 103 may be using a very low RFID reader; e.g., Effective Isotropic Radiated Power (ERIP) or a metalized-directional-reading shield; so that only the closest tag may be read:

• • IF differential GPS is available 105,
  • THEN (YES) read the differential GPS location coordinate 107 and write the differential GPS location coordinates 108 to the non-volatile memory of the RFID tag:
  • ELSE (NO), write the visual or directional coordinates 106 to the non-volatile memory of the RFID tag.

Optionally, even when differential GPS location coordinates 108 are available, the visual or directional coordinates 106 can also be written to the non-volatile memory of the RFID tag. The visual or directional coordinates 103 can consist of locating the position of an RFID tag within the installation using a camera or laser rangefinder to determine the distance and angular bearing from pre-surveyed physical datums and/or using a camera to determine the location within a pre-plotted physical grid marked upon the installation. The RFID tag moisture and temperature reading 110 is made after the transponder ID (TID) and tag location have been established.

As the RFID readings continue to be taken, the data for each RFID tag is checked 111 for an Out-of-Family (OOF) reading when compared to all the other RFID tags read.

• • IF (YES) tag reading is OOF,
  • THEN begin a diagnostic routine 112 to determine the problem.
  • IF the reading anomaly 113 has been resolved (or addressed),
  • THEN (YES) send all the tag information 114 to the cloud application database;
  • ELSE (NO) continue diagnostics 112 routines.
  • IF all tags in an installation have been read and location mapped 116,
  • THEN (YES) the topographical mapping is complete 118;
  • ELSE (NO) continue 117 to read 102 more tags.

The installation-verification method depicted in the flowchart of FIG. 6B consists of two basic functions/steps: (1) Readout test data all RFID sensor tags with water placed on installed panels; and (2) Determine whether any RFID sensor tag readings are OOF. The installation-verification method is used to determine whether an installed EIFS is performing adequately under water-loading and/or wetted test conditions prior to being placed in service.

The installation verification process begins 200 after the EIFS with intrinsic moisture-sensing capability has been installed on a structure and only after the installation topography mapping method of FIG. 6A have been completed. The verification begins 201 by wetting the membrane or panels on all or part of an installation 202. This may require the spraying an air barrier or EIFS surface with water. After wetting, the RFID data readouts 203 are made and compared to the baseline readings 118C from the topological mapping 204:

• • IF an RFID sensor reading 205 is OOF,
  • THEN (YES) enter installation problem routines 206 to locate the leak or moisture-infiltration point;
  • ELSE (NO) send the installation verification data 208 along with the date and time to the cloud application 115b; the installation verification has passed and is completed 209.

For OOF readings, SPC and other statistical methods known in the art can be used to help establish the control limits where readings that fall outside the control limits are deemed as OOF. The cloud-based application can be used to calculate and establish the preliminary control limits used for installation-verification checks. Additionally, after many installations have been made and verified, the control limits can be adjusted based on expected normal sensor-tag-reading behavior under installation verification conditions for each type of installation. As an example, the drainage plane of an EIFS installation can be expected to allow moisture to enter under wetted conditions, but the drainage plane will then dry out over time. Therefore, EIFS-panel-moisture readings can be dynamic in nature, with moisture readings that fluctuate with time, and departures from the expected dynamic behavior constitutes an OOF condition.

V. Alternative Embodiments and Other Variations

The various embodiments and variations thereof described herein, including the descriptions in any appended Claims and/or illustrated in the accompanying Figures, are merely exemplary and are not meant to limit the scope of the inventive disclosure. It should be appreciated that numerous variations of the invention have been contemplated as would be obvious to one of ordinary skill in the art with the benefit of this disclosure.

Hence, those ordinarily skilled in the art will have no difficulty devising myriad obvious variations and improvements to the invention, all of which are intended to be encompassed within the scope of the Description, Figures, and Claims herein.

Claims

1. An improved moisture-sensing-insulation panel for use in above-ground building structures, having a proximal side that is intended to be installed facing the interior of a building structure and a distal side that is intended to be installed facing away from the interior of a building structure, comprising:

a structural panel disposed on said proximal side of said improved moisture-sensing-insulation panel;

a waterproof and vapor-impermeable moisture-barrier membrane, disposed on the distal side of said structural panel;

an insulating panel affixed to the distal side of said moisture-barrier membrane having a plurality of vertical-drainage channels disposed on the proximal side of said insulating panel and adjacent to said moisture-barrier membrane, forming a drainage plane;

at least one moisture-sensing channel extending between at least two opposing edges of said insulating panel and exposed to said moisture-barrier membrane, said at least one moisture-sensing channel having a proximal surface and containing within it a moisture-sensing membrane, wherein: said at least one moisture-sensing channel intersects at least most of said-vertical drainage channels, said moisture-sensing membrane is comprised of: a first conductive metalized coating, a second conductive metalized coating with a thin polymer or fluoropolymer membrane, a wicking layer is disposed upon between said first and second conductive metalized coatings, said wicking layer substantially comprised of hydrophilic material, and one or more moisture-sensing devices disposed on the distal side of said at least one moisture-sensing channel, in electrical communication with each of said first and second conductive metalized coatings; wherein: said moisture-sensing membrane has a width that is less than the width of said at least one moisture-sensing channel to create a gap that allows for moisture to drain and contact said wicking layer, and said first and second conductive metalized coatings are electrically isolated from each other; and

a strengthening layer disposed on the distal side of said insulating panel.

2. The improved moisture-sensing-insulation panel of claim 1, wherein at least one of said one or more moisture-sensing devices is comprised of:

a semi-permeable membrane disposed over the proximal side of said moisture-sensing membrane, over the area where said moisture-sensing device resides, wherein: said semi-permeable membrane has a plurality of perforations of a size of less than 5 microns in diameter, and said semi-permeable membrane helps facilitate the detection of the buildup of basecoat materials that compromise the effectiveness of the drainage plane and resists the ionic contamination of said moisture-sensing device;

mastic sealant applied to the longitudinal edges of said moisture-sensing device to resist ionic contamination; and

a wireless RFID tag in electrical communication with each of said first and second conductive metalized coatings disposed on the distal side of said semi-permeable membrane.

3. The improved moisture-sensing-insulation panel of claim 2, wherein at least one of said one or more moisture-sensing devices is adapted to measure coplanar capacitance across said sensing membrane.

4. The improved moisture-sensing-insulation panel of claim 2, wherein at least one of said one or more moisture-sensing devices' wireless RFID tag is further comprised of an internal test load adapted to facilitate self-testing and diagnostic checks of the moisture-detection device residing within said at least one moisture-sensing channel.

5. The improved moisture-sensing-insulation panel of claim 2, wherein at least one of said one or more moisture-sensing devices is adapted to measure biplanar capacitance across said sensing membrane.

6. The improved moisture-sensing-insulation panel of claim 2, wherein at least one of said one or more moisture-sensing devices is adapted to measure resistance across said sensing membrane.

7. The improved moisture-sensing-insulation panel of claim 2, wherein any cavity between said wireless RFID tag and the other layers of said moisture-sensing membrane is filled with insulating material and/or an elastomeric adhesive potting compound in order to minimize the trapping of moisture and further protect said wireless RFID tag.

8. The improved moisture-sensing-insulation panel of claim 1, wherein there are two of said at least one moisture-sensing channel, with the two moisture-sensing channels arranged in an X-pattern, extending from corner to corner of said improved moisture-sensing insulating panel.

9. The improved moisture-sensing-insulation panel of claim 1, wherein there are a plurality of said at least one moisture-sensing channel, with the moisture-sensing channels densely arranged in a crossing patterns such that the moisture-sensing plane extends over the entire improved moisture-sensing insulating panel.

10. The improved moisture-sensing-insulation panel of claim 1, wherein there is one of said at least one moisture-sensing channel, with the moisture-sensing channel arranged in a diagonal pattern, extending from one lower corner to the opposite upper corner of said improved moisture-sensing panel.

11. The improved moisture-sensing-insulation panel of claim 1, wherein said at least one moisture-sensing channel is arranged in a horizontal pattern, extending from one vertical edge to the opposite vertical edge of said improved moisture-sensing panel.

12. The improved moisture-sensing-insulation panel of claim 11, wherein a plurality of small vertical channels are cut into the surface of said insulating panel in order to augment the augment the ability of said at least one moisture-sensing channel to detect moisture.

13. The improved moisture-sensing-insulation panel of claim 1, further comprising a plurality of bar-code patterns are ink-stamped or printed onto the distal side of said improved moisture-sensing insulating panel, wherein said bar codes are encoded with the unique digital ID of the wireless RFID tags of said installed wireless moisture-sensing devices that are co-located with said bar codes.

14. The improved moisture-sensing-insulation panel of claim 1, further comprising a plurality of stenciled or printed “keep-away” areas disposed on the distal surface of said insulating panel, wherein said plurality of stenciled or printed “keep-away” areas are spatially aligned with said at least one moisture-sensing channel and any moisture-sensing devices disposed therein such that persons installing said improved moisture-sensing insulation panel on a structure are provided visual indications of the locations of said plurality of moisture-sensing channels and devices to avoid damaging any moisture-sensing devices.

15. A method to detect and process moisture-detection signals within a building structure, said building structure comprising at least one improved moisture-sensing insulation panels according to claim 1, the method comprising the steps of:

installing a building structure that comprises at least one improved moisture-sensing insulation panel according to claim 1;

using an RFID reader, mapping the locations of each moisture-sensing device contained in said at least one improved moisture-sensing insulation panel;

wirelessly transferring RFID reader data to and from each moisture-sensing device contained in said at least one improved moisture-sensing insulation panel;

remotely collecting and storing baseline data from said moisture-sensing devices contained in said at least one improved moisture-sensing insulation panel;

using an RFID reader, detecting moisture infiltration into said building structure by reading the RFID tags for said moisture-sensing devices contained in said at least one improved moisture-sensing insulation panel;

using an RFID reader, determining the location of the moisture infiltration into said roofing structure by reading data from the RFID tags for said moisture-sensing elements contained in said at least one improved moisture-sensing membrane;

wirelessly transferring RFID reader data to and from each moisture-sensing element contained in said at least one improved moisture-sensing membrane; and

remotely collecting and storing data from said moisture-sensing elements contained in said at least one improved moisture-sensing membrane.

16. The method of claim 15, wherein the mapping step uses a GPS device in conjunction with said RFID reader to map the locations of each moisture-sensing device contained in said at least one improved moisture-sensing insulation panel.

17. The method of claim 15, further comprising the steps of:

using statistical methods to determine when moisture readings become out-of-family (OOF);

using predictive analytics for at least one improved moisture-sensing membrane for said building structure; and

using encryption to protect both said transferred and stored data gathered from the at least one improved moisture-sensing insulation panel of said building structure.

18. The method of claim 15, further comprising the step of establishing a “keep-away” zone or visual markers on the surface of said at least one improved moisture-sensing membrane in order to prevent damage said each moisture-sensing elements contained in said at least one improved moisture-sensing membrane during the installation of said roofing structure.

19. The method of claim 15, wherein said RFID-tag readings are accomplished by one or more of the following means:

using a remotely-controlled or autonomous flying drone that can fly within the RFID tags' range to make readings; and/or

using a mounted RFID reader with a directional reading shield, differential GPS device, and high-definition cameras or video-recording devices on a vehicle and driving slowly around the perimeter of said building structure to make readings.

20. The method of claim 15, wherein said moisture-sensing devices contained in said at least one improved moisture-sensing installation panel use electrical impedance within a sensor-detection element or elements to sense the presence of moisture by measuring one or more of the following:

biplanar capacitance;

electrical resistance;

both biplanar capacitance and electrical resistance; and/or

changes in the antenna RLC impedance of the RFID-enabled sensor itself.