IP Library Granted Patent US 12,509,828
Granted Patent B1
US 12,509,828 · App. 18/049,066 · Granted Dec 30, 2025

Sensor deployment for modular pavement slabs

Inventors: Tim Sylvester (Raytown, MO); Mustafa Tekinay (Overland Park, KS)
Assignee: INTEGRATED ROADWAYS IP LLC
E01C11/00E01C5/005G01G3/125G01G19/022G01G19/025G01G19/52G01L1/246G01L17/00G01M5/0041G01P3/36E01C2201/00
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Quick Facts
Patent No.
US 12,509,828
App. No.
18/049,066
Granted
Dec 30, 2025
Kind
B1
Abstract

A segment of roadway includes a body having a top surface and a sensor array comprising one or more optical fiber cables embedded in the body. The sensor array includes an integrity sensor and a temperature sensor. The integrity sensor is configured to monitor the body for structural damage and has a length of greater than fifty centimeters (50 cm). The temperature sensor is configured to detect temperature within the body and is surrounded by an air gap encased in a housing.

Claims (21)

1 . A segment of roadway comprising: a body having a top surface; and a sensor array comprising one or more optical fiber cables embedded in the body, the sensor array comprising an integrity strain sensor and a temperature sensor, the integrity strain sensor being configured to monitor the body for structural damage, the temperature sensor being configured to detect temperature within the body and being surrounded by an air gap encased in a housing; wherein the sensor array further comprises a plurality of vehicle-strain sensors configured to detect strain on the body resulting from vehicles traveling across the top surface; and wherein the temperature sensor operates at a scanning rate within ten percent (10%) of scanning rate(s) of the plurality of vehicle-strain sensors.

2 . The segment of roadway according to claim 1 , further comprising a processor configured to determine movement of the vehicles at least in part by using temperature data from the temperature sensor to analyze or interpret electrical signals from the plurality of vehicle-strain sensors.

3 . The segment of roadway according to claim 1 , wherein the plurality of vehicle-strain sensors each have a length extending substantially parallel to a direction of travel, with at least one of the length and a spatial resolution along the direction of travel being equal to or less than fifty centimeters (50 cm), and the integrity strain sensor has at least one of a spatial resolution and a length of greater than fifty centimeters (50 cm).

4 . The segment of roadway according to claim 1 , wherein each of the plurality of vehicle-strain sensors is separated from each other of the plurality of vehicle-strain sensors along a width axis perpendicular to a direction of travel by at least two inches (2 in.).

5 . The segment of roadway according to claim 1 , further comprising a processor configured to collect multiple electrical signals across time from each of the plurality of vehicle-strain sensors and to analyze the electrical signals to determine one or more of: (A) risk of a structural defect in the body, (B) risk of a problem with underlying sub-grade beneath the body, and (C) movement of passing objects across the top surface.

6 . The segment of roadway according to claim 1 , wherein the plurality of vehicle-strain sensors operate at a scanning rate of at least five hundred Hertz (500 Hz).

7 . The segment of roadway according to claim 1 , wherein the one or more optical fiber cables are embedded in a configuration that includes a bend with a bend radius of at least twenty millimeters (20 mm).

8 . The segment of roadway according to claim 7 , wherein each of the plurality of vehicle-strain sensors is separated from the bend by at least one centimeter (1 cm).

9 . The segment of roadway according to claim 1 , wherein each of the plurality of vehicle-strain sensors is separated from each other of the plurality of vehicle-strain sensors by at least one centimeter (1 cm).

10 . The segment of roadway according to claim 1 , wherein

a length of the body along a direction of travel is bisected by a length midpoint,

a width of the body perpendicular to the direction of travel is bisected by a width midpoint,

the plurality of vehicle-strain sensors are distributed across the body such that at least thirty percent (30%) of the vehicle-strain sensors are positioned on a first side of the length midpoint, at least thirty percent (30%) are positioned on a second, opposite side of the length midpoint, at least thirty percent (30%) are positioned on a first side of the width midpoint, and at least thirty percent (30%) are positioned on a second, opposite side of the width midpoint.

11 . The segment of roadway according to claim 1 , wherein the plurality of vehicle-strain sensors are distributed across at least fifty percent (50%) of a length of the body along a direction of travel, and the plurality of vehicle-strain sensors are oriented lengthwise substantially parallel to the direction of travel.

12 . The segment of roadway according to claim 1 , wherein a first of the one or more optical fiber cables enters and exits the housing respectively at entry and exit points, and the length of the first optical fiber cable within the housing is at least one percent (1%) greater than a shortest distance between the entry and exit points of the housing.

13 . The segment of roadway according to claim 1 , wherein any segments of the one or more optical fiber cables that intersect in a plane parallel to the top surface are separated from one another along a depth axis by a distance of at least two-tenths of an inch (0.2 in.).

14 . The segment of roadway according to claim 1 , wherein the body comprises a precast slab, further comprising a plurality of load-transferring connectors embedded along at least one of a plurality of sides of the slab and attached to an adjacent structure, the plurality of load-transferring connectors being configured to transfer load on the precast slab corresponding to the passing vehicles between the precast slab and the adjacent structure.

15 . The segment of roadway according to claim 14 , further comprising a reinforcement layer embedded in the body.

16 . The segment of roadway according to claim 15 , wherein at least one of the one or more optical fiber cables is fixed to the reinforcement layer.

17 . The segment of roadway according to claim 15 , wherein the plurality of sides of the slab respectively define a length of the body in a direction of travel and a width of the body perpendicular to the length, and the reinforcement layer is configured in a grid pattern and extends across at least seventy percent (70%) of the length of the slab and across at least seventy percent (70%) of the width of the slab.

18 . The segment of roadway according to claim 1 , wherein the integrity strain sensor operates at a scanning rate of less than two hundred Hertz (200 Hz).

Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 18, 2025
From: INTEGRATED ROADWAYS, INC.
To: INTEGRATED ROADWAYS IP LLC
Reel/Frame 072666/0944 →
COURT APPOINTMENT Recorded Apr 22, 2025
From: INTEGRATED ROADWAYS, INC.
To: RALLY CAPITAL SERVICES, LLC
Reel/Frame 070912/0708 →
CHANGE OF NAME Recorded Mar 7, 2025
From: INTEGRATED ROADWAYS, LLC
To: INTEGRATED ROADWAYS, INC.
Reel/Frame 070439/0345 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 25, 2022
From: SYLVESTER, TIM; TEKINAY, MUSTAFA
To: INTEGRATED ROADWAYS, LLC
Reel/Frame 061527/0460 →
Continuity (9)
Continuation 18048886 · Oct 24, 2022
Continuation In Part 17851163 · Jun 28, 2022
Continuation 17471470 · Sep 10, 2021
Continuation In Part 17226159 · Apr 9, 2021
Continuation 16528024 · Jul 31, 2019
Continuation 15889718 · Feb 6, 2018
Provisional Application 63076767 · Sep 10, 2020
Provisional Application 62594822 · Dec 5, 2017
Provisional Application 62455287 · Feb 6, 2017
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