# US 12,759,014 B2 · Methods and systems for making environmental sensors utilizing powder dispensing techniques > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,014 B2 - Document ID: US12759014B2 - Status: Granted - Kind: B2 - Application number: 18/385,704 - Filed: 2023-10-31 - Published: 2025-05-01 - Granted: 2026-10-13 - Earliest claimed: 2023-10-31 - Assignees: Zebra Technologies Corporation - Applicants: Temptime Corporation - Inventors: Brian S. Huffman; Thi N. Do; Deniz Boyu; Marielle K. Smith - Web page: https://patentgrep.com/patent/US12759014B2 ## CPC - B05C 19/04: the particulate material being projected, poured or allowed to flow onto the surface of the work (B05C19/02 takes precedence; involving spraying or electrostatic projection B05B ){(B05C19/005 takes precedence)} - B05C 5/0212: {only at particular parts of the articles (at particular part of web, band, strip, belt or ribbon B05C5/025)} - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B32B 2305/54: Filled microcapsules - G01D 1/18: with arrangements for signalling that a predetermined value of an unspecified parameter has been exceeded (G01D1/14 takes precedence) - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - G01D: MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR ## Abstract Disclosed is a process to manufacture an environmental sensor. The process includes dispensing a dry powder material to a first area on a media element, wherein the powder material includes a plurality of microcapsules, each microcapsule encapsulating an environmental indicator material. The process further includes dispensing an adhesive to the media element. After the powder material and the adhesive have been dispensed to the media element, the powder material is in contact with the dispensed adhesive, and the adhesive holds the powder material in position. ## Claims ### Claim 1 A process to manufacture an environmental sensor, the process comprising: dispensing a dry powder material to a first area on a media element, wherein the powder material comprises a plurality of microcapsules, each microcapsule encapsulating an environmental indicator material; and dispensing an adhesive to the media element, wherein after the powder material and the adhesive have been dispensed to the media element, the powder material is in contact with the dispensed adhesive, and the adhesive holds the powder material in position. ### Claim 2 (depends on 1) The process of claim 1, wherein the plurality of microcapsules release the environmental indicator material when ruptured, wherein the environmental indicator material is configured, in response to exposure to a predetermined environmental condition, to change from an original state to a second state producing an observable effect, wherein the plurality of microcapsules prevent an occurrence of the observable effect while the environmental indicator material is encapsulated and allow the occurrence of the observable effect when the environmental indicator material is exposed to the predetermined environmental condition after at least a portion of the plurality of microcapsules are ruptured, wherein the process further comprises rupturing at least a portion of the plurality of microcapsules releasing the environmental indicator material, and wherein the observable effect comprises at least one effect selected from the group consisting of a color state change, a change in transparency, a change in hue, a change in an electrical property, a change in conductivity, a change in capacitance, a movement of the environmental indicator material along a substrate, and combinations thereof. ### Claim 3 (depends on 2) The process of claim 2, wherein the predetermined environmental condition comprises at least one condition selected from the group consisting of temperature excursion above a predetermined temperature threshold for at least a predetermined amount of time, temperature excursion below a predetermined temperature for at least a predetermined amount of time, cumulative exposure to temperature over a time period above a predetermined threshold for at least a predetermined amount of time, exposure to a particular chemical, oxygen exposure, ammonia exposure, exposure to a particular chemical above a threshold concentration, exposure to a particular chemical above the threshold concentration for at least a predetermined amount of time, exposure to at least a predetermined amount of radiation of a particular type, ultraviolet light exposure, humidity exposure, exposure to a humidity level above a predetermined threshold, and exposure to a humidity level above a predetermined threshold for at least a predetermined amount of time. ### Claim 4 (depends on 3) The process of claim 3, wherein the predetermined environmental condition comprises temperature excursion above a predetermined threshold for at least a predetermined amount of time. ### Claim 5 (depends on 3) The process of claim 3 wherein the predetermine environmental condition comprises exposure to a humidity level above a predetermined threshold for at least a predetermined amount of time. ### Claim 6 (depends on 2) The process of claim 2, wherein the observable effect comprises a color state change. ### Claim 7 (depends on 2) The process of claim 2, wherein the observable effect comprises a change in an electrical property. ### Claim 8 (depends on 2) The process of claim 2, wherein the observable effect comprises movement of the environmental indicator along a substrate. ### Claim 9 (depends on 2) The process of claim 2, wherein the plurality of microcapsules, prior to their rupture, prevent the observable effect by containing the environmental indicator material when the environmental indicator material liquifies. ### Claim 10 (depends on 2) The process of claim 2, wherein the plurality of microcapsules, prior to their rupture, prevent the observable effect by protecting the environmental indicator material from exposure to the predetermined environmental condition. ### Claim 11 (depends on 1) The process of claim 1, further comprising: applying a wick to the media element, wherein the wick covers at least a portion of the first area of the media element. ### Claim 12 (depends on 11) The process of claim 11, wherein the plurality of microcapsules release the environmental indicator material when ruptured, wherein the environmental indicator material is configured, in response to exposure to a predetermined environmental condition, to change from an original state to a second state producing an observable effect, wherein the plurality of microcapsules prevent an occurrence of the observable effect while the environmental indicator material is encapsulated and allow the occurrence of the observable effect when the environmental indicator material is exposed to the predetermined environmental condition after at least a portion of the plurality of microcapsules are ruptured; and wherein the process further comprises rupturing at least a portion of the plurality of microcapsules releasing the environmental indicator material into contact with the wick. ### Claim 13 (depends on 12) The process of claim 12, wherein the media element comprises an electrical component, wherein the wick covers at least a portion of the first area of the media element and at least a portion of the electrical component, wherein the predetermined environmental condition comprises a temperature excursion above a predetermined temperature threshold, and wherein in response to exposure to a temperature above the predetermined temperature threshold, the environmental indicator material changes from the original state to the second state producing the observable effect of changing an electrical property of the electrical component. ### Claim 14 (depends on 13) The process of claim 13, wherein the electrical component is positioned outside of the first area, and wherein in response to exposure to the temperature above the predetermined temperature threshold, the environmental indicator material moves along the wick to the electrical component producing the observable effect of changing the electrical property of the electrical component. ### Claim 15 (depends on 12) The process of claim 12, wherein the predetermined environmental condition comprises a temperature excursion above a predetermined temperature threshold, and wherein in response to exposure to a temperature above the predetermined temperature threshold, the environmental indicator material changes from the original state to the second state producing the observable effect of changing a color of at least a portion of the wick of the media element. ### Claim 16 (depends on 1) The process of claim 1, wherein at least a portion of the plurality of microcapsules are ruptured based on a force greater than a predetermined threshold, the force being at least one of a pressure force, a shear force, a frictional force, or a cutting force applied to the media element. ### Claim 17 (depends on 16) The process of claim 16, wherein the force is a pressure force applied to the media element. ### Claim 18 (depends on 1) The process of claim 1, further comprising: applying a wick to the media element, wherein at least a portion of the wick is proximate the first area, so that liquid released from the microcapsules is absorbed by the wick. ### Claim 19 (depends on 1) The process of claim 1, further comprising rupturing the microcapsules by applying heat to the microcapsules. ### Claim 20 (depends on 1) The process of claim 1, further comprising rupturing the microcapsules by applying a combination of heat and pressure to the microcapsules.