Water leak detection systems for flat commercial roof structures

• US 10,458,877 B1
• Filed: 04/26/2018
• Issued: 10/29/2019
• Est. Priority Date: 04/26/2018
• Status: Active Grant

• Current Assignee: Molex LLC (KOCH Industries Incorporated)
• Original Assignee: Molex LLC (KOCH Industries Incorporated)
• Inventors: Fulton, Steven J., Sharma, Pankaj, Hennes, Jay, Cole, Jesse J., Ganser, III, Martin L., Balder, Daniel A., Irwin, Robert, Deppe, Michael
• Primary Examiner(s): Blouin, Mark S
• Application Number:
  US15/963,226
• Publication Number:
  US 20190331546A1
• Time in Patent Office: 551 Days
• Field of Search: 340605
• CPC Class Codes: E04D 13/006 Provisions for detecting water leakage
• CPC Class Codes: G01M 3/16 using electric detection means G01M3/045, G01M3/06, G01M3/12, G01M3/20, G01M3/24, G01M3/26 take precedence

Abstract

A leak detection system for flat commercial roof structures is disclosed in order to detect and subsequently repair a leak as soon as possible such that any damage to the roof, as well as to other structural and/or insulation components of the overall roof structure, can be minimized due to the absorption or migration of the water. The leak detection system may comprise elongated water detection sensor strips to be fixedly secured to at least two edge portions of insulation board assemblies, or alternatively, electrical circuits may be provided over the entire expanse of the major upper surface portion of each insulation board assembly, or alternatively still further, rolls of water detection sensor strips may be applied to different regions of the flat commercial roof structure.

Claims

1. A water leak detection system for use in connection with flat commercial roof structures, comprising:

an insulation board assembly, with a flat top and bottom surface and four side surfaces, fixedly secured to the flat commercial roof structure;

a water detection sensor strip having a pair of separate electrical circuits fixedly secured thereon and spaced apart from each other by means of a predetermined gap so as to thereby define a normally open electrical circuit upon said water detection sensor strip, said water detection sensor strip being fixedly secured to at least two side surfaces of said insulation board assembly;

an electrical power source electrically connected to said normally open electrical circuit defined upon said water detection sensor strip; and

a control station electrically connected to said normally open electrical circuit defined upon said water detection sensor strip for receiving a water detection signal, from said normally open electrical circuit defined upon said water detection sensor strip, which is generated from said normally open electrical circuit defined upon said water detection sensor strip when water migrates into said gap defined between said pair of separate electrical circuits so as to effectively bridge said gap and thereby close said normally open electrical circuit.

2. The water leak detection system as set forth in claim 1, wherein:

said insulation board assembly comprises a laminated structure comprising a central core fabricated from a closed-cell non-absorbent foam, and a pair of cardboard sheets disposed upon opposite upper and lower major surface portions of said central core.

3. The water leak detection system as set forth in claim 1, wherein:

said water detection sensor strip is fixedly secured to at least two adjacent side surfaces of said insulation board assembly.

4. The water leak detection system as set forth in claim 3, wherein:

said water detection sensor strip, fixedly secured to said at least two adjacent side surfaces of said insulation board assembly, are secured to a front side surface of said insulation board assembly and a right side surface of said insulation board assembly.

5. The water leak detection system as set forth in claim 4, wherein:

said water detection sensor strip, fixedly secured to said front side surface of said insulation board assembly and said right side surface of said insulation board assembly, also comprise water detection sensor strip extensions which wrap around a left side surface of said insulation board assembly and a rear side surface of said insulation board assembly.

6. The water leak detection system as set forth in claim 5, further comprising:

a plurality of electrical connectors respectively provided upon said portions of said water detection sensor strip covering said front side surface of said insulation board assembly and said right side surface of said insulation board assembly, as well as upon said water detection sensor strip extensions extending over said left side surface of said insulation board assembly and said rear side surface of said insulation board assembly, so as to permit a plurality of insulation board assemblies, likewise provided with said water detection sensor strip, said water detection sensor strip extensions, and said plurality of electrical connectors, to be electrically connected to each other.

7. The water leak detection system as set forth in claim 6, wherein:

each one of said plurality of electrical connectors comprises three, leaf-spring contacts which are respectively connected to ground, electrical power input, and data output channels through means of UART (universal asynchronous receiver-transmitter) hardware.

8. The water leak detection system as set forth in claim 7, wherein:

said insulation board assembly is provided with its own uniquely identifiable controller which communicates with said control station by means of said data output channel such that the location, at which a water leak is detected, is able to be accurately identified and reported to said control station by means of said data output channel of said UART (universal asynchronous receiver-transmitter) hardware.

9. The water leak detection system as set forth in claim 6, wherein:

said plurality of insulation board assemblies are arranged within a grid structure wherein said plurality of insulation board assemblies are aligned with each other in vertically extending columns and horizontally extending rows.

10. The water leak detection system as set forth in claim 6, wherein:

said plurality of insulation board assemblies are arranged within a grid structure wherein said plurality of insulation board assemblies are aligned with each other in horizontally extending rows but are misaligned with respect to each other in vertically extending columns such that said grid structure has a “

brick”

appearance.

11. A water leak detection system for use in connection with flat commercial roof structures, comprising:

an insulation board assembly fixedly secured to the flat commercial roof structure, wherein said insulation board assembly comprises upper and lower major surface portions, wherein the insulation board substantially covers an entire surface area of the flat commercial roof structure;

a pair of separate electrical circuits, spaced from each other by means of a predetermined gap, fixedly secured to said upper major surface portion of said insulation board assembly so as to substantially cover all portions of said upper major surface portion of said insulation board assembly and thereby define a normally open electrical circuit upon said upper major surface portion of said insulation board assembly, each one of said pair of electrical circuits comprises a plurality of electrical paths wherein each electrical path of a first one of said pair of electrical circuits is disposed adjacent to an electrical path of a second one of said pair of electrical circuits such that said electrical paths of said first one of said pair of electrical circuits are disposed in an interdigitated manner with respect to said electrical paths of said second one of said pair of electrical circuits;

an electrical power source electrically connected to said normally open electrical circuit defined upon said upper major surface portion of said insulation board assembly; and

a control station electrically connected to said normally open electrical circuit defined upon said upper major surface portion of said insulation board assembly for receiving a water leak detection signal, from said normally open electrical circuit defined upon said upper major surface portion of said insulation board assembly, which is generated from said normally open electrical circuit defined upon said upper major surface portion of said insulation board assembly when water migrates into said gap defined between said pair of two separate electrical circuits so as to close said normally open electrical circuit.

12. The water leak detection system as set forth in claim 11, wherein:

said insulation board assembly comprises a laminated structure comprising a central core fabricated from a closed-cell non-absorbent foam, and a pair of cardboard sheets disposed upon opposite upper and lower major surface portions of said central core.

13. The water leak detection system as set forth in claim 11, further comprising:

a plurality of electrical connectors respectively provided upon front, right side, left side, and rear edge portions of said insulation board assembly so as to permit a plurality of insulation board assemblies, likewise provided with said plurality of electrical connectors, to be electrically connected to each other.

14. The water leak detection system as set forth in claim 13, wherein:

each one of said plurality of electrical connectors comprises three contacts which are respectively connected to ground, electrical power input, and data output channels through means of UART (universal asynchronous receiver-transmitter) hardware.

15. The water leak detection system as set forth in claim 14, wherein:

said plurality of insulation board assemblies are arranged within a grid structure wherein said plurality of insulation board assemblies are aligned with each other in vertically extending columns and horizontally extending rows.

16. The water leak detection system as set forth in claim 14, wherein:

said plurality of insulation board assemblies are arranged within a grid structure wherein said plurality of insulation board assemblies are aligned with each other in horizontally extending rows but are misaligned with respect to each other in vertically extending columns such that said grid structure has a “

brick”

appearance.

17. A water leak detection system for use in connection with flat commercial roof structures, comprising:

a flat substrate; and

a plurality of rolls of water detection strips, each one of said rolls of water detection strips having a pair of separate electrical circuits fixedly secured thereon and spaced apart from each other by means of a predetermined gap so as to thereby define a normally open electrical circuit upon each one of said water detection strips, said plurality of water detection strips being fixedly secured to said flat substrate when said plurality of rolls of water detection strips are unrolled, each one of said pair of separate electrical circuits comprises a plurality of electrical paths wherein each electrical path of a first one of said pair of electrical circuits is disposed adjacent to an electrical path of a second one of said pair of electrical circuits such that said electrical paths of said first one of said pair of electrical circuits are disposed in an interdigitated manner with respect to said electrical paths of said second one of said pair of electrical circuits;

a bus line electrically connected to each one of said normally open electrical circuits defined upon said plurality of water detection strips; and

a control station electrically connected to said bus line for receiving a water detection signal, from any one of said normally open electrical circuits defined upon said plurality of water detection strips, which is generated from a particular one of said plurality of normally open electrical circuits defined upon said plurality of water detection strips when water migrates into said gap defined between said pair of separate electrical circuits defined upon said particular one of said plurality of normally open electrical circuits so as to effectively bridge said gap and thereby close said normally open electrical circuit.

18. The water leak detection system as set forth in claim 17, wherein:

said plurality of rolls of water detection strips can be applied to roof structures having various different geometrical configurations.

19. The water leak detection system as set forth in claim 17, wherein:

said plurality of rolls of water detection strips can be applied to roof structures in various different patterns.

20. The water leak detection system as set forth in claim 17, wherein:

said plurality of rolls of water detection strips can be applied to roof structures with various different distances defined between successive ones of said plurality of rolls of water detection strips.

21. The water leak detection system as set forth in claim 17, wherein:

measured resistance values across said pair of separate electrical circuits fixedly secured upon any one of said plurality of rolls of water detection strips is indicative of the location of the water leak as detected by said one of said plurality of rolls of water detection strips.

22. The water leak detection system as set forth in claim 17, wherein:

a plurality of microcontroller units (MCUs) are respectively connected to each one of said plurality of rolls of water detection strips and to said bus line; and

said control station is connected to said bus line so as to be able to uniquely address and identify which water detection strip is issuing a water leak detection signal whereby the location of the water leak is easily and readily identifiable.