INTEGRATED SYSTEM FOR LEAK DETECTION USING CONDUCTIVE INK SENSOR ARRAYS IN A ROOFING ASSEMBLY

Description

RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application Ser. No. 63/700,231, filed Sep. 27, 2024, entitled Integrated System for Leak Detection Using Conductive Ink Sensor Arrays on Roofing Membranes, and to U.S. Provisional Patent Application Ser. No. 63/735,199, filed Dec. 17, 2024, of same title, the entire disclosures of which are incorporated herein by reference in their entireties for all purposes.

TECHNICAL FIELD

The present invention relates to systems for automatically detecting leaks in building roofs.

Summary of the Invention

The present system provides continuous monitoring for detecting leaks in a roofing assembly. An advantage of the present system of continuous monitoring is that small leaks are detected quickly before they have the chance to grow into larger leaks and damage the roof. By catching leaks early, the present system averts the potential for significant water damage.

Being automated, the present leak detection system avoids the problem of scheduling and performing manual inspections. The present approach also reduces the potential for human error in leak detection. Since the present system is very accurate in locating leaks, it thereby streamlines maintenance and ensures more effective repair work. In addition, the present leak detection system can easily be integrated into existing building management protocols.

In preferred aspects, the present system provides a system for detecting leaks in roofing membranes, comprising: (a) an insulation board; (b) a pattern of conductive ink positioned at a location above or on top of the insulation board; (c) a roofing membrane positioned above the pattern of conductive ink; (d) a central processor; and (e) a plurality of communication modules that communicate with the central processor.

Each communication module in the present system is electrically or wirelessly connected to the pattern of conductive ink to detect leaks. The present communication modules are configured to detect the presence of water on a portion of the pattern of conductive ink and to transmit this data to the central processor such that the central processor can provide continuous monitoring of water leaks across the pattern of conductive ink.

In one preferred embodiment, the pattern of conductive ink may be printed directly onto a substrate that is positioned between the bottom of the roofing membrane and the top of the insulation board. This substrate may fully cover the insulation board (thereby essentially fully covering the roof surface). In such an embodiment, the leak detection communication modules can be disposed in an array across the patterns of conductive ink. Alternatively, however, the substrate may instead only cover a smaller region of the roof such as overlapping seams between the edges of adjacent sections of roofing membranes. In this particular embodiment, the plurality of communication modules may instead be disposed in a line across the patterns of conductive ink (at the overlapping roofing membrane edges).

In alternative embodiments, the pattern of conductive ink may be printed directly onto the top of the insulation board, or directly onto the bottom of the roofing membrane.

In various preferred aspects, the leak detection communication modules may be secured directly to the top of the roofing membrane (either with mechanical fasteners or adhesives) to the top of the roofing membrane.

In various embodiments, the plurality of leak communication modules may be connected together by power lines, or they may instead be each independently battery powered. The individual communication modules each transmit their leak detection data to the central processor across a wireless network. Such data transmission may be done using many different approaches, including but not limited to a LoRaWAN or BlueTooth wireless network. The advantage of using a LoRaWAN network is that it requires very little power to operate. As such, the communication modules may be battery powered for years without the need to access the communication modules or their batteries. It is to be understood, however, that the wireless network may be a LoRaWAN or BlueTooth network, or any other suitable network.

In preferred embodiments, each of the communication modules detect the presence of water on a portion of the pattern of conductive ink by detecting changes in impedance across portions of the pattern of conductive ink.

The present system includes various assembly geometries. For example, the plurality of communication modules may be positioned on top of the roofing membrane while the pattern of conductive ink is positioned at a location underneath the roofing membrane. As such, the communication modules and the pattern of conductive ink may be positioned on opposite sides of the roofing membrane. Alternatively, however, the plurality of communication modules and the pattern of conductive ink may both be positioned underneath the roofing membrane (i.e.: on the same side of the roofing membrane).

In optional embodiments, a coverboard may be positioned on top of the insulation board between the insulation board and the pattern of conductive ink. The pattern of conductive ink may optionally even be printed on top of this coverboard.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side elevation view of the present system with an array of electronic communication modules positioned on top of a roofing membrane and a conductive ink substrate positioned below the roofing membrane, with the conductive ink substrate positioned on top of an insulation board.

FIG. 1B is a system similar to FIG. 1A but adds a coverboard between the insulation board and the conductive ink substrate.

FIG. 2 is an exploded perspective view corresponding to FIG. 1A.

FIG. 3A is a perspective view showing a sheet of the conductive ink substrate being positioned between overlapping edges of a pair of roofing membranes.

FIG. 3B is a top plan view corresponding to the assembled system of FIG. 3A.

FIG. 4 is a perspective view of an embodiment of the present system in which the conductive ink is printed directly onto the top of the insulation board.

FIG. 5 is an embodiment of the present system in which the conductive ink is printed directly onto the bottom of the roofing membrane.

FIG. 6A is a top perspective view of a T-Shaped junction for connecting conductive ink pathways on one insulation board to connective ink pathways on an adjacent insulation board with a conductive insert inserted between adjacent insulation boards. FIG. 6B is a side elevation view corresponding to FIG. 6A. FIG. 6C is an exploded perspective view corresponding to FIG. 6A. FIG. 6D is a side elevation view corresponding to FIG. 6C.

FIG. 7 is a sectional side elevation view of a combined T-Shaped junction and sensor hardware assembly positioned between the top edges of a pair of adjacent insulation boards.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention provides a system for automatically and continuously detecting leaks in roofing membranes. FIG. 1 illustrates an embodiment of this system without a coverboard whereas FIG. 1B illustrates an embodiment of this system with an optional coverboard installed between the insulation boards and the roofing membrane.

Referring first to FIG. 1A, the present system provides a leak detection system comprising:

• • an insulation board 10;
  • a pattern of conductive ink 20 positioned at a location above insulation board 10;
  • a roofing membrane 30 positioned above the pattern of conductive ink 20;
  • a central processor 50; and
  • a plurality of communication modules 40.

As will be explained, the present “pattern of conductive ink” may be a pattern of conductive ink printed directly onto one of the members of the roofing assembly or it may be a pattern of conductive ink printed onto a separate substrate 25 that is inserted between the insulation board 10 and the roofing membrane 30.

As seen in FIG. 1A, the pattern of conductive ink 20 may be printed on substrate 25. If an optional coverboard 60 is used as in FIG. 1B, then the substrate 20 can be positioned on top of coverboard 60.

FIG. 2 is an exploded perspective view corresponding to FIG. 1A. In various embodiments, each communication module 40 is electrically connected to the pattern of conductive ink 20. In preferred aspects, the connector system used for connecting the electronics of communication module 40 to the printed conductive wire pattern 20 on substrate 25 may be a connector such as described in Published US Patent Application 2021/0273363, entitled Electrical Connector. It is to be understood, however, that other suitable connector systems may also be used.

In accordance with the present system, each leak detection communication module 40 is configured to detect the presence of water on a portion of the pattern 20 of conductive ink. An example of a suitable sensor array for communication module 40 is found in U.S. Pat. No. 11,980,177, entitled Differential Pest Sensor. This system operates by comparing impedances across first and second circuits, and measuring impedance drops. This is because water on the conductive ink will cause conduction across the ink array that will cause a local, detectable decrease in impedance. Simply put, the present of water causes a short circuit that results in an impedance drop. As described in U.S. Pat. No. 11,980,177, the conductive ink pattern may include loops, fingers, and multiple long looping pathways of conductive wires. A similar example of a suitable sensor (for use as communication module 40) is also described in Published Patent Application WO2024/149982, entitled Leak Detection. The system described in this patent application also detects impedance across a respective sensing circuit from among a plurality of sensing circuits. Each sensing circuit is configured such that the corresponding impedance across the sensing circuit decreases when the sensing circuit is exposed to a liquid. As can be seen in Published Patent Application WO2024/149982, each of the sensing circuits may comprise a pair of conductive tracks separated by a corresponding gap. The conductive pattern may optionally be laid out as interdigitated fingers of conductive lines that form a wide area of sensing circuits. A wide variety of suitable designs are possible. In operation, positive and ground tracks of each sensing circuit are biased at different voltages, with an impedance between them provided by the gap.

It is to be understood that the present sensor or communication module system 40 is not limited to any of the embodiments or systems described in U.S. Pat. No. 11,980,177 or Published Patent Application WO2024/149982. However, both of U.S. Pat. No. 11,980,177 and Published Patent Application WO2024/149982 are incorporated herein by reference in their entireties for all purposes.

In preferred embodiments, each communication module 40 transmits data to central processor 50 such that central processor 50 provides continuous monitoring of water leaks across the pattern of conductive ink 20. By analyzing the impedance across several circuits and requiring a set number of them to fall within a predefined range, the present system can detect the presence of leaks without the need for invasive roof inspections. In preferred aspects, the present system has a parallel electric structure. As such, each branch of the conductive line grid operates independently, such that a leak affecting one section can be quickly isolated and identified.

In addition, the present system may preferably use LoRaWAN modules to transmit data, thereby ensuring prompt detection and reporting of leaks. This data transmission method advantageously allows for potential integration with other communication methods. In dense urban areas, these transmitters can wirelessly transmit data packets up to 2 km, and in rural areas where line-of-sight transmission is possible, the data transmission may be as far as up to 20 km (using low power wide-area network technology).

In preferred embodiments, the present conductive ink is made from cross-linked polymers, thereby being moisture resistant. As a result, water leaks are less likely to damage or wash away the conductive lines themselves.

As seen in FIG. 2, the plurality of communication modules 40 may be disposed in an array across the patterns of conductive ink. In such an arrangement, each communication module 40 is monitoring a separate region or portion of the overall substrate 25 for water intrusion. As can also be seen, communication modules 40 may be secured to the top of roofing membrane 30. For example, they may be mechanically fastened onto the top of roofing membrane 30 or adhered to the top of roofing membrane 30. In this illustrated embodiment, the plurality of communication modules 40 are each independently battery powered. Alternatively, however, the plurality of leak detection communication modules may instead be connected together by power lines.

As seen in FIG. 2, substrate 20 may fully cover the insulation board 10. This has the advantage of providing continuous leak detection across the entire surface of the roofing assembly. This wide coverage may not, however, be necessary in all cases. For example, FIGS. 3A and 3B illustrate an alternate embodiment of the present system in which a sheet or substrate 25 of the conductive ink pattern 20 is only positioned between the overlapping edges of a pair of roofing membranes 30A and 30B. In this embodiment, a smaller number of communication modules 40 are required, and these communication modules 40 may be positioned in a line (as opposed to a 2-D array pattern as in FIG. 2). Attachment of communication modules 40 to the edge of the roofing membrane 30A may be accomplished using any of the above-described methods. The advantage of installing the present leak detection system at only the overlapping edges of adjacent roofing membranes 30A and 30B is that it focusses effort on one of the most likely locations for water intrusion. Specifically, FIG. 3A is a perspective view showing a sheet of the conductive ink substrate being positioned overlapping edges of a pair of roofing membranes, and FIG. 3B is a top plan view corresponding to the assembled system of FIG. 3A. As seen in these Figs., a substrate 25 with printed conductive lines 20 thereon is positioned between the overlapping edges of roofing membranes 30A and 30B. When the overlapping edges of these roofing membranes have been sealed together as seen in FIG. 3B, the leak detection communication modules 40 will be in electrical communication with the pattern of conductive lines 20 in substrate 20. It is to be understood, however, that a separate substrate 25 is not necessary and that the conductive line pattern 20 may instead be printed on the top or bottom of the edges of the overlapping roofing membranes 30A and 30B, all keeping within the scope of the present invention.

Next, FIG. 4 shows a perspective view of an embodiment of the present system in which the conductive ink 25 is printed directly on top of the insulation board 10. This embodiment has the advantage of avoiding a separate printed substrate sheet 25. The leak detection electronics would operate as described with respect to the functioning of communication modules 40 and conductive lines 20.

FIG. 5 shows an embodiment of the present system in which the conductive ink 20 is instead printed directly on the bottom of roofing membrane 30. This embodiment also has the advantage of avoiding a separate printed substrate sheet 25. The leak detection electronics would also operate as described with respect to the functioning of communication modules 40 and conductive lines 20.

In the various above-described embodiments, different geometries are possible. For example, the plurality of communication modules 40 may be positioned on top of the roofing membrane 30 and the pattern of conductive ink 20 may be positioned underneath roofing membrane 30. Alternatively, however, the plurality of communication modules 40 and the pattern of conductive ink 20 may both be positioned underneath roofing membrane 30.

In optional embodiments using a coverboard 60 (as in FIG. 1B), the coverboard 60 may be positioned on top of insulation board 10 at a location between the insulation board 10 and the pattern of conductive ink 20. The pattern of conductive ink may be printed on a substrate 25 or simply printed on top of the coverboard 60 itself, all keeping within the scope of the present invention.

FIGS. 6A to 6D show various illustrations of a T-Shaped junction for connecting conductive ink pathways on one insulation board to connective ink pathways on an adjacent insulation board. In operation, conductive insert 70 is dimensioned to be received between side edges of adjacent insulation boards 10. Conductive insert 70 may be T-shaped as shown to contact both top and side surfaces of the adjacent insulation boards 10. In this embodiment, the pattern of conductive ink may also be positioned on the side of insulation boards 10. Conductive inserts 70 permit continuous conduction across the insulation boards, facilitating leak detection from one insulation board to the next. This conduction may be both across the top surfaces (or bottom surfaces, or both top and bottom surfaces) of the insulation boards as well as along the sides of the insulation boards. An advantage of having the conductive ink on the sides of insulation boards 10 is that it would provide sensitive leak detection in the side-to-side gaps between adjacent insulation boards. This would provide effective leak detection in the specific “gap” area in which leaks could otherwise form.

FIG. 7 is a sectional side elevation view of a combined T-Shaped junction and sensor hardware assembly positioned between the top edges of a pair of adjacent insulation boards. In this embodiment, the conductive insert 75 may house a communication module 40 therein. In this specific embodiment, the edges of insulation boards 10 may be beveled as shown to accommodate communication module 40 therebetween. This design has the advantage of finding a convenient place to “hide” the communication modules 40.

In various embodiments, the communication modules may be positioned at corner intersections of the insulation boards 10 across the roof. It is to be understood that the communication modules 40 can be positioned on top of the roofing membrane (as in FIG. 1A to 5), or underneath the roofing membrane 30 (for example between the adjacent insulation boards as seen in FIG. 7).

Lastly, it is to be understood that the conductive ink can also be printed or positioned both above and below the insulation boards, thereby providing two parallel layers of leak detection (i.e.: across the top and bottom surfaces of the insulation boards 10).