Flexible Sensor Strip for Underfloor Liquid Leak Detection

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Solution Overview

Problem

Existing solutions for detecting liquid, such as water, flowing over a floor surface or spreading between the floor surface and a floor covering are bulky, complex, or not readily applicable, particularly in industrial or commercial environments with refrigerating apparatuses, leading to potential damage and safety hazards.

Innovation Solution

A flat, elongated sensor strip with conductive tracks on a flexible insulating substrate, positioned under the floor covering, detects liquid or humidity using exposed conductive tracks and a passive sensor unit for data processing, adaptable to various environments and scalable for multiple detection zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a fluid detection cable with conductive members is used to detect liquid presence, then liquid detection capability is provided, but the thick cross-section prevents detection of liquid spreading between floor surface and floor covering

Engineering Contradiction:

Improveliquid detection capabilityVSAvoidcable cross-section thickness

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent replaces the thick cable structure with a thin flexible film containing conductive patterns. This thin film can be positioned between the floor surface and floor covering to detect liquid spreading in the gap, while maintaining electrical conductivity for sensing purposes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent transitions from a mechanical cable-based detection system to a planar conductive pattern system printed on flexible substrate. This substitution enables the sensor to conform to flat surfaces and detect liquids in thin gaps that a bulky cable cannot access.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a sensing device is packaged entirely into a housing, then protection and integration are improved, but the bulky configuration prevents detection of liquid spreading between floor surface and floor covering

Engineering Contradiction:

Improvedevice protection and integrationVSAvoidsensing device volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent eliminates the need for a bulky housing by using a thin flexible film as the sensor substrate. This film can be easily positioned and secured between the floor surface and floor covering, providing both protection through its flexible nature and the necessary sensing functionality without excessive volume.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If simple conductive wires are used as sensor electrodes, then manufacturing simplicity is achieved, but complex positioning and spacing requirements make deployment difficult

Engineering Contradiction:

Improvesensor electrode simplicityVSAvoiddeployment complexity

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent uses printed conductive patterns on flexible substrate that can be mass-produced with precise geometries already embedded in the design. This eliminates the need for manual positioning and spacing of individual wires during deployment, as the sensing pattern is replicated directly from the printed circuit board design.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent combines multiple functions into a single printed circuit board structure: the conductive patterns serve as both the sensing electrodes and the structural support, eliminating the need for separate positioning mechanisms and simplifying both manufacturing and deployment.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides efficient, cost-effective detection of liquid spreading, preventing damage and safety hazards, with data transmission to a remote unit for monitoring and control, suitable for industrial or commercial settings with refrigerating apparatuses.

Implementation Method 1

a plurality of conductive tracks (101, 102, 111-115) provided on the insulating substrate (S) and extending substantially in the longitudinal direction (x), and at least one insulating layer (I) covering the conductive tracks (101, 102, 111-115) with the exception of one or more selected detection areas (DA)

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12498289B2Sensor strip for liquid or humidity detection and applications and uses thereof

Publication Date: 2025.12.16 INTECHFLOOR SA

AI summary

A sensor strip for detecting a presence of liquid, especially water, flowing over a selected region of a floor surface, or a level of humidity in the selected region of the floor surface. The sensor strip includes a substantially flat and elongated insulating substrate made of flexible material and designed to be laid on the floor surface. The sensor strip exhibits a width (measured in a transverse direction), a length (measured in a longitudinal direction), and a thickness (measured perpendicularly to the longitudinal and transverse directions). The sensor strip includes a plurality of conductive tracks which are provided on the insulating substrate and extend substantially in the longitudinal direction, and at least one insulating layer covering the conductive tracks with the exception of one or more selected detection areas where parts of the conductive tracks are exposed for detection of the presence of liquid or of the level of humidity.