Patent Publication Number: US-7217104-B2

Title: Method and system for liquid leak detection, notification and removal

Description:
This application claims priority to the commonly-titled U.S. provisional application Ser. No. 60/430,303, filed on Dec. 2, 2002, the disclosure of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The invention relates to a modular liquid leak detection, notification, and removal system to remove a collection of liquid. 
   BACKGROUND OF THE INVENTION 
   Water leakage, floods and liquid overflow conditions can cause significant and permanent structural and property damage. For example, a cesspool overflow can ruin carpeting, flooring and upholstery. Floods, leaks and overflows can short electrical circuits and ruin electrical appliances and components. Cesspool overflow is unpleasant and can be damaging. A toilet flusher may break resulting in a continuous flow of water into a cesspool unbeknown to the occupants of a structure. This continuous flow of water can very quickly fill a cesspool beyond its capacity resulting in flood conditions and the consequential damage to personal property mentioned above. 
   In some systems, when an overflow condition occurs, an audible alarm, bell, siren or lights becomes activated. If nobody is present, the alarm sound or lights will go unnoticed. 
   Utility pumps are pumps that are often used in various situations where water or liquid must be drained or moved and which can be used as a standalone pump-apart from any interconnected system. Utility pumps are typically AC powered and typically there are available voltage sources which supply about 110 Volts AC. However, the cost of an AC powered pump is usually much higher than that of a DC powered pump. In addition, one can receive an electrical shock if the conventional, high voltage 110 Volt AC utility pump is exposed to water. Thus, there is a need for a system that uses a low-cost, DC powered pump that can be plugged into a standard AC outlet and used with relative safety to notify a person of a leak and remove the liquid that has been detected. 
   Heretofore, there were no relatively low-cost, modular systems available which address the problems identified above and which incorporate leak detection, notification, removal and or containment of the liquid from the area in a single inexpensive, functionally—efficient design as does the proposed system as set forth herein. 
   SUMMARY OF THE INVENTION 
   One aspect of the invention concerns its ability to integrate each component identified herein in a low-cost, flexible modular system for removal and notification of a collection of liquid. The invention enables the use of various available components in a relatively simple and safe system which includes a pump and at least one liquid sensor, a specifically designed bucket, and other modular components to form a functional system. 
   The invention is modular in that various components can be added or removed from the system as desired. For example, the system has the capacity to be connected modularly to a notification system and telephone dialer. Also, the system is designed so that the pump may be utilized separate and apart from the water sensor, hose and bucket, with the use of a manual switch which is incorporated into the unit. The liquid detection, notification and removal system has the capacity to be tested periodically to ascertain if all components are working properly. 
   The pump used in this invention is preferably a low-cost, low-voltage utility pump. The invention preferably includes a low voltage DC pump, powered by AC power, such as 110 volts. Preferably, the pump will be a 12 to 24 volt DC powered pump. This relatively low voltage pump is safer than a higher voltage pump because the risk of receiving a severe shock when the pump is immersed in fluid is lower. In the event no external (AC or DC) power supply is available, another embodiment of the invention allows the pump and peripherals to be operated on battery power, e.g., 12 volt DC power. Thus, the invention provides a measure of convenience, cost-savings and flexibility and safety. 
   The invention enables the use of a telephone dialer to notify an outside party by telephone that there may be a leak or flood condition. The invention can also be arranged so that a collection of liquid can be sensed and DC voltage can be passed to a pump via a relay. The pump can then transport the liquid into a container or to another location. 
   In one embodiment of the invention, a transformer/converter (sometimes referred to as a DC transformer) will convert AC power to low voltage DC power, such as, for example, standard 110 Volts AC power to 12 Volts DC power. This low voltage power is used to supply power to the pump and other modular components that may be used, such as a notification means. 
   Thus, the invention provides the following: 1) low cost liquid leak/flood detection, 2) removal of liquid without a significant risk of a severe electrical shock, 3) an inexpensive means for notifying a person that a collection of liquid has formed, 4) a means for transporting, via a pump, a collection of liquid, 5) modular connections to adapt the base system in a variety of configurations and 6) a means whereby the system pump may be powered by DC battery. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic of the components for use with the first embodiment of the flood detection, warning and removal or storage device, wherein the liquid is pumped into a bucket. 
       FIG. 2  is a schematic of the components for use with the second embodiment of the device wherein the liquid is pumped via a long hose to a different area for removal or drainage. 
       FIG. 3  shows an embodiment of the pump and control unit wherein the pump may be used as a utility pump without the need for sensors  5  or  10  to sense liquid and without notification means. 
       FIG. 4  is a wiring diagram of a first embodiment of the invention. 
       FIG. 5  is a wiring diagram of a second embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The characteristics of the components and the modular manner of their integration in the systems of the invention are described. As shown in  FIG. 1 , system  1  of the invention shows a modular system which comprises several components, several of which can be added or removed to the system, which can therefore be called modular.  FIG. 1  shows a sensor  5 , sensor  10 , control unit  22 , power supply  24 , pump  20 , hose  35  and bucket  30 . 
   The system is used to collect liquid  2  in bucket  30  or, alternatively, liquid  2  can be diverted elsewhere using pump  20  with a hose  35  that is sufficiently long to divert liquid  2  to its desired location. Pump  20  may be mounted to a bucket  30 . Hose  35  preferably is molded for connection to pump  20  and, more particularly, connected to a hose bib, which may be incorporated as an integral part of pump  20 . 
     FIG. 4  is a wiring diagram of the preferred embodiment of the invention.  FIG. 4  also shows the following optional components which may be added to the system via the modular electrical connections which will accommodate: audible indicator  42 , visual indicator  44  and telephone system  50 ; together, these three components comprise notification means  40  ( FIG. 1 ). Audible indicator can be siren, bell or other suitable means which can be heard or detected. Visual indicator  44  is preferable a flashing light, although other suitable means can be used. Although not shown, a battery may be used, instead of AC power, to operate the pump and other components, if any are present. 
   The system enables detection, notification and containment, or removal, of a collection of liquid  2 . In addition, pump  20  can be readily detached from control unit  22  and used in other appropriate applications. 
   Operationally, the system shown in  FIG. 1  may function as follows. Sensor  5  detects a small amount of moisture or liquid  2 . Sensor  5  triggers a relay  15  which passes electrical power from power supply  24  (not shown) to control unit  22  (described in more detail below). Control unit  22  activates notification means  40  to notify person(s) that liquid  2  has collected. Preferably, notification means  40  will continue to notify person(s) that liquid is present for as long as liquid is detected by sensor  5 . In an alternative embodiment, the notification means  40  can be arranged so that it only notifies the user a desired number of times. 
   If an additional amount of liquid collects, a second sensor  10  will trigger a second relay  17  which passes electrical power to control unit  22  which activates pump  20 . Pump  20  causes liquid  2  to flow through hose  35  to either bucket  30 , or to a desired location. Once a sufficient amount of liquid  2  has been removed, sensor  10  is deactivated which results in the pump  20  being shut off. Alternatively, pump  20  may be used as a portable utility pump without the need for sensor  5  or  10  to sense liquid. 
   The sensors  5  and  10 , control unit  22 , and pump  20  shown in  FIG. 1  are described separately below. 
   Preferably, pump  20  and sensors  5  and  10  are mounted at different vertical positions inside a pump-sensor housing  21 , which is shown by the dotted lines in  FIG. 1 . Housing  21  is preferably made of plastic. Because pump  20  is low voltage and sensors  5  and  10  are essentially waterproof, housing  21  may be submersed in liquid with little risk of electrical shock. Housing  21  will have a sufficient number of holes such that if it is placed in a collection of liquid  2 , an initial collection of liquid  2  will come into contact with sensor  5  and an additional collection of liquid will come in contact with a sensor  10  and pump  20 . To show the components within it, housing  21  is shown by the dotted lines in  FIG. 1 . 
   In  FIG. 1 , housing  21  preferably should be placed in an area where liquid is likely to collect, such as a low point or near a known leak, a sink, a water tank, a washing machine, a toilet, a plumbing system a water line, or a basement crawl spaces. In industrial conditions, liquids used in various stages of processing, transferring, piping, and storing can result in overflows or liquid spills and that fact may be considered when deciding where to place housing  21 . Proper placement of housing  21  allows the system to sense and pump liquid  2 . To enhance operation of the system, the user could create a small depression in the floor (preferably about ½ inch depression) so that liquid  2  will flow or sink to this area and can be sensed by sensors  5  and  10  or both and removed by pump  20 . 
   Sensors  5  and  10  preferably use an open collector electronic trigger which simulates a simple dry condition, such that neither sensor is activated in a dry condition. Sensor  5  includes electrical contacts, preferably two contacts  7  which extend horizontally at the same height with respect to the bottom of housing  21  (see  FIGS. 1 and 2 ). Contacts  7  are positioned inside housing  21  at the desired height for sensing and activating notification means  40 . The vertical placement of the two contacts  7  of sensor  5  will depend on the application and the minimum level of liquid desired to be detected (for notification). The vertical placement of sensor  5  (and therefore contacts  7 ) preferably can be adjusted by the user of the system, depending on the urgency of the need to be notified of a collection of liquid. For the typical application of the invention, sensor  5  will be vertically positioned such that its contacts  7  are approximately ⅜ of an inch above the bottom of housing  21 . If that is the case, when a moisture or liquid bridge as low as 1/16 of an inch of liquid  2  has collected inside housing  21  such that some amount of liquid makes contact with sensor  5 , an electrical condition between contacts  7  of sensor  5  will complete a circuit which sends current to, and activates, an electronic relay switch  15  ( FIG. 4 ), which, if one is present, causes notification means  40  to notify that a collection of liquid has been sensed. 
   When sensor  5  is activated, electronic relay switch  15  sends current (which passes the switch current), across a wire (not shown) which preferably is plugged in (via a modular plug-in) to control unit  22 . Control unit  22  then coordinates activation of notification means  40  which is preferably powered by a low voltage, generally, 12 to 24 volts DC power. 
   Preferably, assuming an inexpensive sensor is used, sensor  5  operates in conditions where the electric conductivity of the liquid is equal to or greater than the electric conductivity of plain water. This means that water will activate sensor  5  and some liquids, such as saltwater, have a greater capacity to conduct electric current than water and will activate the sensor even more readily than would water. An example of a sensor that may be used with the invention is produced by George Risk Industries, Incorporated in Kimball, Nebr., such as model PS-2800 or model PS-2600. 
   In the preferred embodiment of the invention, which is shown in  FIG. 1 , if liquid  2  continues to collect after sensor  5  has been activated, a second sensor, sensor  10 , which has two horizontal contacts  12 , will become activated. Activation of sensor  10  will cause pump  20  to be activated. Preferably, sensor  10  is the same as sensor  5 , which advantageous because, for example, it simplifies the selection of components and potentially lowers costs. Sensor  10 , however, is mounted at a higher vertical height within housing  21 . Thus, operationally, it will take a deeper collection of liquid  2  to trigger sensor  10  than the depth of liquid required to trigger sensor  5 . 
   As in sensor  5 , the vertical position of sensor  10  in housing  21  can be adjusted depending on the application desired and the sensitivity of pump  20 . To meet the needs of many household applications and to allow a large number of different types of pumps to be used with the system, contacts  12  of sensor  10  are preferably placed at a vertical height of about ⅜ of an inch above the bottom of housing  21 . If that is the case, when a moisture or liquid bridge as low as ⅜ of an inch of liquid  2  forms within housing  21  and some amount of liquid comes into contact with sensor  10 , an electrical condition between two sensor contacts  12  of sensor  10  will complete a circuit which sends current to, and activates, a second electronic relay, switch  17  ( FIG. 4 ), which in turn operates pump  20 . 
   In the preferred embodiment of the invention, for as long as sensor  10  is activated (i.e., while contacts  12  complete the bridge of liquid  2 ), pump  20  will continue to operate to remove liquid  2 . This should allow removal of substantially all of the undesirable collected liquid  2 , without burning out pump  20 , as discussed above. Like the notification means, pump  20  is preferably powered by a low voltage, generally, 12 to 24 volts DC power. 
   The preferred embodiment of the invention uses two sensors because having two sensors can provide early notification of a collection of liquid and a later activation of pump when a sufficient amount of water has collected to allow the pump to operate without a substantial risk it will run dry and get damaged. Although a two sensor system is preferred, in an alternative embodiment of the invention, one sensor (e.g., sensor  5 ) is used to simultaneously activate both the notification means and the pump, as shown in  FIG. 5 . Depending on the purposes for which it will be used and the pump used in the system, either a single or dual sensor system may be desired and used, consistent with the principles of the invention. In a single sensor system, there is one sensor that activates one relay which simultaneously delivers DC voltage to both the pump and, if present, the notification means  40 , which would preferably be connected in parallel (see  FIG. 5 ). 
   The control unit  22  will be used to control and supply power to notification means  40  and pump  20 . Control unit  22  preferably has several modular inputs and outputs for this purpose. Inputs preferably may include an AC supply of power  24 , wires from sensors  5  and  10 , and plug-ins for an optional DC power supply (preferably 12 V DC) and notification means  40  (e.g., audible indicator  42 , such as a siren, and a telephone dialer system  50 ). Control unit  22  can utilize AC power, such as from a standard 110 volt AC, 15 amp power source (not shown in  FIG. 1 ) or a DC power supply. The DC power supply can be a low voltage battery, preferably 9–16 V DC, more preferably 12 V DC. For example, a typical car batter can be used. 
   Preferably, control unit  22  comprises a box with a removable front panel (neither is shown in the figures). The front panel includes modular plug-ins to add various devices in modular fashion, including plug-ins for notification means  40  and a DC power supply. Front panel also includes a three-way switch (and relay) to switch the unit to off, AC power on, DC power on. In addition, the front panel of control unit  22  has a manual override switch, in the form of a bypass switch  18 , which will bypass sensor  10  thereby activating pump  20 . Bypass switch  18  preferably has three positions: on (automatic), off and bypass (manual). 
   Inside the control unit  22  is included electronic relay switches  15  and  17 , bypass switch  18 , and power board  24 . These components of control unit  22  are housed within a control box housing, which should not be exposed to water since it is typically not watertight and since may transmit 110 volts AC power. Attached to the bottom of the box is a power device  24  and relays  15  and  17 . Power device is used to supply electrical power to notification means  40  and to pump  20 . Power device  24  includes a board which includes transformer/converter  27  (which can be referred to as a DC transformer). When AC power is being used, transformer/converter  27  is used to change relatively high AC voltage to relatively low AC or DC voltage; for example, generally from 110 volts AC to 12 to 24 Volts DC. This voltage step down increases the safety of the system and enables a low cost, low voltage pump  20  to be used. One example of a suitable power device  24  includes transformer/converter  27  such as model PS 25-12 manufactured by Astrodyne Corporation, Taunton, Mass., although many other suitable units are readily available. 
   The main output of control unit  22  is a wire, preferably about 10 feet long, which extends from the control unit  22  to housing  21  of pump  20  and sensors  5  and  10 . This appropriately long wire allows the control unit  22  to be sufficiently separated from liquid, which may increase safety (e.g., help avoid electrical shock). Although it may be made watertight with some expense, in any case, control box  22  preferably should not be exposed to liquid because of the high voltage it contains and because of the modular plug-ins on its front panel, described above. 
   Pump  20  is preferably powered by a low voltage supply, preferably 12 volts DC but preferably not more than 24 volts DC, and low amperage power to minimize the risk of electrical shock if pump  20  is exposed to liquid. Preferably, pump is a low-cost pump, such as DC pump which does not operate as a wet vacuum. 
   Because of the manner in which pump  20  is powered by the control unit  22  and connected, it can be used as a utility pump without the need for sensor  5  or  10  to sense liquid and without activation of notification means  40 , as mentioned above with respect to bypass switch  18 . Pump  20  does not have to be dedicated to this system and can be used for general utility purposes, not necessarily associated with sensing a collection of liquid  2 . The manner of integrating the components used in this system readily allows pump  20  to be used in other applications when needed. In particular, pump  20  can also be detached from bucket  30  and used as any general utility or household pump to transfer or move liquids, independent of the operation of any sensor and bucket. Bucket  30  may be placed in a different area than pump-sensor housing  21 . This will provide a means of pumping fluid to another location or larger container for collection. 
   Pump  20  preferably has sufficient pumping ability to raise liquid  2 , preferably, for example, approximately 8 to 10 feet such that pump  20  can be used for a wide variety of household applications such as draining a pool or hot tub. The diameter of hose  35  may be adjusted, however, depending on the pumping power of pump  20  and the desired height needed to raise liquid  2 . 
   Notification means  40  is shown in  FIG. 1 . Notification means  40  may include audible indicator  42 , visual indicator  44  and telephone system  50  ( FIG. 4 ). Audible indicator  42  can be siren, bell or other suitable means, in any combination, which can be heard or detected. Visual indicator  44  is preferable a light emitting components (preferably a flashing light), although other suitable means can be used. Notification means  40  is preferably powered by 12 V DC provided or transformed by control unit  22 . 
   Electric relay switch  15  sends electric current to notification means  40  using a length of electric wire, so that notification means  40  may be placed in a location removed from the vicinity of a collection liquid  2 . Each component of notification means  40  can be added or removed, modularly, from the system as the user&#39;s preference. 
   The telephone system  50  appropriate for the invention is described. The telephone system  50  (shown in  FIGS. 1–2 ) includes a dialer  52  (shown in  FIGS. 4–5 ), which may be coupled to an optional telephone  54  (not shown), which may be land-based, cellular or other available technology. Telephone system  50  receives power from electronic relay switch  15  or from an optional DC battery (preferably 9–16 V DC). The telephone system  50  is preferably connected electrically to dialer  52  via a conductive cable, which has a small modular connector on each end. The cable serves as a conduit of low voltage power (preferably 9–16 V DC) and triggering signals for the system to trigger dialer to place a call shortly after sensor  5  has detected a collection of liquid  2 , such as from a leak. Dialer  52  may be configured to include a prerecorded announcement. Operationally, when a liquid condition is present and detected by sensor  5 , the control unit  22  activates telephone system  50 , which sends the correct triggering signal to dialer  52  via the cable. One example of a dialer which may be used is a Linear Security Model PD-2. 
     FIG. 2  shows the second embodiment of the invention. This embodiment of system  3  does not include a bucket, but instead uses hose  35  of sufficient length to divert liquid  2  to another area. Other than that distinction, the embodiment shown in  FIG. 2  contains the same components, connected in the same way as the embodiment shown in  FIG. 1 . 
     FIG. 3  shows another embodiment of the invention, system  4 , whereby pump  20  is used as a utility pump. Pump  20 , control unit  22  and hose  35  are described with respect to the embodiment shown in  FIG. 1 . 
   By way of example,  FIG. 4  shows a wiring diagram of the preferred embodiment of the invention configured in the following manner. A power supply  24  is a 110 Volt AC or standard house current. Transformer/converter  27  changes power supply  24  to a low voltage DC power, preferably 12 volts (DC). When sensor  5  senses a liquid bridge, current will pass through sensor  5  to electronic switch  15  which sends current to activate notification means  40 . As an example, the notification means  40  shown in  FIG. 4  includes audible indicator  42 , visual indicator  44 , and telephone system  50 . These three elements are shown connected in parallel to each other because, in the preferred embodiment of the invention, they all utilize the same voltage, preferably 12 volts DC, as a source of power and turn on at the same time. Although this arrangement is preferred, it is not required and the principles of the invention allow more flexibility. 
   Preferably, components of notification means  40  will continue to be activated for as long as sensor  5  senses a liquid bridge, unless notification means  40  has been manually deactivated. Alternatively, notification means  40  could be activated for an initial period of time or an initial number of times, depending on the users desire. 
   If fluid continues to collect and reaches contacts  12  of sensor  10  (which are positioned vertically higher than contacts  7  of sensor  5 ) such that a liquid bridge between contacts  12  is formed, current will pass through sensor  10  to electronic switch  17  which sends current to activate pump  20 . Pump  20  will continue to operate until there is no longer a liquid bridge between contacts  12  of sensor  10 , which becomes deactivated. 
   Bypass switch  18  permits pump  20  to be used as a utility pump without operation of sensors  5  or  10  or notification means  40 . Pump-sensor housing  21  can be disconnected from control unit  22  and placed near a collection of liquid to be pumped. When placed in bypass mode, bypass switch  18  will send low voltage current directly to the pump  20 . 
     FIG. 5  shows a second embodiment of the invention, whereby a single sensor is used to activate the notification means  40  and the pump  20 , as described above. 
   The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Modifications and alterations will occur to others upon a reading and understanding of this specification. This is especially true given the modular nature of the components that can be used with the invention. Therefore, this invention includes all which modifications and alterations encompassed within the spirit of the following claims.