阅读说明：本技术 扁平柔性导电流体传感器线缆和连接器 (Flat flexible conductive fluid sensor cable and connector ) 是由 R·谢维洛 S·斯台普福特 P·沃尔什 M·佩雷 于 2020-06-14 设计创作，主要内容包括：所描述的实施例提供一种能够以长的长度制造的扁平导电流体传感器线缆,其包括柔性基体、两个或更多个扁平导体,以及流体可渗透覆盖材料,所述流体可渗透覆盖材料被布置成当导电流体接触导电流体传感器线缆时允许导电流体在两个或更多个导体之间形成导电路径。(The described embodiments provide a flat conductive fluid sensor cable that can be manufactured in long lengths, comprising a flexible substrate, two or more flat conductors, and a fluid permeable cover material arranged to allow a conductive fluid to form a conductive path between the two or more conductors when the conductive fluid contacts the conductive fluid sensor cable.)

1. An electrically conductive fluid sensor cable comprising:

a base body having an adhesive surface and extending in an extending direction;

a fluid permeable material disposed on the adhesive surface of the substrate; and

a first uninsulated flat conductor and a second uninsulated flat conductor, each of the first uninsulated flat conductor and the second uninsulated flat conductor being positioned laterally and electrically insulated from each other and positioned in a layer between the base and the fluid permeable material, and each of the first uninsulated flat conductor and the second uninsulated flat conductor extending in an extending direction along the bonding surface of the base;

wherein the base, the first and second uninsulated flat conductors, and the fluid permeable material are adhered together to form a laminate structure of the conductive fluid sensor cable configured to seal the first and second uninsulated flat conductors between the base and the fluid permeable material, wherein the fluid permeable material directly covers and contacts the first and second uninsulated flat conductors and, in the presence of a conductive fluid, allows the conductive fluid to permeate through the fluid permeable material and contact the first and second uninsulated flat conductors and form a conductive path between the first and second uninsulated flat conductors.

2. The electrically conductive fluid cable of claim 1, wherein the fluid permeable material comprises a unitary piece of material.

3. The electrically conductive fluid cable of claim 1, wherein the electrically conductive fluid cable is flexible.

4. The electrically conductive fluid cable of claim 1, wherein the fluid permeable material comprises a wicking material having characteristic expansion properties.

5. The electrically conductive fluid cable of claim 1, wherein said laminate structure is characterized by an overall thickness of less than 0.2 mm.

6. The conductive fluid cable of claim 1, wherein the matrix comprises a dielectric material.

7. The electrically conductive fluid cable of claim 6, wherein the matrix comprises a fluid permeable material.

8. The conductive fluid cable of claim 1, wherein the first and second uninsulated flat conductors include at least one of the group consisting of flat conductive foil strips, flat conductive foils, printed conductive inks, flat wires, and conductive traces.

9. The electrically conductive fluid cable of claim 1, wherein each of the first and second uninsulated flat conductors includes a first surface and an opposing second surface, wherein the fluid permeable material directly covers and contacts the respective second surfaces of the first and second uninsulated flat conductors, and wherein the respective first surfaces of the first and second uninsulated flat conductors contact the adhesive surface of the substrate.

10. The conductive fluid cable of claim 1, further comprising:

a third uninsulated flat conductor positioned laterally with respect to the first and second uninsulated flat conductors, in the layer between the substrate and the fluid permeable material, and extending in the direction of extension along the bonding surface of the substrate; and

a jumper conductor configured to electrically connect a third uninsulated flat conductor to the other of the first uninsulated flat conductor and the second uninsulated flat conductor in a manner such that the third uninsulated flat conductor is electrically insulated from and electrically connected to the other of the first uninsulated flat conductor and the second uninsulated flat conductor, wherein the jumper conductor is configured to complete an electrical circuit between the third uninsulated flat conductor and the other of the first uninsulated flat conductor and the second uninsulated flat conductor.

11. The conductive fluid cable of claim 10, wherein the conductive fluid cable is connected to a sensor system configured to detect the conductive path and generate a fluid status signal in response thereto, and wherein the sensor system is configured to detect a completed circuit between the third uninsulated flat conductor and the other of the first and second uninsulated flat conductors and generate a cable status signal in response thereto.

12. The conductive fluid cable of claim 1, wherein the conductive fluid cable is connected to a sensor system configured to detect the conductive path and generate a fluid status signal in response thereto.

13. The conductive fluid cable of claim 12, wherein the conductive fluid cable is connected to the sensor system by a crimp connector at one end of the conductive fluid cable, the crimp connector comprising:

a top clasp hingeably mounted to a bottom body in which are mounted a plurality of barbs, each of the plurality of barbs corresponding to a given one of the conductors of the conductive fluid cable and each of the plurality of barbs being connected to a respective one of a plurality of pins configured to be received in a connector of the sensor system, wherein the press-fit connector is configured to make an electrical connection between each of the plurality of barbs and a respective one of the conductors when the top clasp is closed such that the wedge of the top clasp presses the conductor against the respective barb.

14. The conductive fluid cable of claim 12, wherein the conductive fluid cable is connected to the sensor system by a male socket connector at one end of the conductive fluid cable, the male socket connector having a plurality of conductive segments of a socket, each of the plurality of conductive segments of a socket corresponding to a given one of the conductors of the conductive fluid cable.

15. The conductive fluid cable of claim 14, further comprising a female stereo connector at another end of the conductive fluid cable, the female stereo connector configured to receive a male stereo receptacle connector of a subsequent section of the cable, thereby extending a length of the cable.

16. The electrically conductive fluid cable of claim 14, further comprising a crimp connector having a first top clasp hingeably mounted to a bottom body and a second top clasp hingeably mounted to the bottom body, the bottom body having a plurality of barbs mounted therein, each of the plurality of barbs corresponding to a given one of the conductors of the first and second sections of the electrically conductive fluid cable, wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and a corresponding one of the conductors of the first section of the electrically conductive fluid cable when the first top clasp is closed such that the wedge of the first top clasp presses the conductor against the corresponding barb, and wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and the corresponding one of the conductors of the first section of the electrically conductive fluid cable when the second top clasp is closed such that the wedge of the second top clasp presses the conductor against the corresponding barb, an electrical connection is made between each of the plurality of barbs and a corresponding one of the conductors of the second section of the electrically conductive fluid cable.

17. A fluid sensing system configured to detect the presence of a fluid, the fluid sensing system comprising:

an electrically conductive fluid sensor cable comprising:

a base body having an adhesive surface and extending in an extending direction;

a fluid permeable material disposed on the adhesive surface of the substrate; and

a first uninsulated flat conductor and a second uninsulated flat conductor, each of the first uninsulated flat conductor and the second uninsulated flat conductor being positioned laterally and electrically insulated from each other and positioned in a layer between the base and the fluid permeable material, and each of the first uninsulated flat conductor and the second uninsulated flat conductor extending in an extending direction along the bonding surface of the base;

wherein the base, the first and second uninsulated flat conductors, and the fluid permeable material are adhered together to form a laminate structure of the conductive fluid sensor cable configured to seal the first and second uninsulated flat conductors between the base and the fluid permeable material, wherein the fluid permeable material directly covers and contacts the first and second uninsulated flat conductors and, in the presence of a conductive fluid, allows the conductive fluid to permeate through the fluid permeable material and contact the first and second uninsulated flat conductors and form a conductive path between the first and second uninsulated flat conductors; and

a sensor connected to a conductive fluid cable, the sensor comprising:

a processor configured to receive a signal indicative of the formed conductive path and to generate a fluid detection signal in response thereto, the fluid detection signal being transmitted to one or more remote devices.

18. The fluid sensing system of claim 17, wherein the electrically conductive fluid cable further comprises:

a third uninsulated flat conductor positioned laterally with respect to the first and second uninsulated flat conductors, in the layer between the substrate and the fluid permeable material, and extending in the direction of extension along the bonding surface of the substrate; and

a jumper conductor configured to electrically connect a third uninsulated flat conductor to the other of the first uninsulated flat conductor and the second uninsulated flat conductor in a manner such that the third uninsulated flat conductor is electrically insulated from and electrically connected to the other of the first uninsulated flat conductor and the second uninsulated flat conductor, wherein the jumper conductor is configured to complete an electrical circuit between the third uninsulated flat conductor and the other of the first uninsulated flat conductor and the second uninsulated flat conductor.

19. The fluid sensing system of claim 18, wherein the processor is configured to detect a completed circuit between the third uninsulated flat conductor and the other of the first uninsulated flat conductor and the second uninsulated flat conductor and, in response to such detection, generate a cable status signal that is transmitted to one or more remote devices.

20. The fluid sensing system of claim 17, wherein the electrically conductive fluid cable is a flat flexible cable, and wherein the fluid permeable material comprises a unitary wicking material having characteristic swelling properties.

21. The fluid sensing system of claim 17, wherein the layered structure of the electrically conductive fluid cable is characterized by an overall thickness of less than 0.2mm, and wherein the matrix comprises a dielectric material.

22. The fluid sensing system of claim 17, wherein the matrix comprises a fluid permeable material.

23. The fluid sensing system of claim 17, wherein said first and second uninsulated flat conductors comprise at least one of the group consisting of flat conductive foil strips, flat conductive foils, printed conductive inks, flat wires, and conductive traces.

24. The fluid sensing system of claim 17, wherein each of said first and second uninsulated flat conductors includes a first surface and an opposing second surface, wherein said fluid permeable material directly covers and contacts the respective second surfaces of said first and second uninsulated flat conductors, and wherein the respective first surfaces of the first and second uninsulated flat conductors contact the adhesive surface of the substrate.

25. The fluid sensing system of claim 17, wherein the fluid sensing system comprises a crimp connector at one end of an electrically conductive fluid cable, the crimp connector connected to the fluid sensing system, the crimp connector comprising:

a top clasp hingeably mounted to a bottom body in which are mounted a plurality of barbs, each of the plurality of barbs corresponding to a given one of the conductors of the conductive fluid cable and each of the plurality of barbs being connected to a respective one of a plurality of pins configured to be received in a connector of the sensor system, wherein the press-fit connector is configured to make an electrical connection between each of the plurality of barbs and a respective one of the conductors when the top clasp is closed such that the wedge of the top clasp presses the conductor against the respective barb.

26. The fluid sensing system of claim 17, wherein the fluid sensing system comprises a female stereo connector configured to receive a male stereo socket connector at one end of the conductive fluid cable, the male stereo socket connector having a plurality of conductive segments of a socket, each of the plurality of conductive segments of the socket corresponding to a given one of the conductors of the conductive fluid cable.

27. The fluid sensing system of claim 26, wherein the electrically conductive fluid cable comprises a female stereo connector at another end of the electrically conductive fluid cable, the female stereo connector configured to receive a male stereo receptacle connector of a subsequent section of cable, thereby extending the length of the cable.

28. The fluid sensing system of claim 17, further comprising a crimp connector having a first top clasp hingeably mounted to a bottom body and a second top clasp hingeably mounted to the bottom body, the bottom body having a plurality of barbs mounted therein, each of the plurality of barbs corresponding to a given one of the conductors of the first and second sections of the electrically conductive fluid cable, wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and a corresponding one of the conductors of the first section of the electrically conductive fluid cable when the first top clasp is closed such that the wedge of the first top clasp presses the conductor against the corresponding barb, and wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and the corresponding one of the conductors of the first section of the electrically conductive fluid cable when the second top clasp is closed such that the wedge of the second top clasp presses the conductor against the corresponding barb, an electrical connection is made between each of the plurality of barbs and a corresponding one of the conductors of the second section of the electrically conductive fluid cable.

Background

Water and other fluid leaks can cause significant damage to property and electronics if not detected and repaired in a timely manner. Various humidity and fluid sensors are available on the market and typically include a pair of electrical probes that conduct an electrical current when both probes contact a continuum of conductive fluid, such as non-distilled water (e.g., water with dissolved salts and other ionic compounds, as is typical in tap water). The probe is connected to a conductive fluid sensor that drives a notification system, such as an audio or visual indicator, that indicates the presence or absence of conductive fluid across the probe. The notification system may also generate one or more signals that drive other devices. For example, when the conductive fluid is detected, the notification system may actuate a relay that turns off the water supply and/or turns on the pump.

Some conductive fluid sensors use a length of cable to run the sensing probe, the cable including individual moisture sensors at multiple locations along the cable. These cables are expensive to manufacture and typically must be terminated on a cable-side connector or reinforced on each end of the cable and are therefore typically available only in fixed, predetermined lengths. There is a need for improved cables and connectors for use with conductive fluid sensing systems for detecting conductive fluid leaks.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

One aspect provides an electrically conductive fluid sensor cable that includes a base having an adhesive surface and extending in an extension direction. A fluid permeable material is disposed on the adhesive surface of the substrate. The cable includes first and second uninsulated flat conductors. The first and second uninsulated flat conductors are positioned laterally and electrically insulated from each other and positioned in a layer between the matrix and the fluid permeable material. Each of the first and second uninsulated flat conductors extends in an extending direction along the bonding surface of the base. The base, the first and second uninsulated flat conductors, and the fluid permeable material are adhered together to form a laminated structure of the conductive fluid sensor cable. The laminated structure seals the first and second uninsulated flat conductors between the matrix and the fluid permeable material, and the fluid permeable material directly overlies and contacts the first conductor and the second conductor. The fluid permeable material allows the conductive fluid to permeate through the fluid permeable material and contact the first and second uninsulated flat conductors and form a conductive path between the first and second uninsulated flat conductors in the presence of the conductive fluid.

In one embodiment, the fluid permeable material comprises a unitary material. In one embodiment, the electrically conductive fluid cable is flexible. In one embodiment, the fluid permeable material is a wicking material having characteristic swelling properties. In one embodiment, the laminated structure is characterized by an overall thickness of less than 0.2 mm. In one embodiment, the substrate is a dielectric material. In one embodiment, the matrix is a fluid permeable material. In one embodiment, the first conductor and the second conductor are implemented as one of: flat conductive foil strips, flat conductive foils, printed conductive inks, flat wires, and conductive traces. In one embodiment, each of the first and second conductors has a first surface and an opposing second surface, and the fluid permeable material directly covers and contacts the respective second surfaces of the first and second conductors, and the respective first surfaces of the first and second conductors contact the adhesive surface of the substrate.

In one embodiment, the electrically conductive fluid cable comprises a third uninsulated flat conductor positioned laterally with respect to the first conductor and the second conductor, located in a layer between the base and the fluid permeable material, and extending in an extension direction along the bonding surface of the base. A jumper conductor electrically connects the third conductor to one of the first and second conductors in a manner such that the third conductor is electrically insulated from and electrically connected to the other of the first and second conductors, wherein the jumper conductor completes an electrical circuit between the third conductor and the other of the first and second conductors.

In one embodiment, the conductive fluid cable is connected to a sensor system configured to (i) detect the conductive path and generate a fluid status signal in response to the detection, and (ii) detect a completed circuit between the third conductor and the other of the first conductor and the second conductor and generate a cable status signal in response to the detection. In one embodiment, the conductive fluid cable is connected to a sensor system configured to detect the conductive path and generate a fluid status signal in response to the detection.

In one embodiment, the conductive fluid cable is connected to the sensor system by a crimp connector at one end of the conductive fluid cable. The crimp connector includes: a top clasp hingeably mounted to a bottom body in which are mounted a plurality of barbs, each of the plurality of barbs corresponding to a given one of the conductors of the conductive fluid cable and each of the plurality of barbs being connected to a respective one of a plurality of pins configured to be received in a connector of the sensor system, wherein the press-fit connector is configured to make an electrical connection between each of the plurality of barbs and a respective one of the conductors when the top clasp is closed such that the wedge of the top clasp presses the conductor against the respective barb.

In one embodiment, the electrically conductive fluid cable is connected to the sensor system by a male socket connector at one end of the electrically conductive fluid cable, the male socket connector having a plurality of electrically conductive segments of a socket, each of the plurality of electrically conductive segments of a socket corresponding to a given one of the conductors of the electrically conductive fluid cable.

In one embodiment, the conductive fluid cable further comprises a female stereo connector at the other end of the conductive fluid cable, the female stereo connector configured to receive a male stereo receptacle connector of a subsequent section of the cable, thereby extending the length of the cable.

In one embodiment, the electrically conductive fluid cable includes a crimp connector having a first top clasp hingeably mounted to a bottom body and a second top clasp hingeably mounted to the bottom body, the bottom body having a plurality of barbs mounted therein, each of the plurality of barbs corresponding to a given one of the conductors of the first and second segments of the electrically conductive fluid cable, wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and a corresponding one of the conductors of the first segment of the electrically conductive fluid cable when the first top clasp is closed such that the wedge of the top clasp presses the conductor against the corresponding barb, and wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and the corresponding one of the conductors of the first segment of the electrically conductive fluid cable when the second top clasp is closed such that the wedge of the top clasp presses the conductor against the corresponding barb, an electrical connection is made between each of the plurality of barbs and a corresponding one of the conductors of the second section of the electrically conductive fluid cable.

Another aspect provides a fluid sensing system for detecting the presence of a fluid. The sensing system includes an electrically conductive fluid sensor cable. The conductive fluid sensor cable includes a base body having an adhesive surface and extending in an extending direction. A fluid permeable material is disposed on the adhesive surface of the substrate. The cable includes first and second uninsulated flat conductors. The first and second uninsulated flat conductors are positioned laterally and electrically insulated from each other and positioned in a layer between the matrix and the fluid permeable material. The first and second uninsulated flat conductors each extend in an extending direction along the bonding surface of the base. The substrate, the first and second uninsulated flat conductors, and the fluid permeable material are bonded together to form a laminated structure of the conductive fluid sensor cable. The laminated structure seals the first and second uninsulated flat conductors between the matrix and the fluid permeable material, and the fluid permeable material directly overlies and contacts the first conductor and the second conductor. In the presence of the electrically conductive fluid, the fluid permeable material allows the electrically conductive fluid to permeate through the fluid permeable material and contact the first and second uninsulated flat conductors, which forms an electrically conductive path between the first and second uninsulated flat conductors. The sensor is connected to the conductive fluid cable. The sensor includes a processor configured to receive a signal indicative of the formed conductive path and generate a fluid detection signal in response to the received signal, the fluid detection signal being transmitted to one or more remote devices.

In one embodiment, the electrically conductive fluid cable further comprises a third uninsulated flat conductor positioned laterally with respect to the first conductor and the second conductor, located in a layer between the base and the fluid permeable material, and extending in an extension direction along the bonding surface of the base. A jumper conductor electrically connects the third conductor to one of the first and second conductors in a manner such that the third conductor is electrically insulated from and electrically connected to the other of the first and second conductors, wherein the jumper conductor is configured to complete an electrical circuit between the third conductor and the other of the first and second conductors. In one embodiment, the processor is configured to detect a completed circuit between the third conductor and the other of the first and second conductors and generate a cable status signal in response to the detection, the cable status signal being transmitted to the one or more remote devices.

In one embodiment, the electrically conductive fluid cable is a flat, flexible cable and the fluid permeable material is a unitary wicking material having characteristic expansion properties. In one embodiment, the laminated structure of the electrically conductive fluid cable is characterized by a total thickness of less than 0.2mm and the matrix comprises a dielectric material. In one embodiment, the matrix comprises a fluid permeable material. In one embodiment, the first conductor and the second conductor are implemented as one of: flat conductive foil strips, flat conductive foils, printed conductive inks, flat wires, and conductive traces. In one embodiment, each of the first and second conductors has a first surface and an opposing second surface, the fluid permeable material directly covers and contacts the respective second surfaces of the first and second conductors, and the respective first surfaces of the first and second conductors contact the adhesive surface of the substrate.

In one embodiment, a fluid sensing system includes a crimp connector at one end of an electrically conductive fluid cable, the compression connector connected to the fluid sensing system, the compression connector including a top clasp hingeably mounted to a bottom body, a plurality of barbs are mounted in the bottom body, each of the plurality of barbs corresponding to a given one of the conductors of the electrically conductive fluid cable, and each of the plurality of barbs is connected to a respective one of a plurality of pins configured to be received in a connector of a sensor system, wherein the compression connector is configured to make an electrical connection between each of the plurality of barbs and a respective one of the conductors when the top clasp is closed such that the wedge portion of the top clasp presses the conductor against the respective barb.

In one embodiment, a fluid sensing system includes a female stereo connector configured to receive the male stereo receptacle connector at one end of the conductive fluid cable, the male stereo receptacle connector having a plurality of conductive segments of a receptacle, each of the plurality of conductive segments of the receptacle corresponding to a given one of the conductors of the conductive fluid cable.

In one embodiment, the conductive fluid cable includes a female stereo connector at another end of the conductive fluid cable configured to receive a male stereo receptacle connector of a subsequent section of the cable, thereby extending the length of the cable.

In one embodiment, the plurality of segments of the electrically conductive fluid cable may be connected by a crimp connector having a first top clasp hingeably mounted to a bottom body and a second top clasp hingeably mounted to the bottom body, the bottom body having a plurality of barbs mounted therein, each of the plurality of barbs corresponding to a given one of the conductors of the first and second segments of the electrically conductive fluid cable, wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and a corresponding one of the conductors of the first segment of the electrically conductive fluid cable when the first top clasp is closed such that the wedge of the top clasp presses the conductor against the corresponding barb, and wherein the crimp connector is configured to make an electrical connection between each of the plurality of barbs and the corresponding one of the conductors of the first segment of the electrically conductive fluid cable when the second top clasp is closed such that the wedge of the top clasp presses the conductor against the corresponding barb, an electrical connection is made between each of the plurality of barbs and a corresponding one of the conductors of the second section of the electrically conductive fluid cable.

Drawings

Aspects, features, and advantages of the concepts, systems, circuits, and techniques described herein will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which like reference numerals refer to similar or identical elements. Reference numerals associated with one drawing introduced in the specification may be repeated in one or more subsequent drawings without additional description in the specification to provide context for other features. Moreover, the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the concepts disclosed herein.

FIG. 1A is a perspective view of a conductive fluid sensor cable installed in an environment;

FIG. 1B is a perspective view of a flexible cable wound on a spool;

FIG. 2A is a perspective view of a portion of a cable implemented according to a described embodiment;

FIG. 2B is a plan view of a cable implemented in accordance with the cable shown in FIG. 2A;

FIG. 2C is a cross-sectional view of the cable shown in FIG. 2A, as viewed along line 2C-2C and in the direction of the arrows;

FIG. 2D is a cross-sectional view of the cable shown in FIG. 2A, as viewed along line 2D-2D and in the direction of the arrows;

FIG. 2E is a perspective view of a portion of a two-sided version of the cable shown in FIG. 2A;

FIG. 3A is a perspective view of a portion of a cable implemented according to a described embodiment;

FIG. 3B is a plan view of the cable shown in FIG. 3A;

FIG. 3B _ a is an enlarged plan view of a portion of the cable of FIG. 3B;

FIG. 3C is a cross-sectional view of the cable shown in FIG. 3A, as viewed along line 3C-3C and in the direction of the arrows;

FIG. 3D is a cross-sectional view of the cable shown in FIG. 3A, viewed along line 3D-3D and in the direction of the arrows;

FIG. 3E is a perspective view of a portion of a two-sided version of the cable shown in FIG. 3A;

FIG. 4A is a perspective view of a portion of a cable implemented according to a described embodiment;

fig. 4B is a plan view of the cable shown in fig. 4A.

FIG. 4B _ a is an enlarged plan view of a portion of the cable of FIG. 4B;

FIG. 4C is a cross-sectional view of the cable shown in FIG. 4A, taken along line 4C-4C and viewed in the direction of the arrows;

FIG. 4D is a cross-sectional view of the cable shown in FIG. 4A, as viewed along lines 4D-4D and in the direction of the arrows;

FIG. 4E is a perspective view of a portion of a two-sided version of the cable shown in FIG. 4A;

FIG. 5A is a top orthogonal view of a cable implemented according to one described embodiment;

FIG. 5B is a cross-sectional view of the cable shown in FIG. 5A, taken along line 5B-5B and viewed in the direction of the arrows;

FIG. 6A is a top orthogonal view of a cable implemented according to an described embodiment;

FIG. 6B is a cross-sectional view of the cable shown in FIG. 6A, taken along line 6B-6B and viewed in the direction of the arrows;

FIG. 7A is a top orthogonal view of a cable implemented according to an described embodiment;

FIG. 7B is an enlarged view of a portion of the cable of FIG. 7A;

FIG. 7C is a cross-sectional view of the cable shown in FIG. 7A, taken along line 7C-7C and viewed in the direction of the arrows;

FIG. 8A is a perspective view of a cable implemented according to an described embodiment;

FIG. 8B is a top orthogonal view of the cable of FIG. 8A;

FIG. 8C is a cross-sectional view of the cable shown in FIG. 8A, taken along line 8C-8C and viewed in the direction of the arrows;

FIG. 8D is a cross-sectional view of the cable shown in FIG. 8A, as viewed along lines 8D-8D and in the direction of the arrows;

FIG. 8E is a cross-sectional view of the cable shown in FIG. 8A, taken along line 8C-8C and viewed in the direction of the arrows, illustrating a different stake thickness than in FIG. 8C;

FIG. 9A is a perspective view of a portion of a cable implemented according to an described embodiment;

FIG. 9B is a top orthogonal view of the cable of FIG. 9A;

FIG. 9C is a cross-sectional view of the cable shown in FIG. 9A, as viewed along lines 9C-9C and in the direction of the arrows;

FIG. 9D is a cross-sectional view of the cable shown in FIG. 9A, as viewed along lines 9D-9D and in the direction of the arrows;

FIG. 9E is a cross-sectional view of the cable shown in FIG. 9A, taken along line 9C-9C and viewed in the direction of the arrows, illustrating a different stake thickness than in FIG. 9C;

FIG. 10 is a block diagram of a conductive fluid sensing system according to described embodiments;

FIG. 11 is a schematic diagram of a conductive fluid sense switch circuit according to a described embodiment;

FIG. 12A is an orthogonal view looking into the cover surface of the first embodiment cable of FIG. 2A, showing an embodiment of a termination end for the cable;

FIG. 12B is a cross-sectional view of the terminating end of the first embodiment cable of FIG. 2A taken along line 2C-2C and viewed in the direction of the arrows;

13A-13L depict an example connector for receiving a cable implemented in accordance with the described embodiments;

FIG. 14 is a system diagram illustrating an embodiment of a conductive fluid sensing and notification system according to the described embodiments;

15A and 15B are top and side views of a flat flexible cable having three conductors according to the described embodiment;

figures 16A-16D are isometric, top, side, and front views of a flat flexible cable and connector assembly according to a described embodiment;

fig. 17A-17F are isometric, top, bottom, left, right and front views of a flat cable crimp connector assembly in an open configuration according to a described embodiment;

fig. 18A-18F are isometric, top, bottom, left, right and front views of a flat cable crimp connector assembly in a closed configuration according to the described embodiments; and

fig. 19A-19E are isometric, top, right, left and front views of the connector pin and cable barb assembly of the flat cable crimp connector assembly of fig. 17A-17F and 18A-18F.

Detailed Description

The described embodiments provide a flat conductive fluid sensor cable that can be manufactured with a long length. The flat conductive fluid sensor cable includes a flexible substrate, two or more flat conductors, and a fluid permeable material. The fluid permeable material allows the conductive fluid to form a conductive path between two or more conductors when the conductive fluid contacts the conductive fluid sensor cable. For example, some embodiments include a substrate having an adhesive surface and extending in an extension direction. A fluid permeable material is disposed on the adhesive surface of the substrate. The first and second uninsulated flat conductors are each positioned laterally and electrically insulated from each other and in a layer between the matrix and the fluid permeable material. The first conductor and the second conductor each extend in an extending direction along the adhesive surface of the base. The substrate, the first and second conductors and the fluid permeable material are adhered together to form a laminated structure of the conductive fluid sensor cable. The laminated structure seals the first conductor and the second conductor between the substrate and the fluid permeable material. The fluid permeable material directly covers and contacts the first conductor and the second conductor. In the presence of the conductive fluid, the fluid permeable material allows the conductive fluid to contact and form a conductive path between the first conductor and the second conductor. An attached sensor detects a conductive path indicative of the presence of a conductive fluid and may generate a signal in response to detecting the presence of the conductive fluid.

Referring now to the drawings, FIG. 1A depicts an environment in which a conductive fluid sensing system is installed. The conductive fluid sensing system comprises a conductive fluid sensor 1 connected to a conductive fluid sensor cable 2. The cable 2 extends from the sensor 1 over the surface 3. If the body of fluid 4 flows into contact with the cable 2 (and crosses over a pair of conductors embedded therein), the fluid forms a resistive connection over the pair of conductors in the cable 2. As used herein, the term "resistive connection" is a conductive path through which current flows characterized by the characteristic impedance of the conductive fluid medium through which the current passes to effect current flow between the conductors of the cable. The conductive fluid sensor 1 detects the flow of current between the conductors and indicates the presence of fluid on the surface 3.

In an embodiment, the conductive fluid sensor cable 2 may be manufactured in long lengths and, when manufactured using flexible materials, may be conveniently stored on the spool 1 until ready to be used, as shown in FIG. 1B. The conductive fluid sensor cable 2 is advantageously manufactured to be low cost, easy to manufacture, and can be cut to any desired length to facilitate installation and deployment in the field.

Fig. 2A-2D show an illustrative embodiment 10 of an electrically conductive fluid sensor cable 2. As shown in fig. 2A-2D, the cable 10 includes a base 11, an adhesive layer 12, a conductive layer 13, and a cover 14. The substrate 11 is composed of a first surface 11_topAnd a second surface 11_bottomIs defined and extends longitudinally along the length L in the direction of extension. Having a top surface 12_topAnd a bottom surface 12_bottomIs arranged with its bottom surface 12_bottomOn the top surface 11 of the substrate 11_topAbove. Having a surface 13_top、13_bottomIs arranged with its bottom surface 13 as a conductive layer 13_bottomOn the top surface 12 of the adhesive layer 12_topAnd has a surface 14_top、14_bottomIs arranged such that its bottom surface 14_bottomOn the top surface 13 of the conductive layer 13_topAnd a top surface 12 of the adhesive layer 12_topOver and in contact with portion 12 d. The conductive layer 13 includes insulated first and second conductors 13a and 13b extending in the extending direction of the base 11 and arranged in parallel spaced apart side by side. In one embodiment, top surface 14 of cover layer 14_topForming the outer surface of cable 10, and bottom surface 14 of covering layer 14_bottomA top surface 12 adhered to the adhesive layer 12_topTo sandwich the conductors 13a, 13b between the adhesive layer 12 and the cover layer 14 to securely hold the conductors 13a, 13b in place within the cable 10. The cover layer 14 comprises a cover material arranged in direct contact with the first and second conductors and arranged to allow fluid contact between the first and second conductors and the conductive fluid when the conductive fluid contacts the cable.

In one embodiment, the substrate 11 is formed of a flexible material (i.e., a material that can be bent without breaking), such as polyimide or polyester, fabric, or the like. The flexible material may also be formed of a generally rigid material (e.g., without limitation, FR-4) with a thickness reduced to tens of microns to achieve sufficient flexibility without failure. In other embodiments, a rigid material may be used to form the matrix, such as, by way of example and not limitation, FR-2 or FR-4, in which case the cable 2 would not be flexible.

In one embodiment, the cover layer 14 is formed using a fluid permeable material that allows fluid to pass from its top surface 14_topTo its bottom surface 14_bottomThrough the layer 14. In one embodiment, the cover layer 14 is implemented using a wicking material having non-conductive, moisture-absorbing, moisture-permeable properties that exhibits capillary action or wicking action in the presence of a fluid to pull the fluid across and through the material. Since different wicking materials absorb fluid at different rates, by deliberately selecting the particular wicking material used as cover layer 14, a coarse control can be achieved over the rate at which an electrically conductive connection is made across conductors 13a, 13b in the presence of an electrically conductive fluid. In one embodiment, cover layer 14 is implemented using a wicking material formed of a fluid absorbent material that swells or expands as it absorbs and retains fluid. The advantage of using such an intumescent wicking material is that the wicking material is more likely to make fluid contact across the conductors 13a, 13b, and such fluid contact is maintained if the wicking material forms somewhat loosely across the conductors 13a, 13 b. Additionally, depending on the type of intumescent wicking material used, the rate at which an electrically conductive connection is formed between the conductors 13a, 13b in the presence of fluid may vary based on the type of material, providing one aspect of control over the reaction time of the electrically conductive fluid sensing circuit. Without limitation, examples of suitable wicking materials include cotton, wool, rayon and other man-made fabrics, knitted materials or other natural or man-made absorbent materials or superabsorbent materials, including fluid permeable sleeves containing fluid-swellable materials that absorb fluids (e.g., superabsorbent gels or other materials).

In alternative embodiments, cover layer 14 is implemented using a dielectric or other non-absorbent but fluid permeable material, such as a fluid permeable membrane. In yet another modified embodiment, the cover layer 14 is implemented using a non-fluid permeable material deposited in non-contiguous portions so as to be arranged to form voids therebetween and therethrough (i.e., no cover material is present). For example, the cover material may be applied and arranged as low resolution dots, strips, stippling portions, which may be fluid permeable or fluid impermeable, and arranged to form void portions (i.e., no material present) that expose portions of the cable conductors 13a, 13b through the cover 14. As a specific example, provided by way of illustration and not limitation, the cover layer may be formed by spraying a low resolution coating of silicone rubber or other elastomer or sprayable dielectric (or a B-staged adhesive that is subsequently exposed to high heat or UV light for final curing), wherein the low resolution coating includes micro-dots arranged to form gaps or voids (i.e., the absence of the cover material 14) therebetween on the surface of the conductors 13a, 13B (as discussed below with reference to fig. 7A-7C). In such embodiments, the micro-dots form a protective cover 14 over the conductors 13a, 13b while leaving micro-voids that expose the conductors 13a, 13b and are capable of collecting and maintaining fluid in fluid contact with the conductors 13a, 13b as the fluid flows or collects on the top surface of the cable 10.

The cover layer 14 serves several purposes: (1) a covering formed to allow fluid to penetrate the cable to enable a conductive connection to be formed across the conductor; (2) help to secure the conductors 13a, 13b in place within the structure of the cable 10 by means of a fluid-permeable securing cover formed on the conductors 13a, 13b in association with the adhesive layer 12; (3) when such a cover layer 14 is implemented using a wicking material, it absorbs water or other conductive fluid and wicks the fluid through the conductors 13a, 13b by capillary action to more reliably ensure that a resistive connection is formed for detection by the conductive fluid sensor 1; (4) the selection of a particular fluid permeable material may serve as a coarse mechanical control of the rate at which the resistive connection is formed (helping to make a quick connection or slowing the formation of the resistive connection); (5) which helps to protect the conductive layer 13 and the adhesive layer 12 from environmental factors; (6) in the absence of fluid, it connects the conductors 13a, 13b with the exposed surface 14 of the covering layer 14_topThe objects that are contacted are electrically insulated, thereby helping to protect personnel and objects from inadvertently causing a short circuit or making a resistive connection across the conductors 13a, 13b when they contact the cable 10.

In one embodiment, the cover layer 14 is made of a fluid permeable materialA single unit (i.e. a single piece, or multiple pieces joined together to form a single piece) that preferably covers all or substantially all of the first surfaces 13top of the conductors 13a, 13b, and the first surface 12 of the adhesive layer 12_topIs not covered by the conductors 13a, 13b, or substantially all of the portion 12 d. Such an embodiment is shown in fig. 2A-2E. In an alternative embodiment, as best shown in fig. 5A-5B, 6A-6B, and 7A-7C, the cover layer 14 is implemented as a plurality of individual portions of fluid permeable material, whereby each individual portion forms a cap over a respective portion of the conductor. Preferably, one or more of the separate portions of such fluid permeable material are also adhered to and form a cover for the portion 12d of the adhesive layer 12, such portions 12d being laterally adjacent on each side of the conductors 13a, 13 b. The fluid permeable material formed on the conductors 13a, 13b and adhered on both sides of each conductor helps to ensure that the conductors remain securely in place when exposed to environmental conditions. In some embodiments, the cable 2 (e.g., the cover layer 14) may be implemented in a desired color so as to be less obtrusive, better blend with surrounding decoration, and/or more aesthetically pleasing.

In one embodiment, layers 11, 12, 13, and 14 are arranged in the order shown in FIGS. 2A-2D. In alternative embodiments, additional layers (not shown) of various materials may be present between the flexible substrate layer 11 and the adhesive layer 12. In another alternative embodiment, the cover layer 14 may be eliminated entirely such that the cable 10 includes only the flexible substrate 11, the adhesive 12, and the conductors 13a, 13 b. In an alternative embodiment, the layer 14 may be realized by a fluid permeable sleeve or sleeve component, such as a woven fiber sleeve, which encapsulates (i.e. surrounds) the combination of the matrix 11, the adhesive 12, the electrically conductive layer 13.

FIG. 2E depicts a double-sided version 10_ DBL of cable 10, including a base layer 11, as shown in FIGS. 2A-2D, and on one surface 11 of the base_topAn adhesive layer 12 (indicated as 12_1), a conductive layer 13 (indicated as 13_1) and a cover layer 14 (indicated as 14_1) and additionally comprises a second surface 11 arranged on the flexible substrate 11_bottomSecond adhesive layer 12_2, second conductive layer disposed on the second adhesive layer 12_213_2, and a second cover layer 14_2 disposed on portions of the second conductive layer 13_2 and the second adhesive layer 12_2, as shown. The layers 12_2, 13_2 and 14_2 are mirrored to the layers 12, 13 and 14 (shown as 12_1, 13_1, 14_1 in fig. 2E) relative to the substrate 11, the substrate being at its respective opposing surface 11_topAnd 11_bottomEach layered stack (12_1/13_1/14_1 and 12_2/13_2/14_2) is supported above.

Fig. 3A-3D depict an alternative embodiment 30 of the conductive fluid sensor cable 2. As shown, cable 30 includes a base 31, an adhesive layer 32, a conductive layer 33, and a cover layer 34. As best shown in fig. 3A, 3C _ a, and 3D, adhesive layer 32 is disposed on substrate 31 in a non-contiguous portion 35 disposed directly on substrate 31. Conductive layer 33 is disposed on adhesive layer 32 and includes conductors 33a, 33b that are electrically insulated from each other in the absence of a conductive fluid. Fig. 3B _ a is an enlarged view of the portion 38 of fig. 3B. As best shown in fig. 3B _ a, a first portion 36 of the top surface of the adhesive portion 35 is adhered to the bottom side of the respective portions of the conductors 33a, 33B, and a second portion 37 of the top of the adhesive portion 35 is adhered to the respective bottom side portion of the cover layer 34. In other words, the conductors 33a, 33b are laminated on (vertically) the portion 35 of the adhesive 32.

In one embodiment, as best shown in fig. 3B and 3B _ a, the adhesive portion 35 includes a plurality of adhesive strips formed perpendicular to the extending direction of the cable 30. Although shown as vertical strips deposited on substrate 31, portions 35 may be any shape and size that satisfies the conditions for adhering conductors 33a, 33b and at least portions of cover layer 34 into substrate 31. For example, in an alternative embodiment (not shown), the adhesive portion 35 may comprise a plurality of strips arranged diagonally on the base with respect to the extension direction of the cable 30. Other arrangements may include, without limitation: cross bars, or other non-continuous shapes, such as dots, spots, dashes, circles, rectangles, etc., are formed on the substrate so long as the adhesive 32 is formed on the substrate 31 such that the portions 35 (alone or with other portions 35) adhere to portions of the bottom sides of the conductors 33a, 33b and portions of the bottom side of the cover layer 34 in a manner that secures the conductors 33a, 33a in place between the substrate 11 and the cover layer 34.

In the embodiment shown in fig. 3A-3D, cable 30 may be formed to include only base 31, adhesive layer 32 on first surface 31a of base 31, conductive layer 33, and cover layer 34. Alternatively, as shown in fig. 3E, a double-sided version of the cable 30_ DBL may be formed by adding laminated layers of an adhesive layer 32_2, a conductive layer 33_2, and a cover layer 34_2 in this order on the second surface 31b of the base 31.

Fig. 4A-4D depict an alternative embodiment 40 of the conductive fluid sensor cable 2. As shown, the cable 40 includes a base 41, a conductive layer 43, an adhesive layer 42, and a cover layer 44. The conductive layer 43 is disposed on the substrate 31 and includes conductors 43a, 43b that are electrically insulated from each other in the absence of a conductive fluid. The conductive layer 43 may comprise non-adhesive conductors 43a, 43b or adhesive conductors. In one embodiment, conductors 43a, 43b comprise strips of conductive foil (including conductive foil, wherein an adhesive is disposed on at least one side of the foil). The adhesive between the conductive layer 43 and the substrate 41 is not shown in fig. 4A-4E, but may optionally include an adhesive to more securely hold the conductors in place on the substrate 31. In one embodiment, the conductors 43a, 43b are printed directly onto the substrate 41 using conductive ink, and thus no adhesive is required.

An adhesive layer 42 is disposed over the conductive layer 43. Fig. 4B _ a is an enlarged view of the portion 48 of fig. 4B. As best shown in fig. 4B _ a, a first portion 46 of the bottom surface of the adhesive portion 45 adheres to a corresponding portion of the top surface of the conductors 43a, 43B, and a second portion 47 of the bottom of the adhesive portion 45 adheres directly to the base 41. The top surface of the adhesive portion 45 is adhered to the corresponding bottom side portion of the cover layer 44. In one embodiment, as best shown in fig. 4B and 4B _ a, the adhesive portion 45 includes a plurality of adhesive strips formed perpendicular to the extending direction of the cable 40. In other words, the adhesive layer 42 is provided in the noncontiguous portion 45 that directly contacts portions of the top sides of the conductors 43a, 43b and portions of the top side of the base 41.

In an alternative embodiment (not shown), the adhesive portion 45 may comprise a plurality of strips arranged diagonally on the base 41 with respect to the extension direction of the cable 40. Other arrangements may include, without limitation: cross bars, or other non-continuous shapes, such as dots, spots, dashes, circles, rectangles, etc., are formed on the substrate 41 so long as the adhesive 42 is formed on the substrate 41 such that portions 45 (alone or with other portions 45) adhere to portions 46 of the top sides of the conductors 43a, 43b and portions 47 of the top side of the substrate 41 in a manner that secures the conductors 43a, 43b in place between the substrate 11 and the cover layer 44, and wherein the top surface of the adhesive layer 42 adheres to the bottom side of the cover layer 44.

In the embodiment shown in fig. 4A-4D, the cable 40 may be formed to include only a base 41, an adhesive layer 42 on a first surface of the base 41, a conductive layer 43, and a cover layer 44. Alternatively, as shown in fig. 4E, a double-sided version of the cable 40_ DBL may be formed by adding laminated layers of the adhesive layer 42_2, the conductive layer 43_2, and the cover layer 44_2 in this order on the second surface of the base 41.

Fig. 5A-5B show a top-down view and a cross-sectional side view of another alternative embodiment 50 of a cable 2, where the cable 50 includes a flexible base layer 51, a conductive layer 53, and a cover layer 54, as shown. The cover layer 54 may be fluid permeable or non-fluid permeable. The support layer 51 preferably comprises a support tape, such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN). Conductive layer 53 preferably comprises copper or copper/tin, or other conductive, flat foil, wire, or conductive ink. In embodiments in which cover layer 54 is non-fluid permeable, cover layer 54 preferably includes an adhesive that is biaxially oriented polyethylene terephthalate (BOPET), e.g.Or other adhesive dielectric film or sealant, and is disposed along the direction of extension L of the cable 50, leaving periodic openings 55 to expose portions 55a, 55b of the conductors 53a, 53b to the environment. Alternatively, the cover layer 54 comprises a fluid permeable material and still leaves voids 56. In one embodiment, the cable 50 may be further encapsulated in a wicking material 56, such as a cloth or fabric made of natural or synthetic fibers, fabric, or a fluid permeable material wrapped with an intumescent material.

Fig. 6A-6B show a top-down view and a cross-sectional side view of another alternative embodiment 60 of a cable 2, where the cable 60 includes a flexible base layer 61, a conductive layer 63, and a cover layer 64, as shown. In this example, the cover layer 64 is applied as a single piece of material layer and contains voids 66 (i.e., the cover layer material is not present) through which portions of the conductors 63a, 63b are exposed through the layer 64 to allow fluid to flow or collect thereon to contact the conductors 63a, 63 b. The cable assembly (61, 62, 63, 64) may be further covered by an outer fluid permeable cover or encased in an outer fluid permeable sleeve 65 to cover the portions of the conductors 63a, 63b exposed through the interstices 66 of the covering. The substrate layer 61 preferably comprises a support tape, such as polyethylene terephthalate (PET), BoPET, or polyethylene naphthalate (PEN). Conductive layer 53 preferably comprises copper or copper/tin, or other conductive, flat foil, wire, or conductive ink. The cover layer 64 preferably comprises bonded BoPET, for exampleOr other adhesive dielectric film or sealant. Alternatively, the cover layer 64 may be a fluid permeable material.

Fig. 7A-7C illustrate an embodiment 70 of a cable 2 having a base layer 71, an adhesive layer 72, a conductive layer 73 comprising conductors 73a, 73b, and a cover layer 74, wherein the cover layer 74 comprises a plurality of particles 75 disposed on the conductive layer 13 and exposed portions of the base/adhesive layer 71/72, for example by applying a low resolution spray of material on the top surface of the exposed portions of the conductors and base/adhesive layer 71/72. As best shown in fig. 7B, which shows an enlarged portion 79 of the top surface of the cable 70 of fig. 7A, the covering layer 74 is formed from a plurality (thousands or more) of particles 75 that form voids between them to allow fluid to permeate through the layer 74 and contact portions of the conductors 73a, 73B. For example, the microparticle 75a covers a part of the conductor 73a, and the microparticle 75b covers a part of the conductor 73b, but there is a gap between the microparticle and another microparticle. Thus, the conductors 73a and 73b remain partially exposed to contact by the penetrating conductive fluid, however, the large number of particles acts to form a low resolution protective outer cover for the cable 70.

It should be understood that any of the cover layers 54, 64, or 74 described in fig. 5A-5B, 6A-6B, and 7A-7B may be used as an implementation of any of the respective cover layers 14, 34, or 35 in the embodiments shown in fig. 2A-2E, 3A-3E, and 4A-4E. Additionally, it should be understood that each of the cable embodiments 10, 30, 40,. 90 may be further encased in a fluid permeable sleeve or otherwise covered in a fluid permeable material (in addition to the respective covering included in the respective cable embodiments).

Fig. 8A-8D illustrate another alternative embodiment 80 of the cable 2. In this embodiment, cable 80 includes a base layer 81, an adhesive layer 82, and a cover layer 84, wherein at least one pair of mutually insulated conductors 83a, 83b are woven, sewn, knitted, braided, or otherwise incorporated into cover layer 84. In one embodiment, the conductors 83a, 83b comprise fine conductive wires, flat conductive ribbons, wires, or other conductive materials. The cover layer 84, in which the conductors 83a, 83b are bonded, is adhered to the base layer 81 by the adhesive layer 82.

The adhesive layer 82 may comprise a continuous adhesive body on which the covering layer 84 and portions of the stitched conductors 83a, 83b are disposed. In an alternative embodiment (not shown in fig. 8A-8D, but implemented in an implementation similar to the portion 35 shown in fig. 3A-3D), the adhesive layer 82 is disposed on a discontinuous portion on the base 81 that is positioned on the base 81 such that when the cable 80 is assembled, a first portion of the adhesive portion adheres to the conductors 83A, 83b and a second portion of the adhesive portion adheres to a portion of the cover layer 84. In one embodiment, similar to the embodiment shown in fig. 3A-3D, the adhesive portion includes a plurality of adhesive strips formed perpendicular to the direction of extension of the cable 80. In alternative embodiments, the adhesive portion may comprise a plurality of strips arranged diagonally with respect to the direction of extension of the cable 80, or may be formed as cross-hatched lines (crossing adhesive to form holes in the adhesive layer) or other non-continuous shapes, such as dots, dashes, circles, rectangles, etc., with the adhesive 82 formed on the substrate 81 such that the adhesive portion (alone or with other adhesive portions) adheres to portions of the conductors 83c, 83d, and portions of the cover layer 84 in a manner that secures the conductors 83c, 83d in place by the adhesive 82 and the cover 84.

In one embodiment, a portion 85 of the conductors 83a, 83b is exposed on the outer surface of the cable 80, while other portions of the conductors 83a, 83b are protected within or below the exposed surface of the cover 84. The size of the exposed portions 85 of the conductors 83a, 83b depends on the knitting size and/or the weave or knitting pattern. In an alternative embodiment shown in FIG. 8E, the cover layer 84 is characterized by pegs (characterized by a thickness t)_pile) The pile projecting on the outer surface by a distance t_pileAnd beyond the protrusions t of the conductors 83a, 83b on the outer surface of the cable 80_conductorSuch that the conductors 83a, 83b are substantially protected from external contact by objects and persons due to the density and piling of the material of the covering layer 84. Thicker fabric stake t on the outer surface of cable 80_pileAllowing the fabric of the covering 84 to act as a weak insulator between the exposed conductor 83 and the object in contact with the fabric post on the outer surface of the cable 80.

Fig. 9A-9E illustrate another alternative embodiment 90 of the cable 2. In this embodiment, cable 90 includes a base layer 91, wherein at least a pair of mutually insulated conductors 92a, 92b are woven, sewn, knitted, braided or otherwise incorporated into base layer 91. In one embodiment, the substrate layer 91 comprises a cloth, fabric, or mesh that is capable of absorbing and wicking liquid. The conductors 92a, 92b comprise thin conductive wires, flat conductive ribbons, or wires. Similar to the discussion in connection with FIGS. 8A-8E, the conductors 92a, 92b may be based on the posts t of the substrate layer 91_pileStakes t to conductors 92a, 92b_conductorAnd/or a woven or knitted pattern to be more or less exposed.

It is noted that each cable embodiment 10, 30, 40 … 90 is shown in the drawings with exaggerated dimensions for ease of understanding. In particular, the thickness of the various layers relative to the width in each of the illustrated embodiments 10, 30, 40 … 90 is exaggerated to enable the structure of the various cables to be shown. In practice, each cable embodiment is typically on the order of a few millimeters in width, one hundred or more microns in thickness, and a few centimeters to several meters in length. In an illustrative embodiment, for example, the cable 10 may have a 3mm spacing between conductors and may have example dimensions as shown in table 1 below:

various materials may be used for each of the matrix, substrate, adhesive, conductor, and wicking/covering layer of each embodiment 10, 30, 40 … 90 of the cable 2. The substrate/support/base layer may, by way of example and not limitation, use a dielectric material such as biaxially oriented polyethylene terephthalate (BOPET), polyethylene terephthalate (PET), polyethylene naphthalate (PEN) or other polyester or polyamide films or electrically insulating materials. The matrix/support/substrate layer may also be implemented using wicking materials such as cloth, fabric, mesh, etc., constructed from natural or synthetic non-conductive fibers. Preferably, as discussed herein, the substrate is flexible; alternatively, the substrate may be rigid or semi-rigid, for example using a material such as FR-2 or FR-4.

Examples of adhesive materials include, but are not limited to, non-conductive resins, adhesives, and/or epoxies. In some embodiments, the adhesive is a B-staged adhesive that can be applied by dispensing or printing and then partially cured using a latent (low reactivity) curing agent such that it remains in a bondable state. Once the components (e.g., substrate, conductor, cover) are placed, the B-staged adhesive is exposed to high heat or UV light for final curing. In one embodiment, the combination of the substrate and the adhesive layer is a prefabricated adhesive flexible BoPET tape, for exampleMelinex and Hostaphan adhesive tapes. It should be understood that the adhesive is characterized by electrical insulating properties to prevent electrical current flow between the conductors through the adhesive. Furthermore, in embodiments where the conductors may have portions that directly contact the substrate, it will be appreciated that the substrate itself must correspondingly be electricalInsulated to prevent current flow between the conductors through the substrate.

The conductive layer or conductor is implemented using a conductive material such as, but not limited to, silver ink, copper, tin-plated copper, gold, nickel, aluminum, and the like. The conductors in each of examples 10, 20 … 90 are preferably flat conductive foils (which may include adhesive tape, flat wire, or printed conductive ink, but may also be round wires, conductive thin wires, conductive traces, etc.).

In one embodiment, the base and conductive layers together comprise a Flat Flexible Cable (FFC) that is manufactured using BoPET tape and a flat foil laminated or adhered thereto. The wicking/overlaminate is adhered to the FFC using a B-stage adhesive. This structure supports a very inexpensive manufacturing process, a durable cable, and promotes accurate reliability by the water sensor connected to the cable.

Thus, the embodiments described may be formed with adhesive only on the base layer, and not on the cover layer. For example, the B-staged adhesive may be disposed on the base layer and the conductor placed and adhered to the base layer. A cover layer of a fluid permeable material is adhered to the adhesive not covered by the conductor disposed on the base layer. Thus, the adhesive is not disposed on the cover layer, allowing the cover layer to remain fluid permeable and thus function as a fluid sensor.

In operation, each cable embodiment 10, 20, … 90 functions as an electrically conductive fluid sensor cable (to be operated with an electrically conductive fluid sensing circuit) by exposing electrically insulated conductors embedded within the cable (either through a fluid permeable layer or a cover arranged to form a void therethrough) to the environment in which the cable is installed. The cover layer (achieved by fluid permeable material and/or by leaving voids between layer materials) allows fluid to permeate the layer when the conductive fluid is in contact with the cable 102. When the cover layer is implemented using a wicking material, the wicking material absorbs the fluid, pulling it through the wicking material, to ensure that the fluid forms a body of electrically conductive fluid that forms an electrically resistive connection between the otherwise insulated (i.e., in the absence of fluid) conductors. By capillary action, the wicking material enhances the likelihood of fluid crossing the two conductors to ensure detection of fluid presence. The conductors of cable 102 are connected to a conductive fluid sensing circuit (discussed below) that detects and indicates the presence of conductive fluid based on current flowing through a resistive connection formed by the conductive fluid across the conductors of cable 102.

Fig. 10 shows an illustrative conductive fluid sensing system 100. System 100 includes a conductive fluid sensing circuit 121 having a first input node 122a and a second input node 122b electrically connected to an input connector 123. The connector 123 is configured to receive, retain, and electrically connect the input nodes 122a, 122b to the respective first and second conductors 103a, 103b of the conductive fluid sensor cable 102 when one end of the conductive fluid sensor cable 2 is inserted into the connector 123. In one embodiment, the conductive fluid sensing circuit 121 includes a switching circuit 125 that generates one or more drive signals on a switching output node 124 whose status indicates the presence or absence of conductive fluid across conductors 103a, 103b on the cable 102. Electronic switches are well known in the art; accordingly, the switching circuit 125 may be implemented in accordance with any suitable switching circuit that generates a drive signal based on the current or measured resistance across the conductors 103a, 103b when the cable 102 is connected to the conductive fluid sensing circuit 121.

Referring to fig. 11, and without limitation, in one embodiment, the electronic switch 125 in the conductive fluid sensing circuit 121 includes a PNP transistor 126 having an emitter E connected to the voltage source Vcc, a collector C connected to circuit ground through a current limiting resistor R1, and a base B connected to circuit Vcc through a current limiting resistor R2 and also connected to one 122a of the input nodes of the connector 123 through a current limiting resistor R3. The other input node 122b is connected to circuit ground. The drive signal on node 124 is connected at transistor collector C. Without conductive fluid on conductors 103a, 103b through cable 102, transistor 126 is in the off mode and no current flows between emitter E and collector C. When the conductive fluid forms a path connecting the conductors 103a, 103b, the resistive connection (shown as resistor R4) allows current flow through R2, driving the base-emitter voltage VBE. When the current through R4 is sufficient, the base-emitter voltage VBE is driven sufficiently to overcome the threshold voltage VT of transistor 126, allowing current flow from emitter E to collector C, and ultimately driving the drive signal node 124 to a voltage level close to Vcc (corresponding to a high logic level) for subsequent circuit use. As will be appreciated, other embodiments may implement other analog and/or digital circuitry as part of conductive fluid sensing circuit 121 in addition to the embodiment shown in FIG. 11.

Connector 123 can be implemented in various ways to receive, retain, and electrically connect cable 102 to conductive fluid sensing circuit 121. Preferably, connector 123 allows cable 102 to be inserted and then later removed to allow the cable to be easily installed and replaced without the need to open the housing of conductive fluid sensing circuit 121 and/or solder connections.

In one embodiment, the connector 123 comprises a Zero Insertion Force (ZIF) connector configured to receive an FFC cable. In such embodiments, the terminating end of the cable to be inserted into the ZIF connector typically requires a strength member added to the end of the cable. Fig. 12A and 12B depict an exemplary termination end 18 of a cable that may be implemented, for example, on the end of the cable 10 of fig. 2A-2D. As shown in fig. 12B, the termination end 18 of the cable 10 may include strength members 16 adhered with an adhesive 15 on the bottom side of the matrix 11 at the termination end 18 of the cable. In addition, the cover 14 does not extend completely to the termination end 18 to expose the conductors 13a, 13b for connection to conductive terminals of a ZIF connector (not shown). In one embodiment, the stiffener 16 preferably comprises a support tape, such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN).

In one embodiment, connector 123 is integrated into the circuitry and housing of conductive fluid sensing circuit 121 and includes features that allow the end of cable 20 to be inserted and retained by connector 123, whereby the connector forms an electrical connection between conductors 103a, 103b of cable 102 and connector input nodes 122a, 122b of conductive fluid sensing circuit 121. Preferably, connector 123 is self-sufficient and does not require external crimping tools to electrically connect cable 102 to circuit 121. Preferably, the connector 123 also does not require any additional termination structure or support on the end of the cable — for example, the connector connects to the original end of the cable, which does not include any additional strength members, connectors, or other structures.

Fig. 12A-12L illustrate an embodiment 200 of a connector 123 that may be used to connect the cable 2 to the conductive fluid sensing circuit 121 and may be used to attach to the original end of the cable (i.e., without additional connectors, terminal reinforcements, or other structures implemented on the cable end), thereby allowing the conductive fluid sensor cable to be cut to any length and used immediately without adding additional interfaces to attach to the connector 123.

Fig. 13A is a plan view showing the connector 200 attached to the sensing circuit 121. As best shown in fig. 13C, the connector 200 has a body with a passage for receiving the end of the cable 102. The channel includes a planar base portion and a pair of vertical sidewalls on each side of the planar base portion. The inner planar base portion is substantially the width of the cable plus a small relative tolerance to allow for loose insertion and assembly, but tight enough that the cable inserted therein is naturally guided and substantially centered between the sidewalls of the channel. The channel of the housing includes a pair of electrically conductive tracks seated on or otherwise embedded in the planar base portion. The spacing of the electrically conductive tracks is such that when the cable 102 is inserted into the channel of the connector, the tracks are aligned with the conductors 103a, 103b on the cable 2. In other words, the spacing and pitch of the tracks substantially match the spacing and pitch of the conductors on cable 102. Each conductive track includes a plurality of piercing projections that project outwardly from the track and into the space defined by the channel. In one embodiment, each piercing projection has a smooth base portion oriented toward the entrance of the channel and at least one piercing tip oriented toward the rear of the channel. This allows the cable to slide along the smooth base portion of the protrusion without being pierced by the piercing protrusion when the cable is inserted, allowing for easy installation.

As best shown in fig. 13B and 13C, the planar base portion may also include one or more retention tabs, which may be formed in the molded connector body or, alternatively, may be seated or otherwise embedded in one or more areas of the planar base portion not occupied by the conductive traces. In one embodiment, the retention projection is a piercing pin that will pierce a non-conductive portion of the cable 102 when the end of the cable 102 is inserted into the channel and the retention cap is seated thereon. In one embodiment, the retention tab is further characterized by having a smooth base portion and oriented such that the smooth base portion faces the entrance of the channel. Alternatively, as best shown in fig. 13B, the retaining projections do not protrude as far from the surface of the planar base portion as the piercing projections of the conductive tracks. In this way, the retaining protrusion does not interfere with the cable insertion channel during insertion of the cable.

Connector 200 also includes a retention cap having a molded compression block attached or molded on its underside that includes cavities or recesses positioned to substantially conform to the respective positions of the piercing and retention protrusions in the channel when the retention cap is properly fitted over the channel. The retaining cover is attached along the upper edge of one side wall of the channel housing by a hinge that allows the cover to rotate from an open position (fig. 13D) to a closed position (fig. 13E). The retaining cap also includes a retaining clip. In one embodiment, the retaining clip is molded into the lid on the edge opposite the hinge. The retaining clip includes a hooked edge that engages an opposing hooked edge formed in an outer surface of the non-hinged sidewall. Thus, referring to fig. 13F-13L, in operation, with the retention cap in the open position, cable 102 is placed at the entrance of the connector channel (fig. 13F) and then slid toward the rear of the channel (fig. 13G) until it contacts the rear wall of the channel (fig. 13H). The retaining cap is then rotated to the closed position (fig. 12I). As the retaining cap is rotated to the closed position, the compression block contacts cable 102 and applies pressure to the surface of cable 102, which in turn presses the opposing surface of cable 102 against the piercing protrusion of the track and the retaining protrusion of the channel. As best shown in fig. 13J-13L, as the retention cap is fully rotated into position, the piercing projections of the track pierce through the base, conductors and cap of the cable 102, and in particular, the conductors 103a, 103b of the cable 102, thereby forming an electrical connection between the conductors 103a, 103b of the cable and the input nodes 122a, 122b of the circuit 121. Similarly, the retention protrusions of the channel pierce through the area of the cable 102 where no conductor is present, creating a retention on the cable such that the cable is securely held in place within the channel of the connector 200.

Referring again to fig. 10, the drive signal D present on the drive signal node 124 may be advantageously used to drive subsequent circuitry. For example, in one embodiment, the drive signal D on node 124 drives one or more inputs of the processor 120, which drives other circuitry to implement various operations based on the state of the output (on node 124) of the drive signal (D) of the conductive fluid sense circuit 121. By way of example and not limitation, the processor 120 may be a Central Processing Unit (CPU), microprocessor, Application Specific Integrated Circuit (ASIC), Programmable Logic Array (PLA), or the like. Processor 120 may be connected to computer memory 127 via a bus (not shown) such that processor 120 may access programming instructions and/or data stored in memory 127. By way of example, and not limitation, memory 127 may be one or more of RAM, ROM, PROM, FPROM, FEPROM, EEPROM, flash memory, or any other suitable computer-readable memory or component now known or later developed. The drive signal D from the conductive fluid sensing circuit 121 may drive one or more alerting devices/circuits, such as an audio alarm 128, a visual alarm (e.g., illuminating LED or other illumination device 129, or displaying text or graphics on the display 130), either directly or indirectly (e.g., via the processor 120, as shown in fig. 10, or through additional circuitry (not shown)). The drive signal D present on the drive signal node 124 may also be used, directly or indirectly, to actuate an auto-close valve and/or control relay 131.

Actuation of any of the devices 128, 129, 130, 131 may be accomplished directly by electrically connecting node 124 directly to the input of the respective actuation device 128, 129, 130, 131. Alternatively, actuation may be accomplished indirectly through one or more intermediate circuits, electrical devices, controllers, and/or network communications. For example, in fig. 10, each of the actuation devices 128, 129, 130, 131 is controlled by the processor 120, which actuates such respective device in response to the state of the drive signal D on node 124. In an embodiment, actuation of the devices 128, 129, 130, 131 may be further based on input from one or more other sensors 134, including but not limited to sensors that detect temperature, humidity, location, and the like. In alternative embodiments, the drive signal D on node 124 may be directly connected to one or more of the actuation devices 128, 129, 130, 131 to enable direct actuation of such devices.

The processor 120 may also be configured to control one or more transmission modules 132 to transmit alerts, such as text messages, phone calls, emails, and the like. The transmission module 132 transmits information indicative of the presence (or absence) of the conductive fluid across the conductors 103a, 103b of the conductive fluid sensor cable 102, and/or the current and/or resistance measured based on the information. In embodiments, the transmission module 132 may include one or more of the following: a cellular modem and antenna; an IEEE 802.11a/b/g/n WiFi module with an antenna; or RF transceivers and antennas implementing transmission protocols in other RF bands and corresponding suitable transmission protocols (e.g., ISM band, 433MHz or 915MHz, bluetooth, ZigBee, etc.). The conductive fluid sensing system 100 may also include additional circuitry such as, but not limited to, a Subscriber Identity Module (SIM) card 135 for a cellular transmission module, a GPS module 133 for detecting and using or transmitting GPS coordinates, other sensors 134 such as temperature sensors, humidity sensors, and the like. The system 100 includes one or more power supplies 136. In one embodiment, the system 100 is self-powered using one or more battery power sources. In some embodiments, the power supply 136 may alternatively or additionally include an AC/DC converter and connect to an AC power source through an AC power outlet connected to a power grid or other AC power source. In some embodiments, the battery power source may be rechargeable, such as by an AC/DC converter and an AC power source (e.g., by a solar cell or other similar power source).

Referring to fig. 14, in one embodiment, the conductive fluid sensor cable 2 may be used in connection with a water sensor alarm notification system. In one embodiment, one or more conductive fluid sensing systems 320a, 320b, 320m (e.g., the respective systems 100 of fig. 10, to which the cable 102 is attached) including conductive fluid sensor cables attached thereto are installed in the environment 300. If, and when, the conductive fluid sensing system 320a, 320b, 320m is triggered because a conductive fluid is detected on its respective connected cable, the respective system 320a, 320b, 320m formulates and transmits a message to the communications hub 310. Communication hub 310 receives the messages and transmits the corresponding messages to a notification server 330 executing on the internet-enabled computer (e.g., in the cloud), which further notifies the user through application notifications on the mobile device in text messages, emails, phone calls, and the like. In one embodiment, each of the sensing systems 320a, 320b, 320m includes an antenna 321a, 321b, 321c modulated to transmit messages using a protocol such as 433MHz, 915MHz, bluetooth, ZigBee, or WiFi. Hub 310 includes a local-range antenna for receiving messages from sensing systems 320a, 320b, 320m, and also includes a remote antenna for transmitting messages to remote notification server 330. In one embodiment, the remote antenna and transmission module implements one or more mid-range and/or long-range protocols, including WiFi, cellular (e.g., LTE-CAT-M1, LTE-NB-IoT, etc.), and other internet protocols. The transmission may also actuate other electrical and/or mechanical devices, such as automatic water shut-off valves, relays, and other mechanical controls.

Although shown in fig. 13A-E as including two conductors 103A, 103b, any number of conductors may be employed. For example, as shown in fig. 15A-B, one embodiment of cable 102 may include three conductors, 1502a, 1502B, 1502 c. In one embodiment, two of the conductors 1502 may be connected together by a jumper (not shown), and the other conductor 1502 may remain electrically isolated from the other two conductors. In such an arrangement, a break in the cable 102 may be detected (e.g., by the conductive fluid sensing system 100) because connecting two of the conductors 1502 together would form a current path circuit from and back to the sensing system 100. If cable 102 breaks, the circuit path formed by connected conductors 1502 will also break. Having a third, electrically insulated conductor also allows the conductive fluid to form a current path between one or both of the connected conductors and the electrically insulated conductor, thereby providing fluid sensing capability in addition to sensing a broken cable. Other numbers of conductors may be envisaged for other beneficial purposes.

Fig. 15B shows a side view of cable 102, which includes base 1504 (and optionally an adhesive layer (not shown)), conductive layer 1502', and cover 1506. In some embodiments, the overall thickness of cable 102 may be about 0.013 inches, and the width of cable 102 may be about 0.4 inches. In some embodiments, conductive layer 1502' may be about 0.003 inches, and the width of each conductor 1502a, b, c may be about 0.062 inches, and each conductor may be separated by a gap of about 0.038 inches. In some embodiments, the base layer 1504 may comprise polyester having a thickness of about 0.001 inches and an adhesive having a thickness of about 0.0015 inches.

Fig. 16A-16D are isometric, top, side and front views of a flat flexible cable and connector assembly 1600. As shown in fig. 16A-16D, the flat flexible fluid sensing cable can include a first length of flat cable 1604a and a second length of flat cable 1604b, which can be connected by an optional cable extension connector 1606. Each of the first and second lengths of flat cable 1604a and 1604b can be implemented as various embodiments of the cable 102 described herein. For example, the illustrative cable lengths 1604a and 1604b may have four conductors 1608a-d disposed on a substrate 1620, although other numbers of conductors may be employed as described herein. As shown, the cable length 1604a may have one end terminated with a pre-shaped connector 1616 that terminates the cable 1604a with a male receptacle connector 1602 (e.g., a 3.5mm male receptacle). As shown in fig. 16B, a male body receptacle 1602 may have one or more conductive contacts, shown as contacts 1602a-d, which may be connected to a respective one of conductors 1608 a-d.

In some embodiments, the cable extension connector 1606 may be a crimp connector having a plurality of barbs 1624 for piercing the matrix 1620 (and/or fluid permeable cover, not shown in fig. 16A-16D) when the top clasps 1610a and 1610b are closed over the cable lengths 1604a and 1604b, respectively. As shown, the cable extension connector 1606 may have a first crimp side to crimp a first cable (e.g., cable length 1604a) and a second crimp side to crimp a second cable (e.g., cable length 1604 b). As shown, each crimp side may have a respective top clasp 1610a and 1610b that interacts with a respective latch 1622a and 1622b of the connector body 1623 such that the top clasp locks in a closed position on the respective cable.

Each crimp side may have a respective set of barbs 1624a, 1624b that pierce the matrix 1620 (and/or the fluid permeable cover not shown in fig. 16A-16D) when the top clasps 1610a and 1610b are closed over the cable lengths 1604a and 1604b, respectively. Generally, each conductor 1608a-d can have a respective set of barbs 1624. Each of the top clasps 1610a, 1610b may have a respective cable wedge 1618a, 1618b to press the cable lengths 1604a and 1604b firmly against the barbs 1624a, 1624b to ensure that the matrix and/or fluid permeable cover is penetrated by the barbs and an electrical connection is established between the barbs 1624 and the respective conductor 1608 of each cable length 1604a, 1604 b.

In other embodiments, the cable length 1604a may be a pre-formed length of the cable 102 terminated with a pre-formed cable extension connector, wherein the pre-formed cable extension connector is a 3.5mm female solid receptacle connector. Similarly, cable length 1604b may be a pre-formed length of cable 102 that terminates at one end with a male stereo receptacle (e.g., connector 1616 and receptacle 1602) that may be connected to a female stereo receptacle connector of cable length 1604. Similarly, cable length 1604b may terminate at its other end with a female three-dimensional receptacle, enabling a user to use a pre-formed cable length to adjust the length of the cable to a desired length. In other embodiments, male and female three-dimensional receptacle connectors may be implemented with crimp connectors such as those described in fig. 16-18, allowing a user to create custom length cables, yet still employ three-dimensional receptacle terminals. In other embodiments, the segments of the cable may be terminated by pre-formed or crimped jumper connectors (not shown). The jumper connector may connect two or more of the conductors 1608a-d together, which may enable the cable 102 to have other functions, such as for detecting a broken or damaged cable, or to carry electrical signals between two or more devices connected to the cable.

Fig. 17A-17F are isometric, top, bottom, left, right and front views of a flat cable crimp connector assembly in an open configuration, and fig. 18A-18F are isometric, top, bottom, left, right and front views of a flat cable crimp connector assembly in a closed configuration. As shown in fig. 17 and 18, the compression connector 1700 may have a top clasp 1702 connected to a bottom body 1714 via a hinge assembly 1710. The top clasp 1702 includes a latch 1704 that interacts with a latch catch 1716 on the bottom body 1714. When the top clasp 1702 is closed, the latch catch 1716 may engage the latch 1704 so that the top clasp 1702 remains closed and the cable wedge 1708 of the top clasp 1702 firmly presses the cable (not shown) against the teeth 1722 of the cable barb 1720.

Each of the cable barbs 1720 may correspond to a given one of the conductors to be crimped in the cable. When the top clasp 1702 is locked in place (e.g., when the latch catch 1716 engages the latch 1704), the teeth 1722 of the cable barb 1720 may pierce the base and/or fluid permeable cover of the cable 102, thereby establishing an electrical connection with the conductors of the cable 102. Thus, the electrical connection between the respective conductors and the respective cable barbs is ensured by the fixed connection between the top clasp 1702 and the bottom body 1714. Each of the cable barbs 1720 can be connected to a connector pin 1718 (or a continuous portion of a connector pin) allowing a cable conductor to be electrically connected to a receptacle, such as the conductive fluid sensing system 100, that receives the connector pin 1718. In some embodiments, the bottom body 1714 can include one or more mounting screws 1712a, 1712b for securely mounting the crimp connector 1700 to the conductive fluid sensing system 100 or some other bulkhead or receiver.

Fig. 19A-19E are isometric, top, right, left and front views of the connector pin and cable barb assembly of the flat cable connector assembly of fig. 17A-17F and 18A-18F. As shown in fig. 19A-19E, each connector pin and cable barb assembly 1900 may have a corresponding pin portion 1908 and barb portion 1904 with teeth 1906 and mounting arms 1902 to securely mount the assembly 1900 in place within the bottom body 1714.

The described embodiments provide a flat conductive fluid sensor cable that can be manufactured in long lengths. The flat conductive fluid sensor cable includes a flexible substrate, two or more flat conductors, and a fluid permeable material. The fluid permeable material allows the conductive fluid to form a conductive path between two or more conductors when the conductive fluid contacts the conductive fluid sensor cable. For example, some embodiments include a substrate having an adhesive surface and extending in an extension direction. A fluid permeable material is disposed on the adhesive surface of the substrate. The first and second uninsulated flat conductors are each positioned laterally and electrically insulated from each other and in a layer between the matrix and the fluid permeable material. The first conductor and the second conductor each extend in an extending direction along the adhesive surface of the base. The substrate, the first and second conductors, and the fluid permeable material are adhered together to form a laminated structure of the conductive fluid sensor cable. The laminated structure seals the first conductor and the second conductor between the substrate and the fluid permeable material. The fluid permeable material directly covers and contacts the first conductor and the second conductor. In the presence of the conductive fluid, the fluid permeable material allows the conductive fluid to contact and form a conductive path between the first conductor and the second conductor. An attached sensor detects a conductive path indicative of the presence of a conductive fluid and may generate a signal in response to detecting the presence of the conductive fluid.

Although the embodiments have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the claims. For example, reference herein to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of claimed subject matter. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. The same applies to the term "embodiment".

As used in this application, the words "exemplary" and "illustrative" are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" or "illustrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs. For the purposes of this description, the terms "coupled," "connected," "connecting," or "connected" refer to any manner known in the art or later developed in which energy is allowed to be transferred between two or more elements, and the interposition of one or more additional elements is contemplated (but not required).

To the extent directional terms are used in the specification and claims (e.g., upper, lower, parallel, perpendicular, etc.), these terms are intended only to facilitate description of the embodiments and are not intended to limit the claims in any way. These terms do not require precision (e.g., precise verticality or precise parallelism, etc.), but normal tolerances and ranges are applicable. Similarly, unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word "about", "approximately" or "substantially" preceded the value or range of values.

It will also be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated herein may be made by those skilled in the art without departing from the scope of the appended claims.