Acoustic Emission Sensor Holder for Non-Metal Extreme Testing
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Solution Overview
Problem
Traditional methods for attaching acoustic emission sensors to non-metallic and non-magnetic materials, such as composite and ceramic materials, are ineffective due to poor adhesion at extreme temperatures and lack of compatibility with these materials, limiting their use in environmental testing.
Innovation Solution
A tubular acoustic emission sensor holder with unitary flexible flaps and partial cylindrically-shaped spacers made from flexible materials, allowing for secure positioning and contact with the sensor across a wide range of environmental conditions, compatible with ASTM standard test methods, and utilizing vacuum bag or sealant tape for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot glue is used to attach acoustic emission sensors, then sensors can be attached to surfaces, but adhesion fails at extreme temperatures (less than -53.89°C or greater than 71.11°C)
Solution Approach 1:
The patent uses disposable adhesive tapes (such as vacuum bag tape or sealant tape) instead of permanent hot glue attachment. These tapes can be applied and removed without degrading, allowing sensors to be attached and detached for repeated testing cycles across extreme temperature ranges without adhesion failure.
Solution Approach 2:
The invention changes the attachment method from thermal bonding (hot glue) to mechanical/adhesive bonding using tapes designed for extreme temperature environments. This parameter change in attachment mechanism allows reliable sensor fixation across temperatures from less than -53.89°C to greater than 71.11°C.
2Reliability
If magnetic clamping fixtures are used to hold sensors, then sensors can be securely attached to metallic surfaces, but they cannot function with non-metallic and non-magnetic composite materials
Solution Approach 1:
The patent creates a universal sensor holder system using adhesive tapes that can attach to any surface type (metallic, non-metallic, magnetic, non-magnetic). This eliminates the limitation of magnetic fixtures and allows the same attachment method to work across all material types, including composite and ceramic materials.
Solution Approach 2:
The adhesive tape acts as an intermediary between the sensor and the test article surface. Rather than relying on direct magnetic or thermal interaction between sensor and surface, the tape mediates the attachment, making the system compatible with all material types regardless of magnetic or thermal properties.
3Manufacturing precision
If acoustic emission sensors are permanently attached to test articles, then sensor positioning is stable, but testing becomes expensive and time-consuming (greater than 10 hours per sensor for curing adhesive)
Solution Approach 1:
The patent transitions from static permanent attachment to dynamic removable attachment using adhesive tapes. Sensors can be quickly applied and removed without curing time, enabling rapid reconfiguration for different test articles while maintaining stable positioning during each test through proper tape selection and application.
Solution Approach 2:
The adhesive tapes are pre-selected and pre-positioned on the sensor holder before sensor installation. This preliminary preparation eliminates the need for on-site adhesive application and curing, reducing test preparation time from over 10 hours to minimal handling time while ensuring stable sensor positioning.
4Ease of operation
If traditional sensor holders are used for non-metallic materials, then attachment can be achieved, but sensor contact and alignment cannot be maintained under extreme environmental conditions
Solution Approach 1:
The patent uses disposable adhesive tapes that are specifically designed to maintain their bonding properties under extreme environmental conditions. These tapes can be applied easily and reliably maintain sensor contact and alignment throughout the test duration, even when exposed to temperatures from less than -53.89°C to greater than 71.11°C and varying humidity levels.
Data Source
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AI summary
A holder for attaching an acoustic emission sensor to a non-metallic and non-magnetic material has a tubular body with a closed top end and an open bottom end through which the sensor is insertable into the tubular body. The closed top end has a plurality of unitary flexible flaps angularly extending inwardly from an inner surface of the enclosed top end. An inner surface of the tubular body has a plurality of spacers extending radially inward proximate the bottom end of the tubular body. The unitary flexible flaps and the spacers fix the sensor within the tubular body. The tubular body may also have a plurality of capture tabs extending outwardly from an exterior surface thereof proximate the open bottom end that are slidably and removably engageable with an engagement keyway in a retainer bracket that is affixed to a non-metallic and non-magnetic material.