Elongated Microstructured Capacitive Sensor for Low-Power RTM Flow Monitoring
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Solution Overview
Problem
Existing flow monitoring technologies, particularly in resin transfer moulding (RTM), face challenges such as the need for bulky systems, complex lithography processes, and the inability to provide reliable, electrically insulated, and small sensors that do not compromise mechanical properties, while also struggling with low flow rate detection and high power consumption.
Innovation Solution
A capacitive microflow sensor using a fibre-like design with embedded electrodes, fabricated through scalable thermal drawing, capable of precise measurements with low power consumption and short response times, integrated into a part preform for resin transfer moulding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional capacitive sensors are used for flow monitoring, then measurement precision is improved, but device complexity and bulkiness increase
Solution Approach 1:
The sensor is segmented into a modular fibre structure with multiple micro-channels and distributed electrodes along the longitudinal axis, allowing the complex sensing function to be divided into simpler repeating units that can be manufactured using standard fibre drawing processes
Solution Approach 2:
The sensor implements a nested structure where micro-channels are embedded within the fibre matrix, electrodes are integrated within the channel walls, and the entire assembly is contained within a protective fibre coating, achieving high functionality in a compact form factor
2Manufacturing precision
If complex lithography processes are used to integrate electrodes, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces complex lithography and photopatterning processes with a mechanical fibre drawing approach, where electrodes are formed through controlled material deposition and structural formation during the extrusion and drawing stages, achieving precise electrode positioning through mechanical control rather than chemical patterning
Solution Approach 2:
The manufacturing process utilizes parameter changes in temperature and mechanical stress during fibre drawing to control electrode formation and positioning, allowing precise integration through thermal and mechanical parameter control rather than complex chemical lithography processes
3Ease of operation
If thermal-based flow sensors are used, then ease of operation is improved, but use of energy increases and reliability deteriorates
Solution Approach 1:
The patent replaces thermal measurement principles with capacitive sensing that measures flow-induced changes in dielectric properties, eliminating the need for heating elements and thermal gradients while maintaining operational simplicity through electrical measurement
4Measurement precision
If discrete location sensors are used, then measurement precision is improved, but productivity deteriorates
Solution Approach 1:
The fibre sensor serves multiple functions simultaneously: it provides distributed flow measurement along its length, monitors dielectric properties of the fluid, and can detect multiple flow parameters at once, achieving both precision and productivity through multi-functional integration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise monitoring of fluid flow rates and properties over a wide range, with low power consumption and minimal mechanical impact, facilitating efficient resin flow control and part quality optimization in RTM processes.
Implementation Method 1
a first electrode (7, 9) and a second electrode (7, 9) arranged in the support 5 longitudinally along the support 5, the first and second electrodes (7, 9) forming together with the support 5 a capacitive sensing element whose capacitance is dependent upon a dielectric constant (or electrical properties more broadly) of one or more materials inside the support 5 and/or outside the support 5
Implementation Method 2
capacitance is dependent upon a dielectric constant (or electrical properties more broadly) of one or more materials inside the support 5 and/or outside the support 5
Data Source
AI summary
The present invention concerns an elongated capacitive sensor for fluid monitoring. The sensor comprising: a fibre support made of a dielectric material or dielectric composite material; and a first electrode and a second electrode arranged longitudinally along the fibre support, the first and second electrodes forming together with the fibre support a capacitive sensing element whose capacitance is dependent upon one or more electrical properties of one or more materials inside the support and/or outside the support, and/or is dependent upon a change of materials configuration and associated overall change of one or more electrical properties inside the support and/or outside the support.