Embedded Sensor Composite Structure with Z-Pins Against Delamination

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Solution Overview

Problem

Existing composite structures face challenges in embedding sensors due to the risk of delamination, especially when sensors are placed internally, which can compromise the structural integrity and require additional layers to mitigate delamination.

Innovation Solution

A composite structure design incorporating z-pins distributed around a sensor to fix fiber sheets together, ensuring the sensor is embedded between layers while maintaining structural integrity, using z-pins to prevent delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors are embedded within the composite structure, then measurement precision is improved, but the composite structure may delaminate due to sheets separating

Engineering Contradiction:

Improvesensor measurement capabilityVSAvoidcomposite structure integrity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Z-pins serve as intermediary elements that mechanically connect overlaying fiber sheets to underlying fiber sheets at sensor locations. The pins extend through multiple sheets and are impregnated with resin to create a strong bonding interface, preventing delamination while allowing sensor embedding between sheets.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution combines different materials (fiber sheets, resin, and z-pins) to create a composite structure that maintains integrity at sensor embedding locations. The z-pins act as reinforcement elements within the composite layup, providing structural support where sensors would otherwise compromise sheet bonding.

Inventive Principle:

Principle #40Composite materials

2Strength

If additional sheets are added to protect embedded sensors, then composite structure strength is improved, but device complexity increases

Engineering Contradiction:

Improvecomposite structure strengthVSAvoidnumber of sheets required

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Z-pins provide localized reinforcement only at sensor embedding locations rather than requiring additional sheets throughout the entire structure. This targeted approach maintains structural integrity where needed while minimizing overall complexity and material usage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The reinforcement function is segmented into discrete z-pins placed at specific locations rather than using continuous additional sheets. This segmentation allows structural support to be provided only where sensors are embedded, reducing the total number of sheets required.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3865286B1Composite structures with embedded sensors and methods for their manufacture

Publication Date: 2026.01.07 HAMILTON SUNDSTRAND CORP

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AI summary

A composite structure (100) includes a first fiber sheet (104), one or more second fiber sheet (106) overlaying the first fiber sheet (104), a sensor (108), and two or more z-pins (110). The sensor (108) is arranged between the first fiber sheet (104) and the one or more second fiber sheet (106). The two or more z-pins (110) extend through the first fiber sheet (104) and the one or more second fiber sheet (106) and are distributed about a periphery (112) of the sensor (108) to fix the one or more second fiber sheet (106) to the first fiber sheet (104) about the periphery of the sensor (108). Sensor arrangements and methods of making composite structures are also described.