Embedded Wireless Sensors in Composite Foam Cores
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Solution Overview
Problem
Embedding sensors in composite structures using conventional methods within the laminate often results in void defects, leading to structural failures in cargo vehicles and other applications.
Innovation Solution
A composite structure with a wireless sensor embedded within the foam core, coupled to the core fiber-reinforced polymer layer via a permeable intermediate layer, allowing data collection without creating structural voids or defects, and a method involving a preform with a foam core, permeable intermediate layer, and fiber-reinforced polymer layers for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If sensors are embedded within the laminate using conventional methods, then data collection capability is achieved, but void defects are created leading to structural failure
Solution Approach 1:
The sensor embedding location is moved from the traditional laminate layer to the foam core, representing a dimensional change in the embedding space. This allows the sensor to be positioned in a different structural zone that does not compromise the laminate's integrity while still enabling data collection from the composite structure.
Solution Approach 2:
A permeable intermediate layer is introduced as a mediator between the foam core and the outer laminate. This intermediate layer allows the sensor to contact the polymer matrix through its pores, enabling data collection while maintaining the structural continuity and integrity of the laminate.
2Reliability
If sensors are embedded in the foam core, then structural integrity is maintained, but sensor contact with polymer matrix may be insufficient
Solution Approach 1:
A permeable intermediate layer with porous structure is used to facilitate contact between the sensor and the polymer matrix. The pores in this intermediate layer allow the polymer matrix to penetrate and establish contact with the sensor, ensuring sensor functionality while maintaining structural integrity.
Solution Approach 2:
The permeable intermediate layer acts as an intermediary that bridges the gap between the foam core location and the polymer matrix. It enables material and signal transmission while maintaining the beneficial separation of sensor placement from the critical laminate structure.
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
The solution enables the collection of data from composite structures without structural defects, enhancing the durability and reliability of cargo vehicles and other applications by ensuring the sensor remains in contact with the polymer matrix, thus maintaining its functionality.
Implementation Method 1
a permeable intermediate layer surrounding the foam core; a fiber-reinforced polymer layer surrounding the permeable intermediate layer; and a wireless sensor positioned within the foam core and attached to an inner surface of the permeable intermediate layer so that the at least one wireless sensor contacts the fiber-reinforced polymer layer via pores of the intermediate layer
Data Source
AI summary
A composite structure with at least one wireless sensor embedded in the core material so that the wireless sensor is capable of collecting data related to the corresponding composite structure without creation of a structural void or defect. For example, the composite structure may include a core layer with a foam core and a core fiber-reinforced polymer layer surrounding the foam core. The at least one wireless sensor may be positioned within the foam core and coupled to an inner surface of the core fiber-reinforced polymer layer.