Frangible Membrane Sensor for Structural Fracture Detection
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Solution Overview
Problem
Conventional methods for monitoring structural integrity, such as visual inspection, X-ray testing, dye penetrant testing, and eddy current testing, are time-consuming, costly, and require disassembly or specialized facilities, making them inefficient for regular maintenance, especially in aircraft and other structural applications.
Innovation Solution
A sensor device featuring a frangible membrane with a breakable conductor sense loop bonded to the structural element, which detects fractures and corrosion without disassembly, using a wireless connection or weep holes to indicate damage through measured electrical property changes, allowing for efficient and non-invasive monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional testing techniques (visual inspection, X-ray, dye penetrant, eddy current) are used to monitor structural integrity, then measurement precision and reliability are improved, but loss of time, device complexity, and ease of operation deteriorate due to disassembly requirements, specialized facilities, and time-consuming procedures
Solution Approach 1:
The frangible membrane sensor is pre-installed and bonded to the structural element during manufacturing or initial setup. The breakable conductor sense loop is positioned within the membrane in advance, so that when structural damage occurs, the sensor is already in place to detect it immediately without requiring time-consuming disassembly or setup of external testing equipment
Solution Approach 2:
The patent replaces complex mechanical inspection systems (visual inspection requiring disassembly, X-ray machines, dye penetrant application procedures) with a simple electrical sensing system. The breakable conductor sense loop provides electrical signal changes that directly indicate structural fractures, substituting elaborate mechanical testing procedures with a straightforward electrical measurement
2Measurement precision
If conventional testing techniques are used, then measurement precision is improved, but device complexity and ease of operation worsen due to specialized facilities and complex procedures
Solution Approach 1:
The patent extracts the essential detection function from complex external testing equipment and embeds it directly into the structure via the frangible membrane sensor. Instead of using external X-ray machines or eddy current testers, the detection capability is integrated into the structure itself through the bonded membrane with embedded conductor, simplifying the overall system
Solution Approach 2:
The frangible membrane with breakable conductor is designed as a simple, inexpensive sensor that can be easily replaced. Unlike expensive, complex testing equipment that requires maintenance and specialized facilities, this disposable-like sensor provides reliable detection until it fails, at which point it can be quickly replaced without complex procedures
3Measurement precision
If visual inspection is used to detect structural damage, then measurement precision is improved for surface defects, but ease of operation and loss of time deteriorate due to required disassembly and removal of installed equipment
Solution Approach 1:
The frangible membrane sensor is pre-installed and bonded to the structural element during manufacturing or initial setup. The breakable conductor sense loop is positioned within the membrane in advance, so that when structural damage occurs, the sensor is already in place to detect it immediately without requiring time-consuming disassembly or setup of external testing equipment
Solution Approach 2:
The frangible membrane acts as an intermediary layer between the structural element and the external environment. It transmits structural damage information to the breakable conductor sense loop, which then provides electrical signals indicating damage. This intermediary system enables detection without requiring direct visual access or disassembly of the 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
Enables quick and reliable detection of structural damage without interrupting operations or requiring specialized facilities, reducing maintenance costs and labor, while providing early warnings for potential corrosion, thus lowering the total cost of ownership and enhancing maintenance efficiency.
Implementation Method 1
A fracture in the bonded structural element induces a disruption in the both the frangible membrane and the thin breakable conductor sense loop. Measured electrical property change of the disrupted conductor sense loop reveals the fracture in the structural element.
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
A sensor device (100) for monitoring and testing the integrity of structural elements (102) is disclosed. A frangible membrane (104) including a thin breakable conductor sense loop (106) is bonded to a structural element (102) to be tested. A fracture in the bonded structural element induces a disruption in the both the frangible membrane (104) and the thin breakable conductor sense loop (106). Measured electrical property change of the disrupted conductor sense loop reveals the fracture in the structural element. Connection to the sensor device may be through a connector or using a wireless reader which remotely energizes the sensor device. The sensor may also be implemented as a gasket and/or employ weep holes (114) to the breakable conductor (106) to reveal possible corrosion as well.