Thin Film Resonator Sensor Embedded by Laser Foil Printing
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Solution Overview
Problem
Conventional methods of Structural Health Monitoring (SHM) face challenges such as fragile sensor methods, limited sensor placement, risk of failure, parasitic effects on structural integrity, and issues with power supply, signal range, integration complexity, transmission delays, cost, and sensor lifespan when using embedded wireless sensors in additive manufacturing.
Innovation Solution
The integration of a structural health monitoring sensor within an additive manufacturing process like laser foil printing (LFP), which uses micromachined planar foils to create a film resonator and waveguide, minimizing size and impact on structural integrity, and utilizing a dielectric ceramic coating for efficient signal transmission and enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing methods (laser powder bed fusion) are used to embed sensors, then sensor integration is achieved, but structural integrity deteriorates due to parasitic effects and lower tensile strength
Solution Approach 1:
The sensor and structural component are merged into a single integrated unit manufactured through laser foil printing. The resonator structure serves dual purposes: as part of the load-bearing structure and as the sensing element, eliminating the need for separate sensor embedding that would compromise structural integrity
Solution Approach 2:
The invention changes the manufacturing parameters by using laser foil printing with metallic foils instead of conventional laser powder bed fusion. This process parameter change results in higher tensile strength (approximately 1000 MPa compared to 500 MPa) while enabling sensor integration through micromachining capabilities
2Strength
If conventional additive manufacturing with metallic foils is used, then structural integrity is improved with tensile strength of approximately 1000 MPa, but sensor integration capability deteriorates due to lack of micromachining
Solution Approach 1:
The manufacturing process is segmented into distinct stages: first manufacturing the structural component with laser foil printing, then applying micromachining processes to create sensor features. This segmentation allows each process to optimize for its specific function while achieving both structural integrity and sensor integration
Solution Approach 2:
The structural component is manufactured first with high tensile strength properties, then micromachining operations are performed afterward to create sensor features. This preliminary action ensures structural integrity is established before adding sensor functionality
3Reliability
If external sensors or wires are used for structural health monitoring, then signal transmission is achieved, but device complexity increases due to power supply, integration, and wiring requirements
Solution Approach 1:
The resonator structure serves itself by using its own mechanical resonance characteristics for sensing. The structure's natural vibration modes provide the sensing mechanism without requiring external power supplies, complex wiring, or additional active components, thereby reducing device complexity while maintaining reliable signal transmission
Solution Approach 2:
The invention replaces electronic sensing systems with mechanics-based resonant sensing. The structural health monitoring is achieved through mechanical resonance frequency shifts rather than electronic sensors and wires, eliminating power supply and complex integration requirements
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
This approach enables effective structural health monitoring with reduced impact on structural integrity, eliminating the need for external wires and power supplies, and providing efficient signal transmission while minimizing costs and environmental hazards.
Implementation Method 1
a dielectric ceramic coating formed within the first and second cavities to create a cavity film and formed within the groove to create a groove film
Implementation Method 2
the groove and the groove film define a film waveguide having a waveguide opening at the exterior surface of the target structure
Implementation Method 3
The first and second cavities and the cavity film define a film resonator
Implementation Method 4
a first layer of micromachined planar foil welded to a target structure, and a second layer of micromachined planar foil welded to the first layer
Data Source
AI summary
A structural health monitoring sensor includes a first layer of micromachined planar foil welded to a target structure, the first layer having a cavity and groove formed therein, the groove extending from the first cavity to the exterior of the target structure. The sensor also having second layer of micromachined planar foil welded to the first layer, the second layer having a second cavity corresponding to the first cavity. The sensor also includes dielectric ceramic coating formed within the cavities and grooves to form a film resonator and film waveguide within the target structure. The resulting waveguide forming an opening on the exterior surface of the target structure. The sensor also includes an adapter attached to the exterior surface of the target structure at the waveguide opening and may be wireless.