Multilayer Functional Fiber for Composite Sensing and Energy Storage

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Solution Overview

Problem

Current fiber-reinforced composite materials are limited in their ability to incorporate functional capabilities such as sensing, actuating, energy storage, and energy absorption, as they primarily serve a structural role with the matrix material carrying negligible structural load.

Innovation Solution

The development of multilayer functional fibers using laser-assisted chemical vapor deposition (LCVD) to create fibers with varying physical properties along their length, incorporating electrode and functional layers that enable specific functions like sensing, actuating, and energy storage when embedded in composite materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional fiber-reinforced composite materials are used, then structural strength is provided, but functional capabilities (sensing, actuating, energy storage, energy absorption) are limited or absent

Engineering Contradiction:

Improvefunctional capabilitiesVSAvoidfiber structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functional layers (electrode layers, functional layers with varying characteristics) with the structural fiber into a single integrated multilayer fiber construct. This merging of structural and functional capabilities into one component resolves the contradiction by enabling sensing, actuating, and energy storage functions without requiring separate discrete devices, thereby increasing adaptability while managing complexity through integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multilayer fiber is designed to perform multiple functions simultaneously - structural support, sensing, actuating, and energy storage/absorption. By making the fiber universal and multi-functional, the patent resolves the contradiction between limited functional capabilities and structural performance, allowing a single component to serve multiple purposes rather than requiring separate specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If the matrix material carries negligible structural load in traditional composites, then fiber reinforcement is effective, but integral sensing and actuating capabilities cannot be incorporated

Engineering Contradiction:

Improvestructural health monitoring capabilityVSAvoidembedded system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges sensing and actuating functionalities directly into the fiber structure itself through integrated electrode and functional layers, rather than requiring separate embedded sensors and actuators in the matrix. This integration resolves the contradiction by providing reliable structural health monitoring capability while minimizing embedded system complexity, as the fiber becomes self-sufficient with built-in functional capabilities.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If laser-assisted chemical vapor deposition is used to create multilayer fibers with varying physical properties, then functional capabilities are enabled, but manufacturing complexity increases

Engineering Contradiction:

Improvefunctional layer propertiesVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating functional layers with physical properties that vary along the length of the fiber using laser-assisted chemical vapor deposition. The laser enables precise spatial control of deposition, allowing different sections of the fiber to have tailored properties (e.g., different thicknesses, compositions, or functional characteristics) while maintaining a relatively simple overall manufacturing process. This resolves the contradiction by enabling high adaptability through localized property variation without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #3Local quality

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 the creation of 'smart structures' with integral sensing and actuating capabilities, enhancing structural health monitoring, temperature and stress sensing, energy storage, and damping, effectively breaking the structural limitations of traditional fiber composites.

Implementation Method 1

a focused laser beam impinging on the seed fiber

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

laser-assisted chemical vapor deposition

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS12133465B2Multilayer functional fiber and method of making

Publication Date: 2024.10.29 FREE FORM FIBERS LLC

AI summary

A method is provided for making a multilayer functional fiber, where the method includes: providing a scaffold fiber; disposing a first electrode layer enclosing the scaffold fiber; disposing a functional layer enclosing the first electrode layer, the functional layer having a functional characteristic varying as a function of longitudinal position along the functional layer; disposing a second electrode layer enclosing the functional layer; and disposing a cladding layer enclosing the second electrode layer. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted method.