Multilayer Nanofiller Sensor for Structural Health Monitoring
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Solution Overview
Problem
Current sensors, particularly those in the form of patches for monitoring physical characteristics in devices like leaktight seals and composite materials, face limitations in sensitivity, accuracy, and durability, especially in harsh environments and complex structural health monitoring applications.
Innovation Solution
Development of a multilayer sensor structure comprising electrically conductive layers with nanofillers in a polymer matrix, combined with insulating layers and controlled crosslinking, which allows for adjustable sensitivity and enhanced durability, integrated into devices as patches for local and comprehensive monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensor structures are used, then manufacturing is simpler, but sensitivity and measurement precision are insufficient
Solution Approach 1:
The patent employs conductive polymer composites (CPCs) containing carbon nanotubes as the sensing element. This composite material combines the electrical conductivity of carbon nanotubes with the mechanical properties of polymer matrices, enabling high sensitivity to mechanical deformations while maintaining structural integrity. The composite structure allows the sensor to detect subtle changes in physical characteristics with superior measurement precision compared to conventional materials.
Solution Approach 2:
The sensor is designed as a multilayer structure with distinct functional layers: conductive CPC layers for sensing, insulating polymer layers for electrical isolation, and protective coatings. This segmentation allows each layer to be optimized for its specific function while working together to achieve high overall sensitivity. The layered architecture enables precise control of electrical pathways and mechanical response characteristics.
2Strength
If thermoplastic materials are used, then ease of manufacture is improved, but rigidity and durability are reduced
Solution Approach 1:
The patent utilizes the degree of crystallinity as a controllable parameter in thermoplastic polymers to adjust rigidity and mechanical strength. By controlling crystallization conditions and crosslinking density, the sensor achieves optimal balance between rigidity for structural stability and processability for manufacturing. The crosslinking degree is specifically controlled to enhance rigidity while maintaining the ability to process the material into sensor structures.
3Duration of action of stationary object
If highly crosslinked thermosetting structures are used, then rigidity and lifetime are improved, but manufacturing complexity increases
Solution Approach 1:
The patent precisely controls the crosslinking degree of thermosetting polymers within specific ranges (greater than 80%, preferably greater than 90%, or even greater than 95%) to achieve optimal long-term durability and environmental resistance. This controlled crosslinking parameter ensures high lifetime and rigidity while managing the complexity of the curing process through standardized formulations and processing protocols.
4Measurement precision
If nanofillers are added to polymer matrix, then electrical conductivity and sensitivity are improved, but manufacturing precision control becomes more difficult
Solution Approach 1:
The patent uses polymer matrices as intermediaries to disperse and distribute carbon nanotube fillers uniformly throughout the sensor structure. The polymer acts as a medium that facilitates even distribution of nanofillers during processing, preventing aggregation and ensuring consistent electrical properties. This intermediary approach simplifies manufacturing precision control while maintaining high sensitivity through proper nanofiller dispersion.
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 sensors provide superior rigidity, lifetime, and sensitivity, enabling accurate data collection and real-time monitoring of device health, including mechanical stress, temperature, and chemical exposure, with improved resistance to environmental factors.
Implementation Method 1
at least one electrically conductive layer, comprising nanofillers, which may in particular be coated or functionalized, in a polymer matrix
Implementation Method 2
when the structure is thermosetting, then the degree of crosslinking thereof is greater than 80%, better still greater than 90%, or even greater than 95%
Data Source
AI summary
The invention relates to a sensor for a physical feature, comprising a structure, preferably a multilayer structure, comprising: at least one electrically conductive layer, comprising nanofillers in a polymer matrix including at least one polymer, and electrical connection means, said structure being thermosetting, thermoplastic, or being a cross-linkable elastomer, characterised in that, when the structure is thermosetting, the degree of cross-linking thereof is higher than 80%, better still higher than 90%, or even 95%; when the structure is a cross-linkable elastomer it includes an amount of cross-linking agent ranging from 5 mol. % to 20 mol. % relative to the number of moles in the structure; and when the structure is thermoplastic, it has a constant resistivity value and preferably a degree of crystallinity ranging from 0% to 60%.