Embedded Sensor Networks for Textile‐Reinforced Thermoplastics: Sensor Network Design and Mechanical Composite Performance

Abstract

Textile-reinforced thermoplastics enable lightweight components suitable for high volume production. Composite-embedded sensor networks allow for additional functionalities like structural health monitoring. In this paper, the design of such embedded sensor networks is described and the necessity to adapt the existing composite manufacturing process is discussed. The impact of the embedded components on the mechanical behavior of textile-reinforced thermoplastics is investigated by comparing the mechanical behavior of specimens with and without dummy inclusions for different load cases. Design suggestions for the electronic components, the network and the composite structure are formulated.

Function‐integrative Lightweight Engineering – Design Methods and Applications

“…Additionally, the integrated elements disturb the composite structure and, thus, can lead to a reduction of the load‐bearing capacity of the component. In literature, the effects of various network components such as piezoceramic elements , thermocouples and metallic strain gauges , fiber optic sensors , or flexible printed circuit boards and electronic components , , , , were investigated. In principal, the integrated components should be designed in such a way that the mechanical properties of the composite material are not significantly affected.…”

“…In this context, the following main issues need to be handled: electrical isolation of the sensor elements to the composite part and environment, load adapted orientation and arrangement of the sensors, integration technology and parameters, electrical contacting, and signal processing as well as evaluation. In regard, to an appropriate isolation, integration and electrical contacting possible solutions are developed in several application‐oriented research projects , , , . There, an isolation of the carbon fiber sensor with polyethylene multifilaments, an electrical contacting via needle electrodes and an integration method using winding technology were considered as preferred options (see Fig.…”

“…Therefore, target‐oriented concepts for measuring and control have to be developed, which are fail‐safe and/or fail‐operational. Holistic approaches and the investigation of the interactions of the used materials, manufacturing processes and parameters as well as environmental conditions lead to new design approaches and rules for function integrative lightweight components and systems , . In this context the following examples show different scenarios, which are relevant for future applications.…”

Novel Hybrid Yarn Textile Thermoplastic Composites for Function‐Integrating Multi‐Material Lightweight Design

“…To give an example, the embedding of electronic elements or even complex electronic networks into components offers a wide range of possibilities to enlarge the functionality and field of application of textile‐reinforced thermoplastic structures. The integration of sensors and actuators facilitating the in‐situ monitoring of structural health and loading was, therefore, the subject of intensive research . Detailed information on that research is available in Weck et al A leaf spring which forms part of the FiF demonstrator vehicle was selected for the demonstration of the advantages of function‐integrating design (see Figure d).…”

Delamination Behaviour of Embedded Polymeric Sensor and Actuator Carrier Layers in Epoxy Based CFRP Laminates—A Study of Energy Release Rates

“…However, the opportunities offered by this modern combination of materials also present new challenges that the fibre composite engineer has to face. This also includes manufacturing-specific aspects such as the integration of sensor and actuator elements into the structure of fibre composite components and its influence on the manufacturing or design process as well as on the mechanical properties [9,20,21]. In this context, several studies were made with regard to designing suitable smart components [9,22,23], adapted manufacturing technologies for function-integrative structures [17,24] and their experimental characterization [15,25,26].…”