Modular sensor for damage detection, manufacturing method, and structural composite material

• US 7,405,391 B2
• Filed: 12/14/2005
• Issued: 07/29/2008
• Est. Priority Date: 12/15/2004
• Status: Active Grant

• Current Assignee: Subaru Corp.
• Original Assignee: Fuji Heavy Industries Limited (Subaru Corp.)
• Inventors: Kojima, Seiji, Ogisu, Toshimichi
• Primary Examiner(s): Epps; Georgia Y.
• Assistant Examiner(s): WILLIAMS, DON J
• Application Number:
  US11/304,262
• Publication Number:
  US 20080156971A1
• Time in Patent Office: 958 Days
• Field of Search: 250/227.11, 250/216, 250/225, 250/227.23, 25022713-22717, 385/12, 385/13, 385/37, 385/55, 385/70, 385/58, 385/60, 385/61, 385/63, 385/66, 385/72, 385/78, 385/85, 385/88, 398/108, 398/161, 356/32, 356/34, 738/00
• US Class Current: 250/227.14
• CPC Class Codes: G01D 5/35303 using a reference fibre, e.g. interferometric devices
• CPC Class Codes: G01M 11/086 Details about the embedment of the optical fiber within the DUT
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G02B 6/3644 the coupling means being through-holes or wall apertures

Abstract

A modular sensor for damage detection with an optical fiber (FBG sensor) to detect a damage of a composite material, having a high level of visibility and manageability, and its manufacturing method is described. A structural composite material embedded with this modular sensor for damage detection is also described.

Claims

1. A modular sensor for damage detection comprising:

an optical fiber including an FBG sensor;

two connectors connected to both end portions of the optical fiber;

two reinforcing tubes to cover both end portions of the optical fiber, and

a tube to partly cover the optical fiber,

wherein the optical fiber movably penetrates the tube and the tube is movable between the two reinforcing tubes.

2. The modular sensor for damage detection as claimed in claim 1, wherein the tube comprises a heat resistant material.

3. The modular sensor for damage detection as claimed in claim 1, further comprising a film covering a portion of the optical fiber.

4. The modular sensor for damage detection as claimed in claim 1, wherein said reinforcing tubes reinforce connecting portions of the optical fiber and the connectors.

6. A structural composite material embedded with the FBG sensor of the modular sensor for damage detection as claimed in claim 1.

7. The structural composite material embedded with the modular sensor for damage detection as claimed in claim 1, wherein the FBG sensor is embedded into a stress concentrating portion of the structural composite material, without being covered with the tube, and the tube is partly embedded into an end portion of the structural composite material.

8. The modular sensor for damage detection as claimed in claim 1, wherein the connectors are configured to connect the optical fiber to a reflection light wave length detector through wires.

9. The modular sensor for damage detection as claimed in claim 1, wherein the connectors are zirconia ferrules.

10. The modular sensor for damage detection as claimed in claim 1, wherein the reinforcing tubes are polyimide tubes.

11. The modular sensor for damage detection as claimed in claim 1, further comprising two films covering portions of the optical fiber, wherein the tube is movable between the films.

5. A manufacturing method for manufacturing a modular sensor for damage detection, comprising:

a tubular member preparing step to prepare a tubular member, provided with an inner diameter which is slightly larger at a center portion and fully larger at both ends than an outer diameter of a tube and which inner diameter increases gradually from the center portion of said tubular member to both ends of the tubular member;

a tube insertion step to insert one end portion of the tube into the tubular member through a first end of the tubular and restrict a movement of the tube in a diameter direction by placing the end portion in a vicinity of the center portion;

an optical fiber insertion step to insert an optical fiber into the tubular member through a second end of the tubular member, and then into the end portion of the tube;

a tubular member removal step to remove the tubular member from the tube and the optical fiber; and

a connector fixing step to fix the connector to an end portion of the optical fiber.

12. A modular sensor for damage detection comprising:

an optical fiber including a FBG sensor; and

a film covering a portion of the optical fiber,

wherein the film is arranged in a position at a distance from the FBG sensor and is structured so that the film gradually narrows in width from a center portion of the film towards both boundaries with the optical fiber.

13. The modular sensor for damage detection as claimed in claim 12, wherein the film comprises a heat resistant material.

14. The modular sensor for damage detection as claimed in claim 12, further comprising a reinforcing tube to reinforce a bonding portion of the optical fiber and the connector.

15. The modular sensor for damage detection as claimed in claim 14, wherein the reinforcing tube is a polyimide tube.

16. A structural composite material embedded with the FBG sensor of the modular sensor for damage detection as claimed in claim 12.

17. The structural composite material embedded with the modular sensor for damage detection as claimed in claim 12, wherein the FBG sensor is embedded into a stress concentrating portion of the structural composite material, and the film is partly embedded into an end portion of the structural composite material.

18. The modular sensor for damage detection as claimed in claim 12, further comprising a connector connected to an end portion of the optical fiber.

19. The modular sensor for damage detection as claimed in claim 18, wherein the connector is configured to connect the optical fiber to a reflection light wave length detector through a wire.

20. The modular sensor for damage detection as claimed in claim 18, wherein the connector is a zirconia ferrule.

21. The modular sensor for damage detection as claimed in claim 12, further comprising a tube to partly cover the optical fiber, wherein the tube is movable with respect to the film.

22. A manufacturing method for manufacturing a structural composite material for damage detection, comprising:

a connecting step for connecting a connector to an optical fiber including an FBG sensor, wherein said connector is made of a heat resistant material which tolerates heat applied when the structural composite material which a modular sensor including the connector and the optical fiber embedded therein is under hot forming;

an embedding step for embedding the modular sensor into the structural composite material;

and a hot forming step for forming the composite material with heat and pressure after the connecting step.

23. The manufacturing method for manufacturing a structural composite material for damage detection as claimed in claim 22, further comprising:

a providing step for providing a reinforcing tube at a bonding portions of the optical fiber and the connector, and performing said providing step before the hot forming step.

24. The manufacturing method for manufacturing a structural composite material for damage detection as claimed in claim 23, wherein the reinforcing tube is a polyimide tube.

25. The manufacturing method for manufacturing a structural composite material for damage detection as claimed in claim 22, further comprising,

a film attaching step for attaching a pair of films such that said pair of films forms a sandwich with the optical fiber including the FBG sensor, and

a film shape adjusting step for adjusting such that the film is structured so that the film gradually narrows in width from a center portion of the film towards a boundary with the optical fiber.