Systems and methods of coupling sensors to a structure

• US 9,107,325 B1
• Filed: 08/05/2010
• Issued: 08/11/2015
• Est. Priority Date: 08/10/2009
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Ihn, Jeong-Beom, Duce, Jeffrey Lynn
• Primary Examiner(s): Gandhi, Jayprakash N
• Assistant Examiner(s): Patel, Mukund G
• Application Number:
  US12/851,375
• Time in Patent Office: 1,832 Days
• Field of Search: 361/760, 361/772, 361/775, 361/777, 298/46, 298/49, 174/254, 174352-397
• US Class Current: 1/1
• CPC Class Codes: G06F 3/05 Digital input using the sampling of an analogue quantity at regular intervals of time , input from a/d converter or output to d/a converter
• CPC Class Codes: G08C 19/16 in which transmission is by pulses
• CPC Class Codes: H05K 1/0219 Printed shielding conductors for shielding around or between signal conductors, e.g. coplanar or coaxial printed shielding conductors
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/10151 Sensor
• CPC Class Codes: H05K 2203/1344 Spraying small metal particles or droplets of molten metal
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49124 On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

Systems and methods of coupling sensors to a structure are disclosed. A particular method includes applying one or more communication traces to the structure. At least one of the one or more communication traces is formed using at least one direct-write technique. The method also includes coupling the one or more communication traces to at least one sensor.

Claims

1. A method comprising:

coupling a connector to a structure, wherein the connector includes a first plurality of conductive elements, wherein the first plurality of conductive elements includes a first set of traces and a second set of traces, and wherein the connector is coupled to at least one sensor;

after coupling the connector to the structure, forming a bus on the structure and the connector by;

applying a second plurality of conductive elements to the structure and to the connector using a first direct-write technique, wherein the second plurality of conductive elements are electrically connected to the first set of traces of the connector, and wherein a first trace of the first set of traces is between a first conductive element of the second plurality of conductive elements and the structure;

applying a third plurality of conductive elements to the structure and to the connector using a second direct-write technique that is distinct from the first direct-write technique, wherein the third plurality of conductive elements are electrically connected to the second set of traces of the connector, and wherein a second trace of the second set of traces is between a second conductive element of the third plurality of conductive elements and the structure;

applying a plurality of shield traces to the structure, wherein a first shield trace of the plurality of shield traces is between the first conductive element and a third conductive element of the second plurality of conductive elements; and

prior to coupling the connector to the structure, coupling a first shield layer to the structure, wherein the first shield layer is between the first conductive element and the structure.

2. The method of claim 1, wherein the first trace is directly coupled to the first conductive element.

3. The method of claim 1, wherein the first shield layer comprises silver ink.

4. The method of claim 1, wherein the first shield layer reduces electrical and mechanical interference with the first trace and the second trace.

5. The method of claim 1, further comprising, after forming the bus on the structure and the connector, coupling a second shield layer to the structure, wherein the first trace is between the second shield layer and the structure.

6. The method of claim 5, wherein the second trace is not between the first shield layer and the second shield layer.

7. The method of claim 5, wherein the first shield trace is between the first shield layer and the second shield layer.

8. The method of claim 7, wherein the plurality of shield traces reduces electrical and mechanical interference with the first trace and the second trace.

9. The method of claim 7, wherein a second shield trace of the plurality of shield traces is between the first conductive element and the second conductive element, and wherein the second shield trace is between the first shield layer and the second shield layer.

10. The method of claim 9, wherein a third shield trace of the plurality of shield traces is between the third conductive element and a fourth conductive element of the third plurality of conductive elements, and wherein the third shield trace is between the first shield layer and the second shield layer.

11. The method of claim 10, wherein the first shield layer is between the second conductive element and the fourth conductive element, and wherein the second shield layer is between the second conductive element and the fourth conductive element.

12. The method of claim 1, wherein the second direct-write technique comprises a deposition process followed by a removal process, wherein the deposition process deposits conductive material onto the structure, and wherein the removal process removes at least a portion of the conductive material from the structure.

13. The method of claim 1, wherein the first direct-write technique comprises a screen printing direct-write technique.

14. The method of claim 1, further comprising monitoring health of the structure using the at least one sensor.

15. A structure, comprising:

a structural element;

a connector coupled to the structural element, wherein the connector is coupled to a health sensor, and wherein the connector includes a first plurality of conductive elements, wherein the first plurality of conductive elements includes a first shield trace located between a first communication trace and a first synchronization trace;

a bus comprising a second plurality of conductive elements applied to the connector using at least two distinct direct-write techniques, wherein a first conductive element of the first plurality of conductive elements is between a second conductive element of the second plurality of conductive elements and the structural element, and wherein the second conductive element is electrically coupled to the health sensor through the first conductive element; and

a shield layer, wherein the shield layer is between the first conductive element and the structural element.

16. The structure of claim 15, wherein the connector is flexible, wherein a dielectric material is located between each of the first plurality of conductive elements, wherein the second plurality of conductive elements includes a second shield trace located between a second communication trace and a second synchronization trace, wherein the dielectric material is located between each of the second plurality of conductive elements, wherein the first communication trace is electrically coupled to the second communication trace, and wherein the first synchronization trace is electrically coupled to the second synchronization trace.

17. The structure of claim 16, wherein a first pitch of the first shield trace is greater than a second pitch of the communication trace.

18. A system, comprising:

a substrate;

a connector coupled to the substrate, wherein the connector is coupled to a sensor and wherein the connector includes a first plurality of conductive elements applied thereto using a particular direct-write technique, wherein the first plurality of conductive elements includes a first shield trace located between a first communication trace and a first synchronization trace;

a bus comprising a second plurality of conductive elements formed on the connector using a plurality of second direct-write techniques, wherein at least one of the second direct-write techniques is distinct from the particular direct write technique, wherein a first conductive element of the first plurality of conductive elements is between a second conductive element of the second plurality of conductive elements and the substrate, and wherein the second conductive element is electrically coupled to the sensor through the first conductive element; and

a shield layer, wherein the shield layer is between the first conductive element and the substrate.

19. The system of claim 18, wherein the sensor comprises a structural health sensor and wherein the structural health sensor is operable to monitor structural health of the substrate and is operable to transmit data related to the structural health of the substrate to at least one second sensor system element via the bus.

20. The system of claim 18, wherein a dielectric material is located between each of the first plurality of conductive elements, wherein the second plurality of conductive elements includes a second shield trace located between a second synchronization trace and a second communication trace, and wherein the second plurality of conductive elements further includes a first out-of-plane shield trace.

21. The system of claim 18, wherein the substrate is flexible and conforms to a surface of a structure to which the substrate is coupled, and wherein the sensor comprises a structural health sensor operable to monitor structural health of the structure to which the substrate is coupled and operable to transmit data related to the structural health of the structure to at least one second sensor system element via the bus.

22. The system of claim 18, wherein the sensor comprises a signal processor, a multiplexor, or an amplifier.

23. The system of claim 18, wherein the first plurality of conductive elements further includes a first power trace and a first communication trace, wherein the second plurality of conductive elements further includes a second power trace and a second communication trace, wherein the second power trace is formed using a first direct-write technique of the plurality of second direct-write techniques, wherein the second communication trace is formed using a second direct-write technique of the plurality of second direct write techniques, wherein a first thickness of the second power trace formed using the first direct-write technique is greater than a second thickness of the second communication trace formed using the second direct-write technique, and wherein the first power trace is electrically coupled to the second power trace.

24. The system of claim 23, wherein the first direct-write technique comprises a plasma flame spray (PFS) direct-write technique and wherein the second direct-write technique comprises a jetted atomized deposition (JAD) direct-write technique.