Novel distributed strain sensing in polymeric materials

Monitoring the state of strain throughout an entire structure is essential to determine its state of stress, detect potential residual stresses after fabrication, and also to help to establish its integrity. Several sensing technologies are presently available to determine the strain in the surface or inside a structure. Large sensor dimensions, complex signal conditioning equipment, and difficulty in achieving a widely distributed system have however hindered their development into robust structural health monitoring techniques. Recently, carbon nanotube forests were spun into a microscale thread that is electrically conductive, tough, and easily tailorable. The thread was integrated into polymeric materials and used for the first time as a piezoresistive sensor to monitor strain and also to detect damage in the material. It is revealed that the created self-sensing polymeric materials are sensitive to normal strains above 0.07% and that the sensor thread exhibits a perfectly linear delta resistance-strain response above 0.3%. The longitudinal gauge factors were determined to be in the 2-5 range. This low cost and simple built-in sensor thread may provide a new integrated and distributed sensor technology that enables robust real-time health monitoring of structures.