Patent Description:
Environmental conditions may affect materials used to make vehicles and other types of structures intended for outdoor use or for use in extreme environments, such as aerospace structures that experience dynamic and various environmental changes throughout their service history (i.e., dry to wet, cold to hot). Environmental testing of such materials at less than -<NUM> (<NUM>°F) and greater than <NUM> (<NUM>°F), and from <NUM>-<NUM>% humidity, is desired to identify, quantify and monitor the properties of such materials before, during and/or after one or more uses to determine if any damage to the materials has occurred.

One type of sensor that has been used for environmental testing, acoustic emission (or AE) sensors, interprets the radiation of acoustic (or elastic) waves in solid materials into usable AE waveforms that help understand how the materials behave. Such acoustic (or elastic) waves occur when a material undergoes changes in its internal structure, for example as a result of crack formation or plastic deformation due to aging, temperature gradients or external mechanical forces. The waves generated by sources of acoustic emission are of practical interest in the fields of structural health monitoring, quality control, system feedback, process monitoring, analysis validation, and others, and may be used to detect, locate and characterize damage to the material. Acoustic emission sensors are therefore useful for detecting flaws and failures in materials and structures, and determining how to apply remedial solutions and repairs to resolve structural issues. In the aerospace field, acoustic emission sensing has been identified as a technology that can be scaled for enhanced fleet inspection from the laboratory setting, to the depot and to field applications. The focus is driven by the need to identify the existence of damage as a function of service hours for the fleet in order to make critical decisions regarding remaining life.

Acoustic emission sensors have been used to monitor aerospace and other structures. Traditional approaches for attaching acoustic emission sensors to the structure to be tested include using hot glue or magnetic clamping fixtures. Many commercially available holders for acoustic emission sensors are magnetic because acoustic emission has predominantly been done on metallic surfaces. Such magnetic holders will not function with non-metallic and non-magnetic composite materials. Hot glue does not have universal application, and does not work during environmental testing at temperatures less than -<NUM> (-<NUM>°F) and greater than <NUM>,<NUM> (<NUM>°F) due to poor surface adhesion. Another solution has been to permanently attach acoustic emission sensors to a test article, but this approach is not feasible when testing large numbers of test articles due to expense and extended dwell time (greater than <NUM> hours per sensor) for curing an adhesive to affix the sensors to the test article.

Non-metallic and non-magnetic materials, such as composite materials, are now used in the manufacture of a wide variety of structures due to their high strength and rigidity, low weight, corrosion resistance and other favorable properties. For example, composite materials have become widely used to manufacture aerospace structures and component parts for aerospace structures such as aircraft ribs, spars, panels, fuselages, wings, wing boxes, fuel tanks, tail assemblies and other component parts of an aircraft because they are lightweight and strong, and therefore provide fuel economy and other benefits. The traditional approaches for attaching acoustic emission sensors to such non-metallic and non-magnetic materials are not effective.

Accordingly, there is a need for improved means for holding or attaching acoustic emission sensors to non-metallic and non-magnetic materials, such as composites and ceramics, during environmental testing of such materials that provide advantages over known acoustic emission sensor holders.

<CIT> states, according to its abstract, a non-destructive non-invasive arrangement is provided for detecting defects, such as voids, or poorly adhering layers in solid objects and laminated materials. A sensing signal is emitted by one transducer and received by two others. All of the sensors are disposed in a housing unit. The difference between the received signals is used to indicate a defect in the work piece proximate one of the transducers. <CIT> states, according to its abstract, a mounting device configured for mounting a sensing device in relation to a supporting structure, and related method of mounting, are disclosed. In at least some embodiments, the mounting device includes a first support component capable of being mounted at least indirectly in relation to the supporting structure, a second support component configured to support the sensing device, and a connecting component coupled between the first and second support components, where the connecting component supports the second support component in relation to the first support component. Also, the mounting device includes an adjustor coupled to at least one of the first support component, the second support component and the connecting component that influences a positioning of the second support component in relation to the first support component. <CIT> states, according to its abstract, a mounting device for supporting a sensing device in relation to a supporting structure, and related method of installing a sensing device, are disclosed. In at least some embodiments, the mounting device includes a first housing portion having a first appendage, and a second housing portion having a second appendage, where the second housing portion is slidable in relation to the first housing portion. The mounting device further includes an actuating portion capable of causing sliding movement between the housing portions, where the sensing device is supported within at least one of the housing portions, hi some embodiments, a rotatable swivel ball on which the sensing device is sup-ported is contained within at least one of the housing portions, and actuation of the actuating portion results in both the coupling of the mounting device to a supporting structure and a setting of a position of the swivel ball.

According to the present disclosure, a holder as defined in the independent claim <NUM> is provided. Further embodiments of the invention are defined in the dependent claims. Although the invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the invention.

The foregoing purposes, as well as others, are achieved by an acoustic emission sensor holder that aligns and maintains the acoustic emission sensor flush with a surface of a non-metallic and non-magnetic material and is compatible with current ASTM standard test methods and test fixtures. The sensor holder provides the capability of keeping the sensor in contact with the material during extreme conditions, and therefore provides a pathway to obtain data across a wide range of environmental conditions that will be advantageous in progressive damage structural analysis, field inspection, material characterization and laboratory level experimental validation.

In accordance with one aspect of the product of the disclosure, a holder for attaching an acoustic emission sensor to a non-metallic and non-magnetic material is disclosed. The holder is comprised of a tubular body having a closed top end and an open bottom end through which the sensor may be inserted into the tubular body. The closed top end is provided with a plurality of unitary flexible flaps angularly extending inwardly from an inner surface of the closed top end. An inner surface of the tubular body has a plurality of partial cylindrically-shaped spacers extending radially inward and upward from the open bottom end of the tubular body. The unitary flexible flaps and the spacers act together to fix the sensor within the tubular body and maintain its positioning within the holder. The unitary flexible flaps and the spacers are made from a flexible material so that the holder can accommodate sensors of varying heights and diameters.

Other objects, features, and advantages of the various embodiments in the present disclosure will be explained in the following detailed description with reference to the appended drawings.

In the following detailed description, various aspects of acoustic emission sensor holders that maintain the positioning and contact of acoustic emission sensors during environmental testing (less than -<NUM> (<NUM>°F), greater than <NUM> (<NUM>°F), and between <NUM>-<NUM> % humidity) of non-metallic and non-magnetic materials including, but not limited to, composite or ceramic materials, are described with reference to aerospace structures to illustrate the general principles in the present disclosure. It will be recognized by one skilled in the art that the present disclosure may be practiced in other analogous applications or environments and/or with other analogous or equivalent variations of the illustrative aspects. For example, the disclosed acoustic emission sensor holders may be used for environmental testing of any type of non-metallic and non-magnetic materials in any industry and may be used with non-metallic and non-magnetic materials of varying shapes, sizes and surface contours including test materials for environmental testing in laboratory or other controlled settings, and completed structures that employ such non-metallic and non-magnetic materials, such as aerospace structures and vehicles, and any other structures for which environmental testing would be beneficial. Such environmental testing may be done during manufacture of the structures, after manufacture of the structures or during use of the structures. It should be noted that those methods, procedures, components, or functions which are commonly known to persons of ordinary skill in the field of the disclosure are not described in detail herein.

In <FIG>, an acoustic emission sensor holder <NUM> in accordance with one aspect of the disclosure is shown affixed to a non-metallic and non-magnetic material <NUM> in the form of a test article or coupon (<FIG>). The holder <NUM> has an acoustic emission sensor <NUM> installed therein with a sensor wire <NUM> (or electrical connection) protruding radially from the sensor <NUM> for connection to acoustic emission monitoring equipment (not shown). The holder <NUM> aligns a bottom surface <NUM> of the sensor <NUM> flush with a surface of the non-metallic and non-magnetic material <NUM> and permits use of current ASTM standard test methods and test equipment.

The holder <NUM> is in the shape of a tubular body <NUM> having a closed top end <NUM> and an open bottom end <NUM> that forms an interface surface <NUM> having an aperture <NUM> at the open bottom end <NUM> of the tubular body <NUM>. The sensor <NUM> is insertable into the tubular body <NUM> through the aperture <NUM>. A recess <NUM> in the tubular body <NUM> is peripherally open toward the aperture <NUM> at the open bottom end <NUM> for receiving the sensor wire <NUM> (or electrical connection) that protrudes radially from the sensor <NUM>, and may form a rectangular shape as shown or any other shape. The tubular body <NUM> also has a base <NUM> forming a lip <NUM> on top of the base <NUM> and peripherally around an exterior surface <NUM> of the tubular body <NUM> that expands the size of the interface surface <NUM> at the open bottom end <NUM> to provide sufficient surface area for sealant tape (described below).

The closed top end <NUM> has a plurality of unitary flexible flaps <NUM> extending angularly inwardly from an inner surface <NUM> of the closed top end <NUM>. Here, two of the unitary flexible flaps <NUM> are shown, each extending angularly inwardly toward each other to provide a force to push down on a top surface of the sensor <NUM> when the sensor <NUM> is installed into the holder <NUM>. An interior surface <NUM> of the tubular body <NUM> has a plurality of spacers <NUM> extending radially inward proximate the open bottom end <NUM>. The unitary flexible flaps <NUM> and the spacers <NUM> act together to fix the sensor <NUM> within the tubular body <NUM>, and may be formed in any shape and size that provides the ability to fix the sensor <NUM> within the tubular body <NUM>. For example, the spacers <NUM> may be formed in a partial cylindrical-shape protruding from the interior surface <NUM> of the tubular body <NUM> and extending upward from the open bottom end <NUM> as shown in the drawings, or the spacers <NUM> may be formed in a partial spherical-shape, oval-shape, or rectangular shape. In addition to the round cross-sectional shape of the tubular body <NUM> as shown, the holder <NUM> may also be formed to have a cross-sectional shape that is square, rectangular or another curved shape to accommodate different shaped sensors <NUM>.

The holder <NUM> is formed with a flexible material as a unitary three-dimensional (<NUM>-D) printed structure. <NUM>-D printing, also known as stereolithography or additive manufacturing, is a printing technology that uses computer-controlled lasers to build three-dimensional structures from liquid polymers and other materials. The holders <NUM> disclosed herein are made from a flexible material. Because the unitary flexible flaps <NUM> at the closed top end <NUM> of the tubular body <NUM> and the spacers <NUM> are made from a flexible material, the holder <NUM> can accommodate sensors <NUM> of varying heights and diameters.

The flexible material that forms the holder <NUM> and its parts should be ductile or flexible enough that the unitary flexible flaps <NUM> can bend but not snap when the sensor <NUM> is placed into the holder <NUM>, and should have some stiffness to provide the downward force on the sensor <NUM>. The flexible material should also be lightweight and have a wide range of operating temperatures to withstand environmental testing conditions, such as composite testing temperatures in the range from about -<NUM> (-<NUM>°F) to <NUM> (<NUM>°F). A flexible material having properties in the ranges shown in Table I could be used to form the holders described in the present disclosure:.

Embrittlement is the temperature at which the material losses ductility, making it brittle. The melting temperature and embrittlement properties may be adjusted depending on the environmental conditions being tested. One material that has these properties and may be <NUM>-D printed is ABS (Acrylonitrile-Butadiene-Styrene). ABS is a thermoplastic material further classified as styrenic plastic.

The holder <NUM> is affixed to the non-metallic and non-magnetic material <NUM> using vacuum bag, sealant tape, or a permanent sealant, which may be positioned on the interface surface <NUM> at the open bottom end <NUM> of the tubular body <NUM>. Vacuum bag or sealant tapes should be able to withstand environmental testing conditions, and have short (less than <NUM> minutes) adhering time. Suitable tapes for this purpose are commercially available, for example, the sealant tapes available from the Airtech Advanced Materials Group of Airtech International, Inc. , Huntington Beach, California, under the trade names GS-<NUM>, AT-<NUM>, AIRSEAL <NUM>, AIRSEAL 3W, AIRSEAL DB, GS-<NUM>, AT-200Y, GS-<NUM>, GS-<NUM> Tacky, GS-<NUM>, GS-<NUM>-<NUM>, GS-43MR, VBS-<NUM> and A-<NUM>-<NUM>. Such sealant tapes are typically available in rolls and are easy to cut and position in desired locations. When affixing the holder <NUM> to the non-metallic and non-magnetic material <NUM>, it is also beneficial to apply vacuum grease or another coupling agent between the sensor <NUM> and the surface of the non-metallic and non-magnetic material <NUM> to couple the acoustic energy between the non-metallic and non-magnetic material <NUM> and the sensor <NUM> or more closely match the acoustic impedance of the disparate materials (e.g. to remove the air boundary by using a coupling agent).

An alternative holder <NUM> for attaching an acoustic emission sensor <NUM> to a non-metallic and non-magnetic material <NUM> and various systems <NUM>, <NUM> using the alternative holder are shown in <FIG>. The alternative holder <NUM> comprises two parts - a cage <NUM> and a retainer bracket <NUM> - removably enagagable with each other by rotating the cage <NUM> into and out of engagement with retainer bracket <NUM>. The cage <NUM> and the retainer bracket <NUM> are each unitary <NUM>-D printed structures using the flexible materials described above, and may be manufactured individually or in groups of alternative holders <NUM>, as shown in <FIG>, to have a modular assemblage <NUM>. In the modular assemblage <NUM>, the plurality of alternative holders <NUM> are retained together at a frange periphery <NUM> around each of the retainer brackets <NUM> in each of the alternative holders <NUM>. The frange periphery <NUM> permits separation of adjacent alternative holders <NUM>. Each alternative holder <NUM> may be readily separated from the other alternative holders <NUM> in the modular assemblage <NUM> by snapping them apart or using a knife or scissor to cut them apart. The modular assemblage <NUM> of alternative holders <NUM> shown in <FIG> may also be used as a group on a non-metallic and non-magnetic material <NUM> to provide minimum spacing between sensors <NUM>.

In this configuration, one or more the retainer brackets <NUM> may be affixed to a non-metallic and non-magnetic material <NUM> and a sensor <NUM> may be easily installed into or removed from the alternative holder <NUM> by simply rotating the cage <NUM> and removing it from the retainer bracket <NUM>. This permits sensors <NUM> to be replaced while maintaining the positioning and configuration of the retainer brackets <NUM> (and thus the sensors <NUM>) on the non-metallic and non-magnetic material <NUM>. There is no need to remove the retainer bracket <NUM> from the non-metallic and non-magnetic material <NUM>.

The cage <NUM> of the alternative holder <NUM> has a similar configuration to the holder <NUM> with a tubular body <NUM> having a closed top end <NUM> and an open bottom end <NUM> through which the sensor <NUM> is inserted into the tubular body <NUM>. The closed top end <NUM> of the tubular body <NUM> has a plurality of unitary flexible flaps <NUM> angularly extending inwardly from an inner surface <NUM> of the closed top end <NUM>, and an interior surface <NUM> of the tubular body <NUM> has a plurality of partial cylindrically-shaped spacers <NUM> extending radially inward and upward from the open bottom end <NUM> of the tubular body <NUM>, for fixing the sensor <NUM> within the tubular body <NUM>. As in the holder <NUM> shown in <FIG>, <FIG> show a closed top end <NUM> with two of the unitary flexible flaps <NUM>, each of the unitary flexible flaps <NUM> extending angularly inwardly toward each other to provide a downward force onto a top surface of the sensor <NUM> when the sensor is installed into the alternative holder <NUM>.

The exterior surface <NUM> of the tubular body <NUM> near the open bottom end <NUM> of the cage <NUM> of the alternative holder <NUM> has a different configuration than that shown in the holder <NUM>. Instead of the base <NUM>, the cage <NUM> in the alternative holder <NUM> has a plurality of capture tabs <NUM> extending outwardly from the exterior surface <NUM> of the tubular body <NUM> to provide a generally flat surface <NUM> in a plane generally perpendicular to the plane of the tubular body <NUM> proximate the open bottom end <NUM>. The capture tabs <NUM> are used to removably engage the cage <NUM> to the retainer bracket <NUM>. <FIG> shows three capture tabs <NUM> positioned around the exterior surface <NUM> of the tubular body <NUM>, but any number can be used depending on the diameter of the cage <NUM>.

The retainer bracket <NUM> has a lower surface <NUM> for attachment to the non-metallic and non-magnetic material <NUM>, a top capture surface <NUM> and an engagement keyway <NUM> disposed between the lower surface <NUM> and the capture surface <NUM> in an aperture <NUM> through the retainer bracket <NUM>. The plurality of capture tabs <NUM> of the cage <NUM> are slidably engagable with the engagement keyway <NUM> in the retainer bracket <NUM> in a rotary motion (in the direction shown by arrow A in <FIG>) to provide a removable locking engagement between the cage <NUM> and the retainer bracket <NUM>. A stop may be provided in the engagement keyway <NUM> to provide notice to the user that the cage <NUM> is locked into the retainer bracket <NUM>. In other aspects, the cage <NUM> may be configured to snap into the retainer bracket <NUM> without rotating, and provide removal by squeezing the sides of the tubular body <NUM> or other means for removing a snap-fitted part.

The lower surface <NUM> of the retainer bracket has the form of an attach pad or leg. A sealant tape as described above is adhered to the lower surface <NUM> of the retainer bracket <NUM> for affixing the alternative holder <NUM> to a non-metallic and non-magnetic material <NUM>.

In the systems <NUM>, <NUM> shown in <FIG> the alternative holders <NUM> are separated from the modular assemblage <NUM> shown in <FIG> and arranged in an array with predetermined spacing. The predetermined spacing between each of the alternative holders <NUM> is provided by a separator <NUM> having a plurality of arms <NUM> positioned, for example, in an X-formation generally perpendicular to each other. Configurations other than X-formations may also be used, such as a straight separator without a crossing arm, or a separator configured to have a spider shape, a triangle, a circular pattern or a free-form pattern. Examples of such alternative patterns are shown in <FIG>. The shape, size and configuration options should be adaptive to the structural requirements. For example, when a repair patch is used for aerospace structures comprising a non-metallic and non-magnetic material <NUM>, the repair patch is typically in the form of an ellipsoidal or circular geometry. The separators <NUM> could be configured to provide a network extending around the perimeter to bound the patch. There are multiple array geometries that may be conceived wherein the density of sensors in a particular area may be adjusted based on structural need, which may be due to known damage morphology or size, structure features and geometry, or the need for quick modifications of the sensor network during use. The systems <NUM>, <NUM> and variations thereof that are disclosed herein are readily adaptive to meet such structural needs. In another example, a long strip or rope of sensors, as shown in <FIG>, may be provided to wrap along a wing, spar, rib, skin of an aircraft or any other type of surface, and be positioned in any desired configuration.

Ends <NUM> of each of the arms <NUM> are engageable with a plurality of retainer brackets <NUM> for positioning a plurality of the alternative holders <NUM> on the non-metallic and non-magnetic material <NUM> with predetermined spacing therebetween. A plurality of separators <NUM> is used with a plurality of alternative holders <NUM> to make a wide variety of configurations for the array of alternative holders <NUM>. The separators <NUM> comprise a flexible material (as described above) that permits positioning of the plurality of alternative holders <NUM> with predetermined spacing on flat surfaces, curved surfaces or surfaces of a non-metallic and non-magnetic material <NUM> with complex geometric shapes, and permits the entire configuration of sensors to actuate and move with the surface (for example, during fatigue loading, or during actual service use, or such that the entire configuration of sensors may be used between two parts that actuate with respect to each other) The separators <NUM> may be attached to the alternative holders <NUM> in any way known for attaching flexible materials together. For example, adhesives may be used, the ends <NUM> of the arms <NUM> can be configured to snap together or to mate together in other ways. The system of <FIG> shows an aspect that uses an adhesive to affix the ends <NUM> of the arms <NUM> to corners of the frange periphery <NUM> of the retainer brackets <NUM>. The system of <FIG> shows an aspect that uses a snap-fit attachment means where the corners of the retainer bracket <NUM> have a bulbous cutout <NUM> that accommodates a bulbous end <NUM> of the arms <NUM> of the separator <NUM>.

In a method <NUM> for affixing acoustic emission sensors to a non-metallic and non-magnetic material, referring to <FIG>, a plurality of alternative holders <NUM> are used with a plurality of separators <NUM> to form a sensor holder array that is affixed to a non-metallic and non-magnetic material <NUM>, which may be a test article or a completed structure, before, during or after manufacture and use of such structure. In step <NUM> of the method, an alternative holder <NUM> is separated from a plurality of alternative holders <NUM> that are retained together in a modular assemblage <NUM> at a frange periphery <NUM> around the retainer brackets <NUM> of each of the alternative holders <NUM>. In step <NUM>, the retainer bracket <NUM> of the separated alternative holder is affixed to the non-metallic and non-magnetic material with a sealant tape as described above. In step <NUM>, the cage <NUM> of the alternative holder <NUM> is removed from the retainer bracket <NUM> by rotating the cage <NUM> out of the engagement keyway <NUM>. A sensor <NUM>, such as an acoustic emission sensor, is then inserted into the tubular body <NUM> of the cage <NUM> in step <NUM> and, in step <NUM>, the cage <NUM> with the installed sensor <NUM> is engaged with the retainer bracket <NUM> by rotating the cage into the engagement keyway <NUM> in the direction shown by the arrow A in <FIG>.

In a further aspect of the method <NUM>, the step <NUM> may be added to create an array of sensor holders with predetermined spacing between each sensor holder. In step 103A, the retainer bracket <NUM> of one of the alternative holders <NUM> is engaged with one end <NUM> of a separator <NUM> having a plurality of arms <NUM> positioned in an X-formation, and the retainer bracket <NUM> of another of the alternative holders <NUM> is engaged at another end <NUM> of the separator <NUM>. The array of alternative holders <NUM> with predetermined spacing is then affixed to the non-metallic and non-magnetic material <NUM> in step <NUM>.

A kit may be provided that includes a plurality of alternative holders <NUM> connected together in a modular assemblage <NUM>, at least one separator <NUM> and sealant tape.

The holders and separators disclosed herein provide a cost and time efficient system and method for affixing sensors, such as acoustic emission sensors, to a non-metallic and non-magnetic material. The holders do not require additional assembly such as springs and screws, and the systems are scalable to account for variations in sensor size and test configurations, and may be used in a wide range of temperature conditions suitable for environmental testing at testing scales ranging from test article or coupon level to complete structures, such as aircraft, and any testing condition, from laboratory to field/depot, thus providing acoustic emission data from diverse environmental conditions.

Claim 1:
A holder (<NUM>) for attaching an acoustic emission sensor (<NUM>) to a non-metallic and non-magnetic material, the holder (<NUM>) comprising a tubular body (<NUM>) having a closed top end (<NUM>) and an open bottom end (<NUM>) through which the acoustic emission sensor (<NUM>) is insertable into the tubular body (<NUM>), the closed top end (<NUM>) having a plurality of unitary flexible flaps (<NUM>) angularly extending inwardly from an inner surface (<NUM>) of the enclosed top end (<NUM>), an inner surface of the tubular body (<NUM>) having a plurality of spacers (<NUM>) extending radially inward proximate the bottom end (<NUM>) of the tubular body (<NUM>), the unitary flexible flaps (<NUM>) and the spacers (<NUM>) fixing the acoustic emission sensor (<NUM>) within the tubular body (<NUM>), wherein the holder (<NUM>) is formed with a flexible material as a unitary three-dimensional printed structure, wherein the unitary flexible flaps (<NUM>) and the spacers (<NUM>) are made from the flexible material so that the holder (<NUM>) can accommodate sensors (<NUM>) of varying heights and diameters.