Micro-fabricated, expandable temperature sensor network for macro-scale deployment in composite structures

We have developed methods for creating a highly expandable temperature sensor network for distributed temperature measurement. Stresses and strains due to network expansion are minimized through finite element analysis. Through the use of a uniquely patterned polyimide substrate and wire pattern an expansion ratio of 1,000% is achieved and the electrical resistance of components is maintained from pre-expansion to full expansion. Platinum resistance temperature detectors and electrodes are integrated directly in the polyimide-based network through a non-standard micro fabrication process. Calibration and interpolation algorithms have been developed for temperature measurement. Real-time distributed temperature measurement has been achieved through this sensor network, and it has shown great potential to be integrated into composites.