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Simulation analysis method of expandable and flexible sensor networks based on the flexible printed circuit process

Aircraft structural health monitoring (SHM) technology is a revolutionary technology based on sensor networks, which has the advantages of ensuring flight safety, extending structural life, and reducing maintenance costs. Due to the large size of aircraft structures and large deformation of morphing wings, the sensor networks integrated into the aircraft structures should be large-area, expandable, and flexible. Island-interconnect structure design in flexible electronics is expected to realize such sensor networks, with the help of large-area and low-cost flexible printed circuit (FPC) process. Mechanical analysis can guide the design of island-interconnect sensor networks. However, few studies have been reported to analyze the mechanical properties of whole island-interconnect sensor networks. This paper proposes a simulation analysis method based on the finite element method for the mechanical analysis of expandable and flexible sensor networks. This method mainly includes two parts: extracting the buckling modes through linear buckling analysis and obtaining the deformation states and mechanical properties through postbuckling behavior analysis. It is applied on the mechanical analysis of island-interconnect sensor networks with different geometry designs, including serpentine, fractal, and irregular island-interconnect sensor networks. Tensile experiments of island-interconnect sensor networks manufactured by the FPC process show that the deformation of experimental results is basically consistent with that of simulation results. In conclusion, the proposed simulation analysis method is appliable for the mechanical analysis of serpentine, fractal, and irregular island-interconnect structure networks, guiding the structural design of expandable and flexible sensor networks for large-area SHM of aircraft.