Filamentary Micro Sensors with Predetermined Breaking Points

Filamentary polymer sensors with predetermined breaking points have been developed. These sensors are produced by radial micro patterning of conductive polymer filaments by ultrasonic hot embossing. Micro structures in the filaments are generated by this fabrication process in less than a second. The dimensions of radial micro grooves in a filament tune the strain at which the filament breaks. This way, overload sensors for ropes or fuses can be realized. For example the discard status or the residual life time of ropes can be controlled with a simple measurement of the electric resistance of sensor filaments. By using different sensors in one rope it is possible to indicate different load cases of the rope.