3-D Woven Active Fiber Composite

Abstract

A three-dimensional woven active fiber composite is disclosed. The composite includes a plurality of actuating fibers configured in a three-dimensional arrangement. The composite further includes a plurality of conductive wire electrodes that are woven through the plurality of actuating fibers. The electrodes may be configured into two dimensional electrode mats that are spaced apart along the length of the composite. Filler fibers may be used between adjacent electrode mats to help reinforce the composite. A sleeve member can also be used to help provide compressive containment for the actuating fibers and conductive wire electrodes.

What is claimed is: 
     
         1 . A woven active fiber composite, comprising:
 a longitudinal direction extending along a length of the woven active fiber composite;   a lateral direction extending along a width of the woven active fiber composite;   a vertical direction extending along a height of the woven active fiber composite;   a plurality of actuating fibers, each actuating fiber extending in the longitudinal direction and having a generally circular cross-sectional shape associated with a first diameter;   a first group of actuating fibers from the plurality of actuating fibers that are spaced apart from one another in the lateral direction;   a second group of actuating fibers from the plurality of actuating fibers that are spaced apart from one another in the lateral direction;   the second group of actuating fibers being spaced apart from the first group of actuating fibers in the vertical direction;   a conductive wire electrode configured to transfer electrical energy to and from the first group of actuating fibers and the second group of actuating fibers, the conductive wire electrode having a generally circular cross-sectional shape associated with a second diameter; and   wherein the conductive wire electrode is in contact with at least one actuating fiber from the first group of actuating fibers and wherein the conductive wire electrode is in contact with at least one actuating fiber from the second group of actuating fibers.   
     
     
         2 . The woven active fiber composite according to  claim 1 , wherein the first diameter is larger than the second diameter. 
     
     
         3 . The woven active fiber composite according to  claim 1 , wherein the first diameter is from 10 micrometers to 200 micrometers. 
     
     
         4 . The woven active fiber composite according to  claim 3 , wherein the first diameter is from 50 micrometers to 150 micrometers. 
     
     
         5 . The woven active fiber composite according to  claim 1 , wherein the second diameter is from 1 micrometer to 200 micrometers. 
     
     
         6 . The woven active fiber composite according to  claim 5 , wherein the second diameter is from 5 micrometers to 25 micrometers. 
     
     
         7 . The woven active fiber composite according to  claim 1 , further comprising at least one filler fiber woven between the plurality of actuating fibers. 
     
     
         8 . The woven active fiber composite according to  claim 7 , wherein the at least one filler fiber has a generally circular cross-section associated with a third diameter. 
     
     
         9 . The woven active fiber composite according to  claim 8 , wherein the third diameter is substantially similar to the second diameter. 
     
     
         10 . The woven active fiber composite according to  claim 1 , wherein the first diameter periodically varies along the longitudinal direction of the plurality of actuating fibers. 
     
     
         11 . A woven active fiber composite, comprising:
 a longitudinal direction extending along a length of the woven active fiber composite;   a lateral direction extending along a width of the woven active fiber composite;   a vertical direction extending along a height of the woven active fiber composite;   a plurality of actuating fibers extending in the longitudinal direction, at least one actuating fiber of the plurality of actuating fibers having a generally circular cross-sectional shape associated with a first diameter;   the plurality of actuating fibers being spaced apart in the lateral direction and the vertical direction;   a plurality of conductive wire electrodes configured to transfer electrical energy to and from the plurality of actuating fibers, each conductive wire electrode of the plurality of conductive wire electrodes having a generally circular cross-sectional shape associated with a second diameter; and   wherein a first set of conductive wire electrodes are woven in a planar configuration between the plurality of actuating fibers, the planar configuration of conductive wire electrodes extending in the lateral direction and the vertical direction.   
     
     
         12 . The woven active fiber composite according to  claim 11 , wherein the second diameter is smaller than the first diameter. 
     
     
         13 . The woven active fiber composite according to  claim 11 , wherein a second set of conductive wire electrodes are woven in a planar configuration between the plurality of actuating fibers, the planar configuration of conductive wire electrodes extending in the lateral direction and the vertical direction and wherein the first set of conductive wire electrodes is spaced apart from the second set of conductive wire electrodes in the longitudinal direction. 
     
     
         14 . The woven active fiber composite according to  claim 13 , wherein the first set of conductive wire electrodes are spaced apart from the second set of conductive wire electrodes from 5 micrometers to 500 micrometers. 
     
     
         15 . The woven active fiber composite according to  claim 13 , wherein the first set of conductive wire electrodes are spaced apart from the second set of conductive wire electrodes from 100 micrometers to 200 micrometers. 
     
     
         16 . The woven active fiber composite according to  claim 13 , wherein the plurality of conductive wire electrodes includes at least three sets of conductive wire electrodes, each set of conductive wire electrodes are woven in a planar configuration between the plurality of actuating fibers, the planar configuration of each set of conductive wire electrodes extending in the lateral direction and the vertical direction; and
 wherein adjacent sets of conductive wire electrodes are spaced apart from each other in the longitudinal direction.   
     
     
         17 . The woven active fiber composite according to  claim 16 , wherein adjacent sets of conductive wire electrodes are evenly spaced. 
     
     
         18 . The woven active fiber composite according to  claim 13 , further comprising at least one filler fiber woven between the plurality of actuating fibers; and
 wherein the at least one filler fiber is disposed between the first set of conductive wire electrodes and the second set of conductive wire electrodes.   
     
     
         19 . The woven active fiber composite according to  claim 18 , wherein the at least one filler fiber has a generally circular cross-section associated with a third diameter. 
     
     
         20 . The woven active fiber composite according to  claim 19 , wherein the third diameter is substantially similar to the second diameter.