Photochromic webbing structures for monitoring UV-induced mechanical strength degradation

Abstract Webbing structures are critical load-bearing components in a wide array of applications from structural restraint layers in inflatable space habitats to safety harness belts used by construction workers. In the field, webbings are subjected to ultraviolet (UV) irradiation from sunlight, leading to material degradation and a loss of mechanical strength. To date, health monitoring of webbings has relied on empirically correlating UV-induced strength loss with variations in their inherent color, which often yields inconsistent and imprecise results. To fill this gap, we propose a novel class of photochromic webbing structures that afford noninvasive monitoring of UV-induced degradation of their mechanical strength. The webbings’ sensing capabilities are achieved by integrating a class of photochromic yarns, fabricated through a pressurized coating process. Under continuous UV irradiation, the proposed photochromic webbings exhibit a substantial color change, demonstrating a sensing lifetime equivalent to several months in field conditions. We establish a strong correlation between the webbings’ photochromic response and their strength loss, supporting the feasibility of the proposed webbings in monitoring their mechanical integrity. To elucidate the sensing mechanism, we propose a physics-based mathematical model that describes the underlying photochemical reactions. Through an asymptotic analysis, we demonstrate that the model accurately predicts the webbing’s long-term photochromic responses under extended UV irradiation. The proposed photochromic webbing structures and the predictive mathematical model could enhance the safety and integrity of webbing-based engineering systems.