Anti-icing Stack Foam Adhesive Layer Ice Release
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Solution Overview
Problem
Rotor blades of wind turbines and helicopters face performance hindrance due to ice formation and erosion from airborne materials like rain, sand, and dust, with existing solutions inadequately addressing ice adhesion and erosion protection.
Innovation Solution
An anti-icing stack is applied to the aerodynamic surface, comprising a first layer with high elongation at break and a foam adhesive layer with a tensile modulus of less than 5 MPa, which reduces ice adhesion by incorporating a soft and thick intermediate layer between the erosion protection layer and the surface, potentially eliminating the need for a separate anti-icing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate anti-icing layer is added to protect against ice adhesion, then ice release properties improve, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the anti-icing function with the erosion protection layer by incorporating ice release additives directly into the erosion protection layer material. This merging eliminates the need for a separate anti-icing layer while maintaining both erosion protection and ice release properties, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The erosion protection layer is designed to perform multiple functions simultaneously: it provides erosion resistance from airborne materials and also delivers anti-icing properties through incorporated additives. This multi-functionality allows a single layer to replace what would traditionally require separate protective layers.
2Reliability
If a thick foam adhesive layer with low tensile modulus is used to reduce ice adhesion, then ice release properties improve, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a foam adhesive layer with particular parameter ranges: thickness of at least 300 micrometers and tensile modulus of less than 5 MPa. By defining these parameter ranges, the invention balances the need for sufficient ice release properties with practical manufacturing capabilities, ensuring that the adhesive layer is thick enough to provide anti-icing function while remaining within controllable manufacturing tolerances.
3Reliability
If the foam adhesive layer thickness is increased to at least 300 micrometers to reduce ice adhesion, then ice release properties improve, but material consumption and weight increase
Solution Approach 1:
The patent optimizes the foam adhesive layer parameters by specifying a minimum thickness of 300 micrometers and a tensile modulus of less than 5 MPa. These parameter changes ensure sufficient ice release properties while avoiding excessive material consumption. The foam structure itself provides high volume with low material density, achieving the required thickness without proportionally increasing material usage.
Data Source
AI summary
Anti-icing stacks for protecting an aerodynamic surface are described. In some embodiments, an anti-icing stack includes an anti-icing layer, an elastomeric erosion protection layer, and an additional layer. The erosion protection layer is disposed between the anti-icing layer and the additional layer. The additional layer has a thickness greater than the thickness of the erosion protection layer and a tensile modulus of no more than the tensile modulus of the erosion protection layer. The additional layer may be a foam adhesive layer.