Conductive Adhesive Bus Bar Attachment for Carbon Nanotube Heaters
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Solution Overview
Problem
Carbon nanotube and graphene heaters used in aircraft de-icing face challenges in connecting to a power source due to the inability to be wired via soldering, leading to delamination issues caused by coefficient of thermal expansion mismatch in thermal cycling environments.
Innovation Solution
A heating assembly that includes a perforated bus bar, a nano-carbon heater, a conductive adhesive forming covalent bonds between the bus bar and the heater, and a pre-preg glass fabric to prevent delamination, allowing for soldered wire connections and minimizing thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon nanotube or graphene heaters are mechanically attached to a bus bar using clamps or other mechanical methods, then the heaters can be connected to a power source, but the wiring attachments delaminate due to coefficient of thermal expansion mismatch in thermal cycling environments
Solution Approach 1:
The patent introduces a conductive adhesive as an intermediary material between the carbon nanotube/graphene heater and the metallic bus bar. This adhesive layer mediates the thermal and mechanical interface, accommodating the coefficient of thermal expansion mismatch between the carbon-based heater and metal bus bar while maintaining reliable electrical and mechanical connection through thermal curing that creates strong adhesive bonds.
Solution Approach 2:
The patent employs a composite bonding system consisting of conductive adhesive material that combines electrical conductivity with adhesive bonding properties. This composite approach allows the connection to simultaneously provide electrical continuity for power transmission and mechanical strength to resist delamination during thermal cycling, overcoming the limitations of purely mechanical attachment methods.
2Ease of manufacture
If other types of heaters that can be more easily attached to a bus bar are used, then the attachment process is simplified, but carbon nanotube or graphene heaters cannot be wired via soldering and require complex mechanical attachment methods
Solution Approach 1:
The patent replaces complex mechanical attachment systems (such as clamps, screws, or mechanical fasteners) with a thermal adhesive bonding process. The conductive adhesive is applied to the interface between the heater and bus bar, then cured through heating to create a permanent bond. This substitution simplifies the manufacturing process by eliminating mechanical assembly steps while providing reliable electrical connection without requiring soldering of carbon-based materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and durable connections between carbon nanotube, graphene, or graphene nanoribbon heaters and a bus bar, preventing delamination and ensuring reliable electrical conductivity under thermal and mechanical stresses.
Implementation Method 1
a coupling agent covalently bonded between the bus bar and the conductive adhesive
Implementation Method 2
a conductive adhesive, wherein the conductive adhesive connects the bus bar to the nano-carbon heater
Implementation Method 3
allowed wiring attachments to be delaminated due to coefficient of thermal expansion (CTE) mismatch in thermal cycling environments
Implementation Method 4
CNTs are both thermally and electrically conductive. Due to these properties, CNTs can be used as heaters to prevent icing on aircraft or other vehicles
Data Source
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AI summary
Disclosed is an attachment between a bus bar and a nano-carbon heater used for de-icing and/or anti-icing in an aircraft or other vehicle. A heating assembly is provided which comprises: a bus bar; a nano-carbon heater; a conductive adhesive connecting the bus bar to the nano-carbon heater; and a pre-preg layer covering the heater and the bus bar. This allows for electrical connections to be made to the heater via the bus bar, and the attachment is strong enough to withstand stress from thermal cycles.