CNT Conduit Heater Resists Vibrational Fatigue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conduits transporting liquids in freezing temperatures are prone to blockage due to ice formation, and existing electrical resistive heaters, such as those using metal resistance wires, are susceptible to fatigue in vibratory environments, leading to potential damage.
Innovation Solution
A carbon nano tube (CNT) heater system is arranged on the outer surface of conduits, comprising a CNT sheet with busbars and protective layers, which can be helically wrapped or fully encased around the conduit, using a hook and loop fastening system for secure attachment, and is designed to be flexible and energy-efficient, absorbing vibrations and impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If metal resistance wires are used in electrical resistive heaters, then Joule heating function is achieved, but the heater is subject to fatigue in vibratory environments leading to damage
Solution Approach 1:
The patent replaces traditional metal resistance wires with carbon nanotube (CNT) heating elements embedded in a flexible circuit board. CNTs provide both the necessary electrical resistance for Joule heating and superior resistance to vibrational fatigue, combining the benefits of metal conductivity with the fatigue resistance of carbon-based materials.
Solution Approach 2:
The heating element is constructed as a flexible circuit board containing CNTs, allowing the heater to conform to the conduit surface while maintaining structural integrity under vibration. This flexible film structure eliminates the fatigue problems associated with rigid metal wires in vibratory environments.
2Temperature
If heaters are wrapped about conduits in freezing environments, then ice formation is prevented, but the heater structure may be damaged by vibration and impact
Solution Approach 1:
The heater uses a flexible circuit board structure that can absorb vibration and impact forces through elastic deformation, preventing damage to the heating elements and electrical connections while maintaining continuous thermal protection of the conduit.
Solution Approach 2:
The flexible circuit board acts as a cushioning structure that absorbs vibrational and impact energy before it can reach and damage the CNT heating elements and electrical traces, protecting the heater assembly in advance of potential damage.
3Power
If metal resistance wires are used, then heating function is provided, but the wires are subject to fatigue and may lead to damage
Solution Approach 1:
The patent employs carbon nanotubes as the heating element material, providing the necessary electrical resistance for power dissipation while offering vastly superior fatigue life compared to metal wires. CNTs maintain their structural and electrical properties over extended periods even in harsh vibratory environments.
Solution Approach 2:
The patent replaces the mechanical metal wire structure with a CNT-based heating element embedded in a flexible substrate, substituting a fatigue-prone mechanical system with a more durable carbon-based structure that resists vibrational damage and extends operational life.
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
The CNT heater system effectively prevents ice buildup on conduits while withstanding vibrational stress, ensuring prolonged operational life and ease of maintenance, and can be configured for various applications including aircraft and water conduits.
Implementation Method 1
The heater(s) often takes the form of an electrical resistive heating element that, when activated, warms the conduit by Joule heating
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A carbon nano tube (CNT) conduit heater system includes a CNT sheet (49) having a first surface and a second surface. A first busbar (84) is electrically coupled to the CNT sheet (49). A second busbar (86) is electrically coupled to the CNT sheet (49). The second busbar (86) is arranged substantially parallel to the first busbar (84). A first protective layer (44) is disposed on the first surface and a second protective layer (46) is disposed on the second surface, wherein the second protective layer (46) is joined to the first protective layer (44) encapsulating the CNT sheet (49) the first busbar (84) and the second busbar (86) forming a heater assembly having a first side and a second side.