Strained Conductive Fiber Heating Mat for Anti-Ice
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Solution Overview
Problem
Conventional resistance heated elements used for de-icing and anti-icing on helicopter rotor blades, such as random carbon mat materials, are not strain-tolerant and prone to deterioration in high-strain environments like those experienced by tiltrotor aircrafts, which require effective ice removal and prevention in extreme climates and icing conditions.
Innovation Solution
A heating mat with a specific orientation of conductive fibers, where one set defines a positive angle less than +45° and another set defines a negative angle greater than -45° relative to the perpendicular direction, is integrated into the rotor blade to provide heat and withstand high strain values, using a composite structure that includes bundles of fibers oriented in a woven fabric or unidirectional sheets to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If random carbon mat material is used for heating elements, then uniform heat distribution and ease of manufacture are improved, but strain tolerance and durability in high-strain environments deteriorate
Solution Approach 1:
The patent employs a composite heating element structure combining carbon fibers embedded in a flexible circuit board substrate. This composite approach integrates the electrical conductivity and heat generation capabilities of carbon fibers with the structural support and strain tolerance of the flexible circuit board, achieving both ease of manufacture and high strain tolerance in tiltrotor aircraft applications.
2Use of energy by moving object
If wire elements are used for resistance heating, then electrical conductivity is improved, but fabrication complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical wire element fabrication with a printed circuit board-based approach. Electrical conductive patterns are printed or embedded onto a flexible substrate, eliminating the need for manual wire winding, connection, and assembly. This substitution dramatically reduces fabrication complexity and cost while maintaining excellent electrical conductivity for heating operations.
3Strength
If thicker rotor blades are used in tiltrotor aircraft, then structural strength and cruising capability are improved, but strain during blade flapping increases
Solution Approach 1:
The patent utilizes the strain characteristics of thick tiltrotor blades by designing a flexible circuit board heating element with appropriate flexibility and strain capacity. The flexible substrate is specifically selected or engineered to accommodate the higher strain levels experienced during blade flapping in tiltrotor configurations, allowing the heating element to maintain electrical functionality while withstanding the increased mechanical stress.
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 solution effectively dissipates heat and withstands high strain during blade flapping, ensuring reliable anti-icing and de-icing capabilities in high-strain environments, such as those encountered by tiltrotor aircrafts, while maintaining structural integrity and efficiency.
Implementation Method 1
De-ice and anti-ice devices including resistance heated elements are commonly used to prevent ice formation and remove ice on rotor blades of a helicopter
Data Source
AI summary
A rotor blade of a helicopter is presented. In an embodiment, the rotor blade includes a body; and a heating mat arranged in the body and configured to supply heat to said body. The heating mat includes a first plurality of fibers and a second plurality of fibers electrically connected to the first plurality of fibers. The first plurality of fibers define a positive angle smaller than about +45° relative to a first direction perpendicular to a longitudinal direction of the body. The second plurality of fibers define a negative angle greater than about −45° relative to the first direction.