Drone Rotor Blade Deicer via Laser Structured Conductive Furrows
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Solution Overview
Problem
Existing deicer systems for helicopters are not transposable to small drones due to the difficulty in arranging heater mats on small rotor blades and the incompatibility with solid rotor masts, and conventional laser direct structuring methods do not suit deicing applications.
Innovation Solution
A method using laser direct structuring to fabricate rotary equipment for drones, where a composite material with an organic metal is structured to create a furrow on the blade for an electrically conductive track, which is then coated with a protective layer, allowing for Joule-effect heating for deicing with minimal electrical energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heater mats are arranged in drone rotor blades, then deicing function is achieved, but the complexity of arrangement and electrical connection becomes too high for small blades
Solution Approach 1:
The patent merges the deicing function directly into the blade structure by integrating the electrically conductive track into the composite material layers of the blade itself, rather than adding separate heater mats. This integration eliminates the need for separate arrangement and connection steps, reducing complexity while maintaining deicing reliability.
Solution Approach 2:
The composite material structure serves multiple functions: it provides structural support for the blade and simultaneously acts as the heating element for deicing through the integrated conductive track. This multi-functionality reduces the number of separate components needed, simplifying the overall system.
2Ease of manufacture
If conventional laser direct structuring is used, then electrically conductive tracks are created, but the tracks are not resistant enough for Joule-effect heating
Solution Approach 1:
The patent uses composite materials with specific electrical properties embedded in the blade structure. The conductive track is formed using materials and methods that provide both manufacturability and the necessary electrical resistance for effective Joule-heating, achieving a balance between ease of manufacture and heating reliability.
3Reliability
If electrical connectors are used to connect wires to heater mats, then electrical connection is achieved, but the connector dimensions are too large for small drone blades
Solution Approach 1:
The electrical connection system is merged directly into the blade's composite structure. The conductive track is formed as an integral part of the blade layers, eliminating the need for separate connectors and wires that would occupy valuable space on small drone blades.
4Strength
If a solid rotor mast is used, then mechanical strength is achieved, but it is incompatible with helicopter-style electricity transfer means
Solution Approach 1:
The rotor mast is designed to serve multiple functions: it provides mechanical support for the rotor blades and simultaneously serves as the electrical connection interface. The solid mast structure incorporates electrical contact surfaces that work with brushes or slip rings, enabling both mechanical strength and electrical power transfer without requiring separate components.
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 effective deicing of small drone blades with optimized electrical energy usage and increased mechanical strength, while the protective layer slows down erosion of the conductive track.
Implementation Method 1
The laser creates microscopic craters and scores in which copper can be firmly anchored by dipping the part in a catalyst bath
Implementation Method 2
Those parts therefore appear to be ill-suited for being subjected to heating by the Joule effect
Data Source
AI summary
A piece of rotary equipment for a drone, the rotary equipment having a rotary assembly including at least one blade. The rotary assembly includes at least one furrow that extends in a skin from a first end to a second end, the at least one furrow being at least arranged over the blade, the at least one furrow presenting at least one change of direction on the blade, the rotary assembly including at least one deicer having an electrically conductive track that extends in the at least one furrow, the electrically conductive track extending from a first terminal to a second terminal, the first terminal being present at the first end and the second terminal being present at the second end, the deicer including a protective layer covering the electrically conductive track.