Electrothermal Heater Mat with Backup Heating and Burnout Detection
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Solution Overview
Problem
Existing electrothermal heater mats in aircraft ice protection systems face space constraints due to the inclusion of a secondary heater element layer, which precludes the addition of a dedicated ground plane, leading to inadequate fault detection and potential structural damage from heater burn-out.
Innovation Solution
Incorporation of a secondary heater element layer that functions as both a temporary ground plane and emergency heater, utilizing a current detector to switch between modes, allowing for fault detection and seamless transition to backup operation without a dedicated ground plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated ground plane is added for fault detection, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent combines the ground plane and secondary heater element into a single integrated layer. The same conductive layer serves dual purposes: providing a reference potential for fault detection and acting as a backup heating element, thereby eliminating the need for separate dedicated ground plane and reducing structural complexity
Solution Approach 2:
The secondary heater element layer is designed to perform multiple functions: it serves as a ground plane for electrical reference and fault detection, and simultaneously functions as an emergency heating element when the primary heater fails. This multi-functionality resolves the contradiction by eliminating the need for a separate dedicated ground plane
2Reliability
If a secondary heater element layer is added for backup heating, then reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the ground plane and secondary heater element into a single integrated layer. The same conductive layer serves dual purposes: providing a reference potential for fault detection and acting as a backup heating element, thereby eliminating the need for separate dedicated ground plane and reducing structural complexity
Solution Approach 2:
The secondary heater element layer is designed to perform multiple functions: it serves as a ground plane for electrical reference and fault detection, and simultaneously functions as an emergency heating element when the primary heater fails. This multi-functionality resolves the contradiction by eliminating the need for a separate dedicated ground plane
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 reliable ice protection with fault detection and backup heating, maintaining structural integrity by using a secondary heater element layer for both ground plane and emergency heating functions, reducing the risk of structural damage from heater burn-out.
Implementation Method 1
a primary heater element layer... the power supply apparatus supplies a heater current to the primary heater element layer
Implementation Method 2
a secondary heater element layer... the power supply apparatus supplies a heater current to the secondary heater element layer
Implementation Method 3
at least one dielectric layer interposed between the primary and secondary heater element layers
Data Source
AI summary
An electrothermal heater for an ice protection system includes a laminated heater mat which comprises a primary heater element layer, a secondary heater element layer, and at least one dielectric layer interposed between the primary and secondary heater element layers, and control apparatus which comprises power supply apparatus and a current detector. The control apparatus is configured to have (i) a first mode in which the power supply apparatus supplies a heater current to the primary heater element layer and does not supply a heater current to the secondary heater element layer and the current detector monitors the secondary heater element layer for detecting a leakage current of the heater current of the primary heater element layer indicative of burn-out of the primary heater element layer and (ii) a second mode in which the power supply apparatus supplies a heater current to the secondary heater element layer and does not supply a heater current to the primary heater element layer. The control apparatus is configured to switch from the first mode to the second mode in response to detection of said leakage current by the current detector.