Embedded Composite Heating Element for Aerospace De-icing
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Solution Overview
Problem
Current structural heating elements face challenges in manufacturing efficiency, energy loss, temperature heterogeneities, and delamination issues, particularly in composite materials used in the building and aerospace industries, where they are needed for applications like de-icing and heating systems.
Innovation Solution
A heating composite element comprising a cured room temperature vulcanizing silicone electrically conductive matrix with multiwall carbon nanotubes or their mixture with carbon black, integrated with copper electrodes and reinforcing materials, manufactured by screen printing and embedded in polymers like phenolic resin or acrylate resin, which provides a modular, efficient, and stable heating solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible heating elements are attached to objects by mechanical fixing or polymer adhesives, then the heating element can be applied to various surfaces, but the system creates unnecessary energy losses and temperature heterogeneities
Solution Approach 1:
The heating element is merged with the composite material by embedding it during the composite manufacturing process, creating an integrated structure that eliminates energy losses associated with mechanical attachment or adhesives while maintaining versatility for various applications
2Reliability
If heating elements are embedded into structural materials, then durability and manufacturing costs are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The heating element is embedded into the composite material during the initial manufacturing process rather than being attached afterward, which simplifies the overall manufacturing workflow while ensuring durable integration of the heating element with the structural material
3Speed
If carbon nanotubes are used as conductive filler in silicone matrix, then electrical conductivity and thermal response are improved, but manufacturing precision becomes more challenging
Solution Approach 1:
The manufacturing process parameters are optimized to achieve uniform distribution of carbon nanotubes in the silicone matrix, controlling variables such as mixing speed, temperature, and curing conditions to ensure consistent electrical conductivity and thermal response while maintaining manufacturing precision
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 offers fast thermal response, resistance to thermal variations, high tear strength, and improved electrical insulation, reducing the risk of delamination and energy loss, while maintaining electrical parameters after thermal and impact cycling.
Implementation Method 1
an electrically conductive matrix comprising: i. a cured room temperature vulcanizing silicone, and ii. a conductive filler selected from a group consisting of: 1. multiwall carbon nanotubes and 2. a mixture of multiwall carbon nanotubes and carbon black
Implementation Method 2
the electrically conductive matrix... manufactured by screen printing... embedded in polymers... provides a modular, efficient, and stable heating solution
Implementation Method 3
a cured room temperature vulcanizing silicone
Data Source
Figure 1a~2
Figure 3a~3c
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AI summary
The present invention relates to a heating composite element comprising a heating assembly and an embedding polymer, wherein the heating assembly consists of an RTV silicone, a conductive filler and copper electrodes. It relates also to a method of preparing the heating composite element and to its use as heating system.