Embedded Electric Heaters for Thermoplastic Composite Anti-Icing
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Solution Overview
Problem
Existing methods for forming thermoplastic composite aircraft components are complex and costly, lacking simpler and less expensive consolidation setups.
Innovation Solution
A method involving the use of embedded electric heaters within the composite preform to consolidate thermoplastic materials, eliminating the need for external heaters and reducing initial setup costs, while also serving as an anti-icing system by heating the component surface to prevent ice accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional external heating methods are used to consolidate thermoplastic composite components, then the consolidation process can be completed, but the setup becomes more complex and expensive
Solution Approach 1:
The patent combines the consolidation heating function and anti-icing heating function into a single integrated heating system. The same heating elements embedded in the composite component serve dual purposes: consolidating the thermoplastic material during manufacturing and preventing ice accumulation during aircraft operation, thereby eliminating the need for separate heating systems.
Solution Approach 2:
The heating system is designed to perform multiple functions: it acts as both a consolidation heater during the manufacturing process and an anti-icing heater during aircraft operation. This multi-functional design simplifies the overall system by replacing what would traditionally require separate heating systems for each function.
2Ease of manufacture
If multiple separate systems are used for consolidation and anti-icing, then each function can be optimized independently, but the overall system cost and complexity increase
Solution Approach 1:
The patent merges the consolidation system and anti-icing system into a single integrated heating system. The same embedded heating elements are used for both consolidating the thermoplastic composite during manufacturing and for preventing ice accumulation during aircraft operation, thereby reducing overall system cost while maintaining both functions.
Solution Approach 2:
The heating system is designed with universal applicability to perform both consolidation and anti-icing functions. This multi-functional design reduces the total number of systems required, lowering material costs, installation complexity, and maintenance requirements while preserving the necessary functional flexibility.
3Adaptability or versatility
If heating elements are embedded within the thermoplastic material, then the anti-icing system is integrated into the component structure, but the manufacturing process becomes more complex
Solution Approach 1:
The heating elements are embedded in the composite component during the initial manufacturing process rather than being installed separately afterward. By incorporating the heating elements into the preform before consolidation, the patent simplifies the overall process and avoids the complexity of post-manufacturing installation while achieving full system integration.
Solution Approach 2:
The manufacturing process merges the placement of heating elements with the consolidation process itself. The heating elements are positioned within the preform and activated during consolidation to heat and bond the thermoplastic material, thereby combining two operations (element placement and material consolidation) into a single integrated process step.
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
Simplifies the formation process, reduces costs, and provides an integrated anti-icing solution without additional heating equipment, ensuring efficient energy use and component integrity.
Implementation Method 1
The consolidating includes heating the thermoplastic material using the electric heater
Implementation Method 2
The thermoplastic bonding material is heated to a bonding temperature using an electric heater to bond the first member and the second member together
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A method is provided during which a preform is provided that includes an electric heater (44) and thermoplastic material. The preform is consolidated to provide an aircraft component (22). The consolidating includes heating the thermoplastic material using the electric heater (44). The electric heater (44) is embedded within the thermoplastic material of the aircraft component (22). The electric heater (44) is configured as a part of a thermal anti-icing system (24) for melting and/or preventing ice accumulation on an exterior surface (28) of the aircraft component (22).