Heater Mat Element Deposition With Laser-Blown Powder Control
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Solution Overview
Problem
Existing electrothermal heater mats for ice protection systems, such as those used in aircraft, face challenges in manufacturing complexity and cost due to the flame spraying process, which limits thickness variations and requires masks for precise geometry, leading to inefficiencies and increased waste.
Innovation Solution
The use of a laser blown powder process for depositing the heater element allows for tailored thickness and geometry without masks, reducing manufacturing complexity and waste, and enabling the production of adaptable, 3D heater mat configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flame spraying process is used to deposit heater element, then heater element can be formed on dielectric layer, but manufacturing complexity increases and thickness variations are limited
Solution Approach 1:
The patent replaces the flame spraying process (thermal field) with a laser blown powder process (optical field). The laser provides precise energy control for melting and depositing metal powder, enabling accurate thickness control without the complexity of flame spraying equipment and mask systems.
Solution Approach 2:
The invention changes the deposition parameters by using laser energy instead of flame, allowing independent control of deposition thickness through laser power, scanning speed, and powder feed rate. This enables variable thickness heater elements in a single continuous process without masks.
2Manufacturing precision
If masks are used during flame spraying to achieve precise heater element geometry, then geometry accuracy is improved, but manufacturing time increases and waste is generated
Solution Approach 1:
The patent removes the mask component entirely from the manufacturing process. The laser blown powder process achieves precise geometry through digital control of the laser path and powder deposition, eliminating the need for physical masks and their associated preparation, positioning, and removal steps.
Solution Approach 2:
The invention uses digital models to guide the laser deposition process, creating a virtual copy of the desired heater element geometry. The laser system follows programmed paths to replicate the exact geometry without physical masking, reducing both time and material waste.
3Adaptability or versatility
If flame spraying is used to deposit heater element with variable thickness, then thickness control is limited, but process simplicity is maintained
Solution Approach 1:
The patent introduces dynamic control to the deposition process through laser scanning. The laser can vary its power, scanning speed, and dwelling time at different locations, enabling real-time adjustment of deposition thickness. This dynamic capability allows variable thickness heater elements while maintaining process integration and simplicity.
Solution Approach 2:
The invention changes multiple deposition parameters simultaneously (laser power, scanning speed, powder feed rate) to achieve variable thickness profiles. This multi-parameter control provides adaptability for different heater element designs without complicating the overall manufacturing process.
4Manufacturing precision
If masks are used for flame spraying, then heater element pattern accuracy is improved, but material waste increases
Solution Approach 1:
The patent replaces the mask-based flame spraying system with a direct digital laser deposition system. Metal powder is deposited only where needed through precise laser control, eliminating the material waste associated with masking and the inability to recover unmasked powder.
Solution Approach 2:
The laser blown powder process is self-guiding through digital control. The system automatically deposits powder only in the required pattern and thickness through programmed laser paths, without requiring external masks to define the pattern. This reduces material waste while maintaining pattern accuracy.
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
This approach enhances manufacturing accuracy, reduces waste, and simplifies the production process, allowing for tailored current flow and reduced hot and cold spots, while enabling the creation of complex geometries without the need for masks or third-party etching.
Implementation Method 1
depositing a heater element on a first one of the dielectric layers by using a laser blown powder process
Implementation Method 2
a deposition tool is arranged to deposit a greater thickness of powder at the first length than at the second length
Implementation Method 3
depositing a heater element on a first one of the dielectric layers by using a laser blown powder process
Implementation Method 4
laminating together the dielectric layers of the stack
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a method of manufacturing an electrothermal heater mat (3), a heater element (6) is deposited on a first one (51) of the dielectric layers (51, 52) of the heater mat (3) by using a laser blown powder process.