Heater Structure Metal Application Sequence
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Solution Overview
Problem
The existing method for making heater structures, which involves grit blasting to expose glass cloth and applying a metal layer, weakens the structure, limits metal choices due to temperature restrictions, and is labor-intensive, especially when forming complex shapes and using busbars.
Innovation Solution
Applying metal to a porous reinforcement material before applying resin, allowing the metal to be absorbed into the material, eliminating the need for grit blasting, enabling higher temperature processes, and simplifying the formation of complex shapes and reducing busbar costs by using porous reinforcement material with applied metal for busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grit blasting is used to expose glass cloth on resin cured surface, then metal layer can be applied to form heater element, but the structure is weakened and durability is reduced
Solution Approach 1:
The glass cloth is impregnated with metal particles before the resin is applied and cured. This preliminary action eliminates the need for subsequent grit blasting to expose the glass cloth, as the metal is already positioned on the reinforcement material. The structure maintains its full strength because no material is removed after curing.
Solution Approach 2:
The conventional sequence is inverted: instead of applying metal after resin curing and grit blasting, the metal is applied to the glass cloth before resin application. This reversal allows the metal to be embedded in the reinforcement material during the curing process, preserving structural integrity while achieving the same heater element formation.
2Ease of manufacture
If low temperature metal spraying is used to avoid melting resin, then heater element can be formed, but the range of usable metals is limited
Solution Approach 1:
Metal particles are applied to the glass cloth before resin application, allowing the use of high temperature metal spraying processes. The resin has not yet been applied, so there is no risk of melting. After curing, the metal layer remains firmly attached to the glass cloth, expanding the range of usable metals to include those requiring high temperature application.
3Ease of manufacture
If metal layer is applied after resin curing, then heater element pattern can be formed, but the bond strength between metal and substrate is reduced
Solution Approach 1:
The glass cloth is impregnated with metal particles before the resin is applied and cured. This allows the metal to become embedded in the reinforcement material during the curing process, creating a strong mechanical bond. The metal layer adheres firmly to the glass cloth fibers, resulting in superior bond strength compared to post-curing application methods.
4Shape
If complex shapes with curves and bends are formed before metal application, then the heater can fit aircraft surfaces, but ensuring constant metal layer thickness becomes time consuming
Solution Approach 1:
The glass cloth is impregnated with metal particles while in its initial state, before final shaping. The metal layer is applied uniformly to the flat or preliminarily formed glass cloth. Subsequent shaping operations can then be performed without concern for maintaining constant metal layer thickness, as the metal is already embedded in the reinforcement material. This significantly reduces manufacturing time and complexity.
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 method enhances durability, allows for a wider range of metal options, improves heat distribution uniformity, and simplifies the manufacturing process by enabling easier automation and the use of higher temperature metal applications, resulting in heater structures with improved shear strength and reduced production costs.
Implementation Method 1
applying a metal or metal alloy to the porous reinforcement material such that at least a portion of the applied metal is absorbed into the porous reinforcement material
Implementation Method 2
applying resin to the porous reinforcement material with metal already applied thereto
Data Source
AI summary
A method of making a heater structure and a corresponding heater structure are disclosed. The method comprises providing a porous reinforcement material such as glass cloth, applying a metal to the porous reinforcement material such as by spraying and applying resin to the porous reinforcement material with metal already applied thereto to make the structure substantially rigid. Applying the metal to the porous reinforcement material before applying the resin provides a number of advantages such as enhanced shear strength between the porous reinforcement material and the applied metal layer and the ability to manipulate the porous reinforcement material with metal applied thereto prior to applying the resin. The heater structure may be used in many applications, some of which arc described.