High-Temperature TPU Conductive Ink for Fatigue-Resistant Heating Traces
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Solution Overview
Problem
Heating elements for electrothermal deicers face issues with material property changes due to etching processes, which affect dimensional tolerances and pose waste disposal challenges, and conductive inks lack sufficient mechanical fatigue resistance.
Innovation Solution
A conductive ink comprising high melting temperature thermoplastic polyurethane and conductive particles, such as silver platelets or nanosilver, with a free radical crosslinker like peroxide, providing enhanced mechanical fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chemical etching process is used to create heating elements, then conductive patterns can be formed, but mechanical properties deteriorate and dimensional tolerances are affected
Solution Approach 1:
The patent replaces the chemical etching process with a conductive ink deposition system that uses a carrier fluid to deposit conductive particles and binder material. This substitution eliminates the harmful chemical etching process while maintaining the ability to form conductive heating patterns on the substrate.
Solution Approach 2:
The patent employs a composite conductive ink formulation consisting of conductive particles (such as silver, aluminum, or carbon), binder material, and carrier fluid. This composite material system provides both electrical conductivity and mechanical integrity without requiring chemical etching of the substrate.
2Ease of manufacture
If chemical etching process is used to create heating elements, then conductive patterns can be formed, but dimensional tolerances are affected
Solution Approach 1:
The patent replaces the chemical etching process with a conductive ink deposition system that uses a carrier fluid to deposit conductive particles and binder material. This substitution eliminates the harmful chemical etching process while maintaining the ability to form conductive heating patterns on the substrate.
Solution Approach 2:
The patent controls the deposition parameters of the conductive ink, including particle size distribution, binder composition, and carrier fluid properties, to achieve precise control over the conductive pattern dimensions and tolerances without relying on chemical etching processes.
3Ease of operation
If conventional conductive ink is used, then ease of application is improved, but mechanical fatigue resistance is insufficient
Solution Approach 1:
The patent employs a composite conductive ink formulation consisting of conductive particles (such as silver, aluminum, or carbon), binder material, and carrier fluid. This composite material system provides both electrical conductivity and mechanical integrity without requiring chemical etching of the substrate.
Solution Approach 2:
The patent modifies the binder material composition and curing parameters to enhance the mechanical fatigue resistance of the conductive ink trace while maintaining ease of application. The binder is formulated to provide flexibility and adhesion that withstands repeated bending cycles.
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 conductive ink exhibits improved fatigue resistance performance in bending cycle tests, making it suitable for applications like rotor blades and fixed wings, and offers robustness against vibration.
Implementation Method 1
The conductive ink may further comprise a free radical crosslinker, such as peroxide
Implementation Method 2
The conductive ink may comprise a high melting temperature thermoplastic polyurethane and a plurality of conductive particles
Data Source
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AI summary
A conductive ink may comprise a high temperature thermoplastic polyurethane (TPU) and a plurality of conductive particles disposed in the high temperature TPU. The plurality of conductive particles may comprise between 60% and 95% of the conductive ink by weight. The high temperature TPU may include a melting point between 120 °C and 200 °C. The conductive ink may be used for external heated composite structures, such as rotor blades, fixed wings, faring, engine lip electrothermal ice protection, or the like. The conductive ink may have enhanced mechanical fatigue resistance.