Laser-Welded Deicer Boot Structure to Prevent Inflation Failure
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Solution Overview
Problem
Existing pneumatic deicer boots for aircraft are prone to stress concentration points and failure when inflated due to sewing or traditional welding methods, which can lead to ineffective ice removal and potential system failure.
Innovation Solution
The use of laser welding to bond non-stretchable and stretchable fabric layers in pneumatic deicer boots, forming inflatable tubes with gaps, which reduces stress concentration points and enhances durability, combined with a polymer layer and weathering layer for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sewing methods are used to assemble deicer boots, then manufacturing is simpler, but stress concentration points occur leading to potential failure
Solution Approach 1:
The patent replaces traditional mechanical sewing methods with laser welding technology. The laser welding process uses a concentrated laser beam to melt and fuse the polymer layers together, eliminating the need for needles, threads, and mechanical stitching. This substitution removes stress concentration points that occur at sewn seams while maintaining manufacturing feasibility through automated laser processing.
Solution Approach 2:
The patent changes the bonding parameters from mechanical (sewing) to thermal (laser welding). By controlling laser parameters such as power, speed, and focal position, the process creates strong bonds without the stress concentrations inherent in mechanical sewing. The laser parameters can be precisely adjusted to optimize both bond strength and manufacturing efficiency.
2Reliability
If laser welding is used to form the inflatable carcass, then stress concentration points are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent replaces mechanical assembly methods with laser welding, which creates continuous fused joints throughout the inflatable carcass structure. This eliminates discrete stress concentration points at seams while the automated laser system manages the increased process complexity through programming and control systems.
Solution Approach 2:
The patent divides the inflatable carcass manufacturing into distinct laser welding operations along different weld lines. By segmenting the welding path into manageable sections that can be programmed and executed sequentially, the complex laser welding process becomes controllable and repeatable, reducing the practical complexity despite the advanced technology used.
3Reliability
If thicker polymeric coating compound is applied to stretchable fabric layer, then protection and welding quality improve, but material usage increases
Solution Approach 1:
The patent applies a thicker polymeric coating specifically to the stretchable fabric layer at the weld interface, where it is most needed for laser welding quality and bonding strength. This localized application of enhanced material provides the necessary protection and welding performance precisely where required, rather than uniformly throughout the entire deicer boot structure.
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 laser-welded deicer boots provide effective ice removal with reduced failure risk, maintaining system integrity and enhancing environmental resistance, ensuring consistent performance.
Implementation Method 1
generating a concentrated laser; focusing the concentrated laser along a first weld line to laser weld together the stretchable fabric layer and the non-stretchable fabric layer
Data Source
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AI summary
Ice may form along the leading edge of an aircraft wing or horizontal and vertical stabilizers. A pneumatic deicer system may be configured to inflate and dislodge ice along the leading edge of lift and control surfaces. The pneumatic deicer system may comprise a laser welded deicing boot (200) attached to the leading edge. The compressed air can be directed to the deicing boot, inflating the deicing boot (200) along inflatable tubes (228) formed by laser welds (214, 216), which can crack and dislodge the ice. A method of manufacturing a laser welded pneumatic deicer boot is also disclosed.