Metal Matrix Composite Heating Element for Aircraft Deicing

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Solution Overview

Problem

Current deicing methods for aircraft are resource-intensive, leading to significant delays and costs, and the use of ethylene glycol-based deicing fluids poses environmental concerns and requires costly recovery systems, while existing systems for deicing vehicles require multiple layers that increase weight and are non-optimal for aircraft wings.

Innovation Solution

A multi-layer hybrid composite material with an outermost electrically conductive metal matrix composite layer for heating, an intermediate electrical insulator layer, and an innermost composite layer, which provides electric heating, structural support, and electromagnetic protection in a single integrated layer, reducing the need for separate heating and protection layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ethylene glycol antifreeze is used as deicing fluid, then deicing effectiveness is achieved, but environmental harm and capital costs for recovery systems increase

Engineering Contradiction:

Improvedeicing effectivenessVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful environmental impact of glycol-based deicing fluids into a benefit by using electric heating as an alternative deicing method that eliminates chemical pollutants while maintaining effective ice removal capability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent replaces the chemical deicing system (ethylene glycol antifreeze) with an electric heating system that uses electrical resistance to generate heat for ice removal, eliminating the need for harmful chemicals

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If glycol recovery system is installed, then environmental compliance is improved, but capital costs increase significantly

Engineering Contradiction:

Improveenvironmental complianceVSAvoidcapital costs

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts the deicing function from the chemical fluid system and implements it through electric heating elements integrated into the aircraft structure, eliminating the need for expensive recovery systems

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the mechanical/chemical recovery system with an electric heating system that directly addresses ice removal without requiring fluid recovery infrastructure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If separate heating layers are added to aircraft structure, then ice protection is improved, but weight and structural complexity increase

Engineering Contradiction:

Improveice protectionVSAvoidaircraft weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the heating function with the existing aircraft structure by integrating electric heating elements into the structural substrate, eliminating the need for separate heating layers and reducing overall weight

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a multi-functional structural substrate that provides both structural support and heating capability through integrated electric heating elements, allowing the same component to serve multiple purposes

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If multi-truck deicing operations are used, then comprehensive deicing is achieved, but time consumption and resource usage increase

Engineering Contradiction:

Improvedeicing completenessVSAvoiddeicing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent enables preliminary heating of aircraft surfaces before ice formation or during ground operations, preventing ice buildup rather than requiring subsequent removal operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent provides continuous ice protection through sustained electric heating, eliminating the need for multiple sequential deicing operations and ensuring constant protection throughout the operational period

Inventive Principle:

Principle #20Continuity of useful action

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 solution reduces deicing time and costs, minimizes wastewater generation, decreases flight delays and cancellations, enhances safety, and eliminates the need for multiple deicing trucks, while maintaining structural integrity and weight efficiency.

Implementation Method 1

The outermost layer comprises an electrically conductive metal matrix composite which conducts electricity to provide electric heating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The intermediate layer comprises an electrical insulator coupled to the outermost layer. The innermost layer comprises an innermost layer composite coupled to the intermediate layer. The intermediate layer electrically insulates the outermost layer from the innermost layer

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS9253823B2Metal matrix composite used as a heating element

Publication Date: 2016.02.02 THE BOEING CO

AI summary

A structural substrate for an aircraft structure and methods are presented. A multi-layer hybrid composite material comprises an outermost layer, an intermediate layer, and an innermost layer. The outermost layer comprises an electrically conductive metal matrix composite that conducts electricity to provide electric heating. The intermediate layer comprises an electrical insulator coupled to the outermost layer. The innermost layer comprises a composite coupled to the intermediate layer. The intermediate layer electrically insulates the outermost layer from the innermost layer.