Negative-TCR Multi-Zone Heater Control for Gap Deicing

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Solution Overview

Problem

Existing multi-zone resistive heaters for aircraft components struggle to effectively heat gaps between zones due to the lack of heating elements, leading to ice formation, which conventional materials with positive temperature coefficient of resistivity (TCR) are inefficient in managing power distribution.

Innovation Solution

Utilizing materials with negative temperature coefficient of resistivity (TCR) for the zones and controlling power distribution to ensure simultaneous heating of both zones, allowing for continuous heat generation at the gap by starting power to the second zone before the first zone ends, within the total allowable system power limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional materials with positive TCR are used in multi-zone resistive heaters, then power distribution can be controlled, but heating effectiveness at gaps between zones is insufficient leading to ice formation

Engineering Contradiction:

Improveice prevention capabilityVSAvoidice formation at gaps

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fundamental parameter of resistivity temperature coefficient from positive to negative. Materials with negative TCR exhibit decreasing resistance with increasing temperature, which fundamentally alters the heating behavior and enables continuous heat generation at zone gaps, preventing ice formation effectively.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The controller implements periodic power transmission to different zones, alternating between first and second zones in time periods. This periodic switching with negative TCR materials ensures that when one zone is powered down, the other zone continues generating heat, maintaining continuous thermal protection at gaps.

Inventive Principle:

Principle #19Periodic action

2Reliability

If power is transmitted to multiple zones simultaneously, then heating coverage is improved, but total power consumption exceeds system limits

Engineering Contradiction:

Improveheating coverageVSAvoidtotal power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system uses periodic power transmission, alternating between first and second zones in sequential time periods. This ensures that at any given moment, only one zone is actively powered, keeping instantaneous power consumption within system limits while providing continuous heating coverage through the alternating pattern.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The controller is configured to start transmitting power to the second zone before completely shutting off power to the first zone. This preliminary action ensures overlapping heat generation periods, maintaining continuous heating coverage at gaps while managing total power consumption within allowable limits.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If power transmission time periods are extended, then heating effectiveness is improved, but power consumption increases beyond allowable limits

Engineering Contradiction:

Improveheating effectivenessVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system implements periodic power transmission with carefully controlled time periods. Each zone receives power for a limited duration before switching to the other zone. This periodic cycling maintains heating effectiveness by ensuring continuous heat generation at gaps while restricting the duty cycle of each zone to keep total power consumption within system limits.

Inventive Principle:

Principle #19Periodic 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 approach ensures continuous heating of gaps, reducing ice buildup by maintaining power draw close to the system limit, thus enhancing deicing efficiency and effectiveness.

Implementation Method 1

a first zone of the multi-zone resistive heater formed from a material having a negative temperature coefficient of resistivity (TCR) and configured to receive a first power to generate thermal energy

Methodology Applied

Scientific EffectNegative temperature coefficient of resistivity (TCR): Thermo-resistive Effect

Implementation Method 2

the gap operates as a dielectric boundary between the first zone and the second zone

Methodology Applied

Scientific EffectDielectric: Dielectric

Data Source

PatentEP3941154B1Control scheme for negative temperature coefficient of resistivity heaters

Publication Date: 2025.11.12 GOODRICH CORP

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Figure 3A~3C

AI summary

A system for controlling a multi-zone resistive heater. The system includes a first zone (202) of the multi-zone resistive heater formed from a material having a negative temperature coefficient of resistivity (TCR) and configured to receive a first power to generate thermal energy. The system further includes a second zone (204) of the multi-zone resistive heater formed from the material having the negative TCR, separated from the first zone by a gap, and configured to receive a second power to generate the thermal energy.