Printed Electrothermal Heater Mat for Aerodynamic Ice Protection
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Solution Overview
Problem
Existing ice protection systems for aerodynamic surfaces are costly and lack adaptability to various surface configurations, and they do not efficiently manage ice formation and shedding on aircraft and wind turbine blades.
Innovation Solution
An electrothermal heater mat with resistive tracks formed by printing thermosetting ink containing electrically conductive particles onto a substrate, allowing for controlled Joulean heating and flexible installation on aerodynamic surfaces, including the use of flexible substrates and additional insulative layers for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional electrothermal ice protection systems are used, then ice protection function is achieved, but manufacturing cost is high and adaptability to various surface configurations is limited
Solution Approach 1:
The patent applies parameter changes by varying the resistivity of the conductive ink material and adjusting the printing parameters (mesh count, ink viscosity, drying temperature) to achieve different heating characteristics. This allows the same printing process to be adapted to various surface configurations and power requirements without changing the fundamental manufacturing approach, thereby improving adaptability while maintaining cost-effectiveness
Solution Approach 2:
The patent creates a universal ice protection system that can be applied to multiple aerodynamic surfaces (wings, propellers, stabilisers, fins, engine nacelles, radomes, helicopter rotor blades, and wind energy turbine blades) using the same conductive ink printing process. This multi-functional approach eliminates the need for different manufacturing systems for different applications, reducing overall manufacturing costs while enhancing adaptability across various surface configurations
2Ease of manufacture
If electrothermal heater mats with printed tracks are used, then manufacturing cost is reduced and adaptability is improved, but manufacturing precision of track resistivity must be controlled
Solution Approach 1:
The patent incorporates feedback mechanisms in the form of test tracks printed alongside the heater tracks, which are measured for resistivity and used to adjust subsequent printing parameters. This closed-loop control ensures that the conductive ink tracks achieve the desired resistivity values within tight tolerances, maintaining manufacturing precision while using the cost-effective printing process
Solution Approach 2:
The patent controls track resistivity precision by adjusting multiple parameters including ink composition (conductive particle concentration, binder ratio), printing parameters (mesh count, printing pressure, ink film thickness), and curing parameters (temperature, time). By optimizing these parameters, the system achieves consistent resistivity values across different production batches without requiring expensive post-processing adjustments
3Object-affected harmful factors
If de-icing process is used to remove ice buildup, then ice shedding risk is managed, but additional weight and energy consumption occur
Solution Approach 1:
The patent implements periodic de-icing cycles where the conductive ink heater tracks are activated intermittently to melt and shed accumulated ice. The control system monitors ice accumulation conditions and triggers heating cycles only when necessary, rather than continuous heating. This periodic action effectively manages ice shedding risk while significantly reducing energy consumption compared to continuous anti-icing operation
Solution Approach 2:
The patent applies local quality by concentrating heating energy only in regions where ice accumulation is detected or anticipated, rather than heating the entire surface uniformly. The conductive ink tracks can be selectively positioned and activated in specific zones, allowing targeted ice removal that minimizes energy consumption while still managing shedding risks from critical areas
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 solution provides adaptable, cost-effective ice protection with precise control over heating, enabling both anti-icing and de-icing functions on complex surfaces, reducing ice accumulation and shedding risks while minimizing power consumption.
Implementation Method 1
an electrical current is caused to pass through the printed tracks to cause Joulean heating
Implementation Method 2
curing such ink
Data Source
AI summary
An electrothermal heater mat for anti-icing or de-icing of a helicopter rotor blade or other aerodynamic surface comprises a substrate, such as a flexible polyimide sheet, bearing tracks of a material of selected electrical resistivity, these tracks being formed by printing onto the substrate with a thermosetting ink loaded with electrically conductive (e.g. carbon) particles. Electrical bus bars/terminals for the supply of electrical energy to the resistive tracks may also be printed, using an ink loaded with particles of higher conductivity material such as copper or silver.