Co-Extruded Probe Heater for Tailored Anti-Icing Coverage
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Solution Overview
Problem
Existing methods for manufacturing heaters for air data probes are labor-intensive and costly, limiting their placement and effectiveness in addressing icing conditions.
Innovation Solution
An additively manufactured heater is formed by coaxially co-extruding a heater wire with a dielectric material onto the air data probe substrate, allowing for precise tailoring of heating in a single-step process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to form heaters for air data probes, then the heaters can be produced with sufficient heating capability, but the manufacturing process becomes labor-intensive and costly
Solution Approach 1:
The patent combines the heater wire and dielectric material into a single co-extruded component, merging two previously separate manufacturing steps into one automated process. This reduces labor intensity and manufacturing complexity while maintaining reliable heating capability through the integrated structure.
Solution Approach 2:
The additively manufactured heater integrates multiple functions into a single component: the heater wire provides thermal heating, while the co-extruded dielectric material provides electrical insulation and structural support. This multi-functionality eliminates the need for separate insulation components and reduces assembly steps.
2Adaptability or versatility
If traditional manufacturing methods are used to form heaters, then standard heating coverage can be achieved, but flexibility in heater placement and tailored heating is limited
Solution Approach 1:
The additive manufacturing process enables local variation in heater properties by controlling the co-extrusion parameters dynamically during deposition. This allows different sections of the heater to have different heating characteristics, dielectric thickness, or wire density, providing both placement flexibility and manufacturing precision simultaneously.
Solution Approach 2:
The manufacturing process is dynamic and programmable, allowing the heater geometry, material distribution, and heating characteristics to be adjusted during manufacturing based on specific application requirements. This enables tailored heating solutions for different probe locations and icing conditions.
3Reliability
If heaters are manually installed on air data probes, then adequate heating coverage can be achieved, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent merges heater installation with structural manufacturing by co-extruding the heater wire and dielectric material directly onto the probe substrate during additive manufacturing. This eliminates separate installation steps, reducing labor intensity and increasing productivity while ensuring complete heating coverage through integrated design.
Solution Approach 2:
The manual mechanical installation process is replaced with an automated additive manufacturing process that deposits the heater components layer-by-layer directly onto the probe. This substitution of automated deposition for manual installation dramatically increases manufacturing efficiency while maintaining reliable heating coverage.
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 method provides flexibility and cost-effectiveness in heater placement, enabling tailored heating to prevent and remove ice growth on air data probes with improved precision and reduced labor intensity.
Implementation Method 1
a heater that is additively manufactured onto an air data probe by coaxially co-extruding a heater wire along with a dielectric material onto a substrate of the air data probe
Implementation Method 2
coaxially co-extruding a heater wire along with a dielectric material onto a substrate of the air data probe
Data Source
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AI summary
A method for forming a heater on a substrate includes feeding a heater wire (112) into a heating zone (114), the heater wire being in contact with a dielectric material (124) within the heating zone, and coaxially co-extruding the heater wire and the dielectric material from the heating zone through a nozzle (116) and onto a substrate such that the heater wire and the dielectric material form a heater for heating the substrate.