Aircraft Structural Battery Heating Layer for Anti-Icing
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Solution Overview
Problem
Aircraft structural components exposed to incoming flows can experience icing issues, and existing anti-icing and de-icing technologies, such as those using bleed air, are inefficient in terms of weight and energy consumption.
Innovation Solution
Integration of a heatable structural component with a layer structure comprising an inner base structure, a heating layer with carbon allotropes, a structural battery formed by consecutive anode and cathode layers with an electroactive coating, and a protective layer, which generates heat through electrical voltage without significant weight addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating mats with electrical resistance heating are arranged on the inside of leading edges, then heat can be generated locally, but weight increases significantly
Solution Approach 1:
The patent integrates a structural battery into the composite material structure of the aircraft component itself. The battery layers (anode, cathode, electrolyte) are embedded within the fiber-reinforced plastic composite, allowing the structural component to serve dual purposes: mechanical support and energy storage/heating, thereby eliminating the need for separate heavy heating mats.
Solution Approach 2:
The structural component performs multiple functions simultaneously: it provides mechanical structural support, stores electrical energy, and generates heat for anti-icing. This multi-functionality is achieved by integrating the battery system directly into the structural composite, allowing one component to replace what would traditionally require separate systems.
2Reliability
If bleed air from compressor stages is used for anti-icing, then ice can be removed, but energy consumption increases
Solution Approach 1:
The structural battery provides self-service by generating the electrical energy required for heating directly from the structural component itself. During aircraft operation, the battery is charged from the aircraft's electrical system, and then autonomously provides power to the heating layer for anti-icing without requiring additional energy from compressor bleed air or other external sources.
Solution Approach 2:
The patent replaces the mechanical pneumatic system (bleed air from compressors) with an electrical system. Instead of using high-pressure gas flow to remove ice, the system uses electrical heating generated by the structural battery, which is more energy-efficient and does not require the mechanical compression and routing of bleed air.
3Weight of moving object
If structural battery layers are integrated into the component, then weight is minimized, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct sequential steps: first providing the base structure, then applying the battery layers (anode, electrolyte, cathode) in specific sequences, and finally curing each layer. This segmentation allows complex multi-functional integration to be achieved through manageable, standardized manufacturing operations rather than attempting to create the entire multi-functional component in a single process.
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 structural battery enhances the anti-icing function by dissipating heat, preventing ice buildup and facilitating de-icing without adding weight to the aircraft, with a temperature increase of up to 35°C achieved, supporting efficient ice prevention and removal.
Implementation Method 1
The at least one heating layer is capable of producing heat, if an electrical voltage is provided
Implementation Method 2
at least one first group of consecutive layers comprising at least one anode layer, at least one first insulating layer, and at least one cathode layer having an electroactive coating, the first group of layers being arranged between the inner base structure and the at least one heating layer
Data Source
AI summary
A structural component for an aircraft including at least one heatable component section having a layer structure including an inner base structure, at least one heating layer having carbon allotropes embedded in a matrix material, at least one first group of consecutive layers including at least one anode layer, at least one first insulating layer, and at least one cathode layer having an electroactive coating. The first group of layers are arranged between the inner base structure and the at least one heating layer, and at least one protective layer is arranged outside the heating layer. The first group of layers constitute a structural battery. The at least one anode layer and the at least one cathode layer are electrically connectable with the heating layer.