Composite ice protection heater and method of producing same
First Claim
1. A noise-attenuating ice protection heater of an aircraft component, the heater comprising:
- (a) a pair of electrically insulating layers;
(b) a plurality of spaced electric heater elements, each heater element comprising a graphite sheet disposed between the insulating layers;
(c) at least one composite support layer, wherein the electric heater elements, the insulating layers, and the support layer include a plurality of spaced openings therethrough;
(d) a pair of spaced bus strips in electrical contact with respective opposed portions of each electric heater element;
(e) an open cell matrix underlying the insulating layers, the heater elements, and the support layer;
(f) wherein the cells of the open cell matrix are in acoustic communication with the spaced openings;
(g) wherein the spaced openings are in acoustic communication with an air mass external to the heater and the aircraft component; and
(h) wherein the electrically insulating layers, the electric heater elements, the support layer, the bus strips, and the open cell matrix are bonded together to form a unitary structure.
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Accused Products
Abstract
The invention includes a composite ice protection heater for an aircraft. The composite heater includes at least one electrically insulating layer, and at least one electric heater element comprising an electrically conductive layer bonded to the insulating layer. The conductive layer may include a pre-impregnated woven fabric that includes a plurality of threads that include an electrically conductive material, such as carbon or graphite fibers. The composite heater can be incorporated into a composite surface structure of an aircraft. The conductive layer and insulating layer may include a plurality of spaced openings through the layers that cooperate with an underlying open-cell matrix to attenuate noise at the associated surface of an aircraft. A desired electrical resistance of the conductive layer may be obtained by introducing a plurality of discontinuities in the layer, such as spaced holes or slits.
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Citations
13 Claims
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1. A noise-attenuating ice protection heater of an aircraft component, the heater comprising:
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(a) a pair of electrically insulating layers; (b) a plurality of spaced electric heater elements, each heater element comprising a graphite sheet disposed between the insulating layers; (c) at least one composite support layer, wherein the electric heater elements, the insulating layers, and the support layer include a plurality of spaced openings therethrough; (d) a pair of spaced bus strips in electrical contact with respective opposed portions of each electric heater element; (e) an open cell matrix underlying the insulating layers, the heater elements, and the support layer; (f) wherein the cells of the open cell matrix are in acoustic communication with the spaced openings; (g) wherein the spaced openings are in acoustic communication with an air mass external to the heater and the aircraft component; and (h) wherein the electrically insulating layers, the electric heater elements, the support layer, the bus strips, and the open cell matrix are bonded together to form a unitary structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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Specification