CNT-based resistive heating for deicing composite structures

• US 8,664,573 B2
• Filed: 04/26/2010
• Issued: 03/04/2014
• Est. Priority Date: 04/27/2009
• Status: Active Grant

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Shah, Tushar K., Malecki, Harry C., Adcock, Daniel Jacob
• Primary Examiner(s): Maldonado, Julio J
• Assistant Examiner(s): BACHNER, ROBERT G
• Application Number:
  US12/767,719
• Publication Number:
  US 20110024409A1
• Time in Patent Office: 1,408 Days
• Field of Search: 219/428, 219/553, 428/323, 977/902
• US Class Current: 219/482
• CPC Class Codes: B64D 15/12 by electric heating electric heating elements in general H05B
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 2202/02 Single-walled nanotubes
• CPC Class Codes: C01B 2202/04 Nanotubes with a specific amount of walls
• CPC Class Codes: C01B 2202/06 Multi-walled nanotubes
• CPC Class Codes: C01B 2202/08 Aligned nanotubes
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: C01B 32/174 Derivatisation; Solubilisation; Dispersion in solvents
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 20/1014 Coating or impregnating materials characterised by the shape, e.g. fibrous materials
• CPC Class Codes: C04B 20/1055 with inorganic materials
• CPC Class Codes: C04B 2111/00982 as construction elements for space vehicles or aeroplanes
• CPC Class Codes: C04B 2111/90 Electrical properties
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5236 Zirconia
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/526 : characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5264 : characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5288 : Carbon nanotubes
• CPC Class Codes: C04B 26/12 : Condensation polymers of aldehydes or ketones
• CPC Class Codes: C04B 26/14 : Polyepoxides
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 35/117 : Composites
• CPC Class Codes: C04B 35/185 : Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/19 : Alkali metal aluminosilicates, e.g. spodumene
• CPC Class Codes: C04B 35/52 : based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C04B 35/62873 : Carbon
• CPC Class Codes: C04B 35/62889 : with a discontinuous coating layer
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/82 : Asbestos; Glass; Fused silica
• CPC Class Codes: C22C 47/02 : Pretreatment of the fibres or filaments
• CPC Class Codes: C22C 49/14 : characterised by the fibres or filaments
• CPC Class Codes: H05B 2214/04 : Heating means manufactured by using nanotechnology
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

A composite structure includes a matrix material and a carbon nanotube (CNT)-infused fiber material that includes a plurality of carbon nanotubes (CNTs) infused to a fiber material. The CNT-infused fiber material is disposed throughout a portion of the matrix material. The composite structure is adapted for application of a current through the CNT-infused fiber material to provide heating of the composite structure. A heating element includes a CNT-infused fiber material includes a plurality of CNTs infused to a fiber material. The CNT-infused fiber material is of sufficient proportions to provide heating to a structure in need thereof.

Claims

1. A composite structure comprising:

a body adapted for use as a structural member of an aircraft wherein the body carries a portion of a load induced by flight of the aircraft;

a fiber substrate dispersed through a portion of the body;

a plurality of carbon nanotubes (CNTs) that have been grown in-situ on the fiber substrate so as to be aligned and oriented perpendicular to the fiber substrate, thereby forming a CNT-infused fiber material; and

a first electrode and a second electrode that are electrically coupled to the portion of the body that comprises the CNT-infused fiber material, wherein application of an electric current through the first and second electrodes and the intervening CNT-infused fiber material generates heat within the CNT-infused fiber material, thereby heating the body of the composite structure, thereby deicing or preventing ice formation on a surface of the composite structure.

2. The composite structure of claim 1, wherein the body is adapted to form a portion of a wing of an airplane.

3. The composite structure of claim 1, wherein the body is adapted to form a portion of a blade of a helicopter.

4. The composite structure of claim 1, wherein the body is adapted to form a portion of a propulsor blade of an airplane.

5. The composite structure of claim 1, further comprising a matrix material that is dispersed through the portion of the body that contains the CNT-infused fiber material.

6. The composite structure of claim 1, wherein the fiber substrate comprises a glass.

7. The composite structure of claim 1, wherein the fiber substrate carbon.

8. The composite structure of claim 1, wherein the fiber substrate a ceramic.

9. The composite structure of claim 1, wherein the plurality of CNTs have been grown as one or more of a group consisting of single-walled CNTs, double-walled CNTs, multi-walled CNTs, and mixtures thereof.

10. The composite structure of claim 1, wherein the plurality of CNTs have been grown to be generally uniform in length and uniform in distribution.

11. The composite structure of claim 1, wherein plurality of CNTs have been grown to have a length of about 1 micron to about 500 microns.

12. The composite structure of claim 1, wherein the plurality of CNTs have been grown to have a length from about 1 micron to about 10 microns.

13. The composite structure of claim 1, wherein the plurality of CNTs have been grown to have a length from about 10 microns to about 100 microns.

14. The composite structure of claim 1, wherein the plurality of CNTs have been grown to have a length from about 100 microns to about 500 microns.

15. The composite structure of claim 1, wherein the plurality of CNTs have been grown to have a uniformity of distribution that is characterized by a density up to about 15,000 nanotubes per square micrometer.

16. The composite structure of claim 1, wherein the fiber substrate is selected from a filament, a tow, a yarn, a tape, a unidirectional tape, a fiber-braid, a woven fabric, a non-woven fiber mat, a fiber ply, and a 3D woven structure.

17. The composite structure of claim 1, wherein the CNT-infused fiber material is disposed near a surface of the body.

18. The composite structure of claim 1, wherein the CNT-infused fiber material is disposed throughout the entire.

19. The composite structure of claim 5, wherein the matrix material comprises one or more of a group consisting of an epoxy, a phenolic resin, a cement, a glass, a thermoplastic, and a thermoset.

20. The composite structure of claim 1, wherein the electric current is created by application of a direct current (DC) voltage from between about 1 to about 24 volts DC.

21. The composite structure of claim 1, wherein the electric current is created by application of an alternating current (AC) voltage between about 60 and about 480 volts AC.

25. The composite structure of claim 19, further comprising a plurality of loose CNTs disposed within the matrix material.

22. A method, comprising the steps of:

growing a plurality of carbon nanotubes (CNTs) in-situ on a fiber substrate such that the CNTs are aligned and oriented perpendicular to the fiber substrate, thereby forming a CNT-infused fiber material;

forming a composite structure of an aircraft, wherein the composite structure is adapted to carry a portion of a load induced by flight of the aircraft, the composite structure having a body having a portion that comprises the CNT-infused fiber material;

electrically coupling a first electrode and a second electrode to the portion of the body that comprises the CNT-infused fiber material, wherein application of an electric current through the first and second electrodes and the intervening CNT-infused fiber generates heat within the CNT-infused fiber material, thereby heating the body of the composite structure, thereby deicing or preventing ice formation on a surface of the composite structure.

23. The method of claim 22, wherein the step of applying an electric current comprises applying a direct current (DC) voltage that is between about 1 and about 24 volts DC.

24. The method of claim 22, wherein the step of applying an electric current comprises applying a alternating current (AC) voltage that is between about 60 and about 480 volts AC.