Additively manufactured heater

Patent metadata

Field	Value
Publication number	US-11565463-B2
Application number	US-202017075327-A
Country	US
Kind code	B2
Filing date	Oct 20, 2020
Priority date	Oct 20, 2020
Publication date	Jan 31, 2023
Grant date	Jan 31, 2023

Abstract

A method for forming a heater on a substrate includes feeding a heater wire into a heating zone, the heater wire being in contact with a dielectric material within the heating zone, and coaxially co-extruding the heater wire and the dielectric material from the heating zone through a nozzle and onto a substrate such that the heater wire and the dielectric material form a heater for heating the substrate.

First claim

The invention claimed is:

1. A method for forming a heater on an air data probe, the method comprising:
feeding a heater wire into a heating zone, the heater wire being in contact with a dielectric material within the heating zone; and
coaxially co-extruding the heater wire and the dielectric material from the heating zone through a single nozzle and onto a body of the air data probe such that the heater wire and the dielectric material form a heater for heating the body of the air data probe;
wherein the heater wire is fully encapsulated by the dielectric material as the heater wire and the dielectric material exit the nozzle; and
wherein the heater is additively manufactured onto the body of the air data probe in a single step.

2. The method of claim 1 , further comprising cutting the heater wire at a pre-determined location.

3. The method of claim 1 , further comprising feeding a dielectric material into the heating zone.

4. The method of claim 3 , wherein the dielectric material is a thermoplastic filament.

5. The method of claim 1 , further comprising running the heater wire through a dielectric pool, the dielectric pool containing the dielectric material.

6. The method of claim 1 , wherein the heater has varying watt density.

7. The method of claim 1 , wherein the heater includes cold leads.

8. A system for forming a heater onto an air data probe, the system comprising:
a heating zone configured to heat a heater wire and a dielectric material; and
a nozzle connected to the heating zone;
wherein the heater wire and the dielectric material are coaxially co-extruded from the heating zone through the nozzle and onto a body of the air data probe to form a heater for heating the body of the air data probe, wherein the heater wire is fully encapsulated by the dielectric material as the heater wire and the dielectric material exit the nozzle; and
wherein the heater is additively manufactured onto the body of the air data probe in a single step.

9. The system of claim 8 , further comprising a wire-cut mechanism connected to the heating zone, wherein the wire-cut mechanism is configured to cut the heater wire.

10. The system of claim 9 , further comprising a dielectric pool positioned between the wire-cut mechanism and the heating zone.

11. The system of claim 8 , wherein a first channel extends through the heating zone, the heater wire extending through the heating zone within the first channel and a second channel extends through the heating zone, a dielectric material entering the heating zone within the second channel.

12. The system of claim 11 , wherein the dielectric material is a thermoplastic filament.

13. The system of claim 8 , wherein the heater has varying watt density.

14. The system of claim 8 , wherein the heater includes cold leads.

Assignees

• Rosemount Aerospace Inc

Inventors

• Wigen Scott
• Seidel Greg Allen

Classifications

• B29C64/118 Primary

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• H05B2203/017

  Manufacturing methods or apparatus for heaters · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• H05B2203/016

  Heaters using particular connecting means · CPC title