Conductive anti-icing coating systems and methods

Patent metadata

Field	Value
Publication number	US-11732145-B2
Application number	US-202117396242-A
Country	US
Kind code	B2
Filing date	Aug 6, 2021
Priority date	Aug 6, 2021
Publication date	Aug 22, 2023
Grant date	Aug 22, 2023

Abstract

The present disclosure provides methods of coating a substrate. A method includes depositing a conductive coating including an electrically conductive material over the substrate to form a conductive layer having a sheet resistivity of about 10 Ω/□ to about 1000 Ω/□. The method includes depositing an anti-icing layer comprising nanomaterials over the conductive layer to form a coating system.

First claim

What is claimed is:

1. A method of coating a substrate, comprising:
depositing a conductive layer comprising an electrically conductive material over the substrate, the conductive layer having a sheet resistivity of about 10 Ω/□ to about 1000 Ω/□; and
depositing an anti-icing layer comprising about 5 wt % to about 25 wt % of nanomaterials over the conductive layer to form a coating system, wherein the anti-icing layer is substantially free of the electrically conductive material.

2. The method of claim 1 , further comprising at least partially curing the conductive layer before depositing the anti-icing layer over the conductive layer.

3. The method of claim 2 , wherein at least partially curing the conductive layer comprises at least partially curing the conductive layer at about 10° C. to about 40° C., about 500 torr to about 760 torr, and at a relative humidity of less than about 50% relative humidity.

4. The method of claim 1 , wherein the electrically conductive material is selected from a group consisting of a polyaniline, a poly(ethylenedioxythiophene), a poly(styrenesulfonate), and mixtures thereof.

5. The method of claim 1 , further comprising combining the electrically conductive material with an adhesive material selected from a group consisting of a polyurethane, a polyvinyl butyral, a polyacrylate, an epoxy, a glycidyl-Si-Zr-containing sol gel, a polyester, a phenoxy resin, a polysulfide, and mixtures thereof.

6. The method of claim 5 , wherein combining the electrically conductive material with the adhesive material comprises dissolving the electrically conductive material in a solvent before combining the adhesive material with the electrically conductive material.

7. The method of claim 1 , wherein the anti-icing layer comprises a polymer selected from a group consisting of a polyurethane, a polyvinyl butyral, a polyacrylate, an epoxy, a glycidyl-Si-Zr-containing sol gel, a polyester, a phenoxy resin, a polysulfide, and mixtures thereof.

8. The method of claim 7 , wherein the conductive layer further comprises an adhesive material selected from a group consisting of a polyurethane, a polyvinyl butyral, a polyacrylate, an epoxy, a glycidyl-Si-Zr-containing sol gel, a polyester, a phenoxy resin, a polysulfide, and mixtures thereof, wherein the polymer and the adhesive material are the same.

9. The method of claim 1 , further comprising combining a thermal stabilizer with the conductive material, wherein the conductive layer comprises the thermal stabilizer in an amount of less than 5 wt % based on weight of the conductive layer.

10. The method of claim 1 , wherein coating the substrate comprises coating one or more electrodes disposed over the substrate.

11. The method of claim 1 , wherein the anti-icing layer is deposited by flow-coating, drop-casting, dipping, spraying, brush coating, spin coating, roll coating, in-mold coating, co-curing, or electrocoating.

12. The method of claim 1 , further comprising curing the anti-icing layer at about 10° C. to about 40° C., about 500 torr to about 760 torr, and a relative humidity of less than about 50% relative humidity.

13. The method of claim 1 , further comprising dissolving the conductive material in a solvent selected from a group consisting of xylene, benzene, toluene, dimethyl sulfoxide, water, and mixtures thereof.

14. The method of claim 13 , wherein the conductive layer is deposited by flow-coating, drop-casting, dipping, spraying, brush coating, spin coating, roll coating, in-mold coating, co-curing, or electrocoating.

15. A coating system, comprising:
a conductive layer comprising an electrically conductive material, the conductive layer comprising a sheet resistivity of about 100 Ω/□ to about 1000 Ω/□; and
an anti-icing layer comprising about 5 wt % to about 25 wt % of a nanomaterial, the anti-icing layer disposed over the conductive layer, wherein the anti-icing layer is substantially free of the electrically conductive material.

16. The coating system of claim 15 , wherein the electrically conductive material is selected from a group consisting of a polyaniline, a poly(ethylenedioxythiophene), a poly(styrenesulfonate), and mixtures thereof.

17. The coating system of claim 15 , wherein the conductive layer comprises an adhesive material selected from a group consisting of a polyurethane, a polyvinyl butyral, a polyacrylate, an epoxy, a glycidyl-Si-Zr-containing sol gel, a polyester, a phenoxy resin, a polysulfide, and mixtures thereof.

18. The coating system of claim 15 , wherein the nanomaterial is selected from a group consisting of silica, alumina, titania, zinc oxide, fluoropolymer, silicone, carbon nanotubes, graphene, graphene oxide, reduced graphene oxide, functionalized graphene, and combinations thereof.

19. A composite airfoil, comprising:
a root section comprising a first surface;
an intermediate section comprising a first surface and coupled with the root section at a first end;
a tip section comprising a first surface and coupled at a first end with a second end of the intermediate section;
a coating system disposed over the first surface of the root section, the first surface of the intermediate section, the first surface of the tip section, or combinations thereof, the coating system comprising:
a conductive layer comprising an electrically conductive material; and
an anti-icing layer comprising about 5 wt % to about 25 wt % of nanomaterials disposed over the conductive layer, wherein the anti-icing layer is substantially free of the electrically conductive material.

20. The composite airfoil of claim 19 , wherein the conductive layer comprises an adhesive material selected from a group consisting of a polyurethane, a polyvinyl butyral, a polyacrylate, an epoxy, a glycidyl-Si-Zr-containing sol gel, a polyester, a phenoxy resin, a polysulfide, and mixtures thereof.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick J
• Priftis Dimitris

Classifications

• C09D5/24 Primary

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title

• B64C7/00

  Structures or fairings not otherwise provided for · CPC title

• C09D7/20

  Diluents or solvents · CPC title

• C09D7/65

  macromolecular (C09D7/41-C09D7/48 take precedence) · CPC title

• C09D129/14

  Homopolymers or copolymers of acetals or ketals obtained by polymerisation of unsaturated acetals or ketals or by after-treatment of polymers of unsaturated alcohols · CPC title