Conductive anti-icing coating systems and methods

Patent metadata

Field	Value
Publication number	US-11976217-B2
Application number	US-202318345193-A
Country	US
Kind code	B2
Filing date	Jun 30, 2023
Priority date	Aug 6, 2021
Publication date	May 7, 2024
Grant date	May 7, 2024

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 10Ω/□ to about 1000Ω/□. 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 coating system, comprising:
a conductive layer comprising an electrically conductive material, the conductive layer comprising a sheet resistivity of about 100Ω/□ to about 1000Ω/□; and
an anti-icing layer comprising a nanomaterial having a contact angle greater than 90 degrees according to ASTM D7334, the anti-icing layer disposed over the conductive layer, wherein the anti-icing layer is substantially free of the electrically conductive material.

2. The coating system of claim 1 , wherein the nanomaterial is surface modified with a hydrophobic material.

3. The coating system of claim 2 , wherein the hydrophobic material is an alkylsilane, alkyldisilazane, fluoropolymer, or a combination thereof.

4. The coating system of claim 1 , wherein the nanomaterial is a nanoparticle, a nanorod, a nanofiber, a nanosheet, or a combination thereof.

5. The coating system of claim 1 , wherein the conductive layer comprises a thermal stabilizer.

6. The coating system of claim 5 , wherein the thermal stabilizer comprises zinc oxide.

7. The coating system of claim 5 , wherein the conductive layer has a thickness of about 15 μm to about 35 μm.

8. The coating system of claim 1 , further comprising an insulating layer underlying the conductive layer.

9. The coating system of claim 1 , wherein the anti-icing layer comprises a polymer.

10. The coating system of claim 9 , wherein the polymer is a sol gel, polysiloxane, polyester, fluoropolymer, a polysiloxane, or a combination thereof.

11. The coating system of claim 1 , wherein the anti-icing layer further comprises low surface energy additives or hygroscopic additives.

12. The coating system of claim 1 , wherein the anti-icing layer comprises a polytetrafluoroethylene (PTFE) and/or a glycol based component.

13. 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 10Ω/□ to about 1000Ω/□; and
depositing an anti-icing layer comprising a nanomaterial having a contact angle greater than 90 degrees according to ASTM D7334 over the conductive layer to form a coating system, wherein the anti-icing layer is substantially free of the electrically conductive material.

14. The method of claim 13 , 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.

15. The method of claim 13 , wherein coating the substrate comprises coating one or more electrodes disposed over the substrate.

16. The method of claim 13 , 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.

17. The method of claim 3 , 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.

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

19. The method of claim 18 , 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.

20. The method of claim 13 , wherein the anti-icing layer further comprises low surface energy additives or hygroscopic additives.

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