Composite structure having an ice protection device, and production method

Patent metadata

Field	Value
Publication number	US-9511871-B2
Application number	US-201214122216-A
Country	US
Kind code	B2
Filing date	May 24, 2012
Priority date	May 26, 2011
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

An ice protection system for de-icing an aircraft and/or for keeping the aircraft free of ice includes a composite structure for an aircraft component and a structural element of an aircraft with an ice protection system that is integrated in the composite structure. The ice protection system includes a flat surface-like electric heating element that is embedded in the composite structure below an outer layer of an outer surface of the aircraft component.

First claim

The invention claimed is:

1. A composite structure for an aircraft component that is a structural element of an aircraft, the composite structure comprising:
a latent heat storage layer composed of a material that stores latent heat due to a phase transition;
an outer surface having an outer layer; and
an ice protection system integrated in the composite structure, wherein the ice protection system is configured to prevent formation of ice or to de-ice the structural element,
wherein the ice protection system has a flat surface-like electric heating element embedded in the composite structure below the outer layer of the outer surface of the aircraft component.

2. The composite structure of claim 1 , wherein the electric heating element is selected from a group of heating elements that comprise
a textile surface structure of electrically conductive fibers,
a conductive layer of a carbon fiber-reinforced graphite,
a plastic layer with a graphite filling material,
a conductive layer of a matrix material loaded with nanotubes, and
a layer comprising at least one conductive path of plastic filled with nanotubes, wherein the conductive path extends through the layer in a distributed manner.

3. The composite structure of claim 2 , wherein the textile surface structure comprises a carbon felt.

4. The composite structure of claim 1 , wherein the outer layer is superposed on the electric heating element, and the outer layer comprises a polyether ether ketone.

5. The composite structure of claim 1 , further comprising:
a composite material substrate made of a carbon fiber-reinforced plastic material on which the heating element is arranged.

6. The composite structure of claim 5 , further comprising:
an insulating layer comprised of an epoxy resin arranged between the heating element and the composite material substrate.

7. The composite structure of claim 1 , further comprising:
at least one contact element in electrical contact with the heating element, the at least one contact element is embedded in the composite structure below the outer layer of the outer surface of the aircraft component.

8. The composite structure of claim 1 , wherein the heating element has a modular structure and comprises a plurality of flat surface-like heating elements.

9. A method for producing an ice protection system for an aircraft, the method comprising:
forming an outer skin of the aircraft by embedding a flat surface-like electric heating element in a composite structure; and
adding, to the composite structure, a latent heat storage layer composed of a material that stores latent heat due to a phase transition.

10. The method of claim 9 , further comprising:
providing a composite material substrate made of a carbon fiber-reinforced composite material;
forming the heating element by applying an electrically conductive layer;
forming an outer surface of the aircraft by coating the electrically conductive layer with a cover layer.

11. The method of claim 10 , further comprising:
applying at least one contact element to form an electrical contact with the electrically conductive layer.

12. The method of claim 10 , wherein the electrically conductive layer is applied in a modular fashion.

13. The method of claim 10 , wherein the composite material substrate is coated with an electrically insulating material prior to the application of the electrically conductive layer.

14. The method of claim 10 , wherein the electrically conductive layer is formed by or with a material that is selected from a group of materials that include
a textile surface structure made of electrically conductive fibers,
graphite reinforced with carbon fibers,
an electrically conductive plastic due to graphite filling, and
nanotubes, in order to form electrically conductive paths.

Assignees

• Steinwandel Juergen
• Englhart Martin
• Jonke Dietrich P
• Piringer Helmut
• Eads Deutschland Gmbh

Inventors

• Steinwandel Juergen
• Englhart Martin
• Jonke Dietrich P
• Piringer Helmut

Classifications

• B64D15/12 Primary

  by electric heating (heating arrangements specially adapted for transparent or reflecting areas H05B3/84) · CPC title

• H05B3/18

  the conductor being embedded in an insulating material · CPC title

• H05B3/145

  Carbon only, e.g. carbon black, graphite · CPC title

• H05B3/26

  heating conductor mounted on insulating base {(for transparent areas H05B3/84, H05B3/86)} · CPC title

• H05B2214/02

  Heaters specially designed for de-icing or protection against icing · CPC title