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 Aircraft de-icing system

Details
Inventors: Rutherford, Robert B.; Dudman, Richard L.;
Assignee: Northcoast Technologies (Chardon, OH)
Primary Examiner: Jordan; Charles T.
Assistant Examiner: Dinh; Tran
Attorney, Agent or Firm: Jones, Day, Reavis & Pogue

An electrothermal zoned de-icing system for an aircraft employs a heat-conducting tape bonded to the leading edge of an aircraft structure. The heat-conducting tape has a spanwise parting strip area, and first and second ice accumulation and shedding zones. The tape comprises a non-metallic electrical and heat conducting layer consisting of flexible expanded graphite foil laminated to an outer heat-conducting layer, in which the thickness of the flexible expanded graphite foil layer in the parting strip area is always greater than the thickness of the foil layer in either of the ice accumulation and shedding zones. Therefore, the parting strip area has a decreased electrical resistance, a greater flow of current, and becomes hotter than the zones in which the foil layer is thinner. Because the flexible expanded graphite foil is a monolithic structure that may be shaped, sculptured or layered to form different thicknesses in different areas, only a single control mechanism for a single set of electric terminals is necessary to produce desired watt densities and temperatures in the parting strip and ice accumulation and shedding zones.

DETAILED DESCRIPTION The invention provides an efficient electrothermal heater that can be used in a de-ice and/or anti-ice system for all aircraft, including general aviation light aircraft, because the watt densities provided by the heater are sufficient to melt or loosen accumulating ice using the power available in large aircraft or in light aircraft augmented with, if necessary, an on-board lightweight, high-output, auxiliary alternator, such as that described above.
In particular, the invention provides a lightweight heat-conducting tape bonded to the surface of an aircraft structure that includes a leading edge, for electrothermally removing ice from or preventing the formation of ice on the surface during in-flight and/or on the ground icing conditions.
Although the heat-conducting tape is herein described for use on aircraft surfaces, the tape may be used for any surface which requires anti-ice or de-ice capability and where a power source is available.
Such applications include roofs, gutters, pipes, automobile hoods and trunks, and the like.
The heat-conducting tape comprises at least two layers laminated to each other under heat and pressure, i.
e.
, a non-metallic electrical and heat-conducting layer consisting of flexible expanded graphite foil, also known as vermiform graphite, laminated to an outer heat-conducting layer that is an electrical insulator and seals the interior of the tape against penetration and water damage.
The tape is bonded (e.
g.
, by an adhesive) to an electrically insulating layer, such that the flexible expanded graphite layer is disposed between the heat-conducting outer layer and the insulating layer.
The electrical insulating layer may be directly bonded to the tape to form a third layer before application to the aircraft surface.
Alternatively, the electrical insulating layer may be a component of the aircraft surface to which the two-layer tape is applied.
One embodiment of the invention, employing such a heat-conducting tape having a uniform thickness for use as an anti-ice/de-ice system, is disclosed in our co-owned, co-pending U



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