Patent Publication Number: US-2021185771-A1

Title: Internal heating trace assembly

Description:
FIELD 
     The present disclosure relates to a heating trace system, and more particularly, to internal heating trace assembly use in a heating trace system. 
     BACKGROUND 
     Internal heating traces may be utilized in tube assemblies to regulate temperature of a fluid disposed in the tube assemblies. Internal heating traces may rely on a controller to prevent overheating. Typical internal heating traces may have relatively loose temperature control. 
     SUMMARY 
     An internal heating trace assembly is disclosed herein. The internal heating trace assembly may comprise: an insulator configured to insulate electricity; a first bus bar disposed within the insulator; a second bus bar disposed within the insulator; and a plurality of ceramic positive temperature coefficient (PTC) elements disposed in parallel between the first bus bar and the second bus bar. 
     In various embodiments, each ceramic PTC element in the plurality of ceramic PTC elements is a ceramic PTC strip. The ceramic PTC strip may extend from the first bus bar to the second bus bar. The ceramic PTC strip may comprise a first side and a second side, wherein the first side soldered to the first bus bar, and wherein the second side is soldered to the second bus bar. Each ceramic PTC element in the plurality of ceramic PTC elements may be a ceramic PTC bead. The internal heating trace assembly may further comprise a first conductive leg and a second conductive leg, the first conductive leg disposed between the first bus bar and the ceramic PTC bead, the second conductive leg disposed between the second bus bar and the ceramic PTC bead. The first conductive leg may be soldered to the first bus bar and the ceramic PTC bead. The second conductive leg may be soldered to the second bus bar and the ceramic PTC bead. The insulator may comprise heat-shrink tubing. 
     A water system for use on an aircraft is disclosed herein. The water system may comprise: a tube including a first inlet, a second inlet, and an outlet, the second inlet disposed between the first inlet and the outlet; an electrical interface disposed at the second inlet; an internal heating trace assembly disposed in the tube, a first end of the internal heating trace assembly coupled to the electrical interface, the internal heating trace assembly comprising: an insulator configured to insulate electricity; a first bus bar disposed within the insulator, the first bus bar in electrical communication with the electrical interface; a second bus bar disposed within the insulator, the second bus bar in electrical communication with the electrical interface; and a plurality of ceramic positive temperature coefficient (PTC) elements disposed in parallel between the first bus bar and the second bus bar. 
     In various embodiments, the internal heating trace assembly may comprise a second end, and wherein the second end is configured to float freely during operation of the water system. The water may be configured to flow from the first inlet to the outlet. Each ceramic PTC element in the plurality of ceramic PTC elements may be a ceramic PTC strip. The ceramic PTC strip may extend from the first bus bar to the second bus bar. The ceramic PTC strip may comprise a first side and a second side. The first side may be soldered to the first bus bar. The second side may be soldered to the second bus bar. Each ceramic PTC element in the plurality of ceramic PTC elements may be a ceramic PTC bead. The internal heating trace assembly may further comprise a first conductive leg and a second conductive leg, the first conductive leg disposed between the first bus bar and the ceramic PTC bead, the second conductive leg disposed between the second bus bar and the ceramic PTC bead. The first conductive leg may be soldered to the first bus bar and the ceramic PTC bead, wherein the second conductive leg is soldered to the second bus bar and the ceramic PTC bead. The insulator may comprise heat-shrink tubing. 
     A method of manufacturing an internal heating trace assembly is disclosed herein. The method may comprise: coupling a first ceramic positive temperature coefficient (PTC) element to a first bus bar; coupling the first ceramic PTC element to a second bus bar; coupling a second ceramic PTC element to the first bus bar; coupling the second ceramic PTC element to the second bus bar; disposing the first ceramic PTC element, the second ceramic PTC element, the first bus bar, and the second bus bar in a heat-shrink tubing; and applying heat to the heat-shrink tubing. In various embodiments, the method may further comprise sealing a first end of the heat-shrink tubing. 
     The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
         FIG. 1  illustrates a plain view showing an aircraft, in accordance with various embodiments; 
         FIG. 2  illustrates a potable water system of an aircraft, in accordance with various embodiments; 
         FIG. 3A  illustrates a cross-sectional view of an internal heating trace assembly, in accordance with various embodiments; 
         FIG. 3B  illustrates a cross-sectional view of an internal heating trace assembly during manufacturing, in accordance with various embodiments; 
         FIG. 4A  illustrates a portion of an internal heating trace assembly, in accordance with various embodiments; 
         FIG. 4B  illustrates a portion of an internal heating trace assembly, in accordance with various embodiments; and 
         FIG. 5  illustrates a method of manufacturing an internal heating trace assembly, in accordance with various embodiments. 
     
    
    
     Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the figures to help to improve understanding of embodiments of the present disclosure. 
     DETAILED DESCRIPTION 
     The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosures, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. 
     The scope of the disclosure is defined by the appended claims and their legal equivalents rather than by merely the examples described. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to tacked, attached, fixed, coupled, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. 
     Disclosed herein is an internal heating trace assembly. The internal heating trace assembly comprises, in various embodiments, a first bus bar, a second bus bar, and a plurality of ceramic Positive Temperature Coefficient (PTC) elements. The ceramic PTC elements may be disposed in parallel between the bus bars. The internal heating trace assembly may further comprise an electrical insulator. The first bus bar, second bus bar, and plurality of ceramic PTC elements may be disposed within the insulator. The internal heating trace assembly, in various embodiments, may be configured to provide temperature control continuously along the length of the internal trace heating assembly. The internal heating trace assembly may generate power savings in a heating trace system. 
     With reference to  FIG. 1 , an aircraft  10  is provided with a fuselage  20 , a left side wing  12  and a right side wing  14 . The left side wing  12  and right side wing  14  are designed to provide lift to the aircraft and enable it to fly. The fuselage  20  may house passengers, as well as various components configured to operate aircraft  10 . In various embodiments, the fuselage  20  may comprise a water system  100 . Water system  100  may be a potable water system, a gray water system, or the like. Water system  100  may be disposed in an area of fuselage  20  that is susceptible to outside temperature control. As such, at high altitudes, water system  100  may be exposed to temperatures below freezing. Water system  100  may be temperature controlled by an internal heating trace assembly. 
     Referring now to  FIG. 2 , a schematic view of a portion of a water system  100  for use on an aircraft  10 , in accordance with various embodiments, is illustrated. The water system  100  comprises a first tube  110 , a second tube  120 , an electrical interface  130 , and an internal heating trace assembly  140 . The first tube  110  may comprise a wye shape, a tee shape, or the like. The first tube  110  may comprise a water inlet  112 , a water outlet  114 , and a heating trace inlet  116 . The second tube  120  may comprise a water inlet  122  and a water outlet  124 . The water inlet  122  of the second tube  120  may be coupled to the water outlet  114  of the first tube  110  by any method known in the art. For example, water inlet  122  of the second tube  120  may be coupled to the water outlet  114  of the first tube  110  by a coupling  118 , such as a threaded fitting, two-ferrule fitting, a single ferrule fitting, a ferrule-less push-fit connector, a collar fitting, or the like. In various embodiments, the coupling  118  may comprise bonding or soldering first tube  110  to second tube  120 . The water system  100  may flow in a first direction B from water inlet  112  from first tube  110  through water outlet  124  of second tube  120 . 
     In various embodiments, electrical interface  130  is disposed at the heating trace inlet  116  of the first tube  110 . The electrical interface  130  may be any electrical interface  130  known in the art, such as an electrical connector or the like. The electrical interface  130  may be in electrical communication with a controller and/or a monitoring system. The electrical interface  130  is coupled to the internal heating trace assembly  140 . The internal heating trace assembly  140  is in electrical communication with the electrical interface  130 . A first end  142  internal heating trace assembly  140  is fixed at the electrical interface  130  and the second end  144  is free within the water system  100 . For example, second end  144  may be free in second tube  120  or an upstream tube in water system  100 . The internal heating trace assembly  140  may be configured to control a temperature of water disposed in water system  100  during operation. In various embodiments, bus wires disposed in the internal heating trace assembly  140  may conduct current from the electrical interface  130  through the length of the internal heating trace assembly  140  during operation. 
     In various embodiments, internal heating trace assembly  140  comprises a plurality of ceramic PTC elements  146  disposed in parallel along a length of the internal heating trace assembly  140 . In various embodiments, each ceramic PTC element in the plurality of ceramic PTC elements  146  may act as a resistor. Each ceramic PTC element in the plurality of ceramic PTC elements  146  is a discrete ceramic PTC element in relation to an adjacent ceramic PTC element. As such, the internal heating trace assembly  140  may be configured to control a temperature of the internal heating trace assembly  140 , and in turn the water in water system  100 , continuously along the length of the internal heating trace assembly  140 . 
     In various embodiments, the plurality of ceramic PTC elements  146  are uniformly spaced about the internal heating trace assembly  140 . In various embodiments, the spacing between adjacent ceramic PTC elements in the plurality of ceramic PTC elements varies along the length of the internal heating trace assembly  140 . As such, an internal heating trace assembly  140  may be configured based on a specific design application. For example, one area may need greater temperature than another area of the internal heating trace assembly  140 , so more PTC elements may be placed in the area that would benefit from greater temperature applied compared to another area of the internal heating trace assembly  140 . Additionally, ceramic PTC elements have greater thermal stability compared to typical PTC polymers; however, ceramic PTC elements may be more brittle than typical PTC polymers. By orienting the ceramic PTC elements in parallel, electrically and physically, the ceramic PTC elements may be more structurally sound compared to a ceramic PTC element extending along the entire length of the internal heating trace assembly  140 . 
     Although water system  100  is disclosed with respect to an aircraft  10 , any water system with temperature control is within the scope of this disclosure. 
     Referring now to  FIG. 3A , a cross-sectional view of internal heating trace assembly  140  along section A-A from  FIG. 2 , in accordance with various embodiments, is illustrated. Internal heating trace assembly  140  comprises a ceramic PTC element  210 , a first bus bar  220 , a second bus bar  230 , and an insulator  240 . In various embodiments, the plurality of ceramic PTC elements  146  from  FIG. 2  may include the ceramic PTC element  210 . The ceramic PTC element  210  may be disposed between, and coupled to, the first bus bar  220  and the second bus bar  230 . In various embodiment, the ceramic PTC element is in electrical communication with the first bus bar  220  and the second bus bar  230 . The first bus bar  220  and the second bus bar  230  may be any conductive element known in the art, such as a wire or the like. The first bus bar  220  and the second bus bar  230  may be electrically coupled to the electrical interface  130  from  FIG. 2 . The first bus bar  220  and the second bus bar  230  may be configured to carry an electrical current and the ceramic PTC element  210  may be configured to act as a resistor in internal heating trace assembly  140 . 
     In various embodiments, insulator  240  is disposed around the first bus bar  220 , the second bus bar  230 , and the ceramic PTC element  210 . The insulator  240  may be any electrical insulator known in the art (e.g., polyethylene, cross linked polyethylene-XLPE, polyvinyl chloride PVC, Polytetrafluorethylene (PTFE), silicone, polyolefin, fluoropolymer, etc.). The insulator  240  may be configured to insulate the electricity generated from the first bus bar  220 , the second bus bar  230 , and the ceramic PTC element  210  from the water disposed in water system  100  from  FIG. 2 . 
     Referring now to  FIG. 3B , a cross-section of internal heating trace assembly  140  during manufacturing, in accordance with various embodiments, is illustrated. In various embodiments, each ceramic PTC element  210  in the plurality of ceramic PTC elements of an internal heating trace assembly may be electrically coupled to the first bus bar  220  and the second bus bar  230  by any method known in the art (e.g., soldering). After the plurality of ceramic PTC elements are coupled to the first bus bar  220  and the second bus bar  230 , the first bus bar  220 , second bus bar  230 , and the plurality of ceramic PTC elements are disposed in an insulator  240 . 
     In various embodiments, the insulator  240  is a heat-shrink tubing  242 . As such, the first bus bar  220 , the second bus bar  230 , and the plurality of ceramic PTC elements may easily be disposed in heat-shrink tubing  242  in its un-shrunk state ( FIG. 3B ). After the first bus bar  220 , the second bus bar  230 , and the plurality of ceramic PTC elements are disposed in the heat-shrink tubing  242 , heat is applied to the heat-shrink tubing  242  by any method known in the art, such as via an oven, a hot air gun, a source of hot gas, or the like. As a result, heat-shrink tubing  242  may shrink and contact the first bus bar  220 , the second bus bar  230 , and the ceramic PTC element  210  (as shown in  FIG. 3A ), resulting in an internal heating trace assembly  140 . The heat-shrink tubing  242  may be any thermoplastic material known in the art, such as elastomeric, fluorinated ethylene propylene (FEP), polyolefin, or the like. The heat-shrink tubing  242  may include an internal layer of hot-melt adhesive to enhance the thermal bond between heat-shrink tubing  242  and the PTC elements  210 . 
     Referring now to  FIG. 4A , a portion of an internal heating trace assembly ( 140 ,  300 ), in accordance with various embodiments, is illustrated. The internal heating trace assembly comprises a first bus bar  220 , a second bus bar  230 , and a plurality of ceramic PTC elements  310  disposed in parallel. Each ceramic PTC element in the plurality of ceramic PTC elements  310  may comprise a first side and a second side. For example, first ceramic PTC element  320  in the plurality of ceramic PTC elements  310  may comprise a first side  322  and a second side  324 . The first side  322  may be coupled to first bus bar  220  by any method known in the art (e.g., soldering). Similarly, second side  324  may be coupled to second bus bar  230  by any method known in the art (e.g., soldering). As such, each ceramic PTC element in the plurality of ceramic PTC elements  310  may comprise a ceramic PTC strip extending from first bus bar  220  to second bus bar  230 . For example, the first ceramic PTC element  320  may comprise a ceramic PTC strip extending from first bus bar  220  to second bus bar  230 . 
     Referring now to  FIG. 4B , a portion of an internal heating trace assembly ( 140 ,  400 ), in accordance with various embodiments, is illustrated. The internal heating trace assembly  400  comprises a first bus bar  220 , a second bus bar  230 , and a plurality of ceramic PTC elements  410  disposed in parallel. Each ceramic PTC element in the plurality of ceramic PTC elements  310  may comprise a ceramic PTC bead. For example, first ceramic PTC element  420  in the plurality of ceramic PTC elements  410  may comprise a ceramic PTC bead  430 . The ceramic PTC bead  430  may be disposed between the first bus bar  220  and the second bus bar  230 . 
     The ceramic PTC bead  430  may be coupled to the first bus bar  220  via a first conductive leg  422  extending from ceramic PTC bead  430  to the first bus bar  220 . Similarly, ceramic PTC bead  430  may be coupled to the second bus bar via a second conductive leg  424  extending from ceramic PTC bead  430  to the second bus bar  230 . In various embodiments, first conductive leg  422  has a first end  421  and a second end  423 . The first end  421  of first conductive leg  422  may be coupled to first bus bar  220  by any method known in the art (e.g., soldering) and the second end  423  of first conductive leg  422  may be coupled to ceramic PTC bead  430  by any method known in the art (e.g., soldering). The second conductive leg  424  may be coupled to ceramic PTC bead  430  and second bus bar  230  in the same manner as first conductive leg  422 . The first conductive leg  422  and the second conductive leg  424  may be any conductive material known in the art (e.g., copper, silver, or the like). 
     Referring now to  FIG. 5 , a method  500  for manufacturing an internal heating trace assembly, in accordance with various embodiments, is illustrated. The method may comprise coupling a ceramic PTC element to a first bus bar (step  502 ). The ceramic PTC element may be a ceramic PTC strip (as illustrated in  FIG. 4A ), a ceramic PTC bead (as illustrated in  FIG. 4B ), or the like. The first bus bar may be any conductive element known in the art, such as a copper wire or the like. The PTC element may be coupled to the first bus bar by soldering, or any other method known in the art. The method may further comprise coupling the ceramic PTC element to a second bus bar (step  504 ). The ceramic PTC element may be coupled to the second bus bar in the same manner as the ceramic PTC element is coupled to the first bus bar. The second bus bar may be of equal length as the first bus bar. 
     The method may further comprise repeating steps  502  and  504  until a plurality of ceramic PTC elements are disposed in parallel between the first bus bar and the second bus bar. The number of ceramic PTC elements for a given application may be a design choice based on the heating requirements of a given system. The method may further comprise disposing the plurality of ceramic PTC elements, the first bus bar, and the second bus bar in a heat-shrink tubing (step  506 ). The heat-shrink tubing may be any heat-shrink tubing known in the art, such as heat-shrink tubing  242  (from  FIG. 3B ). The method may further comprise applying heat to the heat-shrink tubing (step  508 ). By applying heat to the heat-shrink tubing, the heat-shrink tubing may shrink and wrap tightly around the first bus bar, the second bus bar, and the plurality of ceramic PTC elements. 
     The method may further comprise sealing a first end of heat-shrink tubing (step  510 ). The first end may be sealed by any method known in the art, such as a heat-shrink end cap or the like. The second end may have the first bus bar and the second bus bar exposed and/or extending out of the second end of the heat-shrink tubing to allow the first bus bar and the second bus bar to be coupled to an electrical component. In various embodiments, the second end of the heat shrink tubing may be sealed in a manner similar to the first end of the heat-shrink tubing, and the wires may be exposed just prior to use (i.e., just prior to electrically coupling the wires to an electrical component. 
     Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosures. The scope of the disclosures is accordingly to be limited by nothing other than the appended claims and their legal equivalents, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
     Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
     Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element is intended to invoke 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.