Patent Description:
Conventional pneumatic deicers include a rubber surface ply which has a tendency to experience surface cracks. Such surface cracks may result from prolonged exposure to rain, ice, and debris impact, or by polymer degradation due to hydrolysis, ultraviolet radiation, ozone damage, or by repeated exposure to relatively low temperatures. The cracks may propagate laterally and vertically deep into an underlying rubber layer used to seal a fabric body. In response to the cracks reaching the fabric body, the pneumatic deicer may experience tubing inflation malfunctions. <CIT> discloses a method for forming a deicer according to the preamble of claim <NUM>. <CIT> discloses an alternative method for forming a deicer.

According to a first aspect, there is provided a method for forming a deicer according to claim <NUM>.

In any of the foregoing embodiments, each of the first outer layer and the second outer layer are formed to have a thickness of between <NUM> thousandths of an inch (<NUM> millimeters (mm)) and <NUM> thousandths of an inch (<NUM>).

In any of the foregoing embodiments, each of the first outer layer and the second outer layer are formed to have the thickness of between <NUM> thousandths of an inch (<NUM>) and <NUM> thousandths of an inch (<NUM>).

In any of the foregoing embodiments, each of the first outer layer and the second outer layer are formed using a same material.

In any of the foregoing embodiments, the deicer is a pneumatic deicer and the body is configured to receive a gas to inflate the deicer.

In any of the foregoing embodiments, the deicer is an electrothermal deicer and the body is configured to receive electricity and convert the electricity into thermal energy.

In any of the foregoing embodiments, the outer layer includes an aliphatic polyether urethane.

In any of the foregoing embodiments, the deicer includes at least one of a pneumatic deicer and the body is configured to receive a gas to inflate the deicer; or an electrothermal deicer and the body is configured to receive electricity and convert the electricity into thermal energy.

According to a second aspect, there is provided a deicer configured for use in an aircraft according to claim <NUM>.

In any of the foregoing embodiments, each of the first outer layer and the second outer layer are formed from a same material, and formed to have a thickness of between <NUM> thousandths of an inch (<NUM> millimeters (mm)) and <NUM> thousandths of an inch (<NUM>).

In any of the foregoing embodiments, the deicer includes at least one of: a pneumatic deicer and the body is configured to receive a gas to inflate the deicer; or an electrothermal deicer and the body is configured to receive electricity and convert the electricity into thermal energy.

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration.

Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

Referring now to <FIG>, an aircraft <NUM> may include multiple aircraft components. For example, the aircraft <NUM> may include a nosecone <NUM>, one or more wing <NUM>, one or more door <NUM>, a fuselage <NUM>, and one or more gas turbine engine <NUM>. These and other components of the aircraft <NUM> may include, or be coupled to, additional aircraft components. For example, the nosecone <NUM> may include an erosion film <NUM> on an outer surface thereof, the wing <NUM> may have a leading edge <NUM> with a pneumatic or electrothermal deicer <NUM>, and the door <NUM> may have a seal <NUM> formed from a heated elastomer product <NUM>. Each of the erosion film <NUM>, the pneumatic or electrothermal deicer <NUM>, and the heated elastomer product <NUM> may have an inner portion which may face an interior of the component (e.g., the inner portion of the erosion film <NUM> may face the nosecone <NUM>, the inner portion of the pneumatic or electrothermal deicer <NUM> may face the wing <NUM>, and the inner portion of the heated elastomer product <NUM> may face the door <NUM> or the fuselage <NUM>). Each of the erosion film <NUM>, the pneumatic or electrothermal deicer <NUM>, and the heated elastomer product <NUM> may further include an outer layer. The outer layer may be formed from, or may include, an elastomeric material and may be formed using an extrusion process. In various embodiments, the outer layer may face an environment of the aircraft component. For example, the outer portion of the erosion film may face oncoming air, the outer portion of the electrothermal deicer <NUM> may face oncoming air, and the outer portion of the heated elastomer product <NUM> may face air in response to the door <NUM> being opened.

Using extrusion to form an elastomeric outer layer may provide several benefits and advantages over forming an elastomeric outer layer using a conventional method. For example, the use of extrusion allows the outer layer to be relatively thin, thus reducing weight of the aircraft component. Because extrusion allows for the formation of thinner layers, multiple layers may be stacked together to form a desired thickness of the total outer layer. The ability to stack multiple layers together provides benefits such as reducing the likelihood of defects (e.g., cracks, pores, or the like) extending through the outer layer, and simultaneously increasing the likelihood of uniformity of thickness of the outer layer. Thus, the use of extrusion results in a more robust product with an extended operating life and potentially having a lower weight, all desirable characteristics for aircraft components.

Turning to <FIG>, an example of a method <NUM> for forming an aircraft component having an elastomeric surface or erosion ply is shown. The method <NUM> may begin in block <NUM> where an inner portion of the aircraft component is formed. The inner portion of the aircraft component may be formed using any method such as casting, forging, or the like. The inner portion may be formed to have any desirable shape including straight lines, angles, curves, or the like on at least one of edges or surfaces. The inner portion may include at least one of an adhesive, an elastomer, a rubber, a neoprene, a metal, or a woven fabric.

In block <NUM>, two (or more) outer layers are formed using an extrusion process. The outer layer includes an elastomeric material and includes multiple plies (i.e., multiple outer layers) coupled together. Each of the multiple plies is formed using the extrusion process. The extrusion process may include any type of extrusion such as blown extrusion or cast extrusion. The outer layer (whether one or multiple plies) may be formed to have a shape that corresponds to a shape of an outer surface of the inner portion. In some examples, the outer layer may be formed via extrusion into a sheet structure and cut or otherwise reduced to a desired shape, or may be formed via extrusion to have a desired shape of the final outer layer.

Blown extrusion, which may be referred to as blown film extrusion, is a process of extrusion of molten materials and constant inflation of the material to several times its initial diameter. This may result in a thin, tubular product which may be slit to create a flat film. The extrusion may be done via an annular slit die, generally vertically, for the formation of a thin-walled tube. The introduction of air takes place through a hole present in the die's center for blowing up the tube just like a balloon. The cooling of the hot film is done by the high-speed air ring that blows onto it. This air ring is mounted on the top of die.

Cast extrusion includes a molten polymer that travels through a flat die system to adopt its final flat film shape. The die system is formed by the die and feedblock (if the process requires coextrusion) or simply the die, if the process is that of mono-layer extrusion. The process starts with the feeding of plastic resins by means of a gravimetric feeding system to one or more extruders. The materials are then melted and mixed by the extruders, filtered and fed to the die system. Immediately after exiting the die, the molten curtain enters the cooling unit where its temperature is lowered with a water-cooled chill roll to "freeze" the film. The film is then passed downstream where the edges are trimmed, corona treatment is applied (if a fabrication process such as printing or coating is required) and the film is wound into rolls.

In block <NUM>, the one or more outer layer may be coupled to the inner portion. The one or more outer layer may be coupled to the inner portion using any technique such as adhesive, fasteners, an interference or press fit, or the like.

Referring to <FIG>, an example which is not according to the invention, an aircraft component <NUM> may include an inner portion <NUM> and an outer layer <NUM>. An adhesive <NUM> may be applied between the inner portion <NUM> and the outer layer <NUM> and used to couple the outer layer <NUM> to the inner portion <NUM>. In that regard, the adhesive <NUM> resists separation of the outer layer <NUM> from the inner portion <NUM>. The adhesive may be heat-cured, chemically-cured, moisture-cured, anaerobic-cured, or the like.

The outer layer <NUM> may be formed using an extrusion process. In that regard, the outer layer <NUM> may be formed to have a relatively small thickness <NUM>. For example, the total thickness of the outer layer <NUM> may be between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> millimeters (mm) and <NUM>), between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>), or between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>).

The outer layer <NUM> may include a single ply. The material of the outer layer <NUM> may include any elastomeric material. For example, the outer layer <NUM> may include a natural rubber, a synthetic rubber, a silicone, an elastomer, a thermoplastic, a thermoset, a polymeric material, or the like.

Use of the extrusion process results in the outer layer <NUM> being resistant to a relatively wide range of temperatures. Stated differently, use of the extrusion process results in the outer layer <NUM> retaining its physical properties in response to being exposed to a relatively wide range of temperatures. For example, the outer layer <NUM> may be capable of retaining its physical properties in response to being exposed to temperatures between negative one hundred (-<NUM>) degrees Fahrenheit (F) and <NUM> degrees F (-<NUM> degrees Celsius (C) and <NUM> degrees C), between -<NUM> degrees F and <NUM> degrees F (-<NUM> degrees C and <NUM> degrees C), or between -<NUM> degrees F and <NUM> degrees F (-<NUM> degrees C and <NUM> degrees C).

Turning to <FIG>, an example which is not according to the invention, another aircraft component <NUM> may include an inner portion <NUM>, an outer layer <NUM>, and one or more fasteners <NUM>. Whereas the outer layer <NUM> of <FIG> includes a single ply, the outer layer <NUM> of <FIG> includes multiple plies, or multiple outer layers. In particular, the outer layer <NUM> includes a first outer layer <NUM>, a second outer layer <NUM>, and a third outer layer <NUM> stacked on top of each other. The fastener <NUM> may extend through each of the outer layers <NUM>, <NUM>, <NUM> and a portion of the inner portion <NUM> and may fasten each of the outer layers <NUM>, <NUM>, <NUM> the inner portion <NUM> together. In various examples, an adhesive may be used in addition to, or instead of, the fastener <NUM> to couple each of the outer layers <NUM>, <NUM>, <NUM> together.

Each of the outer layers <NUM>, <NUM> is formed using an extrusion process, and may have the same or different thicknesses. The third outer layer <NUM>, if present, may be formed using an extrusion process. Each of the outer layers <NUM>, <NUM>, <NUM> may be formed separately or at the same time using the extrusion process. In some embodiments, a single sheet of outer layer may be formed and may be cut into each of the outer layers <NUM>, <NUM>, <NUM>. In various embodiments, each of the outer layers <NUM>, <NUM>, <NUM> may be formed as separate parts. In various embodiments, each of the outer layers <NUM>, <NUM>, <NUM> may be formed from the same or different materials. For example, each of the outer layers <NUM>, <NUM>, <NUM> may include a natural rubber, or the outer layers <NUM>, <NUM> may include a natural rubber and the outer layer <NUM> may include an elastomer. Each of the outer layers <NUM>, <NUM> may include any one or more of a natural rubber, a synthetic rubber, a silicone, an elastomer, a thermoplastic, a thermoset, a polymeric material, or the like.

Use of the extrusion process allows each of the outer layers <NUM>, <NUM>, <NUM> to have a relatively small thickness. For example, a thickness <NUM> of the each of the outer layers <NUM>, <NUM>, <NUM> may be between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> millimeters (mm) and <NUM>), between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>), or between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>). Additional outer layers may be added in order to achieve a desired thickness of the combined outer layer <NUM>. Because of the separate outer layers <NUM>, <NUM>, <NUM>, a defect in one of the outer layers (e.g., <NUM>) is limited to that layer, and thus the defect is unlikely to extend through the entire outer layer (including the combination of outer layers <NUM>, <NUM>, <NUM>).

Referring now to <FIG>, a method <NUM> for forming a deicer having an elastomeric surface or erosion ply is shown. The method <NUM> may begin in block <NUM> where a body of the deicer is formed. The body, which may also be referred to as a carcass, may be formed using any method such as casting, forging, weaving, sewing, or the like. In various embodiments, the body may be designed to receive a fluid or gas and to inflate in response to receiving such fluid or gas. In that regard, the deicer may be a pneumatic deicer. In various embodiments, the body may be conductive and designed to convert electricity into thermal energy. In that regard, the deicer may be an electrothermal deicer.

The body may include any material such as an elastomeric material (e.g., a neoprene, an elastomer, or the like), a fabric material, or the like.

In block <NUM>, at least one outer layer may be formed using an extrusion process. The outer layer may include an elastomeric material such as a natural rubber, an elastomer, a plastic, a neoprene, a urethane, or the like. In various embodiments, the outer layer may include an aliphatic polyether urethane with a relatively low glass transition temperature (Tg) and a relatively great resistance to ultraviolet light, ozone, and hydrolysis. In various embodiments, the outer layer may include one, two, or more plies coupled together. Each of the plies is formed using the extrusion process. The extrusion process may include any type of extrusion such as blown extrusion or cast extrusion. The outer layer or layers may be formed to have a shape that corresponds to a shape of the body. In various embodiments, the outer layers may be formed via extrusion into a sheet structure and then cut or otherwise reduced to a desired shape, or may be formed via extrusion to have a desired shape of the final outer layer.

In block <NUM>, a bond ply is formed. The bond ply may be formed using any technique and includes any adhesive usable to couple, attached, or fasten the deicer to an aircraft component, such as a wing, nosecone, propeller blade, or the like. In various embodiments, the deicer may be coupled to the aircraft component using a liquid adhesive such that the bond ply is not separately formed. In various embodiments, the bond ply may further include an elastomeric material such as a natural rubber, a neoprene, a urethane, or the like.

In block <NUM>, a natural rubber gum ply is formed. The natural rubber gum ply may be formed using any technique and may include a natural rubber. In various embodiments, the natural rubber gum ply may include another elastomer such as a neoprene, a urethane, or the like.

In various embodiments, the bond ply and the natural rubber gum ply may seal the body. For example, the body may be formed from a fabric material, and the bond ply and the natural rubber gum ply may, together with the body, form an airtight compartment for receiving a gas. In that regard, a separate adhesive may be used to couple the bond ply to the aircraft component.

In block <NUM>, the body, outer layer, bond ply, and natural rubber gum ply are coupled together to form a deicer. These elements may be coupled together using any technique such as fasteners, one or more adhesive, or the like.

In block <NUM>, the deicer may be coupled to a desired location on an aircraft component. For example, the bond ply may be bonded to the desired location in order to fasten the deicer to the desired location on the component.

In block <NUM>, at least one of a power source or a gas source may be coupled to the body. In embodiments in which the deicer is a pneumatic deicer, a gas source may be coupled to the body such that the gas source may provide gas to the body in order to inflate the body. In response to inflation of the body, any ice on the deicer may become cracked and removed from the deicer. In embodiments in which the deicer is an electrothermal deicer, a power source may be coupled to the body such that the power source may provide electricity to the body. In response to receiving the electricity, the deicer may convert the electricity into thermal energy which may in turn melt any ice located on the deicer.

Referring now to <FIG>, a pneumatic deicer <NUM> may be used as a deicer on an aircraft. The pneumatic deicer <NUM> may be formed using a method similar to the method <NUM> of <FIG>. The deicer <NUM> may include a body <NUM>, a bond ply <NUM>, a natural rubber gum ply <NUM>, and an outer layer <NUM>.

The body <NUM> may include a first portion <NUM>, a second portion <NUM>, and a volume <NUM> therebetween. The volume <NUM> may be coupled to a gas source <NUM> such that the volume <NUM> may receive a gas from the gas source <NUM>. In response to receiving the gas, the body <NUM> may expand, thus shattering and removing any ice located on the deicer <NUM>.

The bond ply <NUM> may include any adhesive or other material. The bond ply <NUM> may be coupled to an aircraft component, such as the nosecone <NUM> of <FIG>, in order to couple the deicer <NUM> to the aircraft component.

The natural rubber gum ply <NUM> may include a natural rubber or other elastomer. The natural rubber gum ply <NUM> may be oriented such that the body <NUM> is located between the natural rubber gum ply <NUM> and the bond ply <NUM>.

In various embodiments, the body <NUM> may be formed from a porous material, such as a fabric. In that regard, the bond ply <NUM> and the natural rubber gum ply <NUM> may seal the cavity <NUM> within the body <NUM>, thus reducing the likelihood of leakage of the gas from the body <NUM>. In that regard, the bond ply <NUM> and the natural rubber gum ply <NUM> may be or may include nonporous materials capable of forming an airtight seal.

The outer layer <NUM> includes a first ply <NUM> and a second ply <NUM>. The first ply <NUM> and the second ply <NUM> are each formed using extrusion. In various embodiments, the first ply <NUM> and the second ply <NUM> may be laminated together to form the outer layer <NUM>. Use of two plies provides various benefits and advantages. For example, any defect in the first ply <NUM> or the second ply <NUM> is unlikely to extend through the other of the first ply <NUM> or the second ply <NUM>. Additionally, if a crack forms in the second ply <NUM>, then the first ply <NUM> will act as a crack stopper to reduce the likelihood of the crack extending into the body <NUM> and thus reducing the efficacy of the deicer <NUM>.

The first ply <NUM> may have a first thickness <NUM>, and the second ply <NUM> may have a second thickness <NUM>. The first thickness <NUM> and the second thickness <NUM> may be the same or different. In various embodiments, the first thickness <NUM> and the second thickness <NUM> may be between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>), between <NUM> thousandths of an inch and <NUM> thousandths of an inch (<NUM> and <NUM>), or between three thousandths of an inch and seven thousandths of an inch (<NUM> and <NUM>).

Referring now to <FIG>, an electrothermal deicer <NUM> is shown. The electrothermal deicer <NUM> may have similar features as the pneumatic deicer <NUM> of <FIG>. In particular, the electrothermal deicer <NUM> includes a body <NUM>, a bond ply <NUM>, a natural rubber gum ply <NUM>, and an outer layer <NUM>. The bond ply <NUM>, natural rubber gum ply <NUM>, and outer layer <NUM> may be the same as, or similar to, the corresponding layers in the pneumatic deicer <NUM> of <FIG>.

The body <NUM> may be formed from a conductive material, such as a metal, and may convert electricity into thermal energy (i.e., heat). In that regard, a power source <NUM> may be coupled to the body <NUM> and may provide a voltage or current to the body <NUM>. In response to receiving the voltage or current, the body <NUM> may generate thermal energy. In response to thermal energy being generated by the body, any ice located on the electrothermal deicer <NUM> may melt.

The scope of the disclosure is to be limited by nothing other than the appended claims, 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.

Claim 1:
A method (<NUM>;<NUM>) for forming a deicer (<NUM>), the method comprising:
forming (<NUM>;<NUM>) a body (<NUM>;<NUM>;<NUM>) of the deicer;
forming (<NUM>;<NUM>) an outer layer (<NUM>;<NUM>;<NUM>;<NUM>) of the deicer through extrusion of an elastomeric material; the method characterized in that forming the outer layer of the deicer includes forming a first outer layer (<NUM>) using the extrusion, forming a second outer layer (<NUM>) using the extrusion, and coupling the first outer layer to the second outer layer;
forming (<NUM>) a natural rubber gum ply (<NUM>;<NUM>);
forming (<NUM>) a bond ply (<NUM>;<NUM>);
coupling (<NUM>;<NUM>) the outer layer of the deicer to the body of the deicer, wherein coupling the outer layer of the deicer to the body of the deicer further includes coupling the natural rubber gum ply to the outer layer of the deicer and to the body of the deicer such that the natural rubber gum ply is located between the outer layer and the body; and
coupling the bond ply to the body such that the body is located between the bond ply and the natural rubber gum ply,
wherein the bond ply further comprises an adhesive configured to couple the bond ply to an aircraft component, wherein the bond ply is further configured to couple the deicer to the aircraft component.