Heater assembly for deicing and/or anti-icing a component

Abstract

A heater assembly for deicing and/or anti-icing a component includes a metallic heating element adjacent to a densely woven fabric layer impregnated with a resin that is capable of withstanding temperatures of up to 550° F. (288° C.).

1 . An electrothermal heater assembly suitable for anti-icing and deicing a gas turbine engine component, the electrothermal heater assembly comprising: 
 a metallic heating element; and    a densely woven fabric layer adjacent to the metallic heating element and impregnated with a resin capable of withstanding a heater assembly operating temperature of up to 550° F., wherein the fabric layer includes a fabric material selected from a group consisting of a fiberglass fabric, a ceramic fiber fabric, polymer film, and combinations thereof; and    wherein the fabric material accounts for about 45 to about 70 percent by volume of the fabric layer.    
   
   
       2 . The heater assembly of  claim 1 , wherein the resin is selected from a group consisting of: bismaleimide, phthalonitrile, cyanate ester, polyimide adhesive, and polyimide resin.  
   
   
       3 . (canceled)  
   
   
       4 . The heater assembly of  claim 1 , wherein the fabric layer is less than about 0.005 inches thick.  
   
   
       5 . The heater assembly of  claim 1 , wherein the metallic heating element is a titanium heating element.  
   
   
       6 . The heater assembly of  claim 1 , wherein the heating element has a watt density in a range of about 1 to about 50 watts/in 2 .  
   
   
       7 . The heater assembly of  claim 1 , wherein the metallic heating element is adhered to the fabric layer with an adhesive selected from a group consisting of: the resin and a thermoset adhesive.  
   
   
       8 . The heater assembly of  claim 1 , wherein the metallic heating element is about 0.5 to about 40 mils thick.  
   
   
       9 . The heater assembly of  claim 1 , wherein the fabric layer exhibits a thermal conductivity value of about 10.1 BTU-in/hr-ft 2 -° F.  
   
   
       10 - 20 . (canceled)  
   
   
       21 . An electrothermal heater assembly suitable for anti-icing and deicing a gas turbine engine component, the electrothermal heater assembly comprising: 
 a metallic heating element wherein the heating element has a watt density in a range of about 1 to about 50 watts/in 2 , and wherein the metallic heating element is about 0.5 to about 40 mils thick; and    a densely woven fabric layer adjacent to the metallic heating element and impregnated with a resin capable of withstanding a heater assembly  0 operating temperature of up to 550° F., wherein the fabric layer includes a fabric material selected from a group consisting of a fiberglass fabric, a ceramic fiber fabric polymer film, and combinations thereof; and    wherein the fabric material accounts for about 45 to about 70 percent by volume of the fabric layer wherein the fabric layer is less than about 0.005 inches thick, and wherein the fabric layer exhibits a thermal conductivity value of about 10.1 BTU-in/hr-ft 2 -° F.    
   
   
       22 . The heater assembly of  claim 21 , wherein the resin is selected from a group consisting of bismaleimide, phthalonitrile, cyanate ester, polyimide adhesive, and polyimide resin.  
   
   
       23 . The heater assembly of  claim 21 , wherein the metallic heating element is a titanium heating element.  
   
   
       24 . The heater assembly of  claim 21 , wherein the fabric material accounts for about 45 to about 70 percent by volume of the fabric layer.  
   
   
       25 . An electrothermal heater assembly suitable for anti-icing and deicing a gas turbine engine component, the electrothermal heater assembly comprising: 
 a metallic heating element having first and second surfaces, a watt density in a range of about  1  to about  50  watts/in 2 , and a thickness of about 0.5 to about 40 mils; and    a first densely woven fabric layer adhered to the first surface the metallic heating element and impregnated with a resin capable of withstanding a heater assembly operating temperature of up to 550° F., wherein the fabric layer includes a fabric material selected from a group consisting of a fiberglass fabric, a ceramic fiber fabric, polymer film, and combinations thereof, the first fabric layer being positioned to make direct contact with a portion of the gas turbine engine component.    
   
   
       26 . The heater assembly of  claim 25 , wherein the fabric layer is less than about 0.005 inches thick.  
   
   
       27 . The heater assembly of  claim 25 , wherein the metallic heating element is a titanium heating element.  
   
   
       28 . The heater assembly of  claim 25 , wherein the fabric layer exhibits a thermal conductivity value of about 10.1 BTU-in/hr-ft 2 -° F.  
   
   
       29 . The heater assembly of  claim 25 , wherein the fabric material accounts for about 45 to about 70 percent by volume of the fabric layer.  
   
   
       30 . The heater assembly of  claim 25 , and further comprising: 
 a second densely woven fabric layer positioned adhered to the second surface of the metallic heating element and impregnated with a resin capable of withstanding a heater assembly operating temperature of up to 550° F., wherein the fabric layer includes of a fabric material selected from a group consisting of a fiberglass fabric, a ceramic fiber fabric, a polymer film, and combinations thereof.