Abstract: The present invention is directed to a coated substrate including a substrate that is part of an aerospace, a wind turbine, or a marine structure; and an exterior coating on the substrate, the exterior coating including an icephobic or a low ice adhesion composition including an indicator that is an additive that is detectable or measurable as the exterior coating wears; wherein the indicator provides indicia of wear of the exterior coating; and a method of inspecting the exterior coating on the substrate.

Abstract: Provided are embodiments for method and system for performing an integrated ice protection with prognostics and health management using fiber optic sensors. Embodiments can include reading a signal from each sensor of an array of sensors installed on a surface of a structure or equipment, wherein each sensor is a fiber optic sensor, and generating a map based on reading the signal from each sensor, wherein the map monitors a condition of the surface detected by each sensor. Embodiments can also include determining at least one of an abnormal condition or a failure based at least in part on reading the signal from each sensor; and performing at least one of adjusting power control for the structure or equipment or communicating the abnormal condition or failure of the structure or equipment.

Abstract: A method of making an adhesive for an ice protection assembly includes transferring Z-CNTs from a substrate carrier into the adhesive. De-bonding of the adhesive for ice protection assembly inspection or repair or repositioning at initial installation includes heating the Z-CNTs in the adhesive to soften the adhesive and allow for easy removal.

Abstract: Disclosed is a first method of providing a heating system to an outer skin of an aircraft, that has the steps of forming laser-induced graphene (LIG) on a polymer sheet by directing laser energy towards the polymer sheet; coupling electrical leads to the LIG; and bonding the polymer sheet against the outer skin or erosion protection layer secured to the outer skin so that to the polymer sheet conforms with a shape of the outer skin.

Abstract: A de-icing assembly for a surface of an aircraft includes: a carcass with a first layer, a second layer, and a carcass centerline and a plurality of seams sewn into the carcass, wherein the plurality of seams join the first and second layers of the carcass together. The assembly includes a plurality of inflation passages formed by the plurality of seams and disposed between the first and second layers of the carcass. The system also includes a manifold fluidly connected to and disposed beneath the carcass, the manifold comprising a width and a manifold centerline oriented approximately perpendicular or parallel to the carcass centerline.

Abstract: A heater panel includes a core and a heater/dielectric layer including a positive thermal coefficient (PTC) heater layer between a pair of dielectric layers. A structural facing is included, wherein the heater/dielectric layer is bonded directly between the core and the structural facing. A second structural facing can be bonded to the core opposite the heater/dielectric layer. An impact layer can be bonded to the structural facing, e.g., the first structural facing described above, opposite the heater/dielectric layer. The heater layer can be formed by direct writing a heating element pattern onto a dielectric layer bonded to the core.

Abstract: A carbon allotrope element includes a carbon allotrope layer formed from a carbon allotrope material impregnated with a dielectric resin and having a first surface. The carbon allotrope element further includes a first bus bar in communication with the first surface, and a second bus bar in communication with the first surface and non-adjacent to the first bus bar. The first surface includes a layer of the dielectric resin and a plurality of abraded regions, and each of the first and second bus bars is in communication with one of the plurality of abraded regions of the first surface.

Abstract: A heated floor panel assembly for aircraft includes an impact layer made from a 2-D or 3-D woven high temperature thermoplastic fiber matrix impregnated with a resin. The impact layer can further include woven metallic fibers. The assembly also includes a stack of structural layers, a heating layer, and a core layer for absorbing shear stress.

Abstract: A heated floor panel assembly for aircraft includes an impact layer made from a 2-D or 3-D woven high temperature thermoplastic fiber matrix impregnated with a resin. The impact layer can further include woven metallic fibers. The assembly also includes a stack of structural layers, a heating layer, and a core layer for absorbing shear stress.

Abstract: A heater panel includes a core. A heater/dielectric layer including a positive thermal coefficient (PTC) heater layer between a pair of dielectric layers is bonded to the core in a stack. An impact layer is bonded to the stack, wherein the impact layer includes a first sub-layer for impact absorption that is bonded to the stack and a second sub-layer for cut resistance bonded to the first sub-layer. The second sub-layer has a higher material hardness than that of the first-sub layer.

Abstract: A method of coating a high-pressure fluid vessel comprises filling a high-pressure fluid vessel with a coating solution, draining the coating solution, and drying a remainder of the coating solution in the high-pressure fluid vessel. The coating solution may include a thermoplastic elastomer that is hard with a low glass transition temperature and a high melting temperature. Drying the remainder of the coating solution may form a food grade coating within the high-pressure fluid vessel.

Abstract: An ice protection system may include a blade and an electrothermal heater including a carbon nanotube (CNT) element and a metal element. The CNT element may be a CNT fabric or a CNT yarn. The metal element may be coupled to the CNT element via a metallization process, or the like. The electrothermal heater element may include an electric sheet resistivity between 0.01 and 0.5 ohms/square.

Abstract: A heating element includes a first bus bar disposed to receive current from a power source, and a second bus bar non-adjacent to the first bus bar. The heating element further includes a polymer ink section extending between the first and second bus bars, and the section includes a plurality of PTC polymer inks each different from one another. The second bus bar is electrically connected to the first bus bar via the polymer ink section.

Abstract: A method for reducing the resistivity of a carbon nanotube nonwoven sheet includes providing a carbon nanotube nonwoven sheet comprising a plurality of carbon nanotubes and applying pressure to the carbon nanotube nonwoven sheet to reduce air voids between carbon nanotubes within the carbon nanotube nonwoven sheet.

Abstract: A heating element includes a first bus bar disposed to receive current from a power source, and a second bus bar non-adjacent to the first bus bar. The heating element further includes a polymer ink section extending between the first and second bus bars, and the section includes a plurality of PTC polymer inks each different from one another. The second bus bar is electrically connected to the first bus bar via the polymer ink section.

Abstract: A conformable tank includes a body with a plurality of walls defining a cavity in the body, and an internal support connected to an internal surface of one of the plurality of wall of the body and protruding into the cavity of the body. The body and the internal support are an additively manufactured integral structure formed by a fiber filament reinforced composite material.

Abstract: A carbon allotrope element includes a carbon allotrope layer formed from a carbon allotrope material impregnated with a dielectric resin and having a first surface. The carbon allotrope element further includes a first bus bar in communication with the first surface, and a second bus bar in communication with the first surface and non-adjacent to the first bus bar. The first surface includes a layer of the dielectric resin and a plurality of abraded regions, and each of the first and second bus bars is in communication with one of the plurality of abraded regions of the first surface.

Abstract: Additively manufactured heating elements for tubes are made from a positive temperature coefficient heater ink printed on the tube. A bus bar is likewise printed onto the tube using a conductive ink. The positive temperature coefficient heater ink and bust bar conductive ink are encapsulated with a closing adhesive.

Abstract: An internal heating trace assembly may include a first bus bar, a second bus bar, a plurality of ceramic positive temperature coefficient (PTC) elements, and an insulator. The ceramic PTC elements may be disposed in parallel between the first bus bar and the second bus bar. The insulator may include a heat-shrink tubing. The ceramic PTC element may include a PTC strip or a PTC bead.

Abstract: A conductive ink may comprise a high temperature thermoplastic polyurethane (TPU) and a plurality of conductive particles disposed in the high temperature TPU. The plurality of conductive particles may comprise between 60% and 95% of the conductive ink by weight. The high temperature TPU may include a melting point between 120° C. and 200° C. The conductive ink may be used for external heated composite structures, such as rotor blades, fixed wings, faring, engine lip electrothermal ice protection, or the like. The conductive ink may have enhanced mechanical fatigue resistance.