Abstract: An electrothermal heater mat (3) is provided for an ice protection system for an aircraft (1) or the like. The heater mat (3) is a laminated heater mat and comprises dielectric layers (50-58), a heater element (501) and a conductive ground plane (71-74) for detecting a fault with the heater element (501). The dielectric layers (50-58) are made of thermoplastic material, and the ground plane (71-74) is formed by spraying metal such as copper onto the thermoplastic material of one of the dielectric layers.

Abstract: A dielectric component with electrical connection is provided for a laminated heater mat (3) for an ice protection system for an aircraft (1). The dielectric component with electrical connection comprises at least one dielectric layer (50, 55) comprising thermoplastic material, and the dielectric layer (50) or a stack of the dielectric layers (50, 55) has first and second main surfaces and a hole (505) extending between the first and second main surfaces. A first sprayed metal coating (501) comprises a first portion (503) deposited on the first main surface (502) adjacent to the hole (505) and a second portion (5014) which projects into the hole. A second sprayed metal coating (5013, 5513) comprises a third portion deposited on the second main surface (506, 552) adjacent to the hole (505) and a fourth portion (5015) which projects into the hole (505). The second portion (5014) overlaps the fourth portion (5015) to form a continuous conductive path between the first main surface and the second main surface.

Abstract: An electrothermal heater mat (3) is provided for an ice protection system for an aircraft (1) or the like. The heater mat (3) is a laminated heater mat and comprises dielectric layers (50-58), a heater element (501) and a temperature sensor (507). Each dielectric layer (50-58) comprises thermoplastic material, and the temperature sensor (507) comprises a sprayed metal track (5010, 5012) deposited on a substrate (50, 5019) comprising thermoplastic material. The substrate may be one of the dielectric layers (50) or a separate carrier (5019) which is smaller than the dielectric layers (50-58).

Abstract: An electrothermal heater mat (3) is provided for an ice protection system for an aircraft (1) or the like. The heater mat (3) is a laminated heater mat and comprises dielectric layers (50-58), a heater element (501) and a conductive ground plane (71-74) for detecting a fault with the heater element (501). The dielectric layers (50-58) are made of thermoplastic material, and the ground plane (71-74) is formed by spraying metal such as copper onto the thermoplastic material of one of the dielectric layers.

Abstract: An electrothermal heater mat (3) is provided for an ice protection system for an aircraft (1) or the like. The heater mat (3) is a laminated heater mat and comprises dielectric layers (50-58), a heater element (501) and a temperature sensor (507). Each dielectric layer (50-58) comprises thermoplastic material, and the temperature sensor (507) comprises a sprayed metal track (5010, 5012) deposited on a substrate (50, 5019) comprising thermoplastic material. The substrate may be one of the dielectric layers (50) or a separate carrier (5019) which is smaller than the dielectric layers (50-58).

Abstract: A dielectric component with electrical connection is provided for a laminated heater mat (3) for an ice protection system for an aircraft (1). The dielectric component with electrical connection comprises at least one dielectric layer (50, 55) comprising thermoplastic material, and the dielectric layer (50) or a stack of the dielectric layers (50, 55) has first and second main surfaces and a hole (505) extending between the first and second main surfaces. A first sprayed metal coating (501) comprises a first portion (503) deposited on the first main surface (502) adjacent to the hole (505) and a second portion (5014) which projects into the hole. A second sprayed metal coating (5013, 5513) comprises a third portion deposited on the second main surface (506, 552) adjacent to the hole (505) and a fourth portion (5015) which projects into the hole (505). The second portion (5014) overlaps the fourth portion (5015) to form a continuous conductive path between the first main surface and the second main surface.

Abstract: An electrothermal heater (2) for an ice protection system for an aircraft (1) or the like is provided with improved protection against lightning strikes. The heater (2) comprises a laminated heater mat (3) formed from dielectric layers (51-54) and a heater element (501). A first connector (41) has a first end (415) which is embedded in the heater mat (3) and is electrically connected to the heater element (501) and a second end which extends away from the heater mat for connection to a heater control unit (6). The heater mat (3) further includes first and second conductive ground planes (71, 72) and the first end (415) of the first connector (41) is positioned between the first and second ground planes so as to be shielded thereby and so as to reduce the current induced therein during a lightning strike.