The present disclosure relates to heated panels, and more particularly to heated floor panels such in aircraft.
Positive thermal coefficient (PTC) materials increase in electrical resistance as their temperature rises. PTC materials are useful in heating panels such as used in heating air craft floors, due to their intrinsic limits on temperature. Carbon-based PTC heaters for aircraft floor panels are traditionally fabricated by screen printing a PTC-based ink in a desired heating element pattern as a layer in a series of layers making up the panel. Screen printing requires preparation of the screen, and an excess amount of ink is required for the screen printing process, i.e. more ink must go into the process than actually ends up in the floor panel. The balance of the ink used in the process must be disposed of.
Aircraft floor panels are subject to a wide variety of impacts from dropped objects both sharp and blunt in nature. A floor panel must also be resistant to knife cuts as part of installation and maintenance of the floor panel. A floor panel's ability to withstand both impact and knife cuts is important for promoting a robust floor panel. Traditional surface layer materials used in composite panels are usually unable to withstand repeated or high load impacts as well as knife cuts.
The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved heated panels and process for making the same. This disclosure provides a solution for this need.
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.
The core can include at least one of a honeycomb structure and/or a foam material. The structural facing can be a first structural facing, and a second structural facing can be bonded to the core opposite the heater/dielectric layer. The first structural facing and the second structural facing can each include carbon fiber impregnated with a resin, wherein the resin includes at least one of a thermoplastic material and/or a thermoset material.
An impact layer can be bonded to the structural facing, e.g., the first structural facing described above, opposite the heater/dielectric layer. The impact layer can include at least one of a monolithic metal, a monolithic polymer, a resin-impregnated metal, and/or a resin-impregnated polymer fabric. The heater/dielectric layer can be bonded directly to the core without any intervening layers aside from an adhesive or bonding agent, and the heater/dielectric layer can be bonded directly to the structural facing without any intervening layers aside from an adhesive or bonding agent
A method of making a heater panel includes bonding a heater/dielectric layer that includes a PTC heater layer to directly to a core. The method includes bonding a structural facing directly to the heater/dielectric layer opposite the core so the heater/dielectric layer is bonded directly between the core and the structural facing.
The structural facing can be a first structural facing, and the method can include bonding a second structural facing to the core opposite the heater/dielectric layer. The method can include bonding an impact layer to the structural facing opposite the heater/dielectric layer.
These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a heater panel in accordance with the disclosure is shown in
The heater panel 100 includes a core 102 and a heater/dielectric layer 104. The core 102 includes at least one of a honeycomb structure and/or a foam material. As shown in
Referring again to
An impact layer 114 is bonded to the first structural facing 110 opposite the heater/dielectric layer 104. The impact layer 114 includes at least one of a monolithic metal such as aluminum or titanium, a monolithic polymer, a resin-impregnated metal, and/or a resin-impregnated polymer fabric. Suitable monolithic polymer materials include thermoplastics such as polyetheretherketone, polyaryletherketones, polycarbonate, polyphenylene sulfide, polyetherimide, polyimide, polymethylmethacrylate (acrylic), polyvinylchloride, polyurethane, polyamideimide and thermoset materials such as epoxy, phenolic, BMI, benzoxazine, and polyurethane. The foregoing polymers can be mixed, and can have reinforcement such as aramids (such as Kevlar fibers and Nomex fibers available from DuPont of Wilmington, Del.), fiberglass, basalt, carbon fiber, carbon nanotube, nano steel, steel wire, and titanium wire. Any of the foregoing polymers can be impregnated into the reinforcements assuming temperature compatibility.
A method of making a heater panel, e.g., heater panel 100, includes bonding a heater/dielectric layer, e.g., heater/dielectric layer 104, that includes a PTC heater layer, e.g., PTC heater layer 106, to directly to a core, e.g., core 102. The method includes bonding a structural facing, e.g., structural facing 110, directly to the heater/dielectric layer opposite the core so the heater/dielectric layer is bonded directly between the core and the structural facing.
The method includes bonding a second structural facing, e.g., second structural facing 112, to the core opposite the heater/dielectric layer. The method includes bonding an impact layer, e.g., impact layer 114, to the first structural facing opposite the heater/dielectric layer.
As shown in
The methods and systems of the present disclosure, as described above and shown in the drawings, provide for heater with superior properties relative to traditional heater panels including lighter weight, longer life, improved thermal efficiency, and improved robustness. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.
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