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EP-4253012-B1 - LASER WELDED PNEUMATIC DEICER BOOTS FOR AIRCRAFT

EP4253012B1EP 4253012 B1EP4253012 B1EP 4253012B1EP-4253012-B1

Inventors

  • DATTATRI, SHYAM KUMAR
  • VENKATESHAIAH, HARISH
  • PATIL, Rhushikesh
  • NANJUNDEGOWDA, HARSHAVARDHANA

Dates

Publication Date
20260506
Application Date
20230320

Claims (11)

  1. A method of manufacture for a pneumatic deicer boot, comprising: aligning a non-stretchable fabric layer (208) and a stretchable fabric layer (210) at a welding position; generating a concentrated laser; focusing the concentrated laser along a first weld line (214) to laser weld together the stretchable fabric layer and the non-stretchable fabric layer, wherein the first weld line (214) includes a plurality of air passage gaps to assist in even inflation and deflation between adjacent inflatable tubes of a plurality of inflatable tubes; and focusing the concentrated laser along a second weld line (216) to laser weld together the stretchable fabric layer (210) and the non-stretchable fabric layer (208), wherein the second weld line (216) includes a plurality of air passage gaps to assist in even inflation and deflation between the adjacent inflatable tubes of the plurality of inflatable tubes, wherein a first gap remains between the stretchable fabric layer (210) and the non-stretchable fabric layer (208), and wherein the first gap, the first weld line (214) and the second weld line (216) form a first inflatable tube of the plurality of inflatable tubes; bonding an installation layer to the non-stretchable fabric layer (208) of the inflatable carcass; wherein the non-stretchable fabric layer (208) comprises nylon coated with a first polymeric coating compound; wherein the stretchable fabric layer (210) comprises nylon coated with a second polymeric coating compound; and wherein the second polymeric coating compound is thicker than the first polymeric coating compound.
  2. The method of manufacture of claim 1, wherein the method of manufacture further comprises forming a polymer layer on the stretchable fabric layer (210) of the inflatable carcass.
  3. The method of manufacture of claim 2, wherein the method of manufacture further comprises forming a weathering layer on the polymer layer.
  4. The method of manufacture of claim 3, wherein the method of manufacture further comprises bonding an air inlet to the installation layer.
  5. The method of manufacture of claim 4, wherein the concentrated laser is an infrared laser.
  6. A pneumatic deicer boot (200), comprising: an installation layer (204); and an inflatable carcass (206), comprising: a non-stretchable fabric layer (208); a stretchable fabric layer (210), wherein the non-stretchable fabric layer (208) and the stretchable fabric layer (210) are laser welded together at a first weld line (214) and a second weld line (216), wherein the first weld line (214) includes a plurality of air passage gaps to assist in even inflation and deflation between adjacent inflatable tubes of a plurality of inflatable tubes and wherein the second weld line (216) includes a plurality of air passage gaps to assist in even inflation and deflation between the adjacent inflatable tubed of the plurality of inflatable tubes; and a first inflatable tube (228) of the plurality of inflatable tubes formed by a gap between the first weld line (214) and the second weld line (216); wherein the non-stretchable fabric layer (208) comprises nylon coated with a first polymeric coating compound; wherein the stretchable fabric layer (210) comprises nylon coated with a second polymeric coating compound; and wherein the second polymeric coating compound is thicker than the first polymeric coating compound.
  7. The pneumatic deicer boot of claim 9, wherein the pneumatic deicer boot (200) further comprises a polymer layer (220).
  8. The pneumatic deicer boot of claim 7, wherein the pneumatic deicer boot further comprises a weathering layer (222).
  9. The pneumatic deicer boot of claim 8, wherein the pneumatic deicer boot further comprises a manifold (302) in fluid communication with the first inflatable tube (228).
  10. The pneumatic deicer boot of claim 9, wherein the pneumatic deicer boot further comprises an air inlet (304) disposed at the installation layer (204) and in fluid communication with the manifold (302).
  11. A pneumatic deicer system, comprising: a pneumatic deicer boot, as claimed in claim 6; an air inlet (304) coupled to the installation layer (204) and in fluid communication with the first inflatable tube (228); and a compressed air source in fluid communication with the air inlet (304).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to, and the benefit of, India Provisional Patent Application No. 202241019968, filed April 1, 2022 (DAS Code 62BD) and titled "LASER WELDED PNEUMATIC DEICER BOOTS FOR AIRCRAFT". FIELD This disclosure relates generally to pneumatic deicers for aircraft, more specifically, deicer boots which are laser welded. BACKGROUND Pneumatic deicer boots are a type of ice protection system installed on aircraft to allow deicing in flight. The deicing boots may consist of thick polymer, stretchable composite materials and non-stretchable composite materials installed to the leading edge of any lifting or control surface, such as wings and stabilizers. As atmospheric icing occurs and ice builds up, the pneumatic deicer boot may pressurize and inflate. Pneumatic deicer boots typically rely on compressed air for inflation. Cooled bleed air may be used to inflate the deicing boots. EP 3 219 464 relates to an ultrasonic welding process for an airfoil deicer. US 5 310 142 relates to a deicer assembly. SUMMARY A method of manufacture for a pneumatic deicer boot is disclosed herein. In various embodiments, the method of manufacture can comprise forming an installation layer, forming an inflatable carcass, and bonding the installation layer to the non-stretchable fabric layer of the inflatable carcass. In various embodiments, the forming of the inflatable carcass can comprise aligning a non-stretchable fabric layer and a stretchable fabric layer at a welding position, generating a concentrated laser; focusing the concentrated laser along a first weld line to laser weld together the stretchable fabric layer and the non-stretchable fabric layer, focusing the concentrated laser along a second weld line to laser weld together the stretchable fabric layer and the non-stretchable fabric layer, wherein a gap remains between the stretchable fabric layer and the non-stretchable fabric layer. In various embodiments, the gap, the first weld line and the second weld line form a first inflatable tube. In various embodiments, the concentrated laser can be an infrared laser. In various embodiments, the method of manufacture can further comprise forming a polymer layer on the stretchable fabric layer of the inflatable carcass. In various embodiments, the method of manufacture can further comprise forming a weathering layer on the polymer layer. In various embodiments, the method of manufacture can further comprise bonding an air inlet to the installation layer. The non-stretchable fabric layer comprises nylon coated with a first polymeric coating compound. The stretchable fabric layer comprises nylon coated with a second polymeric coating compound. The second polymeric coating compound is thicker than the first polymeric coating compound. A pneumatic deicer boot is disclosed herein. In various embodiments, the pneumatic deicer can comprise an installation layer and an inflatable carcass. In various embodiments, the inflatable carcass can comprise a non-stretchable fabric layer, a stretchable fabric layer, and an inflatable tube. In various embodiments, the non-stretchable fabric layer and the stretchable fabric layer can be laser welded together at a first weld line and a second weld line. In various embodiments, the pneumatic deicer boot can further comprise a polymer layer. In various embodiments, the pneumatic deicer boot can further comprise a weathering layer. In various embodiments, the pneumatic deicer boot can further comprise a manifold in fluid communication with the first inflatable tube. In various embodiments, the pneumatic deicer boot can further comprise an air inlet disposed at the installation layer and in fluid communication with the manifold. The non-stretchable fabric layer comprises nylon coated with a first polymeric coating compound. The stretchable fabric layer comprises nylon coated with a second polymeric coating compound. The second polymeric coating compound is thicker than the first polymeric coating compound. A pneumatic deicer system is disclosed herein. The pneumatic deicer system can comprise a pneumatic deicer boot and a compressed air source in fluid communication with the pneumatic deicer boot. In various embodiments, the pneumatic deicer boot can comprise an installation layer, an inflatable carcass bonded to the installation layer, and an air inlet coupled to the installation layer. In various embodiments, the inflatable carcass can further comprise a non-stretchable fabric layer, a stretchable fabric layer, wherein the non-stretchable fabric layer and the stretchable fabric layer are laser welded together at a first weld line and a second weld line, and a first inflatable tube. In various embodiments, the air inlet can be in fluid communication with the first inflatable tube. The non-stretchable fabric layer comprises nylon coated with a first polymeric coating compound. The stretchable fabric layer comprises nylon coated with a second