Aircraft Wing De-Icing System Delivers Faster Thermal Response with Thin-Film Heater Technology

Ice formation on aircraft surfaces creates significant operational and safety concerns. Preventing in-flight icing requires a de-icing solution capable of delivering rapid, controlled, and uniform heat while minimizing weight and performance impacts.

EGC collaborated with NASA and leading aircraft manufacturers to address in-flight icing challenges for small aircraft. The project focused on developing an aircraft wing de-icing system capable of improving thermal performance and efficiency compared to conventional metallic resistance heating elements.

The Challenge

Traditional aircraft de-icing systems can create design and performance limitations.

Some approaches rely on de-icing boots or liquid-based systems that can introduce operational drawbacks, including:

• Added system complexity
• Chemical handling requirements
• Potential weight penalties
• Performance drag
• Limited heating effectiveness across large surface areas

The challenge was to develop a heating solution capable of providing rapid, even heating across large wing surfaces while maintaining temperature control and minimizing operational limitations.

The Solution

EGC utilized its thermoelectric thin-film PTC heater technology to create an electrically controlled aircraft wing de-icing system designed for rapid and even heat distribution.

The flexible electrically conductive graphite foil technology was designed to avoid many limitations associated with traditional boot or liquid de-icing systems.

The system was designed to:

• Heat large surface areas without significant weight penalties
• Deliver targeted heating to individual zones
• Automatically break the bond between ice and the heater surface during each cycle
• Control energy delivery across leading-edge and shed zones independently
• Support AC or DC variable input voltages up to 480 VAC

Results & Benefits

The aircraft de-icing system delivered measurable improvements in thermal performance and operational efficiency.

Key results and benefits included:

• Up to 35% faster thermal response than conventional metallic heater elements
• Temperature stability typically maintained within ±3% across the surface
• Watt densities up to 100 W/in²
• Instant temperature rise capability
• Automatic shedding cycles
• Digitally controlled operation
• All-electric design with no weeping chemical emissions
• Parting strip and shed zone design that virtually eliminates runback
• Designed for AC or DC variable input voltages up to 480 VAC
• STC on Columbia 400/350/300 and Cessna Corvalis 400/350; STC on Cirrus SR-22 pending

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