Anti-icing stack

Abstract

Anti-icing stacks for protecting an aerodynamic surface are described. In some embodiments, an anti-icing stack includes an anti-icing layer, an elastomeric erosion protection layer, and an additional layer. The erosion protection layer is disposed between the anti-icing layer and the additional layer. The additional layer has a thickness greater than the thickness of the erosion protection layer and a tensile modulus of no more than the tensile modulus of the erosion protection layer. The additional layer may be a foam adhesive layer.

1 . An aerodynamic surface comprising an edge portion and an anti-icing stack disposed on the edge portion, wherein the anti-icing stack comprises:
 a first layer being an erosion protection layer having an elongation at break as determined according to ASTM test standard D882-12 of greater than 100%;   a foam adhesive layer having a tensile modulus as determined according to ASTM test standard D882-12 of less than 5 MPa, the foam adhesive layer bonding the first layer to the edge portion of the aerodynamic surface, the foam adhesive layer having a thickness of at least 600 micrometers, wherein the thickness of the foam adhesive layer is at least 50% of a total thickness of the anti-icing stack, and   a second layer disposed on the first layer opposite the foam adhesive layer, the second layer being an anti-icing layer.   
     
     
         2 . The aerodynamic surface of  claim 1 , wherein the first layer is a polyurethane-based elastomer, and the second layer comprises either a polysiloxane acrylate copolymer or a polyurethane, an organic thickener, and an ice-release additive. 
     
     
         3 . An anti-icing stack comprising:
 an anti-icing layer;   an elastomeric erosion protection layer; and   an additional layer, wherein the additional layer is a foam layer;   wherein the erosion protection layer is disposed between the anti-icing layer and the additional layer,   wherein the additional layer has a thickness greater than a thickness of the erosion protection layer and a tensile modulus as determined according to ASTM test standard D882-12 of no more than a tensile modulus as determined according to ASTM test standard D882-12 of the erosion protection layer.   
     
     
         4 . The anti-icing stack of  claim 3 , wherein the tensile modulus of the additional layer is no more than 0.5 times the tensile modulus of the erosion protection layer. 
     
     
         5 . The anti-icing stack of  claim 4 , wherein the thickness of the additional layer is greater than 2 times the thickness of the erosion protection layer. 
     
     
         6 . A method of reducing an ice adhesion of an erosion protection layer for an aerodynamic surface, the method comprising:
 disposing a first intermediate layer between the erosion protection layer and the aerodynamic surface, the first intermediate layer comprises a foam adhesive having a thickness greater than a thickness of the erosion protection layer, and a tensile modulus as determined according to ASTM test standard D882-12 of no more than a tensile modulus as determined according to ASTM test standard D882-12 of the erosion protection layer, and   disposing an anti-icing layer on the erosion protection layer opposite the first intermediate layer.   
     
     
         7 . The method of  claim 6 , wherein the step of disposing an anti-icing layer on the erosion protection layer comprises coating and then drying an anti-icing coating composition on the erosion protection layer, the anti-icing coating composition comprising either a polysiloxane acrylate copolymer or a polyurethane dispersion, an organic thickener, a film-forming additive, and an ice-release additive. 
     
     
         8 . The method of  claim 6 , wherein the first intermediate layer has a thickness greater than 2 times a thickness of the erosion protection layer. 
     
     
         9 . The method of  claim 6 , wherein disposing the first intermediate layer between the erosion protection layer and the aerodynamic surface comprises disposing the first intermediate layer on an edge portion of the aerodynamic surface. 
     
     
         10 . The method of  claim 7 , wherein the first intermediate layer has a thickness greater than 2 times a thickness of the erosion protection layer. 
     
     
         11 . The method of  claim 7 , wherein disposing the first intermediate layer between the erosion protection layer and the aerodynamic surface comprises disposing the first intermediate layer on an edge portion of the aerodynamic surface. 
     
     
         12 . The method of  claim 8 , wherein disposing the first intermediate layer between the erosion protection layer and the aerodynamic surface comprises disposing the first intermediate layer on an edge portion of the aerodynamic surface. 
     
     
         13 . The method of  claim 10 , wherein disposing the first intermediate layer between the erosion protection layer and the aerodynamic surface comprises disposing the first intermediate layer on an edge portion of the aerodynamic surface.