Method to create carbon nanotube heaters with varying resistance

Abstract

A method for creating a carbon nanotube heater assembly includes creating a carbon nanotube heater with varying resistances and attaching the carbon nanotube heater to both carrier and encapsulating materials. Creating the carbon nanotube heater with varying resistances is accomplished by applying a carbon nanotube mixture to a substrate, adjusting the thickness or width of the carbon nanotube mixture, and drying the nanotube mixture.

1 . A method for creating a carbon nanotube heater assembly comprising:
 creating a carbon nanotube heater having a varying resistance along a length of the carbon nanotube heater, the step of creating the carbon nanotube heater comprising:
 applying a carbon nanotube coating to a substrate; 
 adjusting the thickness and width of the carbon nanotube coating such that the thickness and width of the carbon nanotube coating varies along the substrate to vary the resistance of the carbon nanotube coating along the substrate; and 
   drying the carbon nanotube coating on the substrate;   attaching a first side of the carbon nanotube heater to a carrier material;   covering a second side of the carbon nanotube heater opposite the first side with an encapsulating material; and   bonding, with an adhesive layer, the encapsulating material to an aircraft part.   
     
     
         2 . The method of  claim 1 , wherein adjusting the at least one of the thickness and the width of the carbon nanotube coating is performed using a tool. 
     
     
         3 . The method of  claim 2 , wherein adjusting the thickness of the carbon nanotube coating is performed by controlling a gap between the tool and the substrate, such that the thickness of the carbon nanotube coating is controlled. 
     
     
         4 . The method of  claim 2 , wherein adjusting the thickness of the carbon nanotube coating further comprises creating at least two different thicknesses. 
     
     
         5 . The method of  claim 2 , wherein the tool has a curvature such that the carbon nanotube coating is contoured when the at least one of the thickness and the width is adjusted. 
     
     
         6 . The method of  claim 1 , wherein adjusting the at least one of the thickness and the width of the carbon nanotube coating is performed by spraying the carbon nanotube coating onto the substrate with a nozzle. 
     
     
         7 . The method of  claim 6 , wherein the nozzle is configured to be adjusted to allow varying of the at least one of the thickness and the width of the carbon nanotube coating. 
     
     
         8 . The method of  claim 6 , wherein the nozzle is programmed to apply the carbon nanotube coating to an aircraft part according to a curvature of the aircraft part. 
     
     
         9 . The method of  claim 1 , wherein adjusting the at least one of the thickness and the width of the carbon nanotube coating is performed by printing. 
     
     
         10 . The method of  claim 1 , wherein the width of the carbon nanotube coating is adjusted by masking one or more parts of the substrate and applying the carbon nanotube coating to parts that are not masked. 
     
     
         11 . The method of  claim 1 , wherein the width of the carbon nanotube coating is adjusted by applying a pattern to the substrate, the pattern determining density of the carbon nanotube coating on the substrate. 
     
     
         12 . The method of  claim 9 , wherein the printing allows varying the at least one of the thickness and the width of the carbon nanotube coating along the substrate. 
     
     
         13 . The method of  claim 9 , wherein the printing allows varying contours of the carbon nanotube coating according to a curvature of an aircraft part.