A method of manufacturing a de-icer assembly includes positioning a first welded-material layer and a second welded-material layer between a die and a die base of a die-based welding system, wherein at least one of the die and the die base includes a welded-portion pattern configured to weld the first welded-material layer to the second welded-material layer in the pattern such that inflatable portions are formed within the welded-portion pattern formed in the de-icer assembly between non-welded sections of the first welded-material layer and the second welded-material layer, pressing the first welded-material layer and the second welded-material layer together between the die and die base, and applying high energy to the die-based welding system using a high energy source such that the first welded-material layer and the second welded-material layer are welded together at the areas in the shape of the welded-portion pattern to form a welded de-icer assembly.

An electro-pneumatic de-icer for an airfoil includes an electrically-powered compressor for compressing air, an air-storage tank for storing compressed air, a source of negative pressure, an airfoil pneumatic boot, and a control valve located between 1) the air-storage tank, 2) the source of negative pressure, and 3) the pneumatic boot for cycling between compressed air to inflate the pneumatic boot and negative pressure to deflate the pneumatic boot for cracking accumulated ice on the airfoil. An airfoil de-icing method lacking engine bleed air extraction includes compressing air with an electrically-powered compressor, storing high-pressure air from the compressor in an air-storage tank, delivering high-pressure air from the air-storage tank to inflate a pneumatic boot located along an airfoil, providing a negative-pressure source, deflating the pneumatic boot with the negative-pressure source, and alternating between inflating and deflating the pneumatic boot for cracking accumulated ice on the airfoil.

An anti-icing system may comprise a deicing boot of an elastomeric material comprising a plurality of tubes, wherein the deicing boot comprises a first set of tubes and a second set of tubes, wherein each of the first set of tubes and the second set of tubes have a corresponding end, and wherein the corresponding end is coupled to a continuous dual wrap end closure.

A method for forming an aircraft component includes forming an inner portion of the aircraft component. The method further includes forming an outer layer of the aircraft component using extrusion of an elastomeric material. The method further includes coupling the outer layer of the aircraft component to the inner portion of the aircraft component.

Ice may form along the leading edge of an aircraft wing or horizontal and vertical stabilizers. A pneumatic deicer system may be configured to inflate and dislodge ice along the leading edge of lift and control surfaces. The pneumatic deicer system may comprise a laser welded deicing boot attached to the leading edge. The compressed air can be directed to the deicing boot, inflating the deicing boot along inflatable tubes formed by laser welds, which can crack and dislodge the ice. A method of manufacturing a laser welded pneumatic deicer boot is also disclosed.

An anti-icing system may comprise a deicing boot of an elastomeric material comprising a plurality of tubes, wherein the deicing boot comprises a first set of tubes and a second set of tubes, wherein each of the first set of tubes and the second set of tubes have a corresponding end, and wherein the corresponding end is coupled to a continuous dual wrap end closure.

A method for forming an aircraft component includes forming an inner portion of the aircraft component. The method further includes forming an outer layer of the aircraft component using extrusion of an elastomeric material. The method further includes coupling the outer layer of the aircraft component to the inner portion of the aircraft component.

A de-icer is provided and includes first and second structural layers that each include centerline and a non-inflatable edge angled with respect to the centerline, edge sealing material disposed to adhere the first and second structural layers together to form a non-inflatable edge area extending along at least the non-inflatable edge and surrounding a central area and stitching. The stitching is disposed to stitch the first and second structural layers together in the central area to form tubes. The tubes include an outermost tube which is closest to and parallel with the non-inflatable edge.

An aircraft flight surface deicing system includes an electromagnetic field generator and a deicing boot configured for attachment to an aircraft flight surface. The boot includes: one or more inflation regions including a first inflation region; one or more magnetic fluid reservoirs in fluid communication with the first inflation region, the one or more fluid reservoirs including a first fluid reservoir; a magnetic fluid contained in a combination of the first inflation regions and the one or more magnetic fluid reservoirs. In a first state, the magnetic fluid is contained in the first fluid reservoir and, in a deicing state, the electromagnetic field generator generates one or more fields that cause the magnetic fluid to exit the first fluid reservoir and travels along a length of the inflation region.

A pneumatic deicing device (1) for breaking and removing an ice deposit accumulated on the outer surface (2) of an aircraft, in particular on an airplane wing. The device (1) includes an outer layer (10) intended to withstand the outside environment, an inner interface layer (50) intended to be bonded to the outer surface of the aircraft, and at least two outer (30) and inner (40) intermediate layers connected to one another by a network of stitches (36) spaced apart to define deicing chambers (35) that can be inflated using injected pressurized air so as to create an expansion of the device causing a mechanical action to break the ice. The inner interface layer (50) with the outer surface (2) of the aircraft includes at least one textile layer (54) having an inner surface (55) intended to be in direct contact with an outer surface (2) of the aircraft.