The invention includes a composite ice protection heater for an aircraft.
The composite heater includes at least one electrically insulating layer,
and at least one electric heater element comprising an electrically
conductive layer bonded to the insulating layer. The conductive layer may
include a pre-impregnated woven fabric that includes a plurality of
threads that include an electrically conductive material, such as carbon
or graphite fibers. The composite heater can be incorporated into a
composite surface structure of an aircraft. The conductive layer and
insulating layer may include a plurality of spaced openings through the
layers that cooperate with an underlying open-cell matrix to attenuate
noise at the associated surface of an aircraft. A desired electrical
resistance of the conductive layer may be obtained by introducing a
plurality of discontinuities in the layer, such as spaced holes or slits.