Hybrid Material Air Data Probe With Conductive Inserts for Deicing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Pitot tubes face challenges in effectively preventing and removing ice accumulation due to their large surface area and inlet diameter, which leads to inefficient heating and potential failure in operation.
Innovation Solution
Incorporating thermally conductive inserts made from materials like annealed pyrolytic graphite, graphite, or copper, coated with chromium or nickel, into the pitot tube structure via direct energy metal deposition to enhance heat transfer and ice melting, while ensuring adhesion and preventing oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a typical pitot tube with large surface area and inlet diameter is used, then it can effectively measure airspeed, but ice accumulation occurs on the tip portion and ice crystals are ingested, causing operational failure
Solution Approach 1:
The patent applies local quality by creating a hybrid material structure where a thermally conductive material (such as copper or aluminum) is selectively positioned in the tip portion of the pitot tube. This localized thermal conductivity enhancement allows efficient heat transfer from the heating element to the tip surface, preventing ice accumulation in the critical measurement area without requiring the entire tube to be made of high-conductivity material.
Solution Approach 2:
The patent employs composite materials by combining a base pitot tube material (typically plastic or composite) with an insert of thermally conductive material. This composite structure provides both the mechanical properties needed for the tube body and the thermal conductivity required in the tip portion, resolving the contradiction between measurement effectiveness and ice prevention.
2Object-affected harmful factors
If heating elements are added to prevent ice accumulation, then ice prevention capability is improved, but the large surface area of the tip portion makes effective heating difficult and energy consumption increases
Solution Approach 1:
By concentrating the thermally conductive material in the tip portion where ice accumulation occurs, the patent achieves efficient heat transfer locally without requiring high power heating elements. The localized thermal conductivity enhancement allows lower energy consumption compared to heating the entire tube surface.
Solution Approach 2:
The thermally conductive insert acts as an intermediary between the heating element and the external environment. It efficiently conducts heat from the heating element to the tip surface, improving heating effectiveness and reducing energy losses, thereby preventing ice accumulation with lower energy consumption.
3Productivity
If the inlet diameter is increased to improve measurement capability, then more air flow is captured, but proportionally more ice crystals are ingested, increasing the risk of operational failure
Solution Approach 1:
The patent changes the thermal parameter (conductivity) of the tip portion material to improve heat transfer efficiency. This allows the system to handle increased ice crystal ingestion by rapidly melting them through efficient thermal conduction, maintaining reliability despite larger inlet diameter for improved productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution improves heat transfer rates within the pitot tube, effectively preventing ice accumulation and ensuring reliable operation by embedding thermally conductive inserts and applying a coating to enhance bonding and prevent oxidation.
Implementation Method 1
the second material has a higher thermal conductivity than the first material
Implementation Method 2
The probe body is formed from a first material by direct energy metal deposition
Implementation Method 3
a coating portion of a chromium or nickel material at least partially fills the one or more through holes
Data Source
AI summary
An air data probe includes a probe body including a probe wall. The probe body is formed from a first material by direct energy metal deposition. An insert is positioned in the probe wall. The insert is formed from a second material different from the first material. The insert is encapsulated in the probe wall via the direct energy metal deposition. A method of forming an air data probe includes forming one or more thermally conductive inserts, and encapsulating the one or more inserts into a wall of an air data probe via direct energy metal deposition. The air data probe is formed from a first material and the one or more inserts are formed from a second material different from the first material.