Additive Manufacturing Air Data Probe Heater Integration

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Solution Overview

Problem

Traditional air data probes face challenges in maintaining heater assembly integrity and dielectric material durability due to casting processes, especially in cold environments, which can affect the accuracy of air speed measurements.

Innovation Solution

The use of additive manufacturing techniques to embed heater elements directly within the wall of the air data probe, allowing for closer proximity to the outer surface and improved thermal conductivity, while utilizing a dielectric material that effectively transmits heat and maintains electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heater elements are mounted within the inner periphery of the wall, then electrical insulation is maintained, but thermal conductivity and proximity to outer surface are reduced

Engineering Contradiction:

Improveheater assembly integrityVSAvoidthermal conductivity

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent combines the heater element, dielectric material, and wall structure into a single integrated component manufactured via additive manufacturing. This merging eliminates the need for separate mounting structures and allows the heater to be positioned optimally within the wall while maintaining electrical insulation through the integrated dielectric material.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dielectric material serves as an intermediary between the heater element and the wall outer surface. It provides necessary electrical insulation while allowing thermal energy to pass through to the outer surface, thus maintaining both electrical safety and thermal conductivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If casting processes are used to embed heater elements, then integration is achieved, but degradation of heater assembly and dielectric material occurs

Engineering Contradiction:

Improveintegration of heater elementsVSAvoidheater assembly durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the traditional casting process with additive manufacturing technology. This substitution allows for precise placement of heater elements and dielectric material without subjecting them to the high temperatures and mechanical stresses of casting, thereby preventing degradation and maintaining component integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The manufacturing process parameters are fundamentally changed from high-temperature casting to controlled additive manufacturing conditions. This parameter change enables the integration of heat-sensitive components like heater elements and dielectric materials without exposing them to damaging thermal and mechanical conditions.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If heater elements are positioned closer to the outer surface, then thermal response is improved, but electrical insulation requirements increase

Engineering Contradiction:

Improvethermal responseVSAvoidelectrical insulation structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The dielectric material and wall structure are merged into a single integrated component through additive manufacturing. This combination provides electrical insulation without requiring separate insulation layers or complex structures, thus maintaining thermal response while ensuring electrical safety.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach enhances the operational reliability and accuracy of air speed measurements by ensuring consistent heater performance and reducing degradation issues, leading to a more robust and precise air data probe.

Implementation Method 1

utilizing an additive manufacturing technique to lay down a conductive portion of a heater element within the wall

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

improved thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a dielectric material and casing is often placed between the electric heater element and the material forming the wall separated by the casing

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Data Source

PatentEP3009847B1One-piece air data probe

Publication Date: 2017.08.02 ROSEMOUNT AEROSPACE INC

Figure 1~2C

AI summary

A method of forming an air data probe (22) comprises the steps of utilizing an additive manufacturing technique to lay down a portion of a wall (34) of an air data probe, and also utilizing an additive manufacturing technique to lay down a conductive portion (44) of a heater element (40) within the wall (34). An air data probe is also disclosed.