Air Data Probe Housing with Air-Gap Isolation Against Thermal Expansion

Solution Overview

Problem

Existing air data probes face damage from excessive heat due to heating elements, which can cause materials within the probes to expand at different rates, leading to potential electrical connection failures.

Innovation Solution

A housing design with an inner and outer wall and an air gap between them, manufactured using additive manufacturing, minimizes heat absorption by potting material, preventing excessive expansion and maintaining electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heating elements are used to prevent ice accretion on the air data probe, then ice prevention is improved, but thermal damage to internal materials and components worsens

Engineering Contradiction:

Improveice preventionVSAvoidthermal damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The housing is divided into inner and outer walls with a gap between them, creating separate thermal zones. This segmentation allows the outer housing to be heated for ice prevention while the inner housing remains thermally isolated to protect sensitive components from excessive heat.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The air gap between the inner and outer housing walls acts as a thermal intermediary or insulator. This gap reduces heat transfer from the heated outer housing to the inner housing, protecting internal components while still allowing the outer housing to reach temperatures necessary for ice prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If excessive heat is applied to the air data probe to ensure no ice accretion, then ice prevention is improved, but material expansion and electrical connection failures worsen

Engineering Contradiction:

Improveice preventionVSAvoidmaterial expansion

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The housing is divided into inner and outer walls with a gap between them, creating separate thermal zones. This segmentation allows the outer housing to be heated for ice prevention while the inner housing remains thermally isolated to protect sensitive components from excessive heat.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The air gap between the inner and outer housing walls acts as a thermal intermediary or insulator. This gap reduces heat transfer from the heated outer housing to the inner housing, protecting internal components while still allowing the outer housing to reach temperatures necessary for ice prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 housing design ensures the electronic components within the air data probe remain functional by reducing heat-induced expansion, allowing the probe to accurately transfer data during heating conditions.

Implementation Method 1

An inner wall is offset from an outer wall such that a gap is positioned between the inner wall and the outer wall

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP4306429B1Air data probe electronics housing with thermal isolating features

Publication Date: 2025.08.27 ROSEMOUNT AEROSPACE INC

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Figure 2A

AI summary

In some applications, aircraft air data probes (10) are heated to prevent rain, ice, or other moisture from attaching to the air data probe, ensuring proper functionality of the air data probe. But the elevated temperatures can have negative effects on the electronic components positioned within the air data probe. Therefore, thermal isolating features are added to a housing to thermally isolate the heated parts of the air data probe from the electronic components within the air data probe, which are required to stay relatively cool for proper functioning.