Air Data Probe Housing Retention for Thermal Expansion Control
Find Innovative SolutionsGenerate Solutions
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 with retention features is used to stabilize the potting material within the air data probe, preventing excessive expansion and maintaining electrical connections by using an additive manufacturing process to create a lattice structure that intertwines with the potting material, minimizing its volume and expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If heating elements are used to prevent ice accretion on the air data probe, then ice prevention is improved, but excessive heat causes damage to materials and electrical connections
Solution Approach 1:
The patent introduces potting material as an intermediary substance that surrounds and protects electrical connections from excessive heat. This potting material acts as a thermal buffer, absorbing and distributing the heat generated by heating elements, thereby preventing direct thermal damage to electrical connections while allowing the probe to maintain sufficient heat for ice prevention.
Solution Approach 2:
The patent employs composite construction by combining different materials with complementary properties: the probe housing uses materials resistant to thermal expansion, electrical connections are embedded in heat-resistant potting material, and heating elements are positioned to distribute heat evenly. This composite approach allows the system to withstand high temperatures without compromising electrical connection integrity.
2Object-affected harmful factors
If heating elements are used to prevent ice accretion on the air data probe, then ice prevention is improved, but materials within the probe expand at different rates causing potential failures
Solution Approach 1:
The patent applies local quality by using different materials with appropriate thermal expansion properties in different locations within the probe. Critical components that are highly sensitive to thermal expansion are surrounded by potting material with matching expansion characteristics, while other areas use materials designed to withstand higher expansion. This localized material selection minimizes differential expansion stresses.
Solution Approach 2:
The patent addresses thermal expansion by carefully selecting materials with complementary thermal expansion coefficients and designing the structure to accommodate controlled expansion. The potting material is specifically chosen to have expansion properties that match or complement the surrounding components, thereby reducing differential expansion. The heating system is also controlled to maintain temperature within parameters that limit excessive expansion.
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 ensures that the electrical connections within the air data probe remain functional during heating, preventing damage and ensuring accurate data transfer to the aircraft's systems.
Implementation Method 1
Some aircraft air data probes are heated to prevent rain, ice, or other moisture from attaching to the probe
Implementation Method 2
there are materials and components within the air data probes in which excess heat is detrimental
Implementation Method 3
A housing with retention features is used to stabilize the potting material within the air data probe, preventing excessive expansion
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
In some applications, aircraft air data probes are heated to prevent rain, ice, or other moisture from attaching to the air data probe. The body (36) of the air data probe (10) and the components positioned within the body of the air data probe can be constructed from differing materials, resulting in differing coefficient of thermal expansions for each component. Retention features (54) are added to a housing to prevent an epoxy potting (34) from expanding outside its intended region and preventing damage to the electronic components within the housing.