Air Data Probe Thin Film Heating System Icing Prevention
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Solution Overview
Problem
External air data probes face malfunctions due to icing in extreme cold weather, and conventional brazing methods for heating elements are costly, difficult, and prone to manufacturing yield loss, leading to local cold spots and potential malfunctions.
Innovation Solution
A thin film heating system is attached to the inner and outer housings of air data probes using thermally conductive adhesives, providing uniform heating and reducing manufacturing costs and yield loss, with the system being adaptable for various air data probes and vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing metal heating elements to air data probes is used, then heating capability is achieved, but manufacturing complexity and cost increase, and manufacturing yield decreases
Solution Approach 1:
The patent replaces the mechanical brazing process with a thermal conduction system using thermally conductive adhesive. Instead of using heat and pressure to join metal elements through metallurgical bonding, the invention uses a thermally conductive material to transfer heat from heating elements to the air data probe surface, simplifying the manufacturing process and reducing complexity.
Solution Approach 2:
The patent changes the bonding method from high-temperature metallurgical joining to a lower-temperature adhesive bonding process. This parameter change in the joining temperature and method allows for easier manufacturing, reduced equipment requirements, and improved manufacturing yield while maintaining heating capability.
2Reliability
If brazing metal heating elements is used, then heating function is provided, but local cold spots occur on the probe surface
Solution Approach 1:
The patent introduces a thermally conductive adhesive as an intermediary material between the heating elements and the air data probe surface. This intermediary ensures efficient and uniform heat transfer across the entire contact area, eliminating local cold spots that occur with brazing while maintaining the heating function.
3Reliability
If brazing process is used for heating elements, then heating capability is achieved, but manufacturing cost increases and production yield decreases
Solution Approach 1:
The patent replaces the complex brazing mechanical system with a simpler adhesive bonding system. This substitution eliminates the need for specialized brazing equipment, reduces process steps, and improves manufacturing yield by providing a more forgiving and easier-to-control bonding process.
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 thin film heating system offers more uniform heating and higher production yields compared to brazed metal elements, effectively preventing icing and ensuring reliable air data probe operations in extreme cold conditions.
Implementation Method 1
A thin film heating system attached by a thermally conductive adhesive to the inner and outer housings of an air data probe
Implementation Method 2
A thin film heating system attached by a thermally conductive adhesive to the inner and outer housings of an air data probe
Data Source
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AI summary
In one embodiment, an air data probe is provided. The air data probe comprises an inner body having an outer surface, an outer body having an inner surface, a thin film heating system having a first surface and a second surface, a first thermally conductive adhesive disposed between the first surface and the outer surface, a second thermally conductive adhesive disposed between the second surface and the inner surface; and wherein the thin film heating system comprises one or more thin film heaters having one or more heating elements disposed in a thermally conductive, electrical insulator.