Air Data Probe Housing Retention Features for Potting Expansion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Excess heat from air data probes can damage materials and components within the probe, particularly affecting the electrical connections and potting materials, leading to potential disconnection and loss of data transfer during flight.

Innovation Solution

Incorporation of a housing with retention features, manufactured via additive manufacturing, which includes a lattice structure of retention features to minimize the expansion of potting material, ensuring it remains within its intended adhesion area and maintains electrical connections under high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heating element is used to prevent ice accretion on the air data probe, then the probe functionality is maintained, but the potting material and electrical connections inside the probe are damaged due to excessive heat

Engineering Contradiction:

Improveprobe functionalityVSAvoidheat damage to internal components

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The housing is segmented into multiple sections with retention features (ridges, grooves, protrusions) that create distinct zones for positioning and securing potting material and electrical connections. This segmentation allows different internal components to be isolated and protected at specific locations within the housing, preventing uniform heat exposure damage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retention features are pre-designed into the housing structure before assembly, creating protective positions for electrical connections and potting material. These features cushion and restrain components against thermal expansion and movement before heat damage can occur, ensuring their integrity during heating operations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Stability of the object's composition

If the potting material is allowed to expand freely under heat, then thermal stress is reduced, but electrical connections become disconnected and data transfer is lost

Engineering Contradiction:

Improvepotting material thermal stabilityVSAvoidelectrical connection integrity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The housing incorporates localized retention features at specific positions where electrical connections and potting material interface. These features provide localized constraint and support exactly where needed to maintain connection integrity, while allowing the rest of the potting material to accommodate thermal expansion freely.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The housing combines different geometric features (ridges, grooves, protrusions) within a single structure to create multiple functional zones. This composite design allows simultaneous thermal management and mechanical retention, accommodating both the expansion needs of potting material and the stability requirements of electrical connections.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If traditional housing designs are used without retention features, then manufacturing is simpler, but internal components cannot be securely positioned under thermal expansion

Engineering Contradiction:

Improvehousing manufacturing simplicityVSAvoidcomponent positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The retention features are designed with specific geometric parameters (ridge heights, groove depths, protrusion dimensions) that are optimized for the expected thermal expansion range of the potting material. These parameterized features provide precise component positioning while maintaining compatibility with standard manufacturing processes for the housing material.

Inventive Principle:

Principle #35Parameter changes

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 retention features prevent the potting material from expanding excessively, maintaining functional electrical connections and ensuring accurate data transfer during heating conditions, enhancing the robustness and reliability of the air data probe.

Implementation Method 1

A heating element is positioned within the body of the air data probe, and the heating element is configured to increase a temperature of the body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the housing includes a plurality of retention features positioned within the housing body... minimize the expansion of potting material, ensuring it remains within its intended adhesion area

Methodology Applied

Scientific EffectThermal expansion constraint: Thermal Expansion

Data Source

PatentUS12479583B2Air data probe electronics housing with retention features

Publication Date: 2025.11.25 ROSEMOUNT AEROSPACE INC

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 of the air data probe 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 are added to a housing to prevent an epoxy potting from expanding outside its intended region and preventing damage to the electronic components within the housing.