Ceramic Probe Head With Embedded Heater for Air Data Ice Control

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Solution Overview

Problem

Existing air data probes face challenges in efficiently arranging heaters within the probe head due to manufacturing limitations and issues such as corrosion, thermal fatigue, and oxidation, particularly at the tip where ice accumulation is prevalent, affecting heating efficiency and reliability.

Innovation Solution

The integration of a ceramic body with embedded heaters using a high temperature co-fired ceramic process allows for tailored heat distribution and improved heater positioning, reducing power requirements and enhancing reliability by embedding heaters within the ceramic body, which is made of materials like aluminum nitride, and incorporating features like posts and water dams to manage ice and water accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional heater arrangements are used in probe heads, then manufacturing is simpler, but heating efficiency and reliability deteriorate due to corrosion, thermal fatigue, and oxidation

Engineering Contradiction:

Improveheater reliabilityVSAvoidheater arrangement complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heater is merged with the ceramic body through co-firing, creating an integrated structure where the heater becomes part of the ceramic matrix. This eliminates separate heater components that are susceptible to corrosion and thermal fatigue, thereby improving reliability while the co-firing process manages manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite material construction by embedding heater elements within the ceramic body. The ceramic matrix provides corrosion and oxidation resistance while the embedded heater provides heating function, creating a composite structure that improves reliability without requiring complex separate arrangements

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If heaters are positioned at the probe tip for effective ice prevention, then heating efficiency improves, but susceptibility to corrosion and thermal fatigue increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidcorrosion and thermal fatigue

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The ceramic body provides localized protection to the heater elements at the probe tip through its inherent corrosion and oxidation resistance. The local quality of the ceramic material at the heater location shields the heater from harmful environmental factors while maintaining heating efficiency

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The ceramic body acts as a protective barrier before the heater is exposed to corrosive and thermal environments. By embedding the heater within the ceramic structure beforehand, the invention provides prior cushioning against corrosion and thermal fatigue that would otherwise affect heaters positioned at the exposed probe tip

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If ceramic body with embedded heaters is used, then heater reliability and heat distribution improve, but manufacturing complexity increases due to high temperature co-fired ceramic process

Engineering Contradiction:

Improveheater reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process merges the heater fabrication and ceramic body formation into a single co-firing operation. This combines multiple steps (heater assembly, ceramic molding, firing) into one integrated process, improving reliability while managing device complexity through process integration

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If uniform heater distribution is used, then manufacturing is easier, but tailored heat distribution for ice management is insufficient

Engineering Contradiction:

Improveheater arrangement easeVSAvoidheat distribution customization

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The embedded heater configuration allows different regions of the ceramic body to have different heating characteristics. The heater can be designed with varying power densities in different zones to match local ice accumulation patterns, providing tailored heat distribution while the ceramic embedding simplifies the overall manufacturing process

Inventive Principle:

Principle #3Local quality

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 solution provides efficient, reliable, and cost-effective heating with rapid temperature response, minimizing heater failure and ensuring accurate pressure measurements by customizing heat distribution and managing ice and water effectively, thus improving the operational integrity of air data probes.

Implementation Method 1

heaters are positioned within air data probes to ensure the air data probes function properly in liquid water, ice crystal, and mixed phase icing conditions

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The probe head includes a ceramic body and a heater embedded within the ceramic body

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3835793B1Ceramic probe head for an air data probe

Publication Date: 2025.10.22 ROSEMOUNT AEROSPACE INC

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AI summary

A probe head (100) for an air data probe includes a ceramic body (116) and a heater (118) embedded within the ceramic body (116).