Weld-Sealed Air Data Probe Insert for Heater Corrosion Protection

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Solution Overview

Problem

Air data probes, such as pitot probes, face heater failure due to corrosion from environmental contamination, as the heater is exposed to moisture and contaminants, leading to reduced functionality and frequent replacement needs.

Innovation Solution

A probe head design that includes an insert with a groove for the heater, an outer shell surrounding the insert and heater, and a tip weld sealing the heater between the insert and outer shell, hermetically encapsulating the heater to prevent exposure to contaminants and improve heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heater is exposed to the environment for functionality, then the heater can perform its heating function, but the heater is susceptible to corrosion from environmental contamination

Engineering Contradiction:

Improveheater reliabilityVSAvoidcorrosion from environmental contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The probe head is divided into separate components: an insert containing the heater and a separate outer shell. This segmentation allows the heater to be isolated within the insert while the outer shell provides environmental protection, resolving the contradiction between heater exposure for functionality and protection from corrosion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The outer shell acts as an intermediary barrier between the heater and the external environment. It provides hermetic sealing that protects the heater from moisture and contaminants while allowing the heater to maintain its heating function, thus resolving the contradiction between functionality and corrosion protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the heater is sealed to prevent corrosion, then the heater is protected from environmental contamination, but heat transfer may be reduced

Engineering Contradiction:

Improveprotection from moisture and contaminantsVSAvoidheat transfer efficiency

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The outer shell is designed as a thin-walled structure that provides hermetic sealing to protect the heater from contaminants. The thin wall design minimizes thermal resistance, allowing effective heat transfer from the heater through the shell while maintaining environmental protection, thus resolving the contradiction between sealing and heat transfer.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a hermetic seal is implemented around the heater, then the heater is protected from corrosion, but the device complexity increases

Engineering Contradiction:

Improveheater protection from corrosionVSAvoidprobe head structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insert and outer shell are designed to mate together through welding and brazing, combining two components into a hermetically sealed assembly. This merging approach provides corrosion protection while keeping the overall structure relatively simple and manufacturable, resolving the contradiction between reliability and device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 design effectively seals the heater from moisture and contaminants, reducing corrosion and improving heat transfer, thereby enhancing the reliability and longevity of air data probes in harsh environments.

Implementation Method 1

The tip weld is between the outer shell and the first end of the insert

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The portion of the heater is hermetically sealed between the insert and the outer shell

Methodology Applied

Scientific EffectHermetic sealing:

Implementation Method 3

heaters are positioned within pitot probes to ensure the pitot probes function properly in rain and icing environments

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 4

the braze is between the insert and the second end of the outer shell adjacent a second end of the insert

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS11428707B2Air data probe with weld sealed insert

Publication Date: 2022.08.30 ROSEMOUNT AEROSPACE INC

AI summary

A probe head of an air data probe includes an insert, a portion of a heater, an outer shell, a tip weld, and a braze. The insert includes a first end, a second end opposite the first end, and a body portion extending between the first end and the second end. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the insert and the portion of the heater. The outer shell includes a tip portion defining a first end of the outer shell and a body portion extending from the tip portion defining a second end of the outer shell. The tip weld is between the outer shell and the first end of the insert, and the braze is between the insert and the second end of the outer shell adjacent a second end of the insert. The portion of the heater is hermetically sealed between the insert and the outer shell.