Patent Description:
Some aircraft air data probes are heated to prevent rain, ice, or other moisture from attaching to the probe, which could negatively impact the functionality of the air data probe. In many cases, the heat is elevated to extremely hot temperatures to ensure there is no ice accretion on the air data probe during flight of the aircraft. However, there are materials and components within the air data probes in which excess heat is detrimental. As such, there is a need for preventing damage to the materials and components positioned within the heated air data probes. <CIT> relates to heating of air data probes for icing prevention under cold weather conditions.

According to the disclosure, the invention is defined by an air data probe as claimed in claim <NUM>.

According to the disclosure, a housing for surrounding electrical components within an air data probe configured to gather data during flight of an aircraft is described. The housing includes an upper surface, a lower surface, an inner surface, an outer surface, a rim positioned adjacent the upper surface, and a lower body positioned adjacent the lower surface. An inner wall is offset from an outer wall such that a gap is positioned between the inner wall and the outer wall. The inner wall and the outer wall converge and are coupled adjacent the lower body of the housing body.

<FIG> is a side view of air data probe <NUM> used on an aircraft (not shown). <FIG> is a partial cross-sectional view of housing <NUM> positioned within air data probe <NUM> taken along Section A-A of <FIG>. <FIG> will be discussed together. Further, hereinafter, air data probe <NUM> will be referred to as probe <NUM>, but it is to be understood that probe <NUM> is referring to air data probe <NUM>. Probe <NUM> is a device which detects or measures a physical property and records, initiates, or otherwise responds to the detected or measured physical property. In some examples, probe <NUM> can be used to detect the total air temperature, air pressure, air velocity, and/or air density, among other properties not specifically described, during flight of an aircraft. Further, in some examples, probe <NUM> can be positioned at the nose cone of an aircraft such that probe <NUM> is positioned partially within the skin of the aircraft and partially outside the skin of the aircraft.

Since a portion of probe <NUM> is positioned outside the skin of the aircraft, probe <NUM> can experience harsh operating conditions including, but not limited to low operating temperatures, ice, rain, sleet, snow, etc. In some examples, to ensure proper functionality of probe <NUM>, probe <NUM> can be heated to prevent ice, rain, or other precipitation from accumulating on probe <NUM> during flight of the aircraft. Heating probe <NUM> can melt ice on probe <NUM>, allowing the precipitation to blow off probe <NUM> during flight conditions. Further, heating probe <NUM> can facilitate evaporation of any precipitation on probe <NUM> during flight conditions. Probe <NUM> is configured to gather air data during flight of the aircraft, providing the pilots of the aircraft critical information during flight conditions. As such, it is important that probe <NUM> is functioning properly and providing the pilots of the aircraft accurate information.

Referring to <FIG>, probe <NUM> includes body <NUM>, flange <NUM>, electrical connector <NUM>, inlet <NUM>, and outlet <NUM>. Body <NUM> is the main structure of probe <NUM> that protects the components within probe <NUM> from environmental conditions. In some examples, body <NUM> can be constructed from at least one metallic material. In other examples, body <NUM> can be constructed from a ceramic material, a polymeric material, and/or a composite material. With that said, the following discussion with focus on an embodiment in which body <NUM> is constructed from a metallic material. Body <NUM> includes inlet <NUM> positioned at a distal end of probe <NUM> and outlet <NUM> positioned generally at a central portion of probe <NUM>. Inlet <NUM> is positioned at a first distal end of probe <NUM>. More specifically, inlet <NUM> is positioned at the distal end of probe <NUM> positioned outside the skin of the aircraft. Inlet <NUM> can be an aperture extending through body <NUM>, allowing air from outside the aircraft to enter and flow through inlet <NUM> into body <NUM>. The air that flows through inlet <NUM> proceeds by flowing through body <NUM> and then exits body <NUM> by flowing outwards through outlet <NUM>. Outlet <NUM> can be an aperture that extends through body <NUM>, allowing air from within body <NUM> to flow out through outlet <NUM> to exit probe <NUM>. In some examples, as shown, outlet <NUM> can be positioned generally at the central portion of probe <NUM> adjacent flange <NUM>.

Flange <NUM> is positioned adjacent outlet <NUM> generally at a central portion of probe <NUM>. Flange <NUM> extends outwards from the main portions of body <NUM> and flange <NUM> extends fully around an outer surface of body <NUM> of probe <NUM>. As such, flange <NUM> is a flat rim or collar extending outwards from body <NUM> around an exterior of body <NUM>. In some examples, flange <NUM> can have a circular cross-section viewing in the axial direction along probe <NUM>. In other examples, flange <NUM> can have a cross-section of any geometric shape. Flange <NUM> is the feature of probe <NUM> that separates the portions of probe <NUM> positioned within and positioned outside the skin of an aircraft. More specifically, the portion of probe <NUM> including inlet <NUM> and outlet <NUM> is positioned on the outside of the skin of the aircraft and the portion of probe <NUM> including electrical connector <NUM> is positioned on the inside of the skin of the aircraft. Electrical connector <NUM> can be any electrical connector that creates an electrical connection between probe <NUM> and electronics on an aircraft. As shown in <FIG>, in some examples electrical connector <NUM> can include a threaded connection for securing probe <NUM> to an aircraft electrical system.

Referring to <FIG>, which is a partial cross-sectional view of probe <NUM> taken along Section A-A of <FIG>, probe <NUM> also includes heating element <NUM>, sensing probe <NUM>, sensing base <NUM>, electrical wires <NUM>, electrical leads <NUM>, housing <NUM>, and potting <NUM>, each of which are positioned within body <NUM> of housing <NUM>. In the example shown, probe <NUM> includes one heating element <NUM> wrapped around an outer surface of probe <NUM>. In another example, probe <NUM> can include more than one heating element <NUM>. In the example shown, heating element <NUM> is wrapped around an outer surface of probe <NUM> to facilitate melting of ice or evaporation of fluid on outer surfaces of probe <NUM>. Heating element <NUM> can be an electrical resistance heating element that increases in temperature when an electrical current is transferred to the electrical resistance heating element. In some examples, heating element <NUM> can be electrical wires or electrical pads, among other options, that increase in temperature when an electrical current is transferred to heating element <NUM>, such that heating element <NUM> increases the temperature of body <NUM>.

Sensing probe <NUM> and sensing base <NUM> are components of probe <NUM> positioned within body <NUM> and generally aligned with a central axis of probe <NUM>. Sensing probe <NUM> is the component of probe <NUM> which detects or measures a physical property of the air flowing through probe <NUM>. More specifically, air from outside the aircraft flows through inlet <NUM> into body <NUM> and follows the flow path, indicated by the arrows in <FIG>, through body <NUM> to outlet <NUM>. As such, the air flowing through probe <NUM> flows past sensing probe <NUM> within body <NUM> and sensing probe <NUM> can gather the desired data from the air flow before the air exits probe <NUM> through outlet <NUM>. Sensing probe <NUM> is coupled to sensing base <NUM> to secure sensing probe <NUM> in a fixed position during operation of probe <NUM>. Further, sensing base <NUM> is coupled to internal surfaces or features of body <NUM> to secure both sensing base <NUM> and sensing probe <NUM> in a fixed position during operation of probe <NUM> on an aircraft.

Electrical wires <NUM> are electrically coupled to and extend from a distal end of sensing probe <NUM> positioned within housing <NUM> of probe <NUM>. Electrical wires <NUM> are configured to transfer data gathered by sensing probe <NUM> to an electrical system and/or a controller on an aircraft. More specifically, a plurality of electrical wires <NUM> are electrically coupled to a plurality of electrical leads <NUM>, and the plurality of electrical leads <NUM> are coupled to electrical connector <NUM> of probe <NUM>. As such, air data gathered by sensing probe <NUM> is transferred through electrical wires <NUM>, through electrical leads <NUM>, through electrical connector <NUM>, and to an electrical controller system of an aircraft. Therefore, electrical wires <NUM>, electrical leads <NUM>, and electrical connector <NUM> allow the transfer of data from sensing probe <NUM> to an aircraft, and breaking the electrical connection between any of the components can prevent the transfer of data from sensing probe <NUM> to an aircraft. As such, maintaining the electrical connection between electrical wires <NUM>, electrical leads <NUM>, and electrical connector <NUM> is critical to maintaining proper functioning of probe <NUM>.

Housing <NUM> is positioned within body <NUM> of probe <NUM> and housing <NUM> is coupled to body <NUM> of probe <NUM>. In some examples, housing <NUM> can be coupled to internal surfaces or features of body <NUM> through a welded connection. As such, in some examples, housing <NUM> can be constructed from a metallic material. In other examples, housing <NUM> can be constructed from a non-metallic material and housing <NUM> can be coupled to body <NUM> through an adhesive, a mechanical feature, or a fastener, among other options. Further, in some examples, housing <NUM> can be axially aligned with a central axis of probe <NUM>. Therefore, in some examples, housing <NUM> can be positioned concentric with body <NUM> of probe <NUM>. Housing <NUM> is fixedly positioned within body <NUM> of probe <NUM> and adjacent sensing base <NUM> of probe <NUM>. Further, housing <NUM> is positioned such that housing <NUM> surrounds the plurality of electrical wires <NUM> extending from sensing probe <NUM>. More specifically, housing <NUM> is positioned such that housing <NUM> surrounds a connection point between the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM> such that the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM> extend within a center opening within housing <NUM>. In addition, the connection point between the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM> is encompassed by potting <NUM>.

Potting <NUM> is positioned within an inner surface of housing <NUM> and potting <NUM> is positioned adjacent an upper surface of housing <NUM>. In some examples, as shown in <FIG>, potting <NUM> extends only a partial distance from an upper surface of housing <NUM> towards a lower surface of housing <NUM>. In other examples, potting <NUM> can extend a full distance from an upper surface of housing <NUM> to a lower surface of housing <NUM>. Further, potting <NUM> can encompass and fully surround the connection point between the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM>. As such, potting <NUM> is configured to aid in securing the connection between the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM>. In some examples, potting <NUM> can provide vibration support to the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM>, and potting <NUM> can act as an electrical isolator between the plurality of electrical wires <NUM>, the plurality of electrical leads <NUM>, and housing <NUM>. In some examples, potting <NUM> can be constructed from a high-temperature epoxy material, such that potting <NUM> is introduced into housing <NUM> as a fluid and then solidifies to produce the vibration support and electrical isolation.

Although potting <NUM> can be constructed from a high-temperature epoxy material, the heat produced by heating element <NUM> of probe <NUM> can have undesirable effects on potting <NUM>. For example, some high-temperature epoxy materials are designed to prevent melting under high temperatures, but if a high enough temperature is reached the high-temperature epoxy material could crack due to its brittle material properties. Further, potting <NUM> is likely to have different material properties than the metallic components surrounding potting <NUM>, such as housing <NUM> and body <NUM> of probe <NUM>. Therefore, potting <NUM> is likely to have a different coefficient of thermal expansion than housing <NUM> and when heat is applied to housing <NUM> and potting <NUM>, the components will expand at differing rates. High-temperature epoxy material generally expand at a greater rate than metallic materials due when heat is applied to the components. As such, when heat is applied to potting <NUM> and housing <NUM>, potting <NUM> can expand at a greater rate than housing <NUM> which can cause potting <NUM> to expand outside its intended adhesion area. In some scenarios, potting <NUM> can expand to an extent that it pulls apart and breaks the connection between the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM>. In turn, this can sever the electrical connection between probe <NUM> and an aircraft, preventing data from transferring from probe <NUM> to the aircraft. To remedy this potential issue, housing <NUM> includes features preventing damage to the plurality of electrical wires <NUM> and the plurality of electrical leads <NUM>.

<FIG> is a perspective view of housing <NUM> shown in <FIG>. <FIG> is a cross-sectional view of housing <NUM> taken along Section B-B of <FIG>. <FIG> will be discussed together. Housing <NUM> includes housing body <NUM> including upper surface <NUM>, lower surface <NUM>, inner surface <NUM>, outer surface <NUM>, rim <NUM>, lower body <NUM>, first alignment feature <NUM>, second alignment feature <NUM>, inner wall <NUM>, and outer wall <NUM>. Upper surface <NUM> is a surface at a first distal end of housing <NUM> and lower surface <NUM> is a surface at a second distal end of housing <NUM>, opposite first distal end. As shown best in <FIG>, inner surface <NUM> is the surface positioned within the walls constituting housing <NUM> and outer surface <NUM> is the surface positioned outside the walls constituting housing <NUM>. In the example shown in <FIG>, housing <NUM> includes a circular cross-section in the axial direction such that housing <NUM> has a generally cylindrical shape. In other examples, housing <NUM> can have an axial cross-section of any geometrical shape.

Rim <NUM> is positioned adjacent upper surface <NUM> of housing <NUM> and rim <NUM> extends fully around a perimeter or circumference of housing <NUM>, about central axis CL of housing <NUM>. Rim <NUM> is a ledge or cutout that extends inwards from outer surface <NUM> towards central axis CL of housing <NUM>. As such, an inner surface or edge of rim <NUM> has a smaller diameter than outer surface <NUM> of housing <NUM>. Rim <NUM> is configured to aid in the proper positioning of housing <NUM> within body <NUM> of probe <NUM>. Lower body <NUM> is positioned adjacent lower surface <NUM> of housing <NUM> and lower body <NUM> extends fully around outer surface <NUM> of housing <NUM>, about central axis CL of housing <NUM>. Lower body <NUM> is a portion of housing <NUM> that extends outwards from outer surface <NUM> of housing <NUM> away from central axis CL of housing <NUM>. As such, lower body <NUM> has a larger diameter than outer surface <NUM> of housing <NUM>. Further, in the example shown, an outer diameter of rim <NUM> is less than an outer diameter of lower body <NUM>. Lower body <NUM> having a larger diameter than rim <NUM> and outer surface <NUM> aids in housing <NUM> being correctly positioned within body <NUM> of probe <NUM>.

As shown in <FIG>, housing body <NUM> also includes first alignment feature <NUM> and second alignment feature <NUM>. First alignment feature <NUM> is positioned adjacent rim <NUM> of housing <NUM> and second alignment feature <NUM> is positioned adjacent lower body <NUM> of housing <NUM>. First alignment feature <NUM> is a cutout or indent extending into housing body <NUM> adjacent rim <NUM> and upper surface <NUM> of housing <NUM>. Second alignment feature <NUM> is a protrusion extending outwards from outer surface <NUM> of housing body <NUM>. In the example shown, first alignment feature <NUM> has a generally rectangular shape, but in another example first alignment feature <NUM> could have any geometric shape. Further, in the example shown, second alignment feature <NUM> is a generally triangular shaped protrusion, but in another example second alignment feature <NUM> could be any geometric shaped protrusion. First alignment feature <NUM> and second alignment feature <NUM> are vertically aligned with respect to a vertical plane extending from lower surface <NUM> of housing <NUM> to upper surface <NUM> of housing <NUM>. First alignment feature <NUM> and second alignment feature <NUM> aid in housing <NUM> being correctly positioned within body <NUM> of probe <NUM>. More specifically, first alignment feature <NUM> and second alignment feature <NUM> are configured to mate with mating features of body <NUM> of probe <NUM> to ensure housing <NUM> is oriented in the correct position while being inserted into body <NUM> of probe <NUM>.

As shown best in <FIG>, housing <NUM> includes inner wall <NUM> and outer wall <NUM>. Inner wall <NUM> is generally a hollow cylinder extending from lower body <NUM> to upper surface <NUM> of housing <NUM>. More specifically, inner wall <NUM> extends a partial distance from lower body <NUM> and outer wall <NUM> of housing <NUM> towards central axis CL and then inner wall <NUM> angles upward such that a portion of inner wall <NUM> is parallel with central axis CL. In the example shown, the portion of inner wall <NUM> parallel with central axis CL is a hollow cylinder with a circular cross-section. In another example, inner wall <NUM> can have a cross-section of any geometric shape. Outer wall <NUM> is generally a hollow cylinder that extends from lower body <NUM> to upper surface <NUM>. Outer wall <NUM> is oriented parallel to central axis CL and outer wall <NUM> is concentric with inner wall <NUM>. In the example shown, outer wall <NUM> is a hollow cylinder with a circular cross-section. In another example, outer wall <NUM> can have a cross-section of any geometric shape.

Outer wall <NUM> fully surrounds an outer circumference of inner wall <NUM>. More specifically, inner wall <NUM> is offset from outer wall <NUM> in a direction towards central axis CL such that a gap is positioned between inner wall <NUM> and outer wall <NUM>. Further, a portion of inner wall <NUM> converges with outer wall <NUM> such that inner wall <NUM> and outer wall <NUM> are coupled adjacent lower body <NUM> of housing <NUM>. The gap between inner wall <NUM> and outer wall <NUM> is an air gap in which air or other gas is free to flow within, discussed further below. In the example shown, inner wall <NUM> and outer wall <NUM> have equal thicknesses. In another example, inner wall <NUM> and outer wall <NUM> can have differing thicknesses. The thickness of inner wall <NUM> and outer wall <NUM> can differ depending on requisite physical properties of housing <NUM>.

Central aperture <NUM> is formed by inner surface <NUM> of inner wall <NUM>. Central aperture <NUM> is axially aligned with central axis CL and central aperture <NUM> extends through housing <NUM> from upper surface <NUM> to lower surface <NUM> of housing <NUM>. Referring again to <FIG>, central aperture <NUM> is configured to allow a distal end of sensing probe <NUM>, electrical wires <NUM>, and electrical leads <NUM> to be positioned within and extend at least partially through central aperture <NUM>. In the example shown, central aperture <NUM> has a circular cross-section in the axial direction of central axis CL. In other examples, central aperture <NUM> could have any geometric shape as its cross-section in the axial direction of central axis CL. Housing <NUM> also includes a plurality of apertures <NUM> extending through upper surface <NUM> of housing body <NUM> to the gap positioned between inner wall <NUM> and outer wall <NUM>. The plurality of apertures <NUM> are configured to allow air or other gas to flow into and out of the gap positioned between inner wall <NUM> and outer wall <NUM>.

Housing <NUM> with inner wall <NUM> and outer wall <NUM> can be manufactured using an additive manufacturing process, such as a laser powder bed fusion process. As such, housing <NUM> is grown in a vertical direction starting at lower surface <NUM> and finishing at upper surface <NUM>. In some examples, housing <NUM> can be constructed from a metallic material. In other examples, housing <NUM> can be constructed from a ceramic material, a polymeric material, and/or a composite material. The plurality of apertures <NUM> positioned adjacent upper surface <NUM> of housing <NUM> also aid in removing any excess material from the gap betweem inner wall <NUM> and outer wall <NUM> that may have accumulated within the gap during the additive manufacturing process/.

Referring again to <FIG>, during assembly of probe <NUM>, housing <NUM> is pressed into body <NUM>, housing <NUM> is then welded or otherwise coupled to body <NUM>, and electrical wires <NUM> are soldered or otherwise electrically coupled to electrical leads <NUM>. Then a liquefied potting <NUM> is dispensed within inner surface <NUM> of inner wall <NUM> of housing <NUM> and the potting <NUM> is subsequently cured and allowed to harden within inner surface <NUM> of inner wall <NUM> of housing <NUM>. The cured potting <NUM> positioned within inner surface <NUM> of inner wall <NUM> encompasses and fully surrounds the connection point between electrical wires <NUM> and electrical leads <NUM>.

During use of probe <NUM> on an aircraft, probe <NUM> is heated through heating element <NUM> and potting <NUM> will increase in temperature and expand in volume. But the gap positioned between inner wall <NUM> and outer wall <NUM> acts as a thermal isolator and the air within the gap absorbs some of the heat before the heat can reach potting <NUM>. As such, the gap (thermal isolator) minimizes the amount of heat absorbed by potting <NUM> and therefore minimizes the amount of expansion of potting <NUM>. Further, potting <NUM> being positioned only within inner surface <NUM> of inner wall <NUM> results in potting <NUM> having less total volume, as compared to a housing without the inner wall, the outer wall, and the air gap between the walls. In turn, the reduced volume of potting <NUM> within housing <NUM> further minimizes the expansion of potting <NUM> within housing <NUM>, as compared to a potting within a housing without the inner wall, outer wall, and air gap.

As such, including inner wall <NUM>, outer wall <NUM>, and the air gap between the walls within housing <NUM> hinders potting <NUM> from growing outside its intended adhesion area. In turn, this prevents potting <NUM> from expanding too much and breaking apart the electrical connection between electrical wires <NUM> and electrical leads <NUM>, ensuring the electronic components within probe <NUM> remain functional during heating of probe <NUM>. Protecting the electronic components within probe <NUM> makes probe <NUM> more robust and allows probe <NUM> to continue working accurately during heating conditions. Probe <NUM> including inner wall <NUM>, outer wall <NUM>, and the air gap between the walls prevents damage to the electronic components within probe <NUM> by ensuring the heat induced on probe <NUM> does not have detrimental effects to the electronic components. As such, probe <NUM> can be heated to prevent rain and ice buildup and probe <NUM> will continue transferring accurate data to the pilot and the co-pilot during flight of the aircraft.

Claim 1:
An air data probe (<NUM>) comprising:
a plurality of electrical wires (<NUM>);
a plurality of electrical leads (<NUM>);
an outlet (<NUM>);
potting (<NUM>);
a body (<NUM>) comprising an inlet (<NUM>) fluidly coupled to the outlet (<NUM>);
a heating element (<NUM>) positioned within the body (<NUM>) of the air data probe (<NUM>), wherein the heating element (<NUM>) is configured to increase a temperature of the body (<NUM>);
a sensing probe (<NUM>) positioned within the body (<NUM>), wherein the sensing probe (<NUM>) includes a sensing base (<NUM>) coupling the sensing probe (<NUM>) to the body (<NUM>); and
a housing (<NUM>) positioned within and coupled to the body (<NUM>), wherein the housing (<NUM>) includes:
a housing body (<NUM>) including an upper surface (<NUM>), a lower surface (<NUM>), an inner surface (<NUM>), an outer surface (<NUM>), an inner wall (<NUM>), and an outer wall (<NUM>);
wherein the inner wall (<NUM>) is offset from the outer wall (<NUM>) such that a gap is positioned between the inner wall (<NUM>) and the outer wall (<NUM>);
wherein the housing (<NUM>) is fixedly positioned within the body (<NUM>) of air data probe (<NUM>) and adjacent to the sensing base (<NUM>) of probe (<NUM>) such that the housing (<NUM>) surrounds the plurality of electrical wires (<NUM>) extending from the sensing probe (<NUM>) and such that the housing (<NUM>) surrounds a connection point between the plurality of electrical wires (<NUM>) and the plurality of electrical leads (<NUM>) such that the plurality of electrical wires (<NUM>) and the plurality of electrical leads (<NUM>) extend within a center opening within housing (<NUM>);
wherein the connection point between the plurality of electrical wires (<NUM>) and the plurality of electrical leads (<NUM>) is encompassed by the potting (<NUM>).