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. <CIT> relates to a heated 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.

According to one aspect, a housing is provided as defined by claim <NUM>.

According to another aspect, an air data probe is provided as defined by claim <NUM>.

<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 and 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 probe <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 increase 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, which 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> is a top view of housing <NUM>. <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>, and retention features <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 best 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 extending through 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 in <FIG>, housing <NUM> includes retention features <NUM> positioned within housing <NUM>. More specifically, housing <NUM> includes a plurality of retention features <NUM> positioned within inner surface <NUM> of housing body <NUM>. Each of the plurality of retention features <NUM> extend from inner surface <NUM> of housing <NUM> towards central axis CL of housing <NUM>. Further, in the example shown, the plurality of retention features <NUM> extend along inner surface <NUM> of housing <NUM> from upper surface <NUM> to lower surface <NUM> of housing <NUM>. In other examples, the plurality of retention features <NUM> may extend along inner surface <NUM> of housing <NUM> only a partial distance from upper surface <NUM> to lower surface <NUM> of housing <NUM>. In addition, as shown best in <FIG>, the plurality of retention features <NUM> extend fully around a circumference of inner surface <NUM> of housing <NUM>.

Each of the plurality of retention features <NUM> extend a partial distance from inner surface <NUM> of housing <NUM> towards central axis CL of housing <NUM>, such that aperture <NUM> is formed in an axial direction along central axis CL of housing <NUM>. Aperture <NUM> is axially aligned with central axis CL and aperture <NUM> extends through housing <NUM> from upper surface <NUM> to lower surface <NUM> of housing <NUM>. Referring again to <FIG>, 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 aperture <NUM>. In the example shown, aperture <NUM> has a circular cross-section in the axial direction of central axis CL. In other examples, aperture <NUM> could have any geometric shape as its cross-section in the axial direction of central axis CL.

The plurality of retention features <NUM> are collectively a lattice structure including one or more repeating three-dimensional open-celled structures. In other words, the plurality of retention features <NUM> includes a plurality of posts or extensions coupled together to form the lattice structure. The lattice structure is a repeating pattern of three-dimensional open-celled structures. Although the lattice structure shown in <FIG> has a specific shape and size, it is to be understood that another example lattice structure could have a different shape and size.

Each of the plurality of retention features <NUM> are positioned non-parallel with upper surface <NUM> and lower surface <NUM> of housing body <NUM>. Housing <NUM> with the plurality of retention features <NUM> is 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>. The additive manufacturing process prevents hanging horizontal posts or extensions within the lattice structure from being formed, and therefore each of the plurality of retention features <NUM> are positioned non-parallel with upper surface <NUM> and lower surface <NUM> of housing body <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.

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 housing <NUM> and the potting <NUM> is subsequently cured and allowed to harden within inner surface <NUM> of housing <NUM>. Therefore, the cured potting <NUM> positioned within housing <NUM> becomes intertwined with the lattice structure of the plurality of retention features <NUM>. Further, the cured potting <NUM> positioned within housing <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 potting <NUM> being intertwined with the lattice structure of the plurality of retention features <NUM> holds potting <NUM> in place and minimizes the amount of expansion of potting <NUM>. Further, the plurality of retention features <NUM> occupy a portion of the volume within inner surface <NUM> of housing <NUM> and therefore there is less total volume of potting <NUM>, as compared to a housing without the plurality of retention features. 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 retention features.

As such, including the plurality of retention features 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 the plurality of retention features 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:
A housing for surrounding electrical components within an air data probe configured to gather data during flight of an aircraft, the housing comprising:
a housing body (<NUM>) including an upper surface (<NUM>), a lower surface (<NUM>), an inner surface (<NUM>), an outer surface (<NUM>), a rim (<NUM>) positioned adjacent the upper surface, and a lower body (<NUM>) positioned adjacent the lower surface; and
a plurality of retention features (<NUM>) positioned within the housing body, wherein each of the plurality of retention features extends from the inner surface of the housing towards a central axis of the housing; and characterised in that:
the plurality of retention features (<NUM>) are collectively a lattice structure including one or more repeating three-dimensional open-celled structures, wherein each of the plurality of retention features are positioned non-parallel with the upper surface and the lower surface of the housing body, and wherein the plurality of retention features are configured such that a cured potting (<NUM>) positioned within the housing becomes intertwined with the lattice structure of the plurality of retention features.