Patent Description:
Air data probes are installed on aircraft to measure air data parameters. Air data parameters may include barometric static pressure, altitude, air speed, angle of attack, angle of sideslip, temperature, total air temperature, relative humidity, and/or any other parameter of interest. Examples of air data probes include pitot probes, total air temperature probes, or angle of attack sensors.

Air data probes are mounted to an exterior of an aircraft in order to gain exposure to external airflow. Thus, air data probes are exposed to the environmental conditions exterior to the aircraft, which are often cold. As such, 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. It can be difficult to successfully arrange the heater within the air data probe. Air data probes are defined in <CIT> and <CIT>.

A probe head of an air data probe is provided as defined by claim <NUM>.

An air data probe is provided as defined by claim <NUM>.

In general, the present disclosure describes an air data probe with a probe head that has an additively manufactured body including unitary water dams, air passageways, and one or more heater bores for a rod heater or heaters, resulting in simplified assembly, enhanced repeatability, and efficient heat distribution. The probe head may also include one or more enhanced conduction areas between or extending from one or more heater bores and an exterior surface of the body to increase and further tailor the heat distribution.

<FIG> is a perspective view of air data probe <NUM>. Air data probe <NUM> includes probe head <NUM>, strut <NUM>, and mounting flange <NUM>. Probe head <NUM> includes first end <NUM> and second end <NUM>.

Air data probe <NUM> may be a pitot probe, a pitot-static probe, or any other suitable air data probe. Probe head <NUM> is the sensing head of air data probe <NUM>. Probe head <NUM> is a forward portion of air data probe <NUM>. Probe head <NUM> has one or more ports positioned in probe head <NUM>. Internal components of air data probe <NUM> are located within probe head <NUM>. Probe head <NUM> is connected to a first end of strut <NUM>. Strut <NUM> is blade-shaped. Internal components of air data probe <NUM> are located within strut <NUM>. Strut <NUM> is adjacent mounting flange <NUM>. A second end of strut <NUM> is connected to mounting flange <NUM>. Mounting flange <NUM> makes up a mount of air data probe <NUM>. Mounting flange <NUM> is connectable to an aircraft.

Probe head <NUM> has first end <NUM> at one end, or an upstream end, and second end <NUM> at an opposite end, or a downstream end. First end <NUM> of probe head <NUM> makes up a tip of probe head <NUM>. Second end <NUM> of probe head <NUM> is connected to strut <NUM>.

Air data probe <NUM> is configured to be installed on an aircraft. Air data probe <NUM> may be mounted to a fuselage of the aircraft via mounting flange <NUM> and fasteners, such as screws or bolts. Strut <NUM> holds probe head <NUM> away from the fuselage of the aircraft to expose probe head <NUM> to external airflow. Probe head <NUM> takes in air from surrounding external airflow and communicates air pressures pneumatically through internal components and passages of probe head <NUM> and strut <NUM>. Pressure measurements are communicated to a flight computer and can be used to generate air data parameters related to the aircraft flight condition.

<FIG> is a partial perspective view of probe head <NUM> of air data probe <NUM>. <FIG> is a cut away view of probe head <NUM> of air data probe <NUM>. <FIG> is a cross-sectional view of probe head <NUM> of air data probe <NUM>. <FIG> is a cross-sectional view of probe head <NUM> of air data probe <NUM>. <FIG> is a cross-sectional view of probe head <NUM> of air data probe <NUM>. <FIG> is a front view of probe head <NUM> of air data probe <NUM>. <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, and <FIG> will be discussed together. Air data probe <NUM> includes probe head <NUM>. Probe head <NUM> includes first end <NUM>, second end <NUM>, body <NUM>, and heater <NUM>. Body <NUM> includes exterior surface <NUM>, inlets 28A, 28B, 28C, and 28D, air passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B, and heater bore <NUM>. Heater bore <NUM> includes interior surface <NUM>.

Probe head <NUM> has first end <NUM> making up the tip of probe head <NUM>. Second end <NUM> is opposite first end <NUM>. Second end <NUM> of probe head <NUM> is connected to strut <NUM> (shown in <FIG>). Body <NUM> of probe head <NUM> extends from first end <NUM> to second end <NUM>. Body <NUM> is a unitary, or single-piece, structure. Body <NUM> is additively manufactured and made of nickel or any other suitable material. Heater <NUM> is positioned within body <NUM>. In this example, that is not part of the claimed invention, a single heater <NUM> extends through a center, or down the middle, of body <NUM>. Heater <NUM> is a rod heater, which includes both rod and rod-like structures. Heater <NUM> may be comprised of an electric resistive wire heater helically wound around a ceramic rod-like core. Heater <NUM> may be tailored such that heater <NUM> has a varying amount of power, or different amounts of power axially along heater <NUM>. For example, electric resistive wire may be wound to result in tighter or looser coils on ceramic core to increase or decrease the amount of coils, and thus the power density along heater <NUM>. Heater <NUM> may have more tightly wound coils at an end of heater <NUM> adjacent first end <NUM> of probe head <NUM> to deliver a greater amount of heat to the tip. Alternatively, heater <NUM> may be uniform such that the power density of heater <NUM> is uniform axially along heater <NUM>.

Exterior surface <NUM> of body <NUM> is an outer surface of body <NUM>. Exterior surface <NUM> of body <NUM> is the outer surface of probe head <NUM>. As such, external airflow contacts exterior surface <NUM>. Body <NUM> has inlets 28A, 28B, 28C, and 28D near first end <NUM> of probe head <NUM>. Inlets 28A, 28B, 28C, and 28D are openings in body <NUM>. In this example, body <NUM> has four inlets 28A, 28B, 28C, and 28D. In alternate examples, body <NUM> has any suitable number of inlets <NUM>. Each inlet 28A, 28B, 28C, 28D is connected to a respective air passageway 30A, 30B, 30C, and 30D. As such, body <NUM> has four air passageways 30A, 30B, 30C, and 30D. Air passageways 30A, 30B, 30C, and 30D extend from respective inlets 28A, 28B, 28C, and 28D to second end <NUM> of probe head <NUM>. Air passageways 30A, 30B, 30C, and 30D surround heater <NUM> such that air passageways 30A, 30B, 30C, and 30D are between heater <NUM> and exterior surface <NUM> of body <NUM>. Air passageways 30A, 30B, 30C, and 30D extend in substantially straight lines and twist up to <NUM> degrees around water dams 32A and 32B. As such, air passageways 30A, 30B, 30C, and 30D may have an undulating geometry from first end <NUM> to second end <NUM> such that air passageways 30A, 30B, 30C, and 30D are redirected around water dams 32A and 32B. Water dams 32A and 32B are positioned in lines of sight of inlets 28A, 28B, 28C, and 28D. Water dams 32A extend radially. In this example, body <NUM> has two water dams 32A and 32B spaced axially from each other. In alternate examples, body <NUM> may have any number of water dams 32A and 32B.

Heater bore <NUM> is a cylindrical opening, or well, extending through a center of body <NUM>. Heater bore <NUM> is positioned between first end <NUM> and second end <NUM>. Heater bore <NUM> is shaped to accept rod heater <NUM>. In this example, body <NUM> has a single heater bore <NUM> for a single heater <NUM>. In alternate examples, body <NUM> may have a plurality of heater bores <NUM> to accommodate a plurality of heaters <NUM>. Heater bore <NUM> has annular interior surface <NUM> that contacts heater <NUM>. Specifically, heater <NUM> is slid into heater bore <NUM> such that heater <NUM> is in contact with interior surface <NUM> of heater bore <NUM>.

Heater <NUM> connects to heater circuitry (not shown) at second end <NUM> of probe head <NUM>, the circuitry going down strut <NUM> (shown in <FIG>) to connect to and get power from internal components of air data probe <NUM>. Heater <NUM> can have different amounts of power along rod heater <NUM> to distribute more heat or less heat depending on the needs of probe head <NUM>, or power can be uniform along heater <NUM> to further simplify manufacturing of heater <NUM>.

Thermal resistance of body <NUM> varies, particularly from heater <NUM> to exterior surface <NUM>, from first end <NUM> to second end <NUM> of probe head <NUM> due to different amounts of material between heater <NUM> and exterior surface <NUM> moving axially from first end <NUM> to second end <NUM> of probe head <NUM>. For example, air passageways 30A, 30B, 30C, and 30D can increase or decrease in diameter to increase or decrease the amount of material between heater bore <NUM> and exterior surface <NUM>, varying the thermal resistance of probe head <NUM> by having more or less metal to carry heat radially outward from heater <NUM>. Less metal in probe head <NUM> moving from first end <NUM> to second end <NUM> reduces the thermal resistance and results in less heat conduction from heater <NUM> to exterior surface <NUM> of probe head <NUM> moving from first end <NUM> to second end <NUM>. As such, probe head <NUM> is conducting less heat near second end <NUM> and diverting more heat toward first end <NUM>, or tip, of probe head <NUM>.

Air passageways 30A, 30B, 30C, and 30D are not fully linear and twist, or undulate, around heater bore <NUM> and water dams 32A and 32B to result in a line-of-sight deflection from first end <NUM>. An absence of a straight path from inlets 28A, 28B, 28C, and 28D, at first end <NUM>, to second end <NUM> of probe head <NUM>, as shown in <FIG>, assists in managing water that could get into probe head <NUM>. Water dams 32A and 32B redirect, or knock down, water particles in the airflow moving through air passageways 30A, 30B, 30C, and 30D. Water dams 32A and 32B block ice and water particles in exterior airflow and prevent ice and water particles from having a direct route down air passageways 30A, 30B, 30C, and 30D and through probe head <NUM>.

Traditional air data probes have a wire heater brazed to a body of a probe head. Other components, such as water dams, may also be positioned within and brazed onto traditional probe heads. As such, probe heads of traditional air data probes have complex heaters incorporated into multi-piece assemblies.

Additive manufacturing allows for more complex internal geometry, including air passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B, and heater bore <NUM>, of probe head <NUM>, which is needed for optimal functionality of air data probe <NUM>. Because body <NUM> is a single unitary piece, air passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B, and heater bore <NUM> are uniform in size, shape, and position among probe heads <NUM> to ensure optimal fit and performance as well as repeatability. For example, heater bore <NUM>, water dams 32A and 32B, and air passageways 30A, 30B, 30C, and 30D are combined with rod heater <NUM> and body <NUM> ensures the best fit between heater <NUM> and body <NUM>. Additively manufactured body <NUM> of probe head <NUM> allows for easier and more effective use of rod-shaped heater <NUM>.

Rod heater <NUM> is simpler than a traditional complex heater brazed into a probe head. Because the power density of rod heater <NUM> can change axially along heater <NUM>, heater <NUM> still maintains the ability to tailor heat distribution within probe head <NUM> by enhancing conduction to the portions of probe head <NUM> that need heat via varied power density of heater <NUM>. Rod heater <NUM> can be a standardized heater among probe heads <NUM>. Heater <NUM> is also easier to manufacture and simplifies the assembly process of probe head <NUM>.

The geometry of air passageways 30A, 30B, 30C, and 30D allows air passageways 30A, 30B, 30C, and 30D to twist around water dams 32A and 32B positioned in their direct path from first end <NUM>. Water dams 32A and 32B prevent ice and water particles from external airflow from moving through probe head <NUM> and decreasing functionality of air data probe <NUM>.

Utilizing additive manufacturing to create more complex internal geometry of body <NUM>, which has a complex one-piece shape that includes air passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B, and heater bore <NUM>, and integrating a simpler form of a heater via rod heater <NUM> achieves the internal shapes and passages needed for optimal functionality of probe head <NUM> while enhancing heat conduction and simplifying manufacturing and assembly of probe head <NUM>.

<FIG> is a partial perspective view of probe head <NUM>. <FIG> is a cut away view of probe head <NUM>. <FIG> is a cross-sectional view of probe head <NUM>. <FIG> is a cross-sectional view of probe head <NUM>. <FIG> is an end view of probe head <NUM>. <FIG>, <FIG>, <FIG>, <FIG>, and <FIG> will be discussed together. Probe head <NUM> includes first end <NUM>, second end <NUM>, body <NUM>, and heaters 124A and 124B. Body <NUM> includes exterior surface <NUM>, inlet <NUM>, air passageway <NUM>, water dam <NUM>, and heater bores 134A and 134B. Heater bore 134A includes interior surface 136A. Heater bore 134B includes interior surface 136B.

Probe head <NUM> has first end <NUM> making up the tip of probe head <NUM>. Second end <NUM> is opposite first end <NUM>. Second end <NUM> of probe head <NUM> is connected to strut <NUM> (shown in <FIG>). Body <NUM> of probe head <NUM> extends from first end <NUM> to second end <NUM>. Body <NUM> is a unitary, or single-piece, structure. Body <NUM> is additively manufactured and made of nickel or any other suitable material. Heaters 124A and 124B are positioned within body <NUM>. In this embodiment, probe head <NUM> has two side-by-side heaters 124A and 124B. Heaters 124A and 124B are spaced radially from each other. As such, heaters 124A and 124B are positioned adjacent exterior surface <NUM> of body <NUM>. Heaters 124A and 124B are rod heaters, which includes both rod and rod-like structures. Each heater 124A, 124B may be comprised of an electric resistive wire heater helically wound around a ceramic rod-like core. Each heater 124A, 124B may be tailored such that heater 124A, 124B has different amounts of power along heater 124A, 124B. For example, electric resistive wire may be wound to result in tighter or looser coils on ceramic core to increase or decrease the amount of coils, and thus the power density along heater 124A, 124B. Heater 124A, 124B may have more tightly wound coils at an end of heater 124A, 124B adjacent first end <NUM> of probe head <NUM> to deliver a greater amount of heat to the tip. Alternatively, heater 124A, 124B may be uniform such that the power density of heater 124A, 124B is uniform along heater 124A, 124B.

Exterior surface <NUM> of body <NUM> is an outer surface of body <NUM>. Exterior surface <NUM> of body <NUM> is the outer surface of probe head <NUM>. As such, external airflow contacts exterior surface <NUM>. Body <NUM> has inlet <NUM> near first end <NUM> of probe head <NUM>. Inlet 128A is an opening in body <NUM>. In this embodiment, body <NUM> has a single inlet 128A. Inlet <NUM> is connected to air passageway <NUM>. As such, body <NUM> has a single air passageway <NUM>. Air passageway <NUM> extends from inlets <NUM> to second end <NUM> of probe head <NUM>. Air passageway <NUM> extends through a center, or down the middle, of body <NUM>. A majority of air passageway <NUM> extends between heaters 124A and 124B such that heaters 124A and 124B are between a majority of air passageway <NUM> and exterior surface <NUM> of body <NUM>. Air passageway <NUM> extends in a substantially straight line and twists up to <NUM> degrees around water dam <NUM>. As such, air passageway <NUM> may have an undulating geometry from first end <NUM> to second end <NUM> such that air passageway <NUM> is redirected around water dam <NUM>. Water dam <NUM> is positioned in the line of sight of inlet <NUM>. Water dam <NUM> extends radially. In this embodiment, body <NUM> has a single water dam <NUM>.

Each heater 124A, 124B is positioned within a heater bore 134A, 134B. Heater bores 134A and 134B are cylindrical openings, or wells, extending along body <NUM> adjacent exterior surface <NUM>. Heater bores 134A and 134B are positioned between first end <NUM> and second end <NUM>. Heater bores 134A and 134B are not aligned. Rather, heater bores 134A and 134B are uniformly offset from exterior surface <NUM> of probe head <NUM>, which is slightly tapered. Each heater bore 134A, 134B is shaped to accept a respective rod heater 124A, 124B. In this embodiment, body <NUM> has two heater bores 134A and 134B to accommodate two heaters 124A and 124B. In alternate embodiments, probe head <NUM> may have one or more than two heaters 124A and 124B, each heater 124A, 124B positioned within a respective heater bore 134A, 134B. Each heater bore 134A, 134B has annular interior surface 136A, 136B that contacts respective heater 124A, 124B. Each heater 124A, 124B is slid into a respective heater bore 134A, 134B such that each heater 124A, 124B is in contact with an interior surface of heater bore 134A, 134B.

Heaters 124A and 124B connect to heater circuitry (not shown) at second end <NUM> of probe head <NUM>, the circuitry going down strut <NUM> (shown in <FIG>) to connect to and get power from internal components of air data probe <NUM>. Heaters 124A and 124B can have different amounts of power along rod heaters 124A and 124B to distribute more heat or less heat depending on the needs of probe head <NUM>, or power can be uniform along heaters 124A and 124B to further simplify manufacturing of heaters 124A and 124B.

Thermal resistance of body <NUM> varies, particularly from each heater 124A, 124B to exterior surface <NUM>, from first end <NUM> to second end <NUM> of probe head <NUM> due to different amounts of material between each heater 124A, 124B and exterior surface <NUM> moving axially from first end <NUM> to second end <NUM> of probe head <NUM>. The thermal resistance of probe head <NUM> can be varied by having more or less metal to carry heat radially outward from heaters 124A and 124B. Less metal in probe head <NUM> moving from first end <NUM> to second end <NUM> reduces the thermal resistance and results in less heat conduction from heaters 124A and 124B to exterior surface <NUM> of probe head <NUM> moving from first end <NUM> to second end <NUM>. As such, probe head <NUM> may conduct less heat near second end <NUM> and divert more heat toward first end <NUM>, or tip, of probe head <NUM>.

Air passageway <NUM> is not fully linear and twists, or undulates, around heater bores 134A and 134B and water dam <NUM> to result in a line-of-sight deflection from first end <NUM>. An absence of a straight path from inlet <NUM> at first end <NUM> to second end <NUM> of probe head <NUM>, as shown in <FIG>, assists in managing water that could get into probe head <NUM>. Water dam <NUM> redirects, or knocks down, water particles in the airflow moving through air passageway <NUM>. Water dam <NUM> blocks ice and water particles in exterior airflow and prevents ice and water particles from having a direct route down air passageway <NUM> and through probe head <NUM>.

Additive manufacturing allows for more complex internal geometry, including air passageway <NUM>, water dam <NUM>, and heater bores 134A and 134B, of probe head <NUM>, which is needed for optimal functionality of air data probe <NUM>. For example, probe head <NUM> is able to have two heater bores 134A and 134B, positioned exactly where needed, as well as the required internal geometry of air passageway <NUM> and water dam <NUM> that probe head <NUM> requires in order to function properly due to additively manufacturing probe head <NUM>. Because body <NUM> is a single unitary piece, air passageway <NUM>, water dam <NUM>, and heater bores 134A and 134B are uniform in size, shape, and position among probe heads <NUM> to ensure optimal fit and performance as well as repeatability. For example, heater bores 134A and 134B, water dam <NUM>, and air passageway <NUM> are combined with rod heaters 124A and 124B and body <NUM> ensures the best fit between heaters 124A and 124A and 124B and body <NUM>. Additively manufactured body <NUM> of probe head <NUM> allows for easier and more effective use of rod-shaped heaters 124A and 124B.

Additive manufacturing allows for two heaters 124A and 124B, positioned side-by-side, to increase the heating ability of probe head <NUM> compared to probe head <NUM> that has a single heater <NUM>, as shown in <FIG>, when more heat is required. Probe head <NUM> can respond to increased heat demands. Heater bores 134A and 134B are additively manufactured exactly where heat is needed such that heaters 124A and 124B provide enough heat within probe head <NUM>. Further, water dam <NUM> and air passageway <NUM> are additively manufactured and shaped differently to accommodate multiple heater bores 134A and 134B. The geometry of air passageway <NUM> allows air passageway <NUM> to twist around water dams <NUM> positioned in its direct path from first end <NUM>. Water dam <NUM> prevents ice and water particles from external airflow from moving through probe head <NUM> and decreasing functionality of air data probe <NUM>.

Rod heaters 124A and 124B are simpler than a traditional complex heater brazed into a probe head. Because the power density of rod heaters 124A and 124B can change axially along heaters 124A and 124B, heaters 124A and 124B still maintain the ability to tailor heat distribution within probe head <NUM> by enhancing conduction to the portions of probe head <NUM> that need heat via varied power density of heaters 124A and 124B. Rod heaters 124A and 124B can be standardized heaters among probe heads <NUM>. Heaters 124A and 124B are also easier to manufacture and simplify the assembly process of probe head <NUM>.

Utilizing additive manufacturing to create more complex internal geometry of body <NUM>, which has a complex one-piece shape that includes air passageway <NUM>, water dams <NUM>, and heater bores 134A and 134B, and integrating a simpler form of heaters via rod heaters 124A and 124B achieves the internal shapes and passages needed for optimal functionality of probe head <NUM> while enhancing heat conduction and simplifying manufacturing and assembly of probe head <NUM>.

<FIG> is a perspective top view of air data probe <NUM> showing enhanced conduction areas <NUM> of probe head <NUM>. <FIG> is a partial perspective front view of probe head <NUM> showing enhanced conduction areas 238A, 238B, 238C, and 238D. <FIG> is a partial perspective front view of probe head <NUM> with part of body <NUM> of probe head <NUM> removed to show enhanced conduction areas 238A, 238B, 238C, and 238D. <FIG> is a cross-sectional view of probe head <NUM> taken along line D-D of <FIG>. <FIG> is a cross-sectional view of probe head <NUM> taken along line E-E of <FIG>, <FIG>, <FIG>, <FIG>, and <FIG> will be discussed together. Air data probe <NUM> includes probe head <NUM>, strut <NUM>, and mounting flange <NUM>. Probe head <NUM> includes first end <NUM>, second end <NUM>, body <NUM>, and heater <NUM>. Body <NUM> includes exterior surface <NUM>, inlets 228A, 228B, 228C, and 228D, air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, heater bore <NUM> (including interior surface <NUM>), and enhanced conduction areas 238A, 238B, 238C, and 238D.

Probe head <NUM> has first end <NUM> making up the tip of probe head <NUM>. Second end <NUM> is opposite first end <NUM>. Second end <NUM> of probe head <NUM> is connected to strut <NUM>. Body <NUM> of probe head <NUM> extends from first end <NUM> to second end <NUM>. Body <NUM> may be a unitary, or single-piece, structure. Body <NUM> is additively manufactured and made of nickel or any other suitable material. Heater <NUM> is positioned within body <NUM>. In this example, that is not part of the claimed invention, a single heater <NUM> extends through a center, or down the middle, of body <NUM>. Heater <NUM> is a rod heater, which includes both rod and rod-like structures. Heater <NUM> may be comprised of an electric resistive wire heater helically wound around a ceramic rod-like core. Heater <NUM> may be tailored such that heater <NUM> has different amounts of power along heater <NUM>. For example, electric resistive wire may be wound to result in tighter or looser coils on ceramic core to increase or decrease the amount of coils, and thus the power density along heater <NUM>. Heater <NUM> may have more tightly wound coils at an end of heater <NUM> adjacent first end <NUM> of probe head <NUM> to deliver a greater amount of heat to the tip. Alternatively, heater <NUM> may be uniform such that the power density of heater <NUM> is uniform along heater <NUM>.

Exterior surface <NUM> of body <NUM> is an outer surface of body <NUM>. Exterior surface <NUM> of body <NUM> is the outer surface of probe head <NUM>. As such, external airflow contacts exterior surface <NUM>. Body <NUM> has inlets 228A, 228B, 228C, and 228D near first end <NUM> of probe head <NUM>. Inlets 228A, 228B, 228C, and 228D are openings in body <NUM>. In this example, body <NUM> has four inlets 228A, 228B, 228C, and 228D. In alternate examples, body <NUM> has any suitable number of inlets <NUM>. Each inlet 228A, 228B, 2228C, 28D is connected to a respective air passageway 230A, 230B, 230C, and 230D. As such, body <NUM> has four air passageways 230A, 230B, 230C, and 230D. Air passageways 230A, 230B, 230C, and 230D extend from respective inlets 228A, 228B, 228C, and 228D to second end <NUM> of probe head <NUM>. Air passageways 230A, 230B, 230C, and 230D surround heater <NUM> such that air passageways 230A, 230B, 230C, and 230D are between heater <NUM> and exterior surface <NUM> of body <NUM>. Air passageways 230A, 230B, 230C, and 230D extend in substantially straight lines and twist up to <NUM> degrees around water dams 232A and 232B. As such, air passageways 230A, 230B, 230C, and 230D may have an undulating geometry from first end <NUM> to second end <NUM> such that air passageways 230A, 230B, 230C, and 230D are redirected around water dams 232A and 232B. Water dams 232A and 232B are positioned in lines of sight of inlets 228A, 228B, 228C, and 228D. Water dams 232A extend radially. In this example, body <NUM> has two water dams 232A and 232B spaced axially from each other. In alternate examples, body <NUM> may have any number of water dams 232A and 232B.

Heater bore <NUM> is a cylindrical opening, or well, extending through a center of body <NUM>. Heater bore <NUM> is positioned between first end <NUM> and second end <NUM>. Heater bore <NUM> is shaped to accept rod heater <NUM>. In this example, body <NUM> has a single heater bore <NUM> for a single heater <NUM>. In alternate examples, body <NUM> may have a plurality of heater bores <NUM> to accommodate a plurality of heaters <NUM>. Heater bore <NUM> has annular interior surface <NUM> that contacts heater <NUM>. Specifically, heater <NUM> is slid into heater bore <NUM> such that heater <NUM> is in contact with interior surface <NUM> of heater bore <NUM>. Exterior surface <NUM>, inlets 228A, 228B, 228C, and 228D, air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, and heater bore <NUM> are all unitary to body <NUM>, forming a single-piece structure.

Enhanced conduction areas 238A, 238B, 238C, and 238D are between heater bore <NUM> and exterior surface <NUM> of probe head <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D are areas of enhanced thermal conduction. Enhanced conduction areas 238A, 238B, 238C, and 238D fill spaces in body <NUM> between internal components including air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, and heater bore <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D are as large as possible, filling areas between internal components of body <NUM> while maintaining a uniform minimum wall thickness (such as about <NUM> thousandths of an inch) of, or offset from, internal components and exterior surface <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D are comprised of material having a higher thermal conductivity than the material forming the rest of body <NUM>. For example, enhanced conduction areas 238A, 238B, 238C, and 238D may be a silver-copper alloy, which has heat conductivity about <NUM> times that of nickel.

Enhanced conduction areas 238A, 238B, 238C, and 238D are created by forming one or more cavities, or pockets, in body <NUM> during additive manufacturing of body <NUM> and filling the cavities with material having a higher conductivity than the material forming the rest of body <NUM>. For example, the cavities may be filled with a silver-copper alloy. The cavities may be filled via multi-material additive manufacturing, via a two-step process by melting in the higher conductivity material in a vacuum furnace process, or via any other suitable process. As such, enhanced conduction areas 238A, 238B, 238C, and 238D may also be unitary to body <NUM>. The higher conductivity material may be in the form of a powder, a wire (such as a pelletized wire), or in any other suitable form prior to filling cavities within body <NUM>.

Heater <NUM> connects to heater circuitry (not shown) at second end <NUM> of probe head <NUM>, the circuitry going down strut <NUM> to connect to and get power from internal components of air data probe <NUM>. Heater <NUM> can have different amounts of power along rod heater <NUM> to distribute more heat or less heat depending on the needs of probe head <NUM>, or power can be uniform along heater <NUM> to further simplify manufacturing of heater <NUM>.

Thermal resistance of body <NUM> varies, particularly from heater <NUM> to exterior surface <NUM>, from first end <NUM> to second end <NUM> of probe head <NUM> due to different amounts of material between heater <NUM> and exterior surface <NUM> moving axially from first end <NUM> to second end <NUM> of probe head <NUM>. For example, air passageways 230A, 230B, 230C, and 230D can increase or decrease in diameter to increase or decrease the amount of material between heater bore <NUM> and exterior surface <NUM>, varying the thermal resistance of probe head <NUM> by having more or less metal to carry heat radially outward from heater <NUM>. Less metal in probe head <NUM> moving from first end <NUM> to second end <NUM> reduces the thermal resistance and results in less heat conduction from heater <NUM> to exterior surface <NUM> of probe head <NUM> moving from first end <NUM> to second end <NUM>. As such, probe head <NUM> is conducting less heat near second end <NUM> and diverting more heat toward first end <NUM>, or tip, of probe head <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D maximize heat conduction by filling the space between internal components of body <NUM> while maintaining a uniform offset from, or wall thickness of, internal components and exterior surface <NUM> needed for the functionality of probe head <NUM>. As such, enhanced conduction areas 238A, 238B, 238C, and 238D may also increase or decrease in size moving axially from first end <NUM> to second end <NUM> of probe head <NUM>. For example, enhanced conduction areas 238A, 238B, 238C, and 238D may be larger near tip, or first end <NUM>, of probe head <NUM>, resulting in higher thermal conductivity and greater heat conduction to first end <NUM>.

Air passageways 230A, 230B, 230C, and 230D are not fully linear and twist, or undulate, around heater bore <NUM> and water dams 232A and 232B to result in a line-of-sight deflection from first end <NUM>. An absence of a straight path from inlets 228A, 228B, 228C, and 228D, at first end <NUM>, to second end <NUM> of probe head <NUM>, as shown in <FIG>, assists in managing water that could get into probe head <NUM>. Water dams 232A and 232B redirect, or knock down, water particles in the airflow moving through air passageways 230A, 230B, 230C, and 230D. Water dams 232A and 232B block ice and water particles in exterior airflow and prevent ice and water particles from having a direct route down air passageways 230A, 230B, 230C, and 230D and through probe head <NUM>.

Traditional air data probes have a wire heater brazed to a body of a probe head. Other components, such as water dams, may also be positioned within and brazed onto traditional probe heads. As such, probe heads of traditional air data probes have complex heaters incorporated into multi-piece assemblies. Additionally, probe head bodies are typically formed of a single material.

Additive manufacturing allows for more complex internal geometry, including air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, heater bore <NUM>, and enhanced conduction areas 238A, 238B, 238C, and 238D of probe head <NUM>, which contribute to optimal functionality of air data probe <NUM>. Because exterior surface <NUM>, inlets 228A, 228B, 228C, and 228D, air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, heater bore <NUM> of body <NUM> form a single unitary piece, air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, and heater bore <NUM> are uniform in size, shape, and position among probe heads <NUM> to ensure optimal fit and performance as well as repeatability. For example, heater bore <NUM>, water dams 232A and 232B, and air passageways 230A, 230B, 230C, and 230D are combined with rod heater <NUM> and body <NUM> ensures the best fit between heater <NUM> and body <NUM>. Further, enhanced conduction areas 238A, 238B, 238C, and 238D formed via multi-material additive manufacturing are uniform among probe heads <NUM>, also ensuring optimal performance and repeatability. Additively manufactured body <NUM> of probe head <NUM> allows for easier and more effective use of rod-shaped heater <NUM> and enhanced conduction areas 238A, 238B, 238C, and 238D.

Rod heater <NUM> is simpler than a traditional complex heater brazed into a probe head. Because the power density of rod heater <NUM> can change axially along heater <NUM>, heater <NUM> still maintains the ability to tailor heat distribution within probe head <NUM> by enhancing conduction to the portions of probe head <NUM> that need heat via varied power density of heater <NUM>. Rod heater <NUM> can be a standardized heater among probe heads <NUM>. Heater <NUM> is also easier to manufacture and simplifies the assembly process of probe head <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D are also integrated into body <NUM> to further tailor heat distribution within probe head <NUM>. Enhanced conduction areas 238A, 238B, 238C, and 238D allow for more heat conduction toward first end <NUM>, or tip, of probe head <NUM> while maintaining a simple manufacture and assembly of probe head <NUM>.

The geometry of air passageways 230A, 230B, 230C, and 230D allows air passageways 230A, 230B, 230C, and 230D to twist around water dams 232A and 232B positioned in their direct path from first end <NUM>. Water dams 232A and 232B prevent ice and water particles from external airflow from moving through probe head <NUM> and decreasing functionality of air data probe <NUM>.

Utilizing additive manufacturing to create more complex internal geometry of body <NUM>, which has a complex one-piece shape that includes air passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B, heater bore <NUM>, and enhanced conduction areas 238A, 238B, 238C, and 238D and integrating a simpler form of a heater via rod heater <NUM> achieves the internal shapes and passages needed for optimal functionality of probe head <NUM> while enhancing heat conduction and simplifying manufacturing and assembly of probe head <NUM>.

<FIG> is a perspective top view of air data probe <NUM> showing enhanced conduction area <NUM> of probe head <NUM>. <FIG> is a partial perspective front view of probe head <NUM> showing enhanced conduction area <NUM>. <FIG> is a partial perspective front view of probe head <NUM> with part of body <NUM> of probe head <NUM> removed to show enhanced conduction area <NUM>. <FIG> is a cross-sectional view of probe head <NUM> taken along line D-D of <FIG>. <FIG> is a cross-sectional view of probe head <NUM> taken along line E-E of <FIG>, <FIG>, <FIG>, <FIG>, and <FIG> will be discussed together. Air data probe <NUM> includes probe head <NUM>, strut <NUM>, and mounting flange <NUM>. Probe head <NUM> includes first end <NUM>, second end <NUM>, body <NUM>, and heaters 324A and 324B. Body <NUM> includes exterior surface <NUM>, inlet <NUM>, air passageway <NUM>, water dam <NUM>, and heater bores 334A and 334B (including interior surface 336A and interior surface 336B, respectively) and enhanced conduction area <NUM>.

Probe head <NUM> has first end <NUM> making up the tip of probe head <NUM>. Second end <NUM> is opposite first end <NUM>. Second end <NUM> of probe head <NUM> is connected to strut <NUM>. Body <NUM> of probe head <NUM> extends from first end <NUM> to second end <NUM>. Body <NUM> may be a unitary, or single-piece, structure. Body <NUM> is additively manufactured and made of nickel or any other suitable material. Heaters 324A and 324B are positioned within body <NUM>. In this embodiment, probe head <NUM> has two side-by-side heaters 324A and 324B. Heaters 324A and 324B are spaced radially from each other. As such, heaters 324A and 324B are positioned adjacent exterior surface <NUM> of body <NUM>. Heaters 324A and 324B are rod heaters, which includes both rod and rod-like structures. Each heater 324A, 324B may be comprised of an electric resistive wire heater helically wound around a ceramic rod-like core. Each heater 324A, 324B may be tailored such that heater 324A, 324B has different amounts of power along heater 324A, 324B. For example, electric resistive wire may be wound to result in tighter or looser coils on ceramic core to increase or decrease the amount of coils, and thus the power density along heater 324A, 324B. Heater 324A, 324B may have more tightly wound coils at an end of heater 324A, 324B adjacent first end <NUM> of probe head <NUM> to deliver a greater amount of heat to the tip. Alternatively, heater 324A, 324B may be uniform such that the power density of heater 324A, 324B is uniform along heater 324A, 324B.

Exterior surface <NUM> of body <NUM> is an outer surface of body <NUM>. Exterior surface <NUM> of body <NUM> is the outer surface of probe head <NUM>. As such, external airflow contacts exterior surface <NUM>. Body <NUM> has inlet <NUM> near first end <NUM> of probe head <NUM>. Inlet 328A is an opening in body <NUM>. In this embodiment, body <NUM> has a single inlet 328A. Inlet <NUM> is connected to air passageway <NUM>. As such, body <NUM> has a single air passageway <NUM>. Air passageway <NUM> extends from inlets <NUM> to second end <NUM> of probe head <NUM>. Air passageway <NUM> extends through a center, or down the middle, of body <NUM>. A majority of air passageway <NUM> extends between heaters 324A and 324B such that heaters 324A and 324B are between a majority of air passageway <NUM> and exterior surface <NUM> of body <NUM>. Air passageway <NUM> extends in a substantially straight line and twists up to <NUM> degrees around water dam <NUM>. As such, air passageway <NUM> may have an undulating geometry from first end <NUM> to second end <NUM> such that air passageway <NUM> is redirected around water dam <NUM>. Water dam <NUM> is positioned in the line of sight of inlet <NUM>. Water dam <NUM> extends radially. In this embodiment, body <NUM> has a single water dam <NUM>.

Each heater 324A, 324B is positioned within a heater bore 334A, 334B. Heater bores 334A and 334B are cylindrical openings, or wells, extending along body <NUM> adjacent exterior surface <NUM>. Heater bores 334A and 334B are positioned between first end <NUM> and second end <NUM>. Heater bores 334A and 334B are not aligned. Rather, heater bores 334A and 334B are offset from exterior surface <NUM> of probe head <NUM>, which is slightly tapered. Each heater bore 334A, 334B is shaped to accept a respective rod heater 324A, 324B. In this embodiment, body <NUM> has two heater bores 334A and 334B to accommodate two heaters 334A and 334B. In alternate embodiments, probe head <NUM> may have one or more than two heaters 324A and 324B, each heater 324A, 324B positioned within a respective heater bore 334A, 334B. Each heater bore 334A, 334B has annular interior surface 336A, 336B that contacts respective heater 324A, 324B. Each heater 324A, 324B is slid into a respective heater bore 334A, 334B such that each heater 324A, 324B is in contact with an interior surface of heater bore 334A, 334B. Exterior surface <NUM>, inlets <NUM>, air passageway <NUM>, water dam <NUM>, and heater bores 334A and 334B are all unitary to body <NUM>, forming a single-piece structure.

Enhanced conduction area <NUM> is between heater bores 334A and <NUM> and exterior surface <NUM> of probe head <NUM>. Enhanced conduction area <NUM> is an area of enhanced thermal conduction. Enhanced conduction area <NUM> surrounds inlet <NUM>, air passageway <NUM>, and water dam <NUM>. Enhanced conduction area <NUM> fills space in body <NUM> between internal components. Enhanced conduction area <NUM> is as large as possible in a portion of body <NUM> adjacent first end <NUM>, filling areas between internal components of body <NUM> while maintaining a uniform minimum wall thickness (such as about <NUM> thousandths of an inch) of, or offset from, internal components and exterior surface <NUM>. In this embodiment, enhanced conduction area <NUM> does not extend to second end <NUM>. Enhanced conduction area <NUM> is comprised of material having a higher thermal conductivity than the material forming the rest of body <NUM>. For example, enhanced conduction area <NUM> may be a silver-copper alloy, which has a heat conductivity about <NUM> times that of nickel.

Enhanced conduction area <NUM> is created by forming a cavity, or pocket, in body <NUM> during additive manufacturing of body <NUM> and filling the cavity with material having a higher conductivity than the material forming the rest of body <NUM>. For example, the cavity may be filled with a silver-copper alloy. The cavities may be filled via multi-material additive manufacturing, via a two-step process by melting in the higher conductivity material in a vacuum furnace process, or via any other suitable process. As such, enhanced conduction area <NUM> may also be unitary to body <NUM>. The higher conductivity material may be in the form of a powder, a wire (such as a pelletized wire), or in any other suitable form prior to filling cavities within body <NUM>.

Heaters 324A and 324B connect to heater circuitry (not shown) at second end <NUM> of probe head <NUM>, the circuitry going down strut <NUM> to connect to and get power from internal components of air data probe <NUM>. Heaters 324A and 324B can have different amounts of power along rod heaters 324A and 324B to distribute more heat or less heat depending on the needs of probe head <NUM>, or power can be uniform along heaters 324A and 324B to further simplify manufacturing of heaters 324A and 324B.

Thermal resistance of body <NUM> varies, particularly from each heater 324A, 324B to exterior surface <NUM>, from first end <NUM> to second end <NUM> of probe head <NUM> due to different amounts of material between each heater 324A, 324B and exterior surface <NUM> moving axially from first end <NUM> to second end <NUM> of probe head <NUM>. The thermal resistance of probe head <NUM> can be varied by having more or less metal to carry heat radially outward from heaters 324A and 324B. Less metal in probe head <NUM> moving from first end <NUM> to second end <NUM> reduces the thermal resistance and results in less heat conduction from heaters 324A and 324B to exterior surface <NUM> of probe head <NUM> moving from first end <NUM> to second end <NUM>. As such, probe head <NUM> may conduct less heat near second end <NUM> and divert more heat toward first end <NUM>, or tip, of probe head <NUM>. Enhanced conduction area <NUM> maximizes heat conduction, particularly near first end <NUM>, by filling the space between internal components of body <NUM> in a front portion of body <NUM> near first end <NUM> while maintaining a uniform offset from, or wall thickness of, internal components and exterior surface <NUM> needed for the functionality of probe head <NUM>. As such, enhanced conduction area <NUM> may also increase or decrease in size moving axially away from first end <NUM> toward second end <NUM> of probe head <NUM>. For example, enhanced conduction area <NUM> may be larger near tip, or first end <NUM>, of probe head <NUM>, resulting in higher thermal conductivity and greater heat conduction to first end <NUM>. Enhanced conduction area <NUM> is also fully annular closer to, or adjacent, first end <NUM>, resulting in greater heat conduction to tip, or first end <NUM>.

Air passageway <NUM> is not fully linear and twists, or undulates, around heater bores 334A and 334B and water dam <NUM> to result in a line-of-sight deflection from first end <NUM>. An absence of a straight path from inlet <NUM> at first end <NUM> to second end <NUM> of probe head <NUM>, as shown in <FIG>, assists in managing water that could get into probe head <NUM>. Water dam <NUM> redirects, or knocks down, water particles in the airflow moving through air passageway <NUM>. Water dam <NUM> blocks ice and water particles in exterior airflow and prevents ice and water particles from having a direct route down air passageway <NUM> and through probe head <NUM>.

Additive manufacturing allows for more complex internal geometry, including air passageway <NUM>, water dam <NUM>, heater bores 334A and 334B, and enhanced conduction area <NUM> of probe head <NUM>, which contribute to optimal functionality of air data probe <NUM>. For example, probe head <NUM> is able to have two heater bores 334A and 334B, positioned exactly where needed, and enhanced conduction area <NUM> as well as the required internal geometry of air passageway <NUM> and water dam <NUM> that probe head <NUM> requires in order to function properly due to additively manufacturing probe head <NUM>. Because exterior surface <NUM>, inlets <NUM>, air passageway <NUM>, water dam <NUM>, heater bores 334A and 334B of body <NUM> form a single unitary piece, air passageway <NUM>, water dam <NUM>, and heater bores 334A and 334B are uniform in size, shape, and position among probe heads <NUM> to ensure optimal fit and performance as well as repeatability. For example, heater bores 334A and 334B, water dam <NUM>, and air passageway <NUM> are combined with rod heaters 324A and 324B and body <NUM> ensures the best fit between heaters 324A and 324A and 324B and body <NUM>. Further, enhanced conduction area <NUM> formed via multi-material additive manufacturing is uniform among probe heads <NUM>, also ensuring optimal performance and repeatability. Additively manufactured body <NUM> of probe head <NUM> allows for easier and more effective use of rod-shaped heaters 324A and 324B and enhanced conduction area <NUM>.

Additive manufacturing allows for two heaters 324A and 324B, positioned side-by-side, to increase the heating ability of probe head <NUM> compared to probe head <NUM> that has a single heater <NUM>, as shown in <FIG>, when more heat is required. Probe head <NUM> can respond to increased heat demands. Heater bores 334A and 334B are additively manufactured exactly where heat is needed such that heaters 324A and 324B provide enough heat within probe head <NUM>. Further, water dam <NUM>, air passageway <NUM>, and enhanced conduction area <NUM> are additively manufactured and shaped differently to accommodate multiple heater bores 334A and 334B. The geometry of air passageway <NUM> allows air passageway <NUM> to twist around water dams <NUM> positioned in its direct path from first end <NUM>. Water dam <NUM> prevents ice and water particles from external airflow from moving through probe head <NUM> and decreasing functionality of air data probe <NUM>. A forward end of enhanced conduction area <NUM> is forward of heaters 324A and 324B in order to provide increased heat distribution to first end <NUM>, which is subject to most extreme icing conditions.

Rod heaters 324A and 324B are simpler than a traditional complex heater brazed into a probe head. Because the power density of rod heaters 324A and 324B can change axially along heaters 324A and 324B, heaters 324A and 324B still maintain the ability to tailor heat distribution within probe head <NUM> by enhancing conduction to the portions of probe head <NUM> that need heat via varied power density of heaters 324A and 324B. Rod heaters 324A and 324B can be standardized heaters among probe heads <NUM>. Heaters 324A and 324B are also easier to manufacture and simplify the assembly process of probe head <NUM>. Enhanced conduction area <NUM> is also integrated into body <NUM> to further tailor heat distribution within probe head <NUM>. Enhanced conduction area <NUM> allows for more heat conduction toward first end <NUM>, or tip, of probe head <NUM> while maintaining a simple manufacture and assembly of probe head <NUM>.

Utilizing additive manufacturing to create more complex internal geometry of body <NUM>, which has a complex one-piece shape that includes air passageway <NUM>, water dams <NUM>, heater bores 334A and 334B, and enhanced conduction area <NUM> and integrating a simpler form of heaters via rod heaters 324A and 324B achieves the internal shapes and passages needed for optimal functionality of probe head <NUM> while enhancing heat conduction and simplifying manufacturing and assembly of probe head <NUM>.

Claim 1:
A probe head (<NUM>; <NUM>; <NUM>) of an air data probe (<NUM>), the probe head comprising:
a unitary body (<NUM>; <NUM>; <NUM>) extending from a first end (<NUM>; <NUM>; <NUM>) to a second end (<NUM>; <NUM>; <NUM>) of the probe head, the body comprising:
an inlet (<NUM>; <NUM>; <NUM>) adjacent the first end of the probe head;
an air passageway (<NUM>; <NUM>; <NUM>) (<NUM>) extending through the body from the inlet to the second end of the probe head; characterized by
a water dam (<NUM>; <NUM>; <NUM>) (<NUM>) extending radially through the body such that the air passageway is redirected around the water dam; and
a plurality of heater bores (<NUM>; 134A, 134B; 334A, 334B) extending within the body; and
a plurality of rod heaters (<NUM>; 124A, 124B; 324A, 324B), (<NUM>), each heater rod being positioned in a heater bore.