# US 10,371,497 B2 · Fully integral epoxy cap probe > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,371,497 B2 - Document ID: US10371497B2 - Status: Granted - Kind: B2 - Application number: 15/832,184 - Filed: 2017-12-05 - Published: 2019-06-06 - Granted: 2019-08-06 - Earliest claimed: 2017-12-05 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Eli Cole Warren; Peter J. Walsh - Web page: https://patentgrep.com/patent/US10371497B2 ## CPC - G01B 7/023: {for measuring distance between sensor and object (G01B7/082 and G01B7/102 take precedence)} - F01D 11/12: using a rubstrip, e.g. erodible. deformable or resiliently-biased part - F01D 11/14: Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing (rotors with blades adjustable in operation F01D7/00) - F01D 17/02: Arrangement of sensing elements - G01B 7/14: for measuring distance or clearance between spaced objects or spaced apertures (G01B7/30 takes precedence) - F05D 2270/80: Devices generating input signals, e.g. transducers, sensors, cameras or strain gauges - F05D 2300/44: Resins - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A fully integral epoxy cap probe may comprise a body having a cavity disposed radially outward of a fan blade and comprising a first material, a frame disposed within the cavity and comprising a second material, a first sensor element and a ground plane disposed within the frame, the first sensor element and the ground plane comprising a third material, and a first soft lead in electronic communication with the first sensor element and the ground plane. ## Claims ### Claim 1 A fully integral epoxy cap probe, comprising: a body having a cavity disposed radially outward of a fan blade and comprising a first material; a frame disposed within the cavity and comprising a second material; a first sensor element and a ground plane disposed within the frame, the first sensor element and the ground plane comprising a third material; and a first soft lead in electronic communication with the first sensor element and the ground plane, wherein the second material and the third material are at least one of a resin, epoxy, and/or thermoset material. ### Claim 2 (depends on 1) The fully integral epoxy cap probe of claim 1, wherein the first material comprises at least one of a composite, a resin, epoxy, and/or thermoset material. ### Claim 3 (depends on 2) The fully integral epoxy cap probe of claim 2, wherein the second material comprises at least one of a hydrophobic dielectric resin, epoxy, and/or thermoset material comprising bisphenol AF diglycidyl ether having fluorinated methyl groups. ### Claim 4 (depends on 3) The fully integral epoxy cap probe of claim 3, wherein the third material comprises at least one of a hydrophobic conductive resin, epoxy, and/or thermoset material comprising bisphenol AF diglycidyl ether having fluorinated methyl groups. ### Claim 5 (depends on 4) The fully integral epoxy cap probe of claim 4, wherein the body comprises a first passage wherein the first soft lead is disposed within the first passage. ### Claim 6 (depends on 5) The fully integral epoxy cap probe of claim 5, wherein the frame comprises a first channel aligned with the first passage, wherein the first soft lead further comprises a lead shield disposed within the first channel. ### Claim 7 (depends on 6) The fully integral epoxy cap probe of claim 6, wherein the frame further comprises a backplane and an enclosing wall extending perpendicular to the backplane, the enclosing wall having an inner face and an outer face, wherein the inner face defines a pocket, wherein the outer face and a sidewall of the cavity define a trench. ### Claim 8 (depends on 7) The fully integral epoxy cap probe of claim 7, wherein the pocket comprises a pocket wall. ### Claim 9 (depends on 7) The fully integral epoxy cap probe of claim 7, wherein the third material is disposed within the trench and the pocket. ### Claim 10 (depends on 9) The fully integral epoxy cap probe of claim 9, further comprising a cap comprising the second material disposed within the cavity over the third material. ### Claim 11 A gas turbine engine comprising: a fan having a blade having a tip; a fan case having an inner aerodynamic surface and a rub strip; the tip proximate the inner aerodynamic surface; and a fully integral epoxy cap probe, comprising: a body having a cavity disposed radially outward of the tip and comprising a first material; a frame disposed within the cavity and comprising a second material; a first sensor element and a ground plane disposed within the frame, the first sensor element and the ground plane comprising a third material, wherein the second material and the third material are at least one of a resin, epoxy, and/or thermoset material; and a first soft lead in electronic communication with the first sensor element and the ground plane. ### Claim 12 (depends on 11) The gas turbine engine of claim 11, wherein the first material comprises at least one of a composite, a resin, epoxy, and/or thermoset material, the second material comprises at least one of a hydrophobic dielectric resin, epoxy, and/or thermoset material comprising bisphenol AF diglycidyl ether having fluorinated methyl groups, and the third material comprises at least one of a hydrophobic conductive resin, epoxy, and/or thermoset material comprising bisphenol AF diglycidyl ether having fluorinated methyl groups. ### Claim 13 (depends on 12) The gas turbine engine of claim 12, wherein the body comprises a first passage wherein the first soft lead is disposed within the first passage. ### Claim 14 (depends on 13) The gas turbine engine of claim 13, wherein the frame comprises a first channel aligned with the first passage, wherein the first soft lead further comprises a lead shield disposed within the first channel. ### Claim 15 (depends on 14) The gas turbine engine of claim 14, wherein the frame further comprises a backplane and an enclosing wall extending perpendicular to the backplane, the enclosing wall having an inner face and an outer face, wherein the inner face defines a pocket, wherein the outer face and a sidewall of the cavity define a trench. ### Claim 16 (depends on 15) The gas turbine engine of claim 15, wherein the pocket comprises a pocket wall. ### Claim 17 (depends on 15) The gas turbine engine of claim 15, wherein the third material is disposed within the trench and the pocket. ### Claim 18 (depends on 17) The gas turbine engine of claim 17, further comprising a cap comprising the second material disposed within the cavity over the third material. ### Claim 19 (depends on 18) The gas turbine engine of claim 18, wherein the first material, the second material, and the third material comprise a monolithic structure. ### Claim 20 A method of manufacturing a fully integral epoxy cap probe, the method comprising: forming a cavity having a sidewall in a first material radially outward of a fan blade; forming a frame comprising a backplane and an enclosing wall, the enclosing wall extending perpendicular to the backplane and defining a pocket radially inward of the enclosing wall, wherein the frame comprises a second material; disposing the frame in the cavity such that the enclosing wall and the sidewall define a trench between the sidewall and the enclosing wall radially outward of the enclosing wall; inserting a soft lead comprising a lead wire and a lead shield into the frame wherein the lead shield is disposed within the trench and the lead wire is disposed within the pocket; filling the trench and the pocket with a third material and filling a remainder of the cavity with the second material; and curing the first material, the second material, and the third material to form a monolithic structure.