Fully integral epoxy cap probe

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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. The fully integral epoxy cap probe of claim 7 , wherein the pocket comprises a pocket wall.

9. The fully integral epoxy cap probe of claim 7 , wherein the third material is disposed within the trench and the pocket.

10. 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.

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.

12. 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.

13. 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.

14. 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.

15. 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.

16. The gas turbine engine of claim 15 , wherein the pocket comprises a pocket wall.

17. The gas turbine engine of claim 15 , wherein the third material is disposed within the trench and the pocket.

18. The gas turbine engine of claim 17 , further comprising a cap comprising the second material disposed within the cavity over the third material.

19. The gas turbine engine of claim 18 , wherein the first material, the second material, and the third material comprise a monolithic structure.

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.