Internal hydroforming method for manufacturing heat pipe wicks using a hollow mandrel and sheath

Abstract

A forming assembly for forming a wick is disclosed. The forming assembly includes a tube expandable to an expanded shape. A wick mesh is configured to be wrapped around the tube. The forming assembly further includes a sheath positionable around the tube and the wick mesh. The tube and sheath are configured to compress the wick mesh and form the wick upon expansion of the tube to the expanded shape.

Description

[Background technology]

[0001] government contracts This invention was made with government support under Contract DE-NE0008853 awarded by the U.S. Department of Energy. The government has certain rights in this invention.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 012,725, filed April 20, 2020, the contents of which are incorporated herein by reference in their entirety.

[0003] The present invention relates generally to heat pipes used in heat transfer systems, and more particularly to a wick within a heat pipe configured to transport the working fluid of the heat pipe from a condenser region to an evaporator region of the heat pipe.

[0004] A heat pipe is a hermetically sealed, two-phase heat transfer component used to transfer heat from a primary side (evaporator section) to a secondary side (condenser section). FIG. 1 illustrates, by way of example, a heat pipe 100 including the aforementioned evaporator section 102 and condenser section 106 with an adiabatic section 104 extending therebetween. The heat pipe 100 further includes a working fluid (e.g., water, liquid potassium, sodium, or an alkali metal) and a wick 108. During operation, the working fluid is configured to absorb heat and evaporate in the evaporator section 102. Saturated vapor carrying the latent heat of vaporization flows through the adiabatic section 104 toward the condenser section 106. In the condenser section 106, the vapor condenses into a liquid pool 110, releasing its latent heat. The condensed liquid is then transported by capillary action back through the wick 108 to the evaporator section 102. The aforementioned flow path of the working fluid is illustrated by the dashed arrows in FIG. 1. The phase change process and two-phase flow circulation continues as long as the temperature gradient between the evaporator and condenser sections is maintained. Due to the very high heat transfer coefficients for boiling and condensation, heat pipes are very effective heat conductors.

[0005] In nuclear systems, heat pipes are utilized by placing the evaporator section of the heat pipe within the core containing the nuclear fuel and the condenser section near a heat exchanger. The nuclear fuel evaporates the working fluid, and the heat exchanger absorbs the latent heat in the condenser section. Examples of heat pipes in nuclear applications are described in U.S. Patent Nos. 5,684,848, 6,768,781, and U.S. Patent Application Publication No. 2016 / 0027536, all of which are incorporated herein by reference in their entireties.

[0006] Another exemplary use of heat pipes in nuclear systems is in microreactors, which are nuclear reactors that generate less than 10 MWe and can be deployed in remote applications. These microreactors are packaged in relatively small vessels, operate without active personnel involvement, and can operate without refueling / repair for longer periods of time than conventional nuclear power plants. One such microreactor is the eVinci microreactor system, designed by Westinghouse Electric Company. The eVinci system is a heat-pipe-cooled nuclear reactor power system that utilizes heat pipes to function as passive heat removal devices, efficiently transferring thermal energy from the reactor core to a heat exchanger.

[0007] Heat pipes used in microreactors are subject to extreme operating temperatures (over 850°C) and require an internal wick made from a material that can withstand these temperatures and is compatible with the working fluid. This wick can be constructed from wire mesh that is rolled and diffusion bonded together into a tubular structure. The wick tube allows the working fluid within the heat pipe to pass radially (e.g., after the latent heat is released and the working fluid is absorbed by the wick) and along its axis (transporting the working fluid back toward the evaporator section by capillary action) while remaining rigid.

[0008] Manufacturing wicks for insertion into heat pipes is a highly complex and meticulous process. Very broadly, wicks are manufactured by rolling a sheet of woven wick mesh material into the desired shape, compressing a material (e.g., a tube) onto the wick to force it into the desired shape, diffusion bonding the mesh together in a vacuum oven while maintaining the wick in compression, and then removing the used material, maintaining the wick in compression during the diffusion bonding process. An example of this method of wick forming is described in U.S. Pat. No. 3,964,902, entitled "METHOD OF FORMING A WICK FOR A HEAT PIPE," the entire disclosure of which is incorporated herein by reference.

[0009] A known method for forming wound wire mesh wicks in preparation for diffusion bonding utilizes a copper mandrel and sheath that are drawn using a drawing operation to permanently deform both the copper mandrel and sheath and compress the wick mesh to its final dimensions. However, copper drawing requires the use of a different size drawing die each time a new size wick is formed. This is a time-consuming and expensive process due to the repeated changes in die design, especially given the continual changes in wick shape design as reactor designs change.

[0010] It is an object of the present disclosure to provide an assembly and method for forming a wick at a cost and time significantly lower than other publicly documented methods, such as the copper drawing process mentioned above. Summary of the Invention

[0011] In various embodiments, a forming assembly for forming a wick is disclosed. The forming assembly includes a tube expandable to an expanded shape. A wick mesh is configured to be wrapped around the tube. The forming assembly further includes a sheath positionable around the tube and the wick mesh. The tube and sheath are configured to compress the wick mesh and form the wick upon expansion of the tube to the expanded shape.

[0012] In various embodiments, a method of forming a wick using a mandrel is disclosed. The method includes placing a wick mesh around the mandrel, placing a sheath around the mandrel and the wick mesh, and connecting a first fitting to the mandrel. The first fitting includes an adapter configured to connect to a pressure source. The method further includes pressurizing the mandrel with the pressure source to hydraulically expand the mandrel such that the mandrel compresses the wick mesh against the sheath and forms the wick.

[0013] In various embodiments, a forming assembly for forming a wick is disclosed. The forming assembly includes an inner housing that is hydraulically expandable to an expanded shape. The wick mesh is configured to be wrapped around the inner housing. The forming assembly further includes an outer housing that is positionable around the inner housing and the wick mesh. The inner and outer housings are configured to compress the wick mesh and form the wick based on the inner housing hydraulically expanding to the expanded shape. [Brief explanation of the drawings]

[0014] The various features of the embodiments described herein, together with their advantages, may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

[0015] [Figure 1] Figure 1 shows the working fluid moving through a heat pipe.

[0016] [Figure 2] FIG. 2 is a mold assembly according to at least one embodiment of the present disclosure.

[0017] [Figure 3] FIG. 3 is a detailed view of a first portion of the molding assembly of FIG. 2, according to at least one embodiment of the present disclosure.

[0018] [Figure 4] FIG. 4 is a detailed view of a second portion of the molding assembly of FIG. 2, according to at least one embodiment of the present disclosure.

[0019] [Figure 5] FIG. 5 is a method of forming a wick using a mandrel according to at least one embodiment of the present disclosure.

[0020] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set forth herein illustrate various embodiments of the present invention in one form, and such exemplifications should not be construed as limiting the scope of the present invention in any manner. DETAILED DESCRIPTION OF THE INVENTION

[0021] The applicant of the present application owns the following patent applications filed concurrently with this application, each of which is incorporated herein by reference in its entirety:

[0022] U.S. Application No. 6 / 853,270, filed April 20, 2020, entitled "INTERNAL HYDROFORMING METHOD FOR MANUFACTURING HEAT PIPE WICKS," inventors John Lojek III et al. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described herein and illustrated in the accompanying drawings. Well-known operations, components, and elements are not described in detail so as not to obscure the embodiments described herein. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus, it will be understood that specific structural and functional details disclosed herein may be representative and exemplary. Variations and modifications thereto may be made without departing from the scope of the claims.

[0023] 2 illustrates a forming assembly 200 according to at least one embodiment of the present disclosure. Forming assembly 200 includes a mandrel, tube, or inner housing 202. By way of example, mandrel 202 may be any suitable hollow shape, such as a circular tube, a square tube, or an oval tube. For a circular tube mandrel 202, the outer diameter may be, by way of example, 0.5 inches. Other embodiments are envisioned in which mandrel 202 has an outer diameter greater than or less than 0.5 inches.

[0024] The mandrel 202 is annealed sufficiently to allow the mandrel 202 to deform and expand outward, or hydraulically expand, when pressure is applied to the inner surface of the mandrel 202, as described in more detail below. Sufficient annealing of the mandrel 202 allows the mandrel 202 to expand without rupturing. The mandrel 202 can be fabricated from any suitable material, such as copper, carbon steel, or any other suitable material that can deform and expand when pressure is applied to the inner surface of the mandrel 202. By way of example, the mandrel 202 can be fabricated with any suitable thickness, such as approximately 0.032 inches. Other embodiments are contemplated in which the mandrel 202 has a thickness greater than or less than 0.032 inches. In one embodiment, the mandrel 202 can have a thickness of approximately 0.03 to 0.04 inches. In another embodiment, the mandrel 202 can have a thickness of approximately 0.02 to 0.05 inches.

[0025] A sheet or multiple layered sheets of wick mesh 204 can be tightly wound or wrapped around the mandrel 202. By way of example, the wick mesh 204 can be fabricated from any suitable material desired to form a wick, such as stainless steel (e.g., 316 stainless steel) or molybdenum. As shown in Figures 2-4, the length of the wick mesh 204 is cut shorter than the length of the mandrel 202. By way of example, the length L of the wick mesh 204 can be cut shorter than the length of the mandrel 202. w The mandrel length L can be approximately 48 inches. m may be approximately 52 inches. Other lengths of the wick mesh 204 and mandrel 202 are contemplated. In various embodiments, the length L of the wick mesh 204 w and the mandrel length L m In one exemplary embodiment, the length L of the wick mesh 204 may be the same or at least substantially the same. w is the mandrel length L mIn one exemplary embodiment, the length L of the wick mesh 204 may be 75% of the w is the mandrel length L m In one exemplary embodiment, the length L of the wick mesh 204 may be 50% of the w is the mandrel length L m In one exemplary embodiment, the length L of the wick mesh 204 may be 25% of the w is the mandrel length L m It may be larger.

[0026] The forming assembly 200 may further include a sheath, outer tube, or outer housing 206. The sheath 206 may be disposed around the mandrel 202 and the wick mesh 204. During operation, as described above, pressure may be applied to the interior surface of the mandrel 202. The mandrel 202, with the wick mesh 204 wrapped around the mandrel 202, may expand outward toward the interior surface of the sheath 206. The sheath 206 and mandrel 202 may compress and deform the wick mesh 204 between them, shaping the wick mesh.

[0027] The sheath 206 can define the final outer diameter or shape of the wick. The sheath 206 can be any suitable cross-sectional shape desired for the wick, such as a circle, an oval, a square, or any shape desired for the wick. As an example, for a circular tubular sheath 206, the outer diameter can be 0.625 inches. Other embodiments are envisioned in which the sheath 206 has an outer diameter greater than or less than 0.625 inches. In one embodiment, the sheath 206 can have an outer diameter of approximately 0.6-0.7 inches. In another embodiment, the sheath 206 can have an outer diameter of approximately 0.5-0.8 inches.

[0028] As shown in Figures 2 to 4, the sheath length L s is the mandrel length L m The length of the wick mesh L may be shorter than wFor example, the sheath length L s may be approximately 50 inches. Having a sheath 206 that is longer than the wick mesh 204 prevents the wick mesh 204 from expanding outward from between the sheath 206 and the mandrel 202, helping to maintain a uniform shape of the wick. In another embodiment, the wick mesh length L w and sheath length L s In another embodiment, the length L of the wick mesh may be the same or at least substantially the same. w is the sheath length L s In one embodiment, the length of the wick mesh L w is the sheath length L s In one embodiment, the wick mesh length L w is the sheath length L s In one embodiment, the wick mesh length L w is the sheath length L s The thickness may be less than 85% of the thickness.

[0029] The sheath 206 may be of different shapes, diameters, lengths, and sizes and can be manufactured to custom dimensions to create wicks of various sizes, shapes, and appearances. While the final size and shape of the wick is determined by the outer diameter or shape of the sheath 206, the final thickness of the wick is determined by the number and thickness of the layers of the wick mesh 204. In one embodiment, the final thickness of the wick is determined by the number of times the wick mesh 204 is wrapped around the mandrel 202 and / or the number of layers of wick mesh 204 used, and the thickness of the wick mesh 204.

[0030] The sheath 206 is cold worked or cold drawn to provide it with high strength, which prevents the mandrel 202 and wick mesh 204 from further deformation when compressed against the inner surface of the sheath 206. The sheath 206 can be made from any suitable material, such as copper, carbon steel, or any other suitable material that can stop the mandrel 202 and wick mesh 204 from further deformation when pressure is applied to the inner surface of the sheath 206.

[0031] The molding assembly 200 may further include a first fitting 220. The first fitting 220 may include a first flange 222 and a first adapter 224. The first flange 222 may be slidable and / or positionable around the first end of the mandrel 202. As shown in FIGS. 2 and 3 , the first adapter 224 may be threadably engaged with the first flange 222. Other suitable means for connecting the first adapter 224 to the first flange 222 are contemplated by the present disclosure, such as, for example, a quick connect or a latch. In another embodiment, the first flange 222 and the first adapter 224 are of unitary construction. The connection between the first flange 222 and the first adapter 224 may be sealed to prevent leakage of pressurized medium between the first flange 222 and the first adapter 224 when the pressurized medium is applied through the first adapter 224 and the first flange 222, as described below. In another embodiment, it is contemplated that an O-ring may be used to further define a seal between the connection of first flange 222 and first adapter 224 .

[0032] The first adapter 224 can include a hydraulic opening 226 that can mate with and / or couple to a pressure source, for example, a hydraulic source. The pressure source can provide a pressurized medium, for example, hydraulic pressure or air, through the first adapter 224 and first flange 222 and into the mandrel 202. The pressurized medium can pressurize the mandrel 202, causing the mandrel 202 and wick mesh 204 to expand or hydraulically expand toward the sheath 206. The pressure source can pressurize the mandrel 202 with the pressurized medium until the mandrel 202 compresses the wick mesh 204 into the sheath 206 and the mandrel 202 is permanently deformed into the wick mesh 204.

[0033] The molding assembly 200 may further include a second fitting 230. The second fitting 230 may include a second flange 232, a second adapter 234, and a cap 236. The second flange 232 may slide and / or be disposed about the mandrel 202. The second adapter 234 may couple with the second flange 232 and the cap 236. As shown in FIGS. 2 and 4 , the second adapter 234 may be threadedly engaged with the second flange 232 and the cap 236. Other suitable means for coupling the second adapter 234 to the second flange 232 and the cap 236 are contemplated by the present disclosure, such as, for example, a quick connect or a latch. In another embodiment, the second flange 232 and the second adapter 234 are of a unitary structure. The connection between the second flange 232, the second adapter 234, and the cap 236 may be sealed to prevent pressurized medium from leaking from the connection therebetween as the pressurized medium flows through the second flange 232, the second adapter 234, and the cap 236. In another embodiment, it is contemplated that an O-ring may be used to further define a seal between the connection of the second flange 232, the second adapter 234, and the cap 236.

[0034] As mentioned above, before pressurizing the mandrel 202, the cap 236 can be removed from the second adapter 234 and all gas within the forming assembly 200 can be evacuated. Once evacuated, the cap 236 is reconnected to the second adapter 234 and pressurized medium is applied through the forming assembly 200 such that as the pressurized medium flows through the second fitting 230, the pressurized medium does not leak out and the mandrel 202 is pressurized.

[0035] As described above, the pressure source can pressurize the mandrel 202 with a pressurizing medium until the mandrel 202 compresses the wick mesh 204 into the sheath 206 and the mandrel 202 is permanently deformed into the wick mesh 204. Once sufficiently pressurized and deformed, the pressurizing medium can be expelled from the forming assembly 200. The now permanently deformed mandrel 202 maintains a compressive force on the wick mesh 204 and sheath 206.

[0036] In preparation for diffusion bonding, the first mating portion 220 and the second mating portion 230 can be removed from the mandrel 202. In another embodiment, the first mating portion 220 and the second mating portion 230 are not removed prior to diffusion bonding. In one embodiment, the first mating portion 220 can be removed by cutting the mandrel 202 at a first cutting point 240, and the second mating portion 230 can be removed by cutting the mandrel 202 at a second cutting point 242. The cutting points 240, 242 are defined by the gap between the end of the sheath 206 and the mating portions 220, 230. Once the first mating portion 220 and the second mating portion 230 are removed from the mandrel 202, the remaining deformed mandrel 202, wick mesh 204, and sheath 206 are diffusion bonded at high temperatures (e.g., above about 900°C) and low vacuum pressure. The mandrel 202 and sheath 206 act as a support structure that maintains compressive support for the wick mesh 204 to maintain its shape during the diffusion bonding process. Once the diffusion bonding process is complete, the mandrel 202 and sheath 206 can be chemically dissolved / removed from the wick, as described in more detail below.

[0037] Referring now to FIG. 5 , a method 300 of forming a wick using a mandrel is disclosed in accordance with at least one embodiment of the present disclosure. Method 300 can include placing 302 a wick mesh around the mandrel, placing 304 a sheath around the mandrel and the wick mesh, and connecting 306 a first fitting to the mandrel. The first fitting can include an adapter that can be connected to a pressure source. Method 300 can further include pressurizing the mandrel with the pressure source, hydraulically expanding the mandrel and compressing the wick mesh against the sheath to form the wick 308. Method 300 can optionally include pressurizing the mandrel so that the mandrel is permanently deformed into the wick. Method 300 can also optionally include depressurizing the mandrel and diffusion bonding the wick and mandrel together. Method 300 can also optionally include chemically removing the mandrel from the wick after diffusion bonding the wick and mandrel together. The method 300 can also optionally include coupling a second fitting to the mandrel and evacuating gas within the mandrel.

[0038] As described above, after the diffusion bonding process, the mandrel 202 and sheath 206 can be chemically dissolved and / or removed from the wick. Chemical dissolution / removal of the mandrel 202 and sheath 206 requires the use of specific chemicals depending on the material of the wick mesh 204. The chemical solution must react with the mandrel 202 and sheath 206 more quickly than with the wick mesh 204 to avoid damaging the wick during the removal process. Therefore, the material selection for the mandrel 202 and sheath 206 must take into account the specific chemicals required for removal and the chemical's ability to not damage the wick. As an example, the mandrel 202 and sheath 206 may be made from copper, and the wick mesh 204 may be stainless steel. As an example, nitric acid has been found to successfully remove the mandrel 202 and sheath 206 from the wick without significantly removing / damaging the wick.

[0039] The above-described forming assembly 202 and method are not limited to a stainless steel wick mesh 204 and a copper mandrel 202 and sheath 206. As an example, in one embodiment, the wick mesh 204 can be made from molybdenum. When using a molybdenum wick mesh 204, the mandrel 202 and sheath 206 materials must be selected taking into account the chemical dissolution / removal factors described above as well as the higher diffusion bonding temperature of molybdenum. As an example, when using a molybdenum wick mesh 204, a carbon steel mandrel 202 and sheath 206 can be used. Different mandrels 202 and sheaths 206 are required for different wick meshes, but the wick manufacturing process described above remains the same.

[0040] The molding assembly 200 described herein is capable of molding wicks of many different sizes and shapes with minimal cost differential. The molding assembly requires only the selection of different mandrels and / or sheath tubes, thereby providing the flexibility to rapidly fabricate wicks of various materials, shapes, and sizes in response to microreactor design changes. The molding assembly has been found to produce permanently deformed wicks containing uniform pore sizes, as confirmed by bubble testing. The molding assembly 200 and associated processes described above produce wicks that have been tested after diffusion bonding and proven to have suitable dimensions (outer diameter, thickness), tolerances (approximately ±0.001 inch diameter), pore sizes, and strength required for heat pipe utilization. The molding assembly 200 and associated processes have also proven highly repeatable through multiple trials. Because the molding assembly 200 only requires the selection of different mandrels 202 and sheaths 206, many different sized wicks can be molded with minimal cost differential, thereby providing the flexibility to rapidly create wicks of various materials, shapes, and sizes as microreactor designs change. [Example]

[0041] Various aspects of the subject matter described herein are set forth in the following examples.

[0042] Example 1 A forming assembly for forming a wick comprising an expandable tube into an expanded shape, the wick mesh being configured to be wrapped around the tube, the forming assembly further comprising a sheath positionable around the tube and the wick mesh, the sheath configured to compress the wick mesh and form the wick upon expansion of the tube into the expanded shape.

[0043] Example 2 The molded assembly of Example 1, wherein the tube comprises an annealed tube.

[0044] Example 3 The molded assembly of example 1 or 2, wherein the sheath comprises a cold drawn sheath.

[0045] Example 4 The mold assembly of any one of Examples 1-3, wherein the sheath is configured to define an outer diameter of the wick.

[0046] Example 5 The molding assembly of any one of Examples 1 to 4, further comprising a first fitting connectable to a tube, the first fitting comprising an adapter connectable to a pressure source.

[0047] Example 6 The molding assembly of example 5, wherein a pressure source is configured to pressurize the tube, causing the tube to transition to an expanded shape and compressing the wick mesh against the sheath.

[0048] Example 7 The molded assembly of Example 6, wherein the tube maintains the wick mesh compressed against the sheath when the pressure source depressurizes the tube.

[0049] Example 8 The mold assembly of any one of Examples 1 to 7, further comprising a second fitting connectable to a pipe, the second fitting comprising an exhaust port.

[0050] Example 9 A method of forming a wick using a mandrel, the method including: placing a wick mesh around the mandrel; placing a sheath around the mandrel and the wick mesh; and connecting a first fitting to the mandrel. The first fitting includes an adapter configured to connect to a pressure source. The method further includes pressurizing the mandrel with the pressure source to hydraulically expand the mandrel such that the mandrel compresses the wick mesh against the sheath and forms a wick.

[0051] Example 10 The method of example 9, further comprising applying pressure to the mandrel such that the mandrel is permanently deformed into a wick.

[0052] Example 11 11. The method of example 9 or 10, further comprising applying a vacuum to the mandrel and diffusion bonding the wick and the mandrel.

[0053] Example 12 12. The method of example 11, further comprising chemically removing the mandrel from the wick after diffusion bonding the wick and the mandrel.

[0054] Example 13 13. The method of any one of Examples 9-12, further comprising coupling a second fitting to the mandrel and evacuating gas within the mandrel.

[0055] Example 14 - A molding assembly for molding a wick comprising an inner housing that is hydraulically expandable to an expanded shape. The wick mesh is configured to be wrapped around the inner housing. The molding assembly further comprises an outer housing positionable around the inner housing and the wick mesh. The inner and outer housings are configured to compress the wick mesh and mold the wick upon hydraulic expansion of the inner housing to the expanded shape.

[0056] Example 15 15. The molded assembly of example 14, wherein the inner housing comprises an annealed tube.

[0057] Example 16 16. The molded assembly of example 14 or 15, wherein the outer housing comprises a cold drawn tube.

[0058] Example 17 17. The mold assembly of any one of Examples 14-16, wherein the outer housing is configured to define the outer diameter of the wick.

[0059] Example 18 18. The molded assembly of any one of Examples 14-17, further comprising a first fitting connectable to the inner housing, the first fitting comprising an adapter connectable to a pressure source.

[0060] Example 19 - The mold assembly of Example 18, wherein the pressure source is configured to pressurize the inner housing, hydraulically expanding the inner housing to an expanded shape and compressing the wick mesh against the outer housing.

[0061] Example 20 The mold assembly of Example 19, wherein the inner housing maintains the wick mesh compressed against the outer housing when the pressure source depressurizes the inner housing.

[0062] Unless otherwise specifically stated as is apparent from the above disclosure, throughout the above disclosure, discussions using terms such as "processing," "computing," "calculating," "determining," "displaying," and the like refer to the acts and processes of a computer system or similar electronic computing device that manipulates and transforms data represented as physical (electronic) quantities in the computer system's registers and memory into other data that is similarly represented as physical quantities in the computer system's memory or registers, or other such information storage, transmission, or display device.

[0063] One or more components may be referred to herein as being "configured to," "configurable to," "operable to," "adapted to," "capable to," "adaptable to," etc. Those skilled in the art will recognize that, unless the context requires otherwise, "configured to" may generally encompass active components and / or inactive components and / or standby components.

[0064] Those skilled in the art will recognize that the terms used in this specification, generally, and in the appended claims in particular (e.g., the body of the appended claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "having at least," the term "include" should be interpreted as "including, but not limited to," etc.). It will be further understood by those skilled in the art that where a specific number of claim recitations are intended to be introduced, such intention will be expressly recited in the claim; in the absence of such recitation, no such intention exists. For example, as an aid to understanding, the following appended claims may contain the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that introducing a claim recitation with the indefinite article "a" or "an" limits any particular claim containing such an introduced claim recitation to claims containing only one such recitation, even when that same claim includes the introductory phrase "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should typically be construed to mean "at least one" or "one or more"), nor should the use of definite articles used to introduce claim recitations.

[0065] Furthermore, even when a specific number of introduced claim recitations is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., an explicit recitation of "two recitations" without other modifiers typically means at least two recitations, or more than two recitations. Furthermore, in such cases where a convention similar to "at least one of A, B, and C, etc." is used, such structure is generally intended in the sense that those skilled in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include, but is not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Conventions similar to "at least one of A, B, or C, etc." is used, generally, such structure is intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include, but is not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those of ordinary skill in the art that typical disjunctive words and / or phrases presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibility of including one of the terms, either of the terms, or both terms, unless the context dictates otherwise. For example, the phrase "A or B" would typically be understood to include the possibilities of "A" or "B" or "A and B."

[0066] With respect to the appended claims, those skilled in the art will understand that the operations recited therein may generally be performed in any order. Also, while various operational flow diagrams are presented in sequences, it should be understood that various operations may be performed in other orders than those illustrated, or may be performed simultaneously. Examples of such alternative orderings may include overlapping, interleaved, interrupted, reordered, incremental, preliminary, supplemental, simultaneous, reverse, or various other orderings, unless the context dictates otherwise. Furthermore, unless the context dictates otherwise, terms such as "responsive to," "related to," or other past tense adjectives are generally not intended to exclude such variations.

[0067] It should be noted that any reference to "one embodiment," "one embodiment," "one example," "one example," etc. means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment," "in one embodiment," "in one example," and "in one example" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0068] Any patent applications, patents, non-patent publications, or other disclosure materials referenced herein and / or listed in any Application Data Sheet are incorporated herein by reference to the extent that such materials are not inconsistent with this specification. Accordingly, and to the extent necessary, the present disclosure as expressly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated herein by reference but that conflicts with existing definitions, descriptions, or other disclosure material set forth herein is incorporated only to the extent that there is no conflict between the incorporated material and the existing disclosure material.

[0069] The terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as "has" and "having"), "include" (and any form of include, such as "includes" and "including"), and "contain" (and any form of contain, such as "contains" and "containing") are open-ended linking verbs. Consequently, a system that "includes," "has," "includes," or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Similarly, an element of a system, device, or apparatus that "includes," "has," "includes," or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

[0070] As used in this disclosure, the terms "substantially," "about," or "approximately," unless otherwise specified, refer to an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In some embodiments, the terms "substantially," "about," or "approximately" mean within 1, 2, 3, or 4 standard deviations. In some embodiments, the terms "substantially," "about," or "approximately" mean within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0071] In summary, numerous benefits resulting from employing the concepts described herein are described. The foregoing description of one or more embodiments is presented for purposes of illustration and description. It is not intended to be exhaustive or limited to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The one or more embodiments were selected and described in order to illustrate the principles and practical applications, thereby enabling those skilled in the art to utilize the various embodiments and with various modifications suitable for the particular use contemplated. The claims filed herein are intended to define the overall scope. The following items are elements that are claimed in the international application: (Item 1) 1. A molding assembly for molding a wick, comprising: a tube expandable to an expanded shape, the tube being configured with a wick mesh wrapped around the tube; a sheath positionable around the tube and the wick mesh, the tube and sheath configured to compress the wick mesh and shape the wick upon expansion of the tube to the expanded shape; and A molding assembly comprising: (Item 2) Item 10. The molding assembly of item 1, wherein the tube comprises an annealed tube. (Item 3) 3. The mold assembly of claim 1 or 2, wherein the sheath comprises a cold drawn sheath. (Item 4) 4. The molding assembly of any one of items 1 to 3, wherein the sheath is configured to define an outer diameter of the wick. (Item 5) 5. The molding assembly according to any one of items 1 to 4, further comprising a first fitting portion connectable to the tube, the first fitting portion comprising an adapter connectable to a pressure source. (Item 6) Item 6. The molding assembly of item 5, wherein the pressure source is configured to pressurize the tube, transitioning the tube to the expanded shape and compressing the wick mesh against the sheath. (Item 7) 7. The molding assembly of claim 6, wherein the tube maintains the wick mesh compressed against the sheath when the pressure source depressurizes the tube. (Item 8) 8. The molding assembly according to any one of items 1 to 7, further comprising a second fitting portion connectable to the pipe, the second fitting portion comprising an exhaust portion. (Item 9) 1. A method of forming a wick using a mandrel, said method comprising: placing a wick mesh around the mandrel; placing a sheath around the mandrel and the wick mesh; coupling a first fitting to the mandrel, the first fitting comprising an adapter configured to couple to a pressure source; pressurizing the mandrel with the pressure source to hydraulically expand the mandrel such that the mandrel compresses the wick mesh against the sheath to form the wick; A method comprising: (Item 10) 10. The method of claim 9, further comprising applying pressure to the mandrel such that the mandrel is permanently deformed into the wick. (Item 11) depressurizing the mandrel; Diffusion bonding the wick and the mandrel; 11. The method of item 9 or 10, further comprising: (Item 12) Item 12. The method of item 11, further comprising chemically removing the mandrel from the wick after diffusion bonding the wick and the mandrel. (Item 13) connecting a second fitting to the mandrel; evacuating gas from within the mandrel; 13. The method according to any one of items 9 to 12, further comprising: (Item 14) 1. A molding assembly for molding a wick, comprising: an inner housing that is hydraulically expandable to an expanded shape, the inner housing being configured with a wick mesh wrapped around the inner housing; an outer housing positionable around the inner housing and the wick mesh, the outer housing and the inner housing configured to compress the wick mesh and shape the wick upon hydraulic expansion of the inner housing to the expanded shape; A molding assembly comprising: (Item 15) Item 15. The mold assembly of item 14, wherein the inner housing comprises an annealed tube. (Item 16) 16. The mold assembly of claim 14 or 15, wherein the outer housing comprises a cold drawn tube. (Item 17) 17. The molding assembly of any one of items 14 to 16, wherein the outer housing is configured to define an outer diameter of the wick. (Item 18) a first fitting portion connectable to the inner housing; 18. The molding assembly of any one of items 14 to 17, wherein the first fitting comprises an adapter connectable to a pressure source. (Item 19) Item 19. The molding assembly of item 18, wherein the pressure source is configured to pressurize the inner housing, hydraulically expanding the inner housing to the expanded shape and compressing the wick mesh against the outer housing. (Item 20) 20. The mold assembly of claim 19, wherein the inner housing maintains the wick mesh compressed against the outer housing when the pressure source depressurizes the inner housing.

Claims

1. 1. A molding assembly for molding a wick, comprising: a tube expandable to an expanded shape, the tube being configured with a wick mesh wrapped around the tube; a sheath positionable around the tube and the wick mesh, the tube and sheath configured to compress the wick mesh and shape the wick upon expansion of the tube to the expanded shape; and a first fitting portion connectable to the pipe; Equipped with the first fitting portion includes an adapter connectable to a pressure source; the pressure source is configured to pressurize the tube, causing the tube to transition to the expanded shape and compressing the wick mesh against the sheath; A molding assembly, wherein the tube maintains the wick mesh compressed against the sheath when the pressure source depressurizes the tube.

2. The mold assembly of claim 1 , wherein the tube comprises an annealed tube.

3. The mold assembly of claim 1 or 2, wherein the sheath comprises a cold drawn sheath.

4. The mold assembly of any one of claims 1 to 3, wherein the sheath is configured to define an outer diameter of the wick.

5. The mold assembly of any one of claims 1 to 4, further comprising a second fitting connectable to the tube, the second fitting comprising an exhaust port.

6. 1. A method of forming a wick using a mandrel, said method comprising: placing a wick mesh around the mandrel; placing a sheath around the mandrel and the wick mesh; coupling a first fitting to the mandrel, the first fitting comprising an adapter configured to couple to a pressure source; pressurizing the mandrel with the pressure source to hydraulically expand the mandrel such that the mandrel compresses the wick mesh against the sheath to form the wick; Including, The method, wherein when the pressurizing is performed, the mandrel maintains the wick mesh compressed against the sheath when the pressure source depressurizes the mandrel.

7. depressurizing the mandrel; Diffusion bonding the wick and the mandrel; The method of claim 6 further comprising:

8. The method of claim 7 further comprising chemically removing the mandrel from the wick after diffusion bonding the wick and the mandrel.

9. Prior to compressing the mandrel, connecting a second fitting to the mandrel; evacuating gas from within the mandrel; The method of any one of claims 6 to 8, further comprising:

10. 1. A molding assembly for molding a wick, comprising: an inner housing that is hydraulically expandable to an expanded shape, the inner housing being configured with a wick mesh wrapped around the inner housing; an outer housing positionable around the inner housing and the wick mesh, the outer housing and the inner housing configured to compress the wick mesh and shape the wick upon hydraulic expansion of the inner housing to the expanded shape; a first fitting portion connectable to the inner housing; Equipped with the first fitting portion includes an adapter connectable to a pressure source; the pressure source is configured to pressurize the inner housing, hydraulically expanding the inner housing to the expanded shape and compressing the wick mesh against the outer housing; A molded assembly, wherein the inner housing maintains the wick mesh compressed against the outer housing when the pressure source depressurizes the inner housing.

11. The mold assembly of claim 10 , wherein the inner housing comprises an annealed tube.

12. 12. The mold assembly of claim 10 or 11, wherein the outer housing comprises a cold drawn tube.

13. The mold assembly of any one of claims 10 to 12, wherein the outer housing is configured to define an outer diameter of the wick.

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