Friction stir welding encapsulated non-typical heat pipe integrated with plate structure and method

Abstract

The application provides a structure and method for integrating a friction stir welding packaged atypical heat pipe with a plate body, which comprises: a device mounting side plate body and a bearing structure plate body; the device mounting side plate body and the bearing structure plate body are arranged in parallel, and after the device mounting side plate body and the bearing structure plate body are butted, an atypical heat pipe structure is formed between the device mounting side plate body and the bearing structure plate body; the atypical heat pipe structure comprises a macroscopic flow channel and a microscopic reflux channel; the macroscopic flow channel is used for connecting the evaporation section and the condensation section of the heat pipe and realizing the evaporation and condensation flow of the working medium; the microscopic reflux channel is used for realizing the capillary reflux of the condensed liquid; the device mounting side plate body and the bearing structure plate body are packaged by friction stir welding along the outer edge to realize the overall sealing of the atypical heat pipe structure. The application eliminates the multiple interface thermal resistances of the traditional skin layer and the glue layer, improves the heat transfer efficiency, the heat management uniform heating capacity, the mechanical properties of the structure and the sealing reliability.

Description

Technical Field

[0001] This application relates to the technical field of plate structures and thermal control systems for satellite or other spacecraft equipment, and in particular to an atypical integrated structure and method for heat pipes and plates encapsulated by friction stir welding. Background Technology

[0002] The key to improving the performance of spacecraft thermal control systems lies in optimizing heat transfer paths to reduce interface layers and improve contact accuracy. Traditional spacecraft thermal control systems generally employ a honeycomb panel with embedded heat pipes. The heat pipes are bonded to the upper and lower skin layers of the honeycomb structure panel, forming a composite heat transfer structure of skin-adhesive layer-heat pipe. The honeycomb panel consists of a surface metal skin and an internal honeycomb core, combining lightweight design with load-bearing capacity. The heat pipe network is used to achieve temperature uniformity across the panel surface, while the skin surface of the honeycomb panel directly contacts the spacecraft's electronic equipment, energy modules, and other heat-generating components (hereinafter referred to as "equipment"), forming the heat transfer path. However, this structural solution has the following technical drawbacks: First, the heat pipes and honeycomb panel are indirectly connected through the adhesive layer and skin layer. The presence of different material interfaces, especially the non-metallic adhesive layer, significantly reduces the heat conduction efficiency between the equipment and the heat pipes. Second, the interlayer bonding strength of the adhesive layer between the heat pipes and the honeycomb panel is limited, preventing the heat pipes from effectively participating in the mechanical load-bearing capacity of the honeycomb panel. Third, the manufacturing process of honeycomb panel structure is highly complex. Traditional pre-embedded heat pipe honeycomb panels need to go through processes such as mold development, heat pipe forming, embedded part pre-installation, and adhesive curing. The production cycle is generally long and the production cost is high.

[0003] Taking the relevant patent on the improvement of load-bearing and thermal control of plate structure in flat satellite as an example, patent publication number CN117699052A discloses a dot matrix structure for a multi-functional outer cabin of a satellite. The proposed pre-embedded heat pipe is connected to the inner surface of the inner cabin by bolt tightening and spot welding. Although the interfacial thermal resistance introduced by the adhesive layer is removed, the load-bearing capacity can be improved to a certain extent. This structure is a plate structure of dot matrix + skin + pre-embedded heat pipe. However, the local deformation of the skin caused by the spot welding process will form a gap between the equipment mounting surface and the honeycomb panel skin. This gap significantly increases the contact thermal resistance, thereby reducing the heat conduction efficiency from the equipment to the heat pipe. The plate-like structure of the 3D-printed Kagome configuration proposed in patent CN110856415A can achieve the integration of structure and heat pipe, effectively reducing interlayer thermal resistance. However, due to the characteristics of additive manufacturing technology, it faces problems such as insufficient microchannel forming accuracy and difficulty in removing support structures. The 3D-printed lattice structure also suffers from insufficient interlayer bonding. At the same time, due to the limitation of the forming size, multiple structural plates need to be spliced ​​to form a large-size plate, but the mechanical properties at the splicing joints are poor, resulting in a reduction in the overall load-bearing capacity of the structure. The above patents also face the problems of production cycle and production cost in terms of manufacturing.

[0004] In summary, the fundamental contradiction in the collaborative design of spacecraft load-bearing and heat dissipation structures stems from the cross-scale manufacturing conflict between the macroscopic load-bearing framework and the microscopic thermal management unit. Traditional split-type solutions (such as honeycomb panel pre-embedded heat pipe structures) achieve functional integration through interface connections such as adhesive bonding. However, the series connection of multiple interfaces in the heat transfer path leads to a significant accumulation of thermal resistance, and the mechanical weakness of the non-metallic adhesive layer makes it difficult for the heat pipe to participate in structural load-bearing. Among existing improved solutions, although split-type structures reduce interface layers through metallization connections, local precision fluctuations cause gaps between the equipment and the mounting plane, thus restricting the efficiency of contact heat conduction. Although integrated designs achieve the co-forming of structure and flow channels through additive manufacturing, insufficient large-scale precision forming capabilities lead to interlayer defects and dimensional limitations.

[0005] It is particularly important to point out that some current solutions for integrally extruding heat pipes and flat plate structures contain design flaws: achieving both a large-size plate and the integrated fabrication of the heat pipe's microstructure is virtually impossible. To obtain the microchannel structure required for the heat pipe, precision micro-recirculation channel forming units are often incorporated into the extrusion die. This limits the overall size of the plate structure, typically to no more than 0.16 meters. Furthermore, the material flow during extrusion causes microstructural deformation, leading to deviations in the micro-recirculation channel dimensions and reducing capillary driving force. This approach of "preserving the microstructure at the expense of overall size" has become a key bottleneck restricting the integration of load-bearing and heat dissipation in large-size plate structures.

[0006] Therefore, the urgent technical problem to be solved is how to provide an integrated structure and method for atypical heat pipes and plates using friction stir welding, so as to eliminate the multiple interfacial thermal resistances of traditional skin layers and adhesive layers, and improve the heat transfer efficiency by ensuring good contact between the device and the atypical heat pipe, while taking into account lightweight and load-bearing capacity, and solving cross-scale problems, which requires both large-size plates and small-size heat pipe structures. Summary of the Invention

[0007] The purpose of this application is to provide an atypical heat pipe and plate integrated structure and method for friction stir welding encapsulation, which eliminates the multiple interfacial thermal resistances of traditional skin and adhesive layers, and ensures good contact between the device and the atypical heat pipe, improves heat transfer efficiency, and takes into account lightweight and load-bearing capacity, while solving cross-scale problems, which can accommodate large-size plates and form small-size heat pipe structures.

[0008] To achieve the above objectives, as a first aspect of this application, this application provides an atypical heat pipe and plate integrated structure encapsulated by friction stir welding, wherein the structure includes: an equipment mounting side plate and a load-bearing structural plate; the equipment mounting side plate and the load-bearing structural plate are arranged in parallel and interlocked, forming a functional area of ​​the atypical heat pipe between the equipment mounting side plate and the load-bearing structural plate;

[0009] The functional area includes macroscopic flow channels and microscopic reflux channels;

[0010] The macroscopic flow channel is a channel for the rapid flow of the working fluid, used to connect the evaporation section and the condensation section of the heat pipe, and to realize the evaporation and condensation flow of the working fluid.

[0011] The micro-reflux channel is used to achieve the reflux of condensed liquid through capillary action;

[0012] The equipment mounting side plate and the load-bearing structure plate are seamlessly welded and sealed along their outer edges using friction stir welding, thereby achieving overall airtight sealing of the functional area.

[0013] The atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, wherein the mating surfaces of the equipment mounting side plate and the load-bearing structure plate are provided with macroscopic flow channels and periodic micro-grooves;

[0014] The macroscopic flow channel is formed by the combination of the macroscopic flow channel channel of the equipment mounting side plate and the macroscopic flow channel channel of the load-bearing structural plate;

[0015] The micro-recirculation channel is formed by the periodic microgrooves of the equipment mounting side plate and the periodic microgrooves of the load-bearing structure plate being arranged alternately, and the assembly gaps form a continuous capillary recirculation path.

[0016] The atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, wherein the structure further includes: at least one intermediate functional plate;

[0017] The intermediate functional panel is arranged in parallel between the equipment mounting side panel and the load-bearing structural panel;

[0018] The intermediate functional plate forms a non-typical heat pipe functional area between itself and the equipment mounting side plate, between itself and the load-bearing structure plate, or between two adjacent intermediate functional plates.

[0019] The atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, wherein macroscopic flow channels and periodic microgrooves are provided on both sides of the intermediate functional plate.

[0020] The macro-flow channels of the intermediate functional plate and the macro-flow channels of the equipment mounting side plate, the macro-flow channels of the intermediate functional plate and the macro-flow channels of the load-bearing structure plate, or the macro-flow channels of two adjacent intermediate functional plates are connected to form the macro-flow channels of the atypical heat pipe structure.

[0021] The periodic microgrooves of the intermediate functional plate and the periodic microgrooves of the equipment mounting side plate, the periodic microgrooves of the intermediate functional plate and the periodic microgrooves of the load-bearing structure plate, or the assembly gaps formed by the staggered arrangement of the periodic microgrooves of two adjacent intermediate functional plates, form the micro-recirculation channel of the atypical heat pipe structure.

[0022] As described above, in the atypical heat pipe and plate integrated structure encapsulated by friction stir welding, the side of the equipment mounting plate facing away from the docking surface is smooth, for direct contact with the equipment to be cooled; a structural reinforcement unit is provided on one side of the load-bearing structural plate facing away from the docking surface, the structural reinforcement unit being a T-shaped reinforcing rib, a double-layer skin structure, or a mesh reinforcement structure.

[0023] In the atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, the cross-sectional shape of a single periodic microgroove in the periodic microgroove of the equipment mounting side plate or load-bearing structure plate is square, trapezoidal, inverted trapezoidal, circular or sinusoidal.

[0024] The atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, wherein the macroscopic flow channel and the microscopic return channel are arranged alternately and at intervals within the functional area.

[0025] The atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above, wherein the macroscopic flow channel and the microscopic return channel are both arranged along the extrusion and extension direction of the equipment mounting side plate and the load-bearing structure plate.

[0026] As a second aspect of this application, this application provides a method for manufacturing an atypical heat pipe and plate integrated structure encapsulated by friction stir welding, characterized in that the method for obtaining the aforementioned atypical heat pipe and plate integrated structure encapsulated by friction stir welding includes:

[0027] Step S1: Based on the thermodynamic and mechanical requirements of the plate structure, design the cross-sectional shape of the equipment mounting side plate and the load-bearing structure plate, and design and manufacture the extrusion die for extruding the slab structure according to the cross-sectional shape.

[0028] Step S2: The equipment mounting side plate and the load-bearing structure plate are integrally formed in one step by extrusion molding process;

[0029] Specifically, the macroscopic flow channel and the periodic micro-groove are simultaneously extruded on the mating surface of the equipment mounting side plate and the bearing structure plate, and structural reinforcement units are simultaneously extruded on the side of the bearing structure plate opposite to the mating surface.

[0030] The manufacturing method of the atypical heat pipe and plate integrated structure encapsulated by friction stir welding as described above further includes:

[0031] Step S3: Cut the equipment mounting side plate and the load-bearing structure plate;

[0032] Step S4: Assemble the finished equipment mounting side plate and the load-bearing structure plate, and use tooling fixtures to control the assembly gap between the equipment mounting side plate and the load-bearing structure plate, so that the macro-flow channels of the equipment mounting side plate and the load-bearing structure plate are aligned to form macro-flow channels, and the periodic micro-grooves of the equipment mounting side plate and the load-bearing structure plate are arranged alternately to form capillary gaps of micro-recirculation channels.

[0033] Step S5: Perform friction stir welding on the outer edge of the assembled equipment mounting side plate and the load-bearing structural plate to complete the encapsulation of the functional area and form an integrated structural plate;

[0034] Step S6: Inject the working fluid into the encapsulated heat pipe cavity through the filling tube, and cold weld the filling tube to complete the sealing and filling of the atypical heat pipe.

[0035] Step S7: Connect the integrated structural plate to the main load-bearing structure of the spacecraft, and install the equipment directly on the smooth surface area of ​​the equipment installation side plate.

[0036] The beneficial effects achieved by this application are as follows:

[0037] (1) This application realizes the large-size, high-integration manufacturing of atypical heat pipe and supporting structure integrated components, avoiding the size process bottleneck of traditional microchannel heat pipes. During the structural assembly process, the large-size macro-channel channels and periodic micro-grooves prefabricated on the equipment mounting side plate and the supporting structure plate are used to form micro-recirculation channels through the assembly gap of the periodic micro-grooves, realizing the heat pipe function without the need for complex micro-machining structures. In terms of encapsulation, friction stir welding is used to seamlessly weld along the edges of the equipment mounting side plate and the supporting structure plate, taking into account both structural connection and sealing requirements, further improving the sealing reliability of atypical heat pipe, reducing the impact on the flatness of the plate surface, significantly reducing the thermal resistance interface, and improving the heat transfer efficiency between the equipment and the heat pipe.

[0038] (2) This application is compatible with multiple material systems and expandable layered structures, which can adapt to different mission thermal control requirements; in terms of manufacturing process, through structural integration and process optimization, the traditional heat pipe embedding process is simplified, reducing production complexity and cost.

[0039] (3) This application achieves the function of heat pipe while taking into account structural load-bearing capacity, forming a large-size, high load-bearing, lightweight and high heat homogenization for aerospace, electronics and other fields. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings.

[0041] Figure 1 This is a schematic diagram illustrating an application scenario of an atypical integrated heat pipe and plate structure using friction stir welding, according to an embodiment of the present invention.

[0042] Figure 2 A schematic diagram showing the T-shaped reinforcing ribs provided for the load-bearing structural plate in an embodiment of the present invention.

[0043] Figure 3 A schematic diagram of a double-layer reinforced structure for the load-bearing structural plate in an embodiment of the present invention.

[0044] Figure 4 This is a cross-sectional view of an atypical heat pipe functional area according to an embodiment of the present invention.

[0045] Figure 5 The diagram shows a periodic microgroove structure formed by splicing two capillary channels in an embodiment of the present invention.

[0046] Figure 6 This is a cross-sectional view of an atypical heat pipe functional area where an intermediate functional plate is provided between the device mounting side plate and the load-bearing structure plate in an embodiment of the present invention.

[0047] Figure 7 This is a schematic diagram showing two intermediate functional panels disposed between the device mounting side panel and the load-bearing structural panel in an embodiment of the present invention.

[0048] Figure 8 This is a schematic diagram of the processing procedure for integrating an atypical heat pipe with a plate using friction stir welding, according to an embodiment of the present invention.

[0049] Figure 9 This is a flowchart illustrating a manufacturing method for an atypical integrated heat pipe and plate structure using friction stir welding, according to an embodiment of the present invention.

[0050] Reference numerals: 1-Equipment mounting side plate; 2-Bearing structural plate; 3-Atypical heat pipe functional area; 31-Macroscopic flow channel; 32-Microscopic reflux channel; 4-Intermediate functional plate; 51-Macroscopic flow channel; 52-Periodic micro-groove; 6-Equipment; 7-Working fluid; 8-Structural reinforcement unit; 9-Friction stir welding seam; 91-First weld; 92-Second weld; 93-Third weld. Detailed Implementation

[0051] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0052] Example 1

[0053] like Figure 1 As shown, this application provides an atypical heat pipe and plate integrated structure encapsulated by friction stir welding. The structure includes: an equipment mounting side plate 1 and a supporting structure plate 2; the equipment mounting side plate 1 and the supporting structure plate 2 are arranged in parallel, and after the equipment mounting side plate 1 and the supporting structure plate 2 are connected, an atypical heat pipe functional region 3 is formed between the equipment mounting side plate 1 and the supporting structure plate 2; matching channel structures are provided on the opposite surfaces of the equipment mounting side plate 1 and the supporting structure plate 2, and after the channel structure of the equipment mounting side plate 1 and the channel structure of the supporting structure plate 2 are matched and connected, a complete cavity of the atypical heat pipe functional region 3 is formed. The atypical heat pipe functional region 3 structure includes a macroscopic flow channel 31 and a microscopic reflux channel 32. The macroscopic flow channel 31 is used to connect the evaporation section and the condensation section of the heat pipe and realize the evaporation and condensation flow of the working fluid 7. The macroscopic flow channel 31 is an important channel connecting the evaporation section and the condensation section. The microscopic reflux channel 32 is used to realize the capillary reflux of the condensate. The equipment mounting side plate 1 and the load-bearing structure plate 2 are seamlessly welded and sealed along their outer edges by friction stir welding to realize the overall enclosure of the atypical heat pipe functional region 3 structure.

[0054] In a specific embodiment of the present invention, the cavity size of the macroscopic flow channel 31 is larger than the cavity size of the microscopic reflux channel 32. The microscopic reflux channel 32 is located between the equipment mounting side plate 1 and the supporting structure plate 2, and is composed of micro-gap formed by interlaced, smaller-sized periodic channels. Under wetting action, the microscopic reflux channel 32 can form a stable capillary force for refluxing condensate, and is a key unit for realizing the capillary reflux mechanism in the atypical heat pipe functional region 3. Both the macroscopic flow channel 31 and the microscopic reflux channel 32 are obtained through precision assembly. The channel structure of the equipment mounting side plate 1 and the channel structure of the supporting structure plate 2 are both large-sized structures, but the microscopic reflux channel 32 formed after the equipment mounting side plate 1 and the supporting structure plate 2 are small-sized structures. Therefore, it can overcome the limitation of cross-size, not rely on traditional microchannel processing methods, avoid the limitation of the overall size of the plate by microstructure processing, and take into account both the macroscopic structural size and the microchannel accuracy. The equipment mounting side plate 1 and the load-bearing structure plate 2 are connected by friction stir welding. Specifically, friction stir welding is performed along the outer edges of the equipment mounting side plate 1 and the load-bearing structure plate 2, as well as the outer edge of the atypical heat pipe functional area 3, to achieve the overall closed encapsulation of the atypical heat pipe functional area 3. The friction stir welding method can reduce the impact on the flatness of the structure and take into account both airtightness and structural strength.

[0055] like Figure 1 The diagram illustrates an application scenario of an atypical heat pipe and plate integrated structure encapsulated by friction stir welding. Various devices 6 are mounted on the outer surface of the device mounting side plate 1 and assembled using bolts. The side of the device mounting side plate 1 facing away from the mating surface is smooth, allowing direct contact with the device 6 to form a metal-to-metal heat transfer path, reducing interfacial thermal resistance. The device mounting side plate 1 and the load-bearing structural plate 2 are connected to the main load-bearing structure of the spacecraft. The device 6 is mounted on the structure encapsulated by the device mounting side plate 1 and the load-bearing structural plate 2. The overall width a0 and overall length b of the device mounting side plate 1 need to be matched according to the dimensions of the main load-bearing structure. The width dimensions a1 and a2 of the load-bearing structural plate 2 are designed based on the layout and load-bearing requirements of the device 6. The load-bearing structural plate 2 can be made into multiple plates distributed below the device mounting side plate 1. The widths a1 and a2 of the load-bearing structural plate 2, as well as its layout, are individually designed according to the layout and heat dissipation requirements of the device 6, thereby reducing the mass of the load-bearing structural plate 2 and achieving structural lightweighting. The load-bearing structural plate 2 can also be designed to have the same dimensions as the equipment installation side plate 1 to enhance the strength of the structural plate.

[0056] In other specific embodiments of the present invention, the equipment mounting side plate 1 and the load-bearing structure plate 2 can be planar structures or can be designed as curved structures.

[0057] As a specific embodiment of the present invention, the mating surfaces of the equipment mounting side plate 1 and the supporting structure plate 2 are provided with macroscopic flow channels 51 and periodic micro-grooves 52; the macroscopic flow channel 31 is formed by piecing together the macroscopic flow channels 51 of the equipment mounting side plate 1 and the macroscopic flow channels 51 of the supporting structure plate 2; the microscopic return channel 32 is formed by the assembly gap after the periodic micro-grooves 52 of the equipment mounting side plate 1 and the periodic micro-grooves 52 of the supporting structure plate 2 are staggered.

[0058] like Figure 4 As shown, based on the heat dissipation requirements of device 6, the cross-sectional dimensions of the macroscopic flow channel 31 (formed by assembling macroscopic flow channels 51) and the microscopic return channel 32 (formed by staggered assembly of periodic microchannels 52) are designed. Specifically, this includes the following key parameters: the cross-sectional width d of the atypical heat pipe functional region 3, the thickness t and width d1 of the macroscopic flow channel 31, and the width d2 of the microscopic return channel 32. When device 6 is working, the vaporized working fluid 7 in the heat pipe evaporation section flows from the macroscopic flow channel 31 to the condensation section, and the liquid working fluid 7 in the condensation section returns to the evaporation section through the microscopic return channel 32 formed by the periodic microchannels 52, completing the heat transfer cycle. Based on the heat dissipation requirements of device 6, the cross-sectional width d of the atypical heat pipe functional region 3 and the thickness t of the macroscopic flow channel 31 are designed. For device 6 with high heat dissipation requirements, the cross-sectional width d and the flow channel thickness t of the atypical heat pipe functional region 3 should be increased as much as possible, provided that the structure meets the strength requirements and process constraints.

[0059] like Figure 4 As shown, the layout design of the micro-recirculation channel 32 formed by the macro-channel 31 and the periodic micro-groove 52 is also based on the heat dissipation requirements of the device 6.

[0060] like Figure 4 As shown, the macroscopic flow channel 31 and the microscopic return channel 32 are arranged alternately in the atypical heat pipe functional region. The number of macroscopic flow channels 31 and microscopic return channels 32 is not limited. Atypical heat pipe functional region 3.

[0061] like Figure 4 As shown, the structural design of the micro-recirculation channel 32 relies on the design of various dimensions of the periodic microgrooves 52. For example, as Figure 4As shown, the dimensional design of the periodic microgrooves 52 encompasses the following key parameters: the depth t1 of the periodic microgrooves 52, the width t2 of the periodic microgrooves 52, and the spacing t3 between the periodic microgrooves 52. The vertical and horizontal gaps of the micro-recirculation channels 32 formed by the interlacing periodic microgrooves 52 are t-t1 and (t2-t3) / 2, respectively. The dimensional design of the depth t1, width t2, and spacing t3 of the periodic microgrooves 52 aims to meet the dimensional constraints of the aluminum extrusion process. This is achieved by inserting the periodic microgrooves 52 of one layer of the structural plate (equipment mounting side plate 1 or load-bearing structural plate 2) into the other layer, forming micro-recirculation channels 32. This allows the micro-recirculation channels 32 to generate effective capillary drive during operation, ensuring rapid recirculation of the working fluid 7 within the heat pipe, thereby meeting the heat homogenization requirements of the equipment 6.

[0062] As a specific embodiment of the present invention, an atypical heat pipe and plate integrated structure encapsulated by friction stir welding further includes: at least one intermediate functional plate 4; the intermediate functional plate 4 is disposed parallel to the equipment mounting side plate 1 between the equipment mounting side plate 1 and the load-bearing structure plate 2; an atypical heat pipe functional region 3 is formed between the intermediate functional plate 4 and the equipment mounting side plate 1, between the intermediate functional plate 4 and the load-bearing structure plate 2, or between two adjacent intermediate functional plates 4.

[0063] As a specific embodiment of the present invention, one, two, or four intermediate functional plates 4 may be provided between the equipment mounting side plate 1 and the load-bearing structural plate 2. The number of intermediate functional plates 4 is not limited, and intermediate functional plates 4 may not be provided. It is set according to design requirements.

[0064] As a specific embodiment of the present invention, macroscopic flow channels 51 and periodic micro-grooves 52 are provided on both sides of the intermediate functional plate 4; the macroscopic flow channels 51 of the intermediate functional plate 4 and the macroscopic flow channels 51 of the equipment mounting side plate 1, the macroscopic flow channels 51 of the intermediate functional plate 4 and the macroscopic flow channels 51 of the supporting structure plate 2, or the macroscopic flow channels 51 of two adjacent intermediate functional plates 4 are connected to form the macroscopic flow channel 31 of the atypical heat pipe functional region 3; the periodic micro-grooves 52 of the intermediate functional plate 4 and the periodic micro-grooves 52 of the equipment mounting side plate 1, the periodic micro-grooves 52 of the intermediate functional plate 4 and the periodic micro-grooves 52 of the supporting structure plate 2, or the periodic micro-grooves 52 of two adjacent intermediate functional plates 4 are staggered and the assembly gap forms the microscopic return channel 32 of the atypical heat pipe functional region 3.

[0065] like Figure 6As shown in the figure, in a specific embodiment of the present invention, an intermediate functional plate 4 is sandwiched between the equipment mounting side plate 1 and the supporting structure plate 2. The intermediate functional plate 4 has macroscopic flow channels 51 and periodic micro-grooves 52 on both sides, thereby forming a double-layer flow channel structure between the equipment mounting side plate 1 and the supporting structure plate 2. That is, a macroscopic flow channel 31 and a microscopic return channel 32 are formed between the equipment mounting side plate 1 and the intermediate functional plate 4, and a macroscopic flow channel 31 and a microscopic return channel 32 are formed between the intermediate functional plate 4 and the supporting structure plate 2.

[0066] like Figure 7 As shown, in another specific embodiment of the present invention, a multi-layered intermediate functional plate 4 with macroscopic flow channels 51 and periodic micro-grooves 52 is sandwiched between the equipment mounting side plate 1 and the supporting structure plate 2 to construct a multi-layered flow channel, thereby significantly enhancing the heat dissipation performance. Based on the further requirements of the equipment 6 for heat dissipation performance, the number of layers of the intermediate functional plate 4, the shape, size, and arrangement of the macroscopic flow channels 51 and periodic micro-grooves 52 are adjusted.

[0067] As a specific embodiment of the present invention, the number of macroscopic flow channels 31 includes at least one; the number of microscopic return channels 32 includes at least one. The number of macroscopic flow channels 31 and microscopic return channels 32 is not limited, nor is the arrangement of macroscopic flow channels 31 and microscopic return channels 32 limited; they can be set according to design requirements.

[0068] like Figure 2 and Figure 3 As shown, a structural reinforcement unit 8 is provided on the side of the load-bearing structural plate 2 facing away from the mating surface (i.e., the side away from the equipment installation side plate 1). The structural reinforcement unit 8 provided on the side of the load-bearing structural plate 2 facing away from the mating surface can be, for example, a T-shaped stiffener, a double-layer skin structure, or a mesh reinforcement structure, thereby improving the overall load-bearing strength. Here, the type of structural reinforcement unit 8 is not limited and is set according to design requirements.

[0069] As a specific embodiment of the present invention, the cross-sectional shape of a single channel in the periodic microgrooves 52 of the equipment mounting side plate 1 or the load-bearing structural plate 2 is square, trapezoidal, inverted trapezoidal, or circular. The cross-sectional shape of a single channel in the periodic microgrooves 52 of the equipment mounting side plate 1 or the load-bearing structural plate 2 is not limited here and can be set according to design requirements.

[0070] like Figure 5 As shown, as an optional solution, the cross-sectional shape design of a single channel in the periodic microgroove 52 can be diversified, covering but not limited to common geometric shapes such as square, trapezoid, inverted trapezoid, and circle. In addition, depending on the specific application requirements, atypical cross-sections of the periodic microgroove 52 can be designed by combining engineering experience, size optimization methods, or topology optimization techniques to meet the capillary-driven recirculation capability requirements under different task scenarios. Figure 4 The diagram illustrates four cross-sectional shapes of the periodic microgrooves 52: inverted trapezoid, trapezoid, semi-circular, and sinusoidal.

[0071] As a specific embodiment of the present invention, both the macroscopic flow channel 31 and the microscopic return channel 32 are arranged along the extrusion direction of the equipment mounting side plate 1 and the load-bearing structural plate 2.

[0072] Both the equipment mounting side panel 1 and the load-bearing structural panel 2 are made of metal materials. For example, the equipment mounting side panel 1 and the load-bearing structural panel 2 are made of metal materials such as aluminum alloy, steel, or copper alloy. Aluminum alloy is generally used to achieve lightweighting.

[0073] As a specific embodiment of the present invention, the equipment mounting side plate 1 and the load-bearing structural plate 2 are manufactured using extrusion molding technology. Specifically, during the aluminum extrusion molding process, the equipment mounting side plate 1 and the load-bearing structural plate 2 include macroscopic flow channels 51 and periodic micro-grooves 52. They can be directly extruded into a flat plate structure or extruded into a cylindrical structure, and then adjusted into a flat plate structure or a curved surface structure with a specific curvature through an unfolding and straightening process. Aluminum extrusion manufacturing has high mass production capacity, effectively improving production efficiency while ensuring dimensional accuracy and consistency during large-scale manufacturing. This application does not limit the use of aluminum extrusion molding technology to manufacture the equipment mounting side plate 1 and the load-bearing structural plate 2; other technologies can also be used.

[0074] As an alternative, the macroscopic flow channel 51 and periodic micro-grooves 52 of the equipment mounting side plate 1 and the load-bearing structural plate 2 can also be manufactured using various processing methods such as machining, laser processing, electrical discharge machining, additive manufacturing, and die stamping. Regardless of the process chosen to form the macroscopic flow channel 51 and periodic micro-grooves 52, they must be cleaned after processing to ensure that there are no residual impurities inside, thus guaranteeing high-precision assembly of the subsequent equipment mounting side plate 1 and load-bearing structural plate 2, and the normal flow of the working fluid 7 in the atypical heat pipe functional area 3 in the working scenario.

[0075] As a specific embodiment of the present invention, the design of an integrated encapsulation structure of an atypical heat pipe functional area 3 and a plate based on friction stir welding mainly includes: the size and structure design of the equipment mounting side plate 1 and the load-bearing structure plate 2, the size and layout design of the macro-flow channel 31 and the micro-return channel 32 formed by the staggered channels, and the size and cross-sectional shape design of the channels (including the macro-flow channel 51 and the periodic micro-channel 52).

[0076] Preferably, the "equipment mounting side plate 1" and the "bearing structure plate 2" have two types of channels pre-set in their channel structure before assembly: one type is a large-size macro-flow channel 31 distributed between the equipment mounting side plate 1 and the bearing structure plate 2, which is formed by structural splicing and is used for the flow and heat exchange of the working fluid 7 between the evaporation section and the condensation section; the other type is a smaller-size periodic micro-channel 52 distributed between the equipment mounting side plate 1 and the bearing structure plate 2, which forms a micro-recirculation channel 32 after assembly, for the recirculation of the working fluid 7 and to maintain the capillary drive capability of the system.

[0077] Preferably, the dimensional parameters of the macro-channels 31 (large channels) and periodic micro-channels 52 (small channels) in the equipment mounting side plate 1 and the load-bearing structural plate 2, such as channel depth, channel width, and the arrangement density and relative layout of the capillary channels, can be customized and optimized according to the heat load distribution, heat exchange path requirements and structural integration conditions of the equipment 6, so as to take into account the synergistic optimization of heat transfer performance and structural function.

[0078] This invention breaks through the traditional mindset of integral molding and innovatively proposes a thermal control integrated structural design method of "large-size extruded substrate + micro-reflow channel in assembly gap + friction stir welding encapsulation". It uses a large-size aluminum alloy extrusion to form an upper load-bearing structural plate 2 with a specific surface structure in one step, and forms a small-size assembly gap during the assembly process to build a continuous microchannel network with capillary drive capability. Finally, friction stir welding is used for seamless encapsulation to ensure the sealing of the micro-reflow channel 32 and the connection strength of the overall structure. Compared to traditional honeycomb panel heat pipe embedding structures, this design achieves direct thermal contact between device 6 and the atypical heat pipe functional area 3, eliminating the multi-layer interface thermal resistance caused by the skin layer and adhesive layer, and significantly improving heat transfer efficiency. Simultaneously, the contact area between the heat pipe and device 6 is significantly increased, enhancing heat homogenization capabilities. The macroscopic flow channel 51 and periodic microgrooves 52 are integrally formed with the main structure, ensuring the thermal control structure also possesses load-bearing capacity, significantly improving the overall structural mechanical properties. In terms of manufacturing, it avoids the limitations on structural dimensions imposed by microchannel processing, simplifies the multiple complex processes of traditional honeycomb panel heat pipe embedding, reduces costs, and improves processing efficiency. Furthermore, this solution offers high customizability and process compatibility in terms of channel size, arrangement, and substrate materials, making it suitable for structures in various spacecraft platforms that require high integration and high performance in thermal control and load-bearing capacity, and also applicable to fields such as automotive and power electronics.

[0079] like Figure 8 As shown, the equipment mounting side plate and the load-bearing structure plate are connected by friction stir welding, and the connection includes multiple friction stir welds 9. The friction stir welds 9 include a first weld 91, a second weld 92, and a third weld 93.

[0080] Example 2

[0081] like Figure 9 The present application provides a method for manufacturing an integrated structure of an atypical heat pipe and a plate encapsulated by friction stir welding, for obtaining a plate structure with an atypical heat pipe encapsulated by friction stir welding, the method comprising:

[0082] Step S1: Based on the thermodynamic and mechanical requirements of the plate structure, design the cross-sectional shape of the equipment installation side plate and the load-bearing structure plate, and design and manufacture the extrusion die for extruding the slab structure based on the cross-sectional shape.

[0083] The design configuration of the equipment installation side plate and the load-bearing structure plate includes: the channel structure, assembly gap and friction stir welding path of the equipment installation side plate and the load-bearing structure plate.

[0084] Specifically, based on thermodynamic simulation data of plate structures, a configuration including channel structure, assembly gaps, and welding paths is established. Based on the mechanical load-bearing performance of plate structures, a configuration is established where the load-bearing structural plate has both load-bearing capacity and lightweight design.

[0085] Step S2: The equipment installation side plate and the load-bearing structure plate are formed in one piece through extrusion molding process.

[0086] Specifically, large-size extrusion processes are used to manufacture the side panels and load-bearing structural panels.

[0087] Preferably, the channel can be formed in one step by extrusion, or it can be formed by other methods, including machining, etching, laser processing, electrical discharge machining, additive manufacturing, etc. The specific method is determined according to the complexity of the cross-sectional shape.

[0088] Preferably, the macro-channels and periodic micro-grooves processed in step S2 are cleaned to ensure that there are no residual impurities in the macro-channels and periodic micro-grooves.

[0089] Step S3: Cut the equipment mounting side plate and the load-bearing structure plate according to the design dimensions.

[0090] Specifically, the equipment mounting side panel and the load-bearing structure panel are laser-cut according to the design dimensions, ensuring neat edges and dimensional accuracy that meets design requirements. Based on the design dimensions of the plate-like structure, the extruded equipment mounting side panel and load-bearing structure panel are then precision-cut to meet subsequent high-precision assembly requirements. The cutting process can utilize high-precision methods such as mechanical cutting or laser cutting to ensure neat edges and accuracy that meets design requirements for the equipment mounting side panel and load-bearing structure panel.

[0091] Step S4: Assemble the finished equipment mounting side plate with the load-bearing structure plate, and use special tooling fixtures to precisely control the assembly gap between the equipment mounting side plate and the load-bearing structure plate.

[0092] Specifically, based on the flow channel design of the atypical heat pipe in the structural plate, the cut equipment mounting side plate and the supporting structural plate are first positioned and assembled to ensure that the assembled flow channel is consistent with the design. Then, the equipment mounting side plate and the supporting structural plate are pressed together using tooling. The purpose of pressing is to prevent the equipment mounting side plate and the supporting structural plate from shifting during the subsequent friction stir welding process, which would damage the assembly gap, i.e., the microscopic reflux channel 32 of the atypical heat pipe.

[0093] Step S5: Perform friction stir welding along the outer edge of the assembled equipment mounting side plate and the load-bearing structural plate to complete the sealing and encapsulation of the heat pipe cavity and form an integrated structural plate.

[0094] Specifically, with Figure 1 Taking the welding sequence of a plate structure with a non-typical heat pipe encapsulated by friction stir welding as an example, the friction stir welding sequence is as follows: Figure 8 As shown, the first step is to encapsulate the atypical heat pipe, such as... Figure 8 As shown in the first weld 91, welding is performed on both sides of the macroscopic flow channel and the microscopic return channel 32. Welding on both sides of the macroscopic flow channel and the microscopic return channel 32 first is to reduce the impact of welding thermal deformation on the assembly accuracy of the atypical heat pipe, thereby reducing the impact of welding on the internal function of the macroscopic flow channel and the microscopic return channel 32. The second step is to perform edge sealing welding on the equipment mounting side plate and the load-bearing structural plate to ensure the integrity of the connection between the equipment mounting side plate and the load-bearing structural plate and the overall structural strength of the structural plate. Figure 8 As shown in the second weld 92, this process can simultaneously weld the end cap without the filling tube to one end of the functional area of ​​the atypical heat pipe. The third step, as... Figure 8 As shown in the third weld 93, the end cap with the liquid filling tube is welded to one end of the heat pipe cavity by friction stir welding.

[0095] Step S6: Inject the working fluid into the encapsulated functional area through the filling tube, and then cold weld the filling tube to complete the sealing and filling of the atypical heat pipe.

[0096] Specifically, non-destructive testing and leakage testing are performed on the functional areas of atypical heat pipes. After the tests are passed, the working fluid is poured into the functional areas of the atypical heat pipes encapsulated by friction stir welding. After filling, the filling tube is cut off and sealed with cold welding pliers.

[0097] Step S7: Connect the integrated structural plate to the main load-bearing structure of the spacecraft, and install the equipment directly on the smooth surface area of ​​the equipment installation side plate.

[0098] As a specific embodiment of the present invention, the above steps can be adapted to either a double-layer structure of the equipment mounting side plate and the load-bearing structure plate, or a structure with one or more intermediate layers sandwiched between the upper and lower plates.

[0099] In a specific embodiment of the invention, the device is installed on the upper end of the atypical heat pipe on the structural plate, fitting snugly against the device mounting side plate. During operation, the heat generated by the device is conducted to the atypical heat pipe. After being heated, the liquid ammonia working fluid inside the evaporation section of the atypical heat pipe absorbs heat and evaporates. The vapor then flows to the condensation section, where it releases heat and condenses back into liquid. The liquid working fluid flows back to the evaporation section under the capillary action of the periodic microchannels within the atypical heat pipe. The working fluid continuously circulates between the evaporation and condensation sections, continuously transferring heat from the evaporation section to the condensation section, thereby maintaining a stable device temperature and achieving effective device temperature control.

[0100] The beneficial effects achieved by this application are as follows:

[0101] (1) This application realizes the large-size, high-integration manufacturing of atypical heat pipe and load-bearing structure integrated components, avoiding the size process bottleneck of traditional microchannel heat pipes. During the structural assembly process, the large-size macro-channel channels and periodic micro-grooves prefabricated on the equipment mounting side plate and load-bearing structure plate are used to form micro-recirculation channels through the assembly gaps of the periodic micro-grooves, realizing the heat pipe function without the need for complex micro-machining structures. In terms of encapsulation, friction stir welding is used to seamlessly weld along the edges of the equipment mounting side plate and load-bearing structure plate, taking into account both structural connection and sealing requirements, further improving the sealing reliability of atypical heat pipe, reducing the impact on the flatness of the plate surface, significantly reducing the thermal resistance interface, and improving the heat transfer efficiency between the equipment and the heat pipe.

[0102] (2) This application is compatible with multiple material systems and expandable layered structures, which can adapt to different mission thermal control requirements; in terms of manufacturing process, through structural integration and process optimization, the traditional heat pipe embedding process is simplified, reducing production complexity and cost.

[0103] (3) This application achieves the function of heat pipe while taking into account structural load-bearing capacity, forming a large-size, high load-bearing, lightweight and high heat homogenization for aerospace, electronics and other fields.

[0104] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0105] In the description of this application, the word "for example" is used to mean "used as an example, illustration, or description." Any embodiment described as "for example" in this application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use the invention. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that the invention can be made without using these specific details. In other instances, well-known structures and processes will not be described in detail to avoid obscuring the description of the invention with unnecessary detail. Therefore, the invention is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed in this application.

[0106] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.

Claims

1. An atypical integrated heat pipe and plate structure encapsulated by friction stir welding, characterized in that, The structure includes: an equipment mounting side plate and a load-bearing structural plate; the side of the equipment mounting side plate facing away from the docking surface is a smooth surface, which is used for direct contact with the equipment to be cooled; The equipment mounting side plate is arranged parallel to and interlocked with the load-bearing structure plate, forming a non-typical heat pipe functional area between the equipment mounting side plate and the load-bearing structure plate; The functional area includes macroscopic flow channels and microscopic reflux channels; The macroscopic flow channel is a channel for the rapid flow of the working fluid, used to connect the evaporation section and the condensation section of the heat pipe, and to realize the evaporation and condensation flow of the working fluid. The micro-reflux channel is used to achieve the reflux of condensed liquid through capillary action; The equipment mounting side plate and the load-bearing structure plate are seamlessly welded and sealed along their outer edges using friction stir welding to achieve overall airtight sealing of the functional area. The cavity size of the macroscopic flow channel is larger than the cavity size of the microscopic return channel; the microscopic return channel is located between the equipment mounting side plate and the load-bearing structure plate, and is composed of micro gaps formed by interlaced, smaller-sized periodic microchannels. Among them, a micro-recirculation channel is formed by inserting the periodic micro-grooves of another layer of the structural plate through the channel gap of one layer of the plate. The vertical and horizontal gaps of the micro-recirculation channel are formed by the interlacing of the periodic micro-grooves. The structure also includes: at least one intermediate functional plate; The intermediate functional panel is arranged in parallel between the equipment mounting side panel and the load-bearing structural panel; The intermediate functional plate and the equipment mounting side plate, the intermediate functional plate and the load-bearing structure plate, or two adjacent intermediate functional plates form a functional area for an atypical heat pipe. Both sides of the intermediate functional plate are provided with macroscopic flow channels and periodic micro-grooves. The macro-flow channels of the intermediate functional plate and the macro-flow channels of the equipment mounting side plate, the macro-flow channels of the intermediate functional plate and the macro-flow channels of the load-bearing structure plate, or the macro-flow channels of two adjacent intermediate functional plates are connected to form the macro-flow channels of the atypical heat pipe structure. The periodic microgrooves of the intermediate functional plate and the periodic microgrooves of the equipment mounting side plate, the periodic microgrooves of the intermediate functional plate and the periodic microgrooves of the load-bearing structure plate, or the assembly gap after the periodic microgrooves of two adjacent intermediate functional plates are staggered, form the micro-recirculation channel of the atypical heat pipe structure. The equipment mounting side plate and the load-bearing structure plate are manufactured using extrusion molding technology. During the aluminum extrusion molding process, the equipment mounting side plate and the load-bearing structure plate contain macroscopic flow channels and periodic micro-grooves.

2. The atypical heat pipe and plate integrated structure encapsulated by friction stir welding according to claim 1, characterized in that, A structural reinforcement unit is provided on one side of the load-bearing structural plate opposite to the mating surface. The structural reinforcement unit is a T-shaped stiffener, a double-layer skin structure, or a mesh reinforcement structure.

3. The atypical heat pipe and plate integrated structure encapsulated by friction stir welding according to claim 1, characterized in that, The cross-sectional shape of a single periodic microgroove in the periodic microgroove of the equipment mounting side plate or load-bearing structural plate is square, trapezoidal, inverted trapezoidal, circular, or sinusoidal.

4. The atypical heat pipe and plate integrated structure encapsulated by friction stir welding according to any one of claims 1-3, characterized in that, The macroscopic flow channels and the microscopic return flow channels are arranged alternately and at intervals within the functional area.

5. The atypical heat pipe and plate integrated structure encapsulated by friction stir welding according to any one of claims 1-3, characterized in that, Both the macroscopic flow channel and the microscopic return flow channel are arranged along the extrusion and extension direction of the equipment mounting side plate and the load-bearing structural plate.

6. A method for manufacturing an atypical integrated heat pipe and plate structure encapsulated by friction stir welding, characterized in that, The method for obtaining the structure according to any one of claims 1-5 includes: Step S1: Based on the thermodynamic and mechanical requirements of the plate structure, design the cross-sectional shape of the equipment mounting side plate and the load-bearing structure plate, and design and manufacture the extrusion die for extruding the slab structure according to the cross-sectional shape. Step S2: The equipment mounting side plate and the load-bearing structure plate are integrally formed in one step by extrusion molding process; Specifically, macroscopic flow channels and periodic micro-grooves are simultaneously extruded on the mating surface of the equipment mounting side plate and the bearing structure plate, and structural reinforcement units are simultaneously extruded on the side of the bearing structure plate opposite to the mating surface.

7. The method for manufacturing the atypical heat pipe and plate integrated structure encapsulated by friction stir welding according to claim 6, the method further comprising: Step S3: Cut the equipment mounting side plate and the load-bearing structure plate; Step S4: Assemble the finished equipment mounting side plate and the load-bearing structure plate, and use tooling fixtures to control the assembly gap between the equipment mounting side plate and the load-bearing structure plate, so that the macro-flow channels of the equipment mounting side plate and the load-bearing structure plate are aligned to form macro-flow channels, and the periodic micro-grooves of the equipment mounting side plate and the load-bearing structure plate are arranged alternately to form capillary gaps of micro-recirculation channels. Step S5: Perform friction stir welding on the outer edge of the assembled equipment mounting side plate and the load-bearing structural plate to complete the encapsulation of the functional area and form an integrated structural plate; Step S6: Inject the working fluid into the encapsulated heat pipe cavity through the filling tube, and cold weld the filling tube to complete the sealing and filling of the atypical heat pipe. Step S7: Connect the integrated structural plate to the main load-bearing structure of the spacecraft, and install the equipment directly on the smooth surface area of ​​the equipment installation side plate.

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