3D-Printed Heat Pipe Structure for Lower Thermal Gradients
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Solution Overview
Problem
Existing heat transfer tubes in electronic devices face challenges in efficiently managing high thermal gradients and structural integration, particularly in applications requiring high thermal and structural requirements, such as aerospace and automotive industries.
Innovation Solution
The integration of heat transfer tubes produced through additive manufacturing, specifically 3D printing, which are embedded within the supporting structure, incorporating longitudinal channels and pores, enhancing capillary transport and reducing thermal gradients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat transfer tubes are integrated into supporting structures using traditional manufacturing methods, then thermal transfer effectiveness is improved, but mounting and assembly times increase
Solution Approach 1:
The patent merges the heat transfer tube and supporting structure into a single integrated component manufactured via additive manufacturing. The heat transfer tube is embedded within the supporting structure's internal geometry, eliminating the need for separate mounting operations and reducing assembly time while maintaining thermal transfer effectiveness.
Solution Approach 2:
The heat transfer tube is pre-integrated into the supporting structure during the additive manufacturing process itself. The tube is positioned within the internal geometry of the structure before finalization, so that when the structure is produced, the tube is already in its operational position, eliminating subsequent mounting steps.
2Reliability
If heat transfer tubes are integrated into supporting structures using traditional manufacturing methods, then thermal transfer effectiveness is improved, but device weight increases
Solution Approach 1:
By combining the heat transfer tube and supporting structure into a single additively manufactured component, the patent eliminates redundant materials and interfaces. The integration allows for optimized material distribution where material is only placed where structurally or thermally necessary, reducing overall device weight.
Solution Approach 2:
The additive manufacturing process enables local optimization of material properties and distribution. The supporting structure can have varying density and material composition in different regions - denser where structural support is needed, less dense in thermal transfer regions - optimizing the weight-strength-thermal performance balance.
3Reliability
If heat transfer tubes are integrated into supporting structures using traditional manufacturing methods, then thermal transfer effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. Instead of separately manufacturing the heat transfer tube and supporting structure then assembling them, both are created in one integrated build process, simplifying the overall manufacturing workflow despite the complex final geometry.
Solution Approach 2:
The invention changes the manufacturing parameter space by adopting additive manufacturing technology. This enables the production of complex integrated geometries that would be difficult or impossible to achieve with traditional subtractive or formative manufacturing methods, thereby reducing manufacturing complexity for integrated designs.
4Reliability
If heat transfer tubes are integrated into supporting structures using traditional manufacturing methods, then thermal transfer effectiveness is improved, but material interfaces increase
Solution Approach 1:
The patent merges the heat transfer tube and supporting structure into a single monolithic component manufactured from the same material via additive manufacturing. This eliminates the material interfaces that would exist between separately manufactured and assembled components, reducing thermal resistance and improving heat transfer effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces mounting and assembly times, weight, and costs while improving thermal performance by minimizing material interfaces and ensuring structural integrity for high-thermal and structural requirements.
Implementation Method 1
the liquid begins to evaporate and expand inside the heat transfer tube, and the vapour reaches an area of the heat transfer tube called 'condenser'
Implementation Method 2
the operating principle is based on the phase change of the working fluid contained within the heat transfer tube: the fluid in liquid state evaporates at the hot end
Implementation Method 3
where it condenses, and returns to the side of the evaporator through a so-called wick
Implementation Method 4
the liquid returns to the evaporator through the wick due to capillary pressure (capillarity)
Implementation Method 5
heat transfer tubes, which are sealed tubes containing a fluid, and that allow heat to be transported in a very effective manner
Data Source
Figure 1~2b)
Figure 3~4c)
AI summary
The present invention comprises: frame (8); and sealed heat transfer tubes (1) fixed to the frame (8), and with: external walls (4), in a longitudinal direction; wick (5) surrounded by the external walls (4), which defines a gap (13) in the heat transfer tube (1); and in liquid (2) and vapour (3) phase, which circulates in the gap (13), between an evaporation section (6), and a condensation section (7); the gap (13) being configured to conduct the vapour heat transfer fluid (3), from the evaporation section (6) to the condensation section (7), and the wick (5) comprising longitudinal channels (10, 11, 12) and pores, to conduct the condensed heat transfer fluid (3) by capillarity, between the condensation section (7) and the evaporation section (6). It improves heat dissipation efficiency.