Composite Thermal Dissipation Panel for Satellite Heat Management
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Solution Overview
Problem
Current heat dissipation systems for satellites face challenges in efficiently managing increasing heat loads while adhering to stringent mass constraints, with aluminum-based structures being costly and difficult to produce, and carbon-based systems posing thermo-elastic issues due to high stiffness and porosity.
Innovation Solution
A heat dissipation device featuring a composite structure with graphitized carbon fibers and carbon nanotubes in an organic resin, combined with aluminum-based heat pipes and structural elements, to achieve optimal thermal conductivity and mechanical resistance with reduced mass and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum-based structures are used for heat dissipation panels and heat pipes, then good thermal conductivity and ease of manufacture are achieved, but weight constraints are violated due to high mass
Solution Approach 1:
The patent applies composite materials by combining carbon fibers with a polymer matrix to create a composite structure that replaces traditional aluminum-based heat dissipation panels and heat pipes. This composite material provides both lightweight properties and adequate thermal conductivity, resolving the contradiction between weight reduction and manufacturing feasibility.
2Weight of moving object
If carbon-based composite structures with graphitized carbon fibers are used, then weight is reduced and thermal conductivity is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies local quality by incorporating graphitized carbon fibers specifically in regions requiring high thermal conductivity (such as heat pipe structures and panel areas adjacent to heat-generating equipment), while using standard carbon fiber composites in other regions. This localized approach reduces overall manufacturing complexity while maintaining thermal performance where critical.
Solution Approach 2:
The patent applies parameter changes by modifying the thermal conductivity parameter of the composite material through the addition of graphitized carbon fibers, which have superior thermal properties. This allows the material to achieve adequate thermal conductivity without requiring the complex manufacturing processes associated with fully graphitized composite structures.
3Temperature
If graphitized carbon fibers are used to improve thermal conductivity, then thermal performance is enhanced, but mechanical strength decreases due to high stiffness modulus and negative thermal expansion coefficient
Solution Approach 1:
The patent applies composite materials by creating a hybrid composite structure that combines graphitized carbon fibers (for thermal conductivity) with standard carbon fibers and a polymer matrix (for mechanical strength). This multi-component composite resolves the contradiction by distributing functions across different material phases.
Solution Approach 2:
The patent applies local quality by orienting graphitized carbon fibers primarily in the thermal conduction paths while using standard carbon fiber reinforcement in directions requiring mechanical strength. This spatial differentiation of fiber types and orientations allows simultaneous optimization of thermal and mechanical properties.
4Weight of moving object
If carbon-based heat pipes are fabricated, then weight is reduced, but porosity issues prevent effective heat transfer fluid circulation
Solution Approach 1:
The patent applies porous materials principle by designing the carbon-based heat pipe structure with controlled porosity that facilitates fluid circulation. The composite material's natural porosity is utilized and optimized to create channels for heat transfer fluid flow, transforming the previously harmful porosity into a functional feature that enables reliable heat transfer while maintaining weight advantages.
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
The solution provides a lightweight, cost-effective, and industrially feasible heat dissipation system that maintains thermal conductivity and mechanical stability under temperature variations, ensuring long-term performance and compatibility with existing manufacturing methods.
Implementation Method 1
graphitized carbon fibers offer highly satisfactory thermal conductivity
Implementation Method 2
the organic resin being loaded with carbon nanotubes
Implementation Method 3
heat pipes, which are usually made of interconnected tubular structures through which a heat transfer fluid circulates
Implementation Method 4
structures incorporating such materials are difficult to manufacture industrially, and their implementation in practical applications proves very costly... carbon exhibits a porosity that is not inherently compatible with the circulation of a heat transfer fluid... carbon-based heat pipes proves very challenging in practice
Data Source
Figure 1~2B
Figure 3~4B
AI summary
The device has a dissipating panel (11) with inner and outer shells (211, 212) made of composite structure having organic resin and carbon fibers, where the organic resin is charged of carbon nanotubes. The structure is formed by alternating succession of layers having sets of carbon fibers arranged along alignments, respectively, where one alignment is perpendicular to another alignment. The shells are assembled at a set of tubular heat pipes (21) and connected via structure elements (22) formed by a honeycomb configuration of aluminum tubes or formed by conductive foam.