Conformal heat pipe assemblies
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Solution Overview
Problem
Conventional heat pipes made of copper generate additional heat when exposed to high-frequency electromagnetic fields, leading to reduced power conversion efficiency and limited power density in electromagnetic power conversion devices due to eddy current-induced heat generation, and are not well-suited for compact winding profiles and require additional insulation, which hampers their effectiveness.
Innovation Solution
The development of heat pipe assemblies with porous wick linings and ceramic insulation, formed from low-electrical conductivity materials like titanium, using electrophoretic deposition for ceramic coatings and additive manufacturing for conformal shapes, allowing direct contact with conductive components and efficient thermal management without additional insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional copper heat pipes are used, then thermal conductivity is improved, but eddy current-induced heat generation increases in high-frequency electromagnetic fields
Solution Approach 1:
The patent applies composite materials by combining titanium (low electrical conductivity) with ceramic coatings (electrophoretically deposited) to create a heat pipe assembly that provides thermal management while minimizing eddy current losses. The titanium base material provides structural integrity and low electrical conductivity, while the ceramic coating enhances surface properties and thermal performance, creating a composite structure that resolves the contradiction between heat transfer capability and eddy current heat generation.
2Temperature
If copper heat pipes are used for thermal management, then heat dissipation is improved, but additional insulation is required which increases device complexity
Solution Approach 1:
The patent extracts the insulation function from the heat pipe assembly by using titanium as the base material, which inherently provides electrical isolation. This eliminates the need for separate insulation layers that would be required with copper heat pipes, thereby reducing device complexity while maintaining effective heat dissipation through the titanium-ceramic composite structure.
3Ease of manufacture
If standard heat pipe designs are used, then manufacturing is simplified, but adaptability to non-standard winding profiles is reduced
Solution Approach 1:
The patent applies segmentation by dividing the heat pipe assembly into modular components: a titanium base structure, electrophoretically deposited ceramic coatings, and porous wick linings. This segmented approach allows each component to be optimized and manufactured separately using standard processes, while the assembled configuration can be adapted to various non-standard winding profiles, thus maintaining manufacturing simplicity while enhancing adaptability.
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
These assemblies provide enhanced thermal performance and mechanical support, enabling improved power density and efficiency by directly managing heat from conductive components within electromagnetic devices, reducing the need for external insulation and accommodating non-standard winding profiles.
Implementation Method 1
The porous wick linings of the walls are configured to hold a liquid phase of a working fluid in the interior chamber
Implementation Method 2
heat from the conductive component vaporizes the working fluid in the porous wick lining of the at least one wall
Implementation Method 3
the working fluid condenses at or within the porous wick lining of at least one other wall to cool the conductive component
Implementation Method 4
an insulating layer coupled with at least one of the walls on a side of the at least one wall that is opposite of the porous wick lining
Data Source
AI summary
A heat pipe assembly includes walls having porous wick linings, an insulating layer coupled with at least one of the walls, and an interior chamber sealed by the walls. The linings hold a liquid phase of a working fluid in the interior chamber. The insulating layer is directly against a conductive component of an electromagnetic power conversion device such that heat from the conductive component vaporizes the working fluid in the porous wick lining of the at least one wall and the working fluid condenses at or within the porous wick lining of at least one other wall to cool the conductive component of the electromagnetic power conversion device. The assembly can be placed in direct contact with the device while the device is operating and/or experiencing time-varying magnetic fields that cause the device to operate.