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 their rectangular or cylindrical configurations do not fit non-standard winding profiles, restricting their use in compact devices.
Innovation Solution
The development of heat pipe assemblies with porous wick linings and a ceramic insulation coating on low-electrical-conductivity materials like titanium, which are conformally shaped using additive manufacturing to fit complex winding profiles, allowing direct contact with conductive components and efficient heat transfer through phase-change mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional copper heat pipes are used for thermal management, then heat transfer capability is improved, but additional heat is generated due to eddy currents in high-frequency electromagnetic fields
Solution Approach 1:
The patent changes the electrical conductivity parameter of the heat pipe material from high (copper) to low (titanium or stainless steel). This parameter change reduces eddy current losses in high-frequency electromagnetic fields while maintaining adequate thermal conductivity through optimized heat pipe structure and phase-change mechanisms
Solution Approach 2:
The patent employs composite material structures including porous wick linings combined with ceramic insulation coatings on titanium or stainless steel substrates. This composite approach enables the heat pipe to achieve both thermal management functionality and electrical isolation from electromagnetic fields
2Ease of manufacture
If standard rectangular or cylindrical heat pipe configurations are used, then manufacturing is simplified, but they cannot fit non-standard winding profiles in compact devices
Solution Approach 1:
The patent extends conventional cylindrical heat pipe geometry to include curved and conformal configurations that can wrap around non-standard winding profiles. The heat pipe assemblies are shaped to match the contours of motor windings, transformer cores, and other electromagnetic device geometries while maintaining sealed interior chambers for working fluid
Solution Approach 2:
The patent employs thin-walled heat pipe structures with flexible conformal geometries that can adapt to complex surfaces. These thin-film heat pipe assemblies maintain structural integrity while conforming to irregular winding shapes, enabling direct thermal contact with heat-generating components
3Temperature
If heat pipes are placed in direct contact with conductive windings, then thermal transfer efficiency is improved, but electrical interference and short circuit risks increase
Solution Approach 1:
The patent introduces electrically insulating materials as intermediaries between the heat pipe and conductive windings. Ceramic coatings (alumina, zirconia) and polymer insulation layers serve as thermal conduits that are electrically isolating, enabling direct thermal contact while preventing electrical interference and short circuits
Solution Approach 2:
The patent creates composite heat pipe structures with electrically insulating ceramic or polymer coatings on conductive metal substrates. This composite structure provides both thermal conductivity for efficient heat transfer and electrical insulation for reliable operation in electromagnetic fields
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 management by minimizing additional heat generation, improving power density, and accommodating non-standard winding shapes, thereby increasing the efficiency and power handling capacity of electromagnetic power conversion devices.
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
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
Implementation Method 4
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
Implementation Method 5
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
Implementation Method 6
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 of the at least one wall
Implementation Method 7
The effectiveness of thermal management approach can restrict the power density... Some known heat pipes are made from a conductive material, such as copper. This conductive material generates additional heat when in the presence of high-frequency electromagnetic fields
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.