Embedded Heat Pipe Interface for Satellite Thermal Panels
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Solution Overview
Problem
Existing thermal systems for Earth-orbiting communication satellites face challenges in efficiently transferring heat between passive thermal panels without occupying external space, which limits component mounting and complicates post-manufacturing thermal coupling.
Innovation Solution
The implementation of an embedded interface within passive thermal panels allows for internal heat pipe coupling between adjacent panels, using an internal channel to receive and compress a non-resident heat pipe, enabling efficient heat transfer without external real estate usage and allowing thermal coupling after panel manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external jumper heat pipes are used to couple adjacent passive thermal panels, then heat transfer between panels is enabled, but external panel space is occupied and component mounting is limited
Solution Approach 1:
The jumper heat pipe is nested within an internal channel of the passive thermal panel, allowing the heat transfer function to be integrated inside the panel structure rather than occupying external space. The channel is specifically dimensioned to receive the jumper heat pipe, creating a nested configuration that resolves the space conflict.
Solution Approach 2:
The internal channel acts as an intermediary structure that facilitates the integration of the jumper heat pipe within the panel. This mediator enables the heat transfer function while keeping the external surface free for component mounting.
2Reliability
If bolted interfaces are used to attach jumper heat pipes to panels, then secure thermal coupling is achieved, but the interface complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The bolted interface mechanism is extracted from the panel assembly process. Instead of requiring bolts and nuts during manufacturing, the jumper heat pipe is simply inserted into the internal channel and retained by friction and compression, eliminating the need for additional fastening components and simplifying assembly.
Solution Approach 2:
The internal channel design provides self-retaining functionality through friction and compression forces. The jumper heat pipe remains securely coupled without external fasteners, allowing the structure to self-maintain the thermal connection through its geometric design rather than requiring additional mechanical fastening systems.
3Reliability
If thermal interface material is applied between heat pipe flanges, then heat transfer efficiency is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The thermal interface material application step is extracted from the assembly process. The direct contact between the jumper heat pipe and resident heat pipe through the internal channel eliminates the need for additional thermal interface materials, thereby simplifying the assembly process and increasing productivity.
Solution Approach 2:
The thermal coupling function is merged directly into the structural design of the internal channel. The channel walls provide both mechanical retention and thermal conduction pathways, combining structural and thermal functions into a single integrated feature that eliminates separate thermal interface requirements.
4Reliability
If heat pipes are embedded within passive thermal panels, then thermal management is improved, but post-manufacturing thermal coupling between panels becomes difficult
Solution Approach 1:
The internal channel is pre-formed within the passive thermal panel during manufacturing, creating a ready-receiver structure that anticipates future thermal coupling needs. This preliminary preparation enables simple post-manufacturing assembly of adjacent panels through straightforward insertion of jumper heat pipes without requiring complex post-assembly operations.
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 solution enhances heat transfer efficiency while freeing up external panel space for component mounting and simplifies the thermal coupling process, improving the overall thermal management of satellites.
Implementation Method 1
Heat input (i.e., from heat-generating electronics) causes the working fluid to evaporate. The evaporated fluid carries the heat towards a colder heat-output section, where heat is rejected as the fluid condenses.
Implementation Method 2
Heat input (i.e., from heat-generating electronics) causes the working fluid to evaporate.
Implementation Method 3
The evaporated fluid carries the heat towards a colder heat-output section, where heat is rejected as the fluid condenses.
Implementation Method 4
The condensate returns to the heat input section (near to heat-generating components) by capillary forces to complete the cycle.
Implementation Method 5
an arrangement that imparts a compressive force to the non-resident heat pipe (once received by the channel) that urges it against the resident heat pipe
Data Source
AI summary
A passive thermal system for use in aerospace vehicles includes a first passive thermal panel having at least one internal resident heat pipe, wherein the first passive thermal panel is further configured to provide an embedded interface between a portion of the resident heat pipe and at least one heat pipe extending from a neighboring passive thermal panel. The embedded interface is facilitated via an internal channel that is adjacent to the internal resident heat pipe. The channel is dimensioned and arranged to receive a portion of a heat pipe extending from a passive thermal panel that will be situated adjacent to the first passive thermal panel. The embedded interface is also facilitated by an arrangement that imparts a compressive force to the non-resident heat pipe that urges it against the resident heat pipe.