Heat Pipe Wick Crimped Bonding for Long Seamless Assemblies
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Solution Overview
Problem
Current methods for manufacturing long heat pipe wicks are complex and require specialized equipment, making it difficult to produce full production length wicks, such as 22' wicks, from standard 48" wicks, which can lead to inadequate cleaning and potential performance issues due to the longer length and increased material handling challenges.
Innovation Solution
A method involving the axial joining of shorter wicks using 3D printed inner and outer rings, a mandrel, and a die to form a wick assembly that can be diffusion bonded, allowing for the creation of wicks of any required length by repeating the assembly process, ensuring a seamless and pressure-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If current methods are used to manufacture long heat pipe wicks, then the wicks can be produced, but the manufacturing process becomes complex and requires specialized equipment
Solution Approach 1:
The patent divides the long wick into multiple shorter standard-length wick segments (e.g., four 48-inch segments to create a 22-foot wick). Each segment is manufactured using standard equipment and processes, then joined together through crimping and diffusion bonding to form the complete long wick assembly, eliminating the need for specialized equipment to manufacture the full length in one piece.
Solution Approach 2:
The patent combines multiple standard-length wick segments with connector rings through crimping and diffusion bonding processes. The connector rings are crimped onto the ends of wick segments and then diffusion bonded to create a seamless, integrated long wick assembly that functions as a single unit despite being constructed from multiple pieces.
2Length of stationary object
If current methods are used to manufacture long heat pipe wicks, then the wicks can be produced, but specialized equipment is required
Solution Approach 1:
By segmenting the long wick into standard-length pieces that can be manufactured with existing equipment, the patent makes the manufacturing process accessible to facilities that already have standard wick manufacturing capabilities, eliminating the need to invest in specialized equipment for producing long continuous wicks.
Solution Approach 2:
The connector rings are designed to be crimped onto the wick segments using standard crimping equipment, and the diffusion bonding process uses conventional heating and vacuum equipment. This allows existing manufacturing facilities to produce long wicks using their current equipment without requiring specialized new equipment.
3Length of stationary object
If longer wicks are produced from standard wicks, then the required length is achieved, but cleaning quality may be inadequate
Solution Approach 1:
Each individual wick segment is cleaned separately during manufacturing while it is still at standard length, ensuring thorough cleaning quality. The segments are then joined together, so the cleaning process is applied to manageable sections rather than a single long continuous wick, maintaining high cleaning standards throughout.
Solution Approach 2:
The cleaning process is performed on each wick segment before the segments are joined together. This preliminary cleaning ensures that each segment meets quality standards independently, and the connector rings are also cleaned and prepared before diffusion bonding, ensuring overall assembly quality without compromising cleaning effectiveness.
4Length of stationary object
If shorter wicks are joined to form long wicks, then the required length is achieved, but connection seams may compromise performance
Solution Approach 1:
The connector rings are crimped onto the wick segments and then diffusion bonded to create a seamless connection. The diffusion bonding process fuses the metal components at the molecular level, creating a continuous structure without weak points or gaps that would compromise wick performance or reliability.
Solution Approach 2:
The connector rings are designed as simple, robust components that can be easily crimped and bonded. While the rings themselves are permanent fixtures, the crimping process uses conventional equipment and the diffusion bonding creates permanent bonds that eliminate the need for complex sealing or sealing mechanisms, ensuring reliable connections.
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 simplifies the production of long wicks by enabling the efficient joining of shorter wicks, ensuring proper cleaning and quality, and maintaining the wick's performance by creating a seamless, pressure-resistant seam, thus overcoming the limitations of existing methods.
Implementation Method 1
the force couples the outer ring, the inner ring, the first wick, and the second wick together to form the wick assembly
Data Source
AI summary
A method of forming a wick assembly is disclosed including positioning an inner ring in a first wick, positioning the inner ring in a second wick, abutting an end of the first wick with an end of the second wick, positioning an outer ring about a portion of the first wick and a portion of the second wick, positioning a mandrel within the inner ring, positioning a die about the outer ring, and applying a force to the die, wherein the force couples the outer ring, the inner ring, the first wick, and the second wick together to form the wick assembly.