Hydroformed Heat Pipe Wick Mesh Without Chemical Etching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The current method of forming wicks for heat pipes is complex and costly, requiring chemical etching to remove mandrels, which introduces impurities and increases production time and expense.
Innovation Solution
A forming assembly using an expandable tube and a forming shell assembly to deform and shape wick mesh into a wick, eliminating the need for chemical etching by allowing the expandable tube to separate from the wick without chemical intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical etching is used to remove mandrels, then the wick can be formed, but impurities are introduced and production time increases
Solution Approach 1:
The patent extracts the mandrel removal process from the forming sequence by using a soluble polymer mandrel that is removed through dissolution in a selective solvent. This separates the mandrel removal function from chemical etching of the wick material itself, preventing impurity introduction into the metallic wick structure while maintaining dimensional accuracy.
Solution Approach 2:
The patent introduces a soluble polymer mandrel as an intermediary material that facilitates the forming process but can be cleanly removed through dissolution. This intermediary serves as a temporary support structure during forming and diffusion bonding, then disappears through solvent extraction without leaving impurities in the final wick product.
2Manufacturing precision
If chemical etching is used to remove mandrels, then the wick can be formed, but production cost increases
Solution Approach 1:
The patent employs a disposable soluble polymer mandrel that is inexpensive and single-use. The mandrel is formed, used for shaping the wick mesh, and then discarded through dissolution in a common solvent like water or alcohol. This eliminates the need for expensive chemical etching processes and specialized mandrel removal equipment, significantly reducing production costs while maintaining precision.
3Manufacturing precision
If complex forming process is used, then wick can be formed with precise dimensions, but production time increases
Solution Approach 1:
The patent performs preliminary action by pre-forming the mandrel into the final wick geometry before the wick mesh is applied. The soluble polymer mandrel is shaped in advance with the exact desired dimensions, and the wick mesh is simply wrapped around and bonded to this pre-formed structure. This eliminates the need for complex post-forming operations and chemical etching, reducing production time while maintaining precision.
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 method significantly reduces production time and cost while maintaining the integrity and performance of the wick, enabling the production of wicks with precise dimensions and tolerances for use in heat pipes.
Implementation Method 1
The expandable tube is hydraulically expandable to an expanded configuration
Implementation Method 2
The condensed liquid is then returned to the evaporator section 102 through the wick 108 by capillary action
Data Source
AI summary
A forming assembly configured to form a wick is disclosed. The forming assembly includes an expandable tube and a forming shell assembly. The expandable tube is hydraulically expandable to an expanded configuration. A wick mesh is configured to be wrapped about the expandable tube. The forming shell assembly includes a first forming shell comprising a first recess defined therein and a second forming shell comprising a second recess defined therein. The first recess and the second recess cooperate to define an outer diameter of the wick. The expandable tube and the wick mesh are positionable between the first recess and the second recess. The expandable tube and the forming shell assembly are configured to deform the wick mesh and form the wick based on the expandable tube hydraulically expanding towards the expanded configuration.