Hydroformed Heat Pipe Wick Mesh Without Chemical Etching
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Solution Overview
Problem
Current methods for manufacturing wicks for heat pipes in nuclear systems are complex, costly, and introduce impurities due to the need for chemical etching to remove mandrels, which increases time and expense.
Innovation Solution
A forming assembly using an expandable tube and forming shell assembly that hydraulically expands to deform and shape the wick mesh without the need for chemical intervention, allowing for the wick to be formed without chemical etching, thus reducing production time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If chemical etching is used to remove mandrels after diffusion bonding, then the wick can be formed with the desired shape, but impurities are introduced into the wick and the manufacturing time and cost increase
Solution Approach 1:
The mandrel is extracted from the wick structure before diffusion bonding occurs. By removing the mandrel prior to the bonding process, there is no need for subsequent chemical etching to remove mandrel remnants, thus eliminating impurity introduction while maintaining the ability to form complex wick shapes through the temporary mandrel structure
Solution Approach 2:
The mandrel removal action is performed preliminarily, before the diffusion bonding process. This preliminary extraction prevents the need for post-bonding chemical etching, thereby avoiding impurity contamination and reducing manufacturing steps while still achieving the desired wick geometry
2Shape
If chemical etching is used to remove mandrels, then the wick shape can be achieved, but the manufacturing time and expense increase
Solution Approach 1:
The mandrel is extracted from the wick structure before diffusion bonding occurs. By removing the mandrel prior to the bonding process, there is no need for subsequent chemical etching to remove mandrel remnants, thus eliminating impurity introduction while maintaining the ability to form complex wick shapes through the temporary mandrel structure
Solution Approach 2:
The mandrel removal action is performed preliminarily, before the diffusion bonding process. This preliminary extraction prevents the need for post-bonding chemical etching, thereby avoiding impurity contamination and reducing manufacturing steps while still achieving the desired wick geometry
3Manufacturing precision
If a complex multi-step process is used to form the wick, then the wick can be formed with the desired properties, but the device complexity and manufacturing cost increase
Solution Approach 1:
The mandrel is extracted from the wick structure before diffusion bonding occurs. By removing the mandrel prior to the bonding process, there is no need for subsequent chemical etching to remove mandrel remnants, thus eliminating impurity introduction while maintaining the ability to form complex wick shapes through the temporary mandrel structure
Solution Approach 2:
The mandrel removal action is performed preliminarily, before the diffusion bonding process. This preliminary extraction prevents the need for post-bonding chemical etching, thereby avoiding impurity contamination and reducing manufacturing steps while still achieving the desired wick geometry
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
The method produces wicks with precise dimensions and strength, eliminating the need for chemical etching, resulting in a more efficient and cost-effective manufacturing process while maintaining the wick's integrity and performance.
Implementation Method 1
The expandable tube is hydraulically expandable to an expanded configuration
Implementation Method 2
deform the wick mesh and form the wick based on the expandable tube hydraulically expanding
Implementation Method 3
diffusion bonding the mesh together in an oven at vacuum levels
Implementation Method 4
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.