Monolithic Mechanical-Thermal Structure with Filament-Lined Holes
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Solution Overview
Problem
Existing mechanical-thermal structures for space and terrestrial applications face challenges with material choice due to thermal expansion issues, leading to mechanical stress and increased cost and mass, particularly when using standard manufacturing methods that require numerous complex parts.
Innovation Solution
A monolithic metal mechanical-thermal structure with filaments lining holes to accommodate heat pipes, allowing for thermal energy transfer and reduced assembly and manufacturing costs through additive manufacturing and extrusion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard manufacturing methods (machining, milling, adhesive bonding, screwing) are used to produce mechanical-thermal structures, then the structure can be assembled with heat pipes, but the number of parts increases and assembly complexity increases, leading to increased mass and cost
Solution Approach 1:
The patent merges multiple separate components (structural elements and heat pipe integration features) into a single monolithic structure manufactured by additive manufacturing. This eliminates the need for machining, milling, adhesive bonding, or screwing operations, reducing the number of parts from multiple components to one integrated structure, thereby simplifying assembly and reducing mass.
2Reliability
If heat pipes are made from the same materials as the mechanical-thermal structure, then thermal expansion compatibility is improved, but material choice is limited and mass increases
Solution Approach 1:
The patent introduces a gap between the heat pipe and the monolithic structure, filled with a heat conductive fluid or metal powder, as an intermediary medium. This allows the heat pipe to be made from materials optimized for thermal performance (such as aluminum with different thermal expansion characteristics) while the gap material mediates the thermal and mechanical interface, preventing direct mechanical stress from differential thermal expansion.
3Adaptability or versatility
If a gap is left between the heat pipe and structure walls to accommodate thermal expansion, then material compatibility is improved, but manufacturing precision requirements increase and cost increases
Solution Approach 1:
The patent fills the gap with metal powder or heat conductive fluid, creating a porous or fluid-filled interface zone. This approach accommodates thermal expansion movements while maintaining thermal contact, and the additive manufacturing process naturally creates this gap space without requiring high-precision machining or assembly tolerances, thus reducing manufacturing precision requirements compared to traditional methods.
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 solution eliminates assembly difficulties and reduces costs by enabling the use of a single, lightweight, thermally conductive material like aluminum, while effectively managing thermal expansion and enhancing thermal energy transfer.
Implementation Method 1
The filaments are in contact with the heat pipe, which allows the transfer of thermal energy from the pipe to the mechanical-thermal structure.
Implementation Method 2
A heat pipe containing a coolant recovers the heat released by a dissipating device at one of these ends, the coolant evaporates and condenses at the other end, releasing the heat to the mechanical-thermal structure
Implementation Method 3
A heat pipe containing a coolant recovers the heat released by a dissipating device at one of these ends, the coolant evaporates and condenses at the other end, releasing the heat to the mechanical-thermal structure
Implementation Method 4
a first stage of manufacturing the mechanical-thermal structure by an additive manufacturing method
Implementation Method 5
The pipe is advantageously realized by an extrusion method
Data Source
AI summary
A monolithic mechanical-thermal structure which is suitable for a space environment is provided, in which the structure contains at least one hole. The walls of the hole are lined with filaments. The monolithic mechanical-thermal structure may be made of metal. And a process for manufacturing the structure is also provided.