Printed Heat Pipe Heater for Compact Space Equipment Integration
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Solution Overview
Problem
Conventional resistance heaters attached to heat pipes in space equipment are time-consuming to integrate, occupy excessive space, and inefficiently consume power.
Innovation Solution
A heat pipe with a heater directly printed onto its surface, comprising multiple layers including electrically non-conductive materials, conductive metals, and an electrostatic dissipation layer, where the resistance heater is positioned between two non-conductive layers, and an electrical power source supplies power to the conductive layers to regulate heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional resistance heaters are attached to heat pipes using adhesive, then the heaters can be integrated onto space equipment, but the integration process becomes time-consuming and the heaters occupy excessive space
Solution Approach 1:
The heater is merged with the heat pipe by directly printing the heater onto the heat pipe surface, eliminating the need for separate adhesive attachment steps. This integration reduces manufacturing complexity and integration time while maintaining effective thermal coupling between the heater and heat pipe.
Solution Approach 2:
The heater is pre-formed on a substrate and then transferred to the heat pipe in a single bonding operation. This preliminary preparation allows for precise heater fabrication off-site, while the final attachment to the heat pipe is accomplished quickly through direct bonding, reducing overall integration time.
2Ease of operation
If conventional resistance heaters are attached to heat pipes, then heating function is provided, but the heaters consume excessive power and occupy large space
Solution Approach 1:
The heater is designed with spatially varying resistance characteristics, allowing different regions of the heater to provide different heating intensities. This localized control enables more efficient power distribution, concentrating heating where needed and reducing overall power consumption compared to uniform conventional heaters.
Solution Approach 2:
The electrical resistance parameters of the heater are optimized through the printing process, allowing precise control of current density and power distribution. By adjusting resistance values in different areas, the heater achieves more efficient power utilization and reduced total power consumption while maintaining effective heating.
3Ease of operation
If conventional resistance heaters are attached to heat pipes, then heating is achieved, but the integration process is complex and time-consuming
Solution Approach 1:
The heater and heat pipe are merged into a single integrated component through direct printing and bonding. This eliminates the need for separate adhesive layers and complex multi-step attachment processes, simplifying the overall device structure and reducing integration complexity while preserving heating functionality.
Solution Approach 2:
The adhesive layer and associated complex attachment mechanisms are extracted from the integration process. By using direct printing and bonding methods, the heater is attached to the heat pipe without requiring separate adhesive materials or complex alignment procedures, significantly simplifying the integration process.
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 results in a compact, efficient heating system that uses less power and reduces integration time, as the printed heater is smaller and more integrated with the heat pipe, facilitating better heat transfer and control.
Implementation Method 1
a resistance heater printed onto the first layer
Implementation Method 2
a heat pipe. The heat pipe may be configured to contain a fluid that flows through the heat pipe to facilitate heat transfer
Data Source
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AI summary
Described herein is a heater for space equipment that includes a heat pipe. The heater also includes a first layer applied to the heat pipe. The first layer may be made from an electrically non-conductive material. The heater additionally includes a resistance heater printed onto the first layer after the first layer is applied to the heat pipe. The heater includes a second layer adjacent the resistance heater. The resistance heater may be positioned between the first layer and the second layer, and the second layer may be made from an electrically non-conductive material.