Stackable Heat Pipe Assembly for Modular Thermal Management
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Solution Overview
Problem
Heat pipes face challenges in mechanically demanding environments and high-temperature applications, requiring specialized designs that increase initial and maintenance costs due to the need for conforming shapes and long distances between heat sources and sinks.
Innovation Solution
A stackable heat pipe assembly comprising conductive metal plates, a conductive metal tube, and a working pipe, with brazing rings made of a copper-silver alloy, allowing for efficient heat transfer and modular expansion, enabling vertical and horizontal expansion while maintaining functionality in challenging conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If heat pipes are designed to conform to specialized shapes for mechanically challenging environments, then adaptability to operating conditions is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The heat pipe system is divided into modular segments that can be stacked vertically. Each segment contains standardized components (heat pipe, conductive plates, TEG modules) that can be independently manufactured and assembled, eliminating the need for complex custom-shaped heat pipes while maintaining adaptability to different operating conditions through flexible stacking configurations.
Solution Approach 2:
The standardized heat pipe segments are designed with universal interfaces and dimensions that allow them to perform multiple functions: heat transfer, structural support, and modular assembly. The same basic heat pipe design can be used in various configurations (vertical, horizontal, stacked) to address different operating conditions without requiring specialized designs.
2Adaptability or versatility
If heat pipes are designed for long distances between heat source and sink, then application range is improved, but initial and maintenance costs increase
Solution Approach 1:
The system uses multiple standardized heat pipe segments of fixed length that can be stacked end-to-end to achieve any required total length. This modular approach allows long-distance heat transfer applications while keeping each individual segment simple and cost-effective to manufacture, replacing the need for single complex long-distance heat pipes.
Solution Approach 2:
Instead of extending heat pipe length in one dimension (which increases complexity and cost), the system achieves extended reach by stacking segments vertically in multiple layers. This dimensional approach allows long-distance heat transfer while maintaining simple, standardized segment designs that are easier and cheaper to manufacture.
3Power
If TEG modules are connected in series to increase operating voltage, then electrical output is improved, but thermal conductivity decreases
Solution Approach 1:
The TEG modules are arranged with different connection configurations in different locations within the stack. Some modules are connected in series to maximize voltage output, while others are connected in parallel to maximize thermal conductivity. This local optimization allows different parts of the system to serve different functions (electrical generation vs. heat transfer) simultaneously.
Solution Approach 2:
The system allows dynamic selection of TEG connection configurations based on operational requirements. The modular design enables reconfiguration of TEG modules between series and parallel connections depending on whether the priority is electrical output or thermal conductivity, providing operational flexibility.
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 stackable heat pipe assembly simplifies implementation by allowing modular expansion and replacement, reducing maintenance and replacement costs, and maintaining performance in mid- to high-temperature environments without compromising functionality.
Implementation Method 1
Heat pipes are passive two-phase heat transfer mechanisms used to efficiently transport heat from one location to another through an evaporation-condensation process
Implementation Method 2
Heat pipes are passive two-phase heat transfer mechanisms used to efficiently transport heat from one location to another through an evaporation-condensation process
Implementation Method 3
Heat pipes are passive two-phase heat transfer mechanisms used to efficiently transport heat from one location to another through an evaporation-condensation process
Implementation Method 4
Heat pipes, combined with thermo-electric generators (TEGs), are applied in waste heat recovery and power generation systems
Implementation Method 5
When the heat pipe side of the TEG system is heated (heat moved thereto) and the other side cooled by air, water, or another suitable medium, such as another heat pipe (heat moved therefrom), a voltage is generated
Data Source
AI summary
A stackable heat pipe assembly and method of making the same comprising first and second conductive metal plates, a conductive metal tube, and a working pipe is provided. The first and second conductive metal plates have first and second contact sides and first and second attachment sides, respectfully. The first conductive metal plate has a through hole therethrough. The first and second attachment sides have first and second planar central portions and first and second walls, first and second top ledges, and first and second expanded walls theresurrounding, respectively. The conductive metal tube has an inner wall having a wick structure thereon. A plurality of brazing rings are used to braze the working pipe to the through hole and the first and second planar central portions to the first and second attachment rim ends, respectively. Either of the first or second contact sides contacts a heat source and is stackable.