Annular Wick Plug Attachment Using Thermal Clamp Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for attaching wick plugs to annular wicks in heat pipes are prone to operator error and damage, especially due to extensive handling and mechanical crimping, which can compromise the seal and introduce leak paths.
Innovation Solution
A method involving a clamp with a lower thermal expansion coefficient than the wick and wick plug, where the assembly is heated to thermally expand and exert a compressive force, ensuring a uniform bond without mechanical crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical crimping is used to attach the wick plug to the wick, then the wick plug can be secured to the wick, but extensive operator handling is required which increases the risk of operator error and damage to the fragile wick
Solution Approach 1:
The patent replaces the mechanical crimping system with a thermal bonding system. The wick plug and wick are heated to a temperature where the wick plug material becomes sufficiently soft or molten, allowing it to bond with the wick through thermal fusion rather than mechanical deformation. This eliminates the need for operators to manually position and crimp the components, thereby reducing operator error risk while maintaining attachment strength.
Solution Approach 2:
The patent changes the temperature parameter of the wick plug and wick assembly during the bonding process. By heating the components to a specific temperature range, the material properties of the wick plug change, enabling it to flow or soften and form a strong bond with the wick. This thermal parameter change replaces the mechanical pressure parameter used in crimping, achieving secure attachment with minimal handling.
2Ease of manufacture
If the wick is handled extensively during assembly, then the wick plug can be attached to the wick, but the fragile wick is susceptible to damage from its own weight and operator manipulation
Solution Approach 1:
The patent employs preliminary positioning where the wick plug is pre-positioned on the wick before heating. This initial placement requires minimal handling, and subsequent thermal processing completes the bonding without further manipulation. The wick is handled only once to establish the initial configuration, after which the thermal process completes the attachment, preserving wick integrity throughout.
Solution Approach 2:
The patent replaces mechanical fastening operations with thermal bonding. Instead of requiring operators to mechanically secure the wick plug through crimping or fastening operations that would involve extensive handling, the process uses heat to fuse the components together. This substitution reduces handling to a single positioning step while maintaining secure attachment.
3Strength
If crimping is performed before bonding, then the wick plug is mechanically secured, but the stresses from crimping relax before bonding, creating potential leak paths at the interface
Solution Approach 1:
The patent eliminates the two-step mechanical crimping followed by bonding process by replacing it with direct thermal bonding. The thermal process applies heat and pressure simultaneously to create a uniform bond across the entire interface between the wick plug and wick, avoiding the stress relaxation problem that occurs when mechanical crimping is performed separately before bonding.
Solution Approach 2:
The patent merges the mechanical securation and bonding operations into a single thermal processing step. Rather than performing mechanical crimping first and then bonding separately, the thermal process accomplishes both functions simultaneously—heating the materials to enable bonding while also applying the necessary pressure for secure attachment, ensuring uniform contact and eliminating leak paths.
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 minimizes wick damage and ensures a strong, uniform contact between the wick and wick plug, reducing the likelihood of leaks and improving the integrity of the heat pipe seal.
Implementation Method 1
heating the clamp, the annular wick, and the wick plug to a temperature sufficient to thermally expand the wick plug and the annular wick to exert a compressive force onto the wick plug and the annular wick by the clamp
Data Source
AI summary
A method of attaching a wick plug to an annular wick with the annular wick defining an outside diameter. The method includes positioning the wick plug at least partially within the annular wick; placing a clamp over the outside diameter of the annular wick; and heating the clamp, the annular wick, and the wick plug to a temperature sufficient to thermally expand the wick plug and the annular wick to exert a compressive force onto the wick plug and the annular wick by the clamp to compress the wick plug and the annular wick together.