Heat Pipe - Structure, Design and Construction

Structure, Design and Construction

A typical heat pipe consists of a sealed pipe or tube made of a material with high thermal conductivity such as copper or aluminium at both hot and cold ends. A vacuum pump is used to remove all air from the empty heat pipe, and then the pipe is filled with a fraction of a percent by volume of working fluid (or coolant) chosen to match the operating temperature. Alternatively, the pipe is heated until the fluid boils, and sealed while hot. Examples of such fluids include water, ethanol, acetone, sodium, or mercury. Due to the partial vacuum that is near or below the vapor pressure of the fluid, some of the fluid will be in the liquid phase and some will be in the gas phase. The use of a vacuum eliminates the need for the working gas to diffuse through any other gas and so the bulk transfer of the vapor to the cold end of the heat pipe is at the speed of the moving molecules. In this sense, the only practical limit to the rate of heat transfer is the speed with which the gas can be condensed to a liquid at the cold end.

Inside the pipe's walls, an optional wick structure exerts a capillary pressure on the liquid phase of the working fluid. This is typically a sintered metal powder or a series of grooves parallel to the pipe axis, but it may be any material capable of exerting capillary pressure on the condensed liquid to wick it back to the heated end. The heat pipe may not need a wick structure if gravity or some other source of acceleration is sufficient to overcome surface tension and cause the condensed liquid to flow back to the heated end.

A heat pipe is not a thermosiphon, because there is no siphon. Thermosiphons transfer heat by single-phase convection. (See also: Perkins tube, after Jacob Perkins.)

Heat pipes contain no mechanical moving parts and typically require no maintenance, though non-condensing gases (that diffuse through the pipe's walls, result from breakdown of the working fluid, or exist as impurities in the materials) may eventually reduce the pipe's effectiveness at transferring heat. This is significant when the working fluid's vapour pressure is low.

The materials chosen depend on the temperature conditions in which the heat pipe must operate, with coolants ranging from liquid helium for extremely low temperature applications (2–4 K) to mercury (523–923 K) & sodium (873–1473 K) and even indium (2000–3000 K) for extremely high temperatures. The vast majority of heat pipes for low temperature applications use some combination of ammonia (213–373 K), alcohol (methanol (283–403 K) or ethanol (273–403 K)) or water (303–473 K) as working fluid. Water, for instance, at low pressure will boil at just above 273 K (0 degrees Celsius) and so can start to effectively transfer latent heat at this low temperature.

The advantage of heat pipes over many other heat-dissipation mechanisms is their great efficiency in transferring heat. They are fundamentally better at heat conduction over a distance than an equivalent cross-section of solid copper (a heat sink alone, though simpler in design and construction, does not take advantage of the principle of matter phase transition). Some heat pipes have demonstrated a heat flux of more than 230 MW/m².

Active control of heat flux can be effected by adding a variable volume liquid reservoir to the evaporator section. Variable conductance heat pipes employ a large reservoir of inert immiscible gas attached to the condensing section. Varying the gas reservoir pressure changes the volume of gas charged to the condenser which in turn limits the area available for vapor condensation. Thus a wider range of heat fluxes and temperature gradients can be accommodated with a single design.

A modified heat pipe with a reservoir having no capillary connection to the heat pipe wick at the evaporator end can also be used as a thermal diode. This heat pipe will transfer heat in one direction, acting as an insulator in the other.