Designing an effective heat pipe mounting solution involves selecting the optimal method for installing heat pipes. This article explores seven common configurations for mounting heat pipes onto a plate, along with their cost and performance implications. Each method uses solder, the most widely used attachment material.
Heat Pipe Mounting Options
Figure 1 illustrated common heat pipe mounting options. Mounting options A-D use a copper base plate to which the heat source is attached. For options E-G, the heat source directly contacts the heat pipe. In the following test setups, red arrows represent the location of the heat source/input.
Figure 1: Common Heat Pipe Mounting Options
Test Setup
Figure 2 shows the experimental setup for evaluating heat pipe mounting performance. Key details include:
- Th: Thermocouple embedded in the heater.
- Tc: Thermocouple that extends through the heater to touch the base.
Figure 2: Heat Pipe Mounting Test Set
CFD Performance Results Using Different TIMs
The choice of thermal interface material (TIM) affects thermal performance significantly. As illustrated in Figure 3, different TIMs can change delta-T values by up to 10%.
Figure 3: Comparison of Different TIM Materials Used in Each Mounting Configuration
Comparing CFD and Bench Test Results
Bench testing aligns closely with computational fluid dynamics (CFD) predictions. On average, bench test results showed a 3.1°C delta-T difference, within 6% of CFD estimates when using a grease TIM.
Figure 4: CFD vs Bench Test
Performance & Cost Implications
The choice of heat pipe mounting method directly influences manufacturing complexity, cost, and thermal efficiency. As designs progress from configuration A to G (see Figure 5):
- Manufacturing process time increases.
- Secondary operations may be required.
- Yield rates decrease.
- Overall costs rise.
Figure 5: Performance and Cost Implications of Each Heat Pipe Mounting Option
Selecting the best method for mounting heat pipes involves balancing thermal performance, manufacturing constraints, and costs. Engineers must evaluate these factors to optimize designs for efficiency and cost-effectiveness.
