Heat pipe wick formation

1. A method for forming a high capacity heat pipe tube with a wick layer in a controlled atmosphere, the method comprising:

wrapping a plurality of layers of a fine mesh screen around a mandrel;

inserting the mandrel and the fine mesh screen into a heat pipe tube;

compressing the fine mesh screen between the mandrel and the heat pipe tube to form an assembly, wherein the compressing of the fine mesh screen comprises applying pressure to an interior of the mandrel and pressing the mandrel and the fine mesh screen against the heat pipe tube;

diffusion bonding the assembly at a predefined temperature achieving self-diffusion of the plurality of layers of the fine mesh screen, whereby the diffusion bonded plurality of layers of fine mesh screen form the wick layer;

cooling the diffusion bonded assembly to room temperature;

etching the mandrel from the diffusion bonded assembly, whereby the heat pipe tube is lined with the wick layer; and

inserting a plug on one or both ends of the heat pipe tube by bonding the plug to the wick layer.

2. The method of claim 1 , wherein the mandrel is etchable in an acid without affecting the wick layer or heat pipe tube.

3. The method of claim 1 , further comprising:

layering filtration cloths with different degrees of fineness, wherein the different degrees of fineness may be composed of different mesh counts or have different grated screens with different effective pore sizes.

4. The method of claim 1 , wherein applying the pressure to the interior of the mandrel further comprises applying the pressure by a hydraulic fluid.

5. The method of claim 4 , wherein the pressure is applied at room temperature with the heat pipe tube contained inside a mold to minimize tube distortion during pressurization.

6. The method of claim 1 , wherein bonding the plug to the wick layer is performed by thermal shrink fit or diffusion bonding.

7. The method of claim 6 , wherein, when diffusion bonding the plug to the wick layer is performed, the method further comprises:

placing a tight fitting ring around the wick layer, the tight fitting ring made from a material that has a lower thermal expansion coefficient than the plug;

heating the wick layer and the plug in a controlled temperature and atmosphere;

expanding the wick layer and the plug relative to the tight fitting ring;

creating a pressure and a temperature that bonds the wick layer and the plug; and

after cooling the bonded wick layer and plug, removing the tight fitting ring from the bonded wick layer and plug.

8. The method of claim 6 , wherein, when diffusion bonding the plug to the wick layer is performed, the method further comprises:

wrapping a plurality of wires around the wick layer at a location above the plug; and

tightening the plurality of wires around the wick layer by crimping, wherein

the plurality of wires have a thermal expansion coefficient less than the plug.

9. A method for forming a porous annular heat pipe wick in a controlled atmosphere, the method comprising:

wrapping a plurality of layers of a fine mesh screen around a mandrel;

inserting the mandrel and the fine mesh screen into a sheath;

compressing the fine mesh screen between the sheath and the mandrel to form an assembly, wherein the compressing of the fine mesh screen comprises applying pressure to an exterior of the sheath;

diffusion bonding the assembly at a predefined temperature, achieving self-diffusion of the plurality of layers of the fine mesh screen to form a porous tube;

cooling the diffusion bonded assembly to room temperature;

etching the mandrel and sheath from the diffusion bonded assembly, leaving the porous tube used as an annular heat pipe wick or artery; and

bonding a plug to the porous tube by welding, brazing, or diffusion bonding.

10. The method of claim 9 , wherein the pressure is applied on the exterior of the mandrel and/or the sheath by swaging the sheath or by drawing the sheath moving the assembly inward.

11. The method of claim 9 , wherein pressure is additionally applied by pressurizing the mandrel on an inside of the assembly, forcing the assembly to press against the sheath.

12. The method of claim 9 , wherein the mandrel, the sheath, or both, are etchable in an acid without affecting the porous tube.

13. The method of claim 9 , further comprising:

layering filtration cloths with different degrees of fineness, wherein the different degrees of fineness may be composed of different mesh counts or have different grated screens with different effective pore sizes.

14. The method of claim 9 , wherein, when diffusion bonding the plug to the porous tube is performed, the method further comprises:

placing a tight fitting ring around the porous tube, the tight fitting ring made from a material that has a lower thermal expansion coefficient than the plug;

heating the porous tube and the plug in a controlled temperature and atmosphere;

expanding the porous tube and the plug relative to the tight fitting ring;

creating a pressure and temperature that bonds the porous tube and the plug; and

after cooling the bonded porous tube and plug, removing the tight fitting ring from the bonded porous tube and plug.

15. The method of claim 9 , wherein, when diffusion bonding of the plug to the porous tube is performed, the method further comprises:

wrapping a plurality of wires around the porous tube at a location above the plug; and

tightening the plurality of wires around the porous tube by crimping, wherein

the plurality of wires have a thermal expansion coefficient less than the plug.