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EP-4701932-B1 - HIGH-LENGTH REDUNDANT THERMAL-CONTROL DEVICE WITH COMPLEX TWO-PHASE STRUCTURES, ASSEMBLY METHOD AND MANUFACTURING METHOD

EP4701932B1EP 4701932 B1EP4701932 B1EP 4701932B1EP-4701932-B1

Inventors

  • MARTINELLI, Matthieu
  • Fourgeaud, Laura

Dates

Publication Date
20260513
Application Date
20240820

Claims (10)

  1. A redundant thermal control device (1, 2, 10) comprising a first two-phase structure (1) and a second two-phase structure (2), characterized in that : - each of the two-phase structures comprises two distinct stages, referred to as the first (5) and second (6) stages, joined together by a tight partition, each of the stages delimiting a tight enclosure (7a, 7b) comprising at least one capillary medium (9a, 9b) for circulation of a two-phase fluid in liquid phase and a vapor channel (8a, 8b) for circulation of the two-phase fluid in vapor phase, each of the two-phase structures comprising at least one assembly end (3, 4) for assembling said two-phase structure with the other two-phase structure, the tight enclosures (7a, 7b) of each two-phase structure being open at the assembly end, the first and second stages each having a connecting end (50, 60; 51, 61) at the assembly end, - the first stage of each of the two-phase structures has, at its assembly end, a protruding segment (52, 53) that extends protruding from the second stage, the connecting end (50) of the first stage of the first two-phase structure coming against or in immediate proximity to the connecting end (51) of the first stage of the second two-phase structure so that, on the one hand, their capillary media meet to form a first continuous liquid path and, on the other hand, their vapor channels (8a) meet to form a first continuous vapor path, while their tight enclosures (7a) are tightly welded together over their entire periphery, a space then remaining between the connecting ends (60, 61) of the second stages of the two-phase structures, - the device further comprises a bridge (10), configured to be accommodated in the space between the connecting ends (60, 61) of the second stages of the two-phase structures, said bridge having a tight enclosure (7c) comprising a capillary medium (9c) for circulation of the two-phase fluid in liquid phase, a vapor channel (8c) for circulation of the two-phase fluid in vapor phase and two open connecting ends (100, 101) that come against or in immediate proximity to the connecting ends (60, 61) of the second stages of the first and second two-phase structures such that the capillary medium of the bridge (9c) and the capillary medium of the second stage (9b) of each of the two-phase structures (1, 2) meet and that the vapor channel of the bridge (8c) and the vapor channel of the second stage (8b) of each of the two-phase structures (1, 2) meet, the capillary medium of the bridge (9c) and the vapor channel of the bridge (8c)) making junction between, respectively, the capillary media (9b) and the vapor channels (8b) of the second stages to form, respectively, a second continuous liquid path and a second continuous vapor path, while the tight enclosures (7c, 7b, 7a) of the bridge and the two-phase structures are tightly welded together over an entire closed contour.
  2. The device according to claim 1, wherein the enclosures (7a, 7c, 7b) of the bridge (10) and the two-phase structures (1, 2) are welded so as to form at least one first outer weld line (20) disposed on external faces of the first stages of the two-phase structures, second outer weld lines (22) disposed on external faces of the second stages and the bridge, and third outer weld lines (23) disposed on external faces of the first stages and the bridge, the first, second and third outer weld lines joined together thus forming a closed and tight weld bead.
  3. The device according to the preceding claim, wherein the connecting ends (50, 51) of the first stages facing each other form at least one peripheral groove for accommodating the first outer weld lines (20).
  4. The device according to one of the preceding claims, wherein the bridge has notches (105) for accommodating a first inner weld line (21) arranged on inner upper faces (54, 55) of the first stages of the first and second two-phase structures, these notches facing the junction of the connecting ends (50, 51) of said first stages.
  5. The device according to one of the preceding claims, wherein the first and second two-phase structures (1, 2) are of the complex structure type generated by additive manufacturing.
  6. A method for assembling a first two-phase structure (1) and a second two-phase structure (2), characterized in that each of the two-phase structures comprises two distinct stages, referred to as the first (5) and second (6) stages, joined together by a tight partition, each of said stages delimiting a tight enclosure (7a, 7b) comprising at least one capillary medium (9a, 9b) for circulation of a two-phase fluid in liquid phase and a vapor channel (8a, 8b) for circulation of the two-phase fluid in vapor phase, each of the two-phase structures comprising at least one assembly end (3, 4) for assembling said two-phase structure with the other two-phase structure, the tight enclosures (7a, 7b) of each two-phase structure being open at the assembly end, the first and second stages each having a connecting end (50, 60; 51, 61) at the assembly end, the first stage of each of the two-phase structures having, at its assembly end, a protruding segment (52, 53) that extends protruding from the second stage, and in that the assembly method comprises the following steps: - positioning the connecting end (50) of the first stage of the first two-phase structure against or in immediate proximity to the connecting end (51) of the first stage of the second two-phase structure so that their capillary media (9a) meet and their vapor channels (8a) meet, a space then remaining between the connecting ends (60, 61) of the second stages of the two-phase structures, - tightly welding the tight enclosures (7a) of the first stages of the two-phase structures together, over their entire periphery, - providing a bridge (10) having a tight enclosure (7c) comprising a capillary medium (9c) for circulation of the two-phase fluid in liquid phase, a vapor channel (8c) for circulation of the two-phase fluid in vapor phase and two open connecting ends (100, 101), the bridge being configured to be accommodated in the space between the connecting ends (60, 61) of the second stages of the two-phase structures and so that its connecting ends (100, 101) then come into contact with or in the immediate vicinity of the connecting ends of the second stages, - inserting said bridge between the connecting ends (60, 61) of the second stages of the first and second two-phase structures, the connecting ends (100, 101) of the bridge being then in contact with or in immediate proximity to the connecting ends of said second stages so that the capillary medium of the bridge (9c) and the capillary medium (9b) of the second stage of each of the two two-phase structures meet and that the vapor channel of the bridge (8c) and the vapor channel (8b) of the second stage of each of the two-phase structures meet, the capillary medium of the bridge (9c) and the vapor channel of the bridge (8c) making junction between, respectively, the capillary media (9b) and the vapor channels (8b) of the second stages to form, respectively, a second continuous liquid path and a second continuous vapor path, - tightly welding the enclosures (7c, 7b, 7a) of the bridge and the two-phase structures following a closed contour.
  7. The assembly method according to claim 6, wherein the connecting end (50) of the first stage of the first two-phase structure (1) has a peripheral shoulder forming a male plug (56), while the connecting end (51) of the first stage of the second two-phase structure (2) has a recess and a peripheral shoulder (57) forming a female plug (58) configured to receive the male plug (56) of the first stage of the first two-phase structure in an interlocking manner.
  8. The assembly method according to claim 7, wherein the recess of the female plug (58) has a longitudinal dimension lower than said male plug (56), such that a peripheral groove appears when said male and female plugs are interlocked, which peripheral groove makes it possible to accommodate first outer weld lines (20) disposed on external faces of the first stages (5) of the first and second two-phase structures (1, 2) as well as a first inner weld line (21) disposed on internal upper faces (54, 55) of said first stages.
  9. The assembly method according to one of claims 6 to 8, wherein the first and second two-phase structures (1, 2) are obtained by additive manufacturing.
  10. A method for manufacturing a redundant thermal control device having a length greater than or equal to 400 mm, intended to extend between a hot source and a cold source and comprising at least two redundant stages, each containing a two-phase fluid, characterized in that it comprises: - producing by additive manufacturing at least a first two-phase structure (1), a second two-phase structure (2) and a bridge (10), wherein each of said first and second two-phase structures comprises a first stage (5) and a second stage (6) joined together by a tight partition, each of said stages delimiting a tight enclosure (7a, 7b) comprising at least one capillary medium (9a, 9b) for circulation of the two-phase fluid in liquid phase and a vapor channel (8a, 8b) for circulation of the two-phase fluid in vapor phase, each of the two-phase structures comprising at least one assembly end (3, 4) for assembling said two-phase structure with the other two-phase structure, the tight enclosures (7a, 7b) of each two-phase structure being open at the assembly end, the first and second stages each having a connecting end (50, 60; 51, 61) at the assembly end, the first stage of each of the two-phase structures having, at its assembly end, a protruding segment (52, 53) that extends protruding from the second stage such that, when the connecting end (50) of the first stage of the first two-phase structure (1) is placed against or in immediate proximity to the connecting end (51) of the first stage of the second two-phase structure (2), their capillary media (9a) meet to form a first liquid path and their vapor channels (8a) meet to form a first vapor path, a space remains between the connecting ends (60, 61) of the second stages of the two-phase structures, and wherein the bridge has a tight enclosure (7c) comprising a capillary medium (9c) for circulation of the two-phase fluid in liquid phase, a vapor channel (8c) for circulation of the two-phase fluid in vapor phase and two open connecting ends (100, 101), the bridge being configured to be accommodated in the space between the connecting ends (60, 61) of the second stages of the two-phase structures and so that its connecting ends (100, 101) then come into contact with the connecting ends of the second stages, the capillary medium (9c) of the bridge and the vapor channel (8c) of the bridge being configured to make a junction between, respectively, the capillary media (9b) and the vapor channels (8b) of the second stages to form, respectively, a second continuous liquid path and a second continuous vapor path, and then - assembling said two-phase structures in accordance with the assembly method according to one of claims 6 to 9.

Description

Technical field of the invention The invention relates to the field of thermal control devices for regulating the temperature of equipment or components of a spacecraft. More particularly, the invention relates to a complex two-phase structure and a method for assembling complex two-phase structures to obtain a redundant thermal control device, as well as a method for manufacturing a redundant thermal control device comprising the fabrication of complex two-phase structures by 3D printing. The document US 10 837 712B discloses a redundant thermal control device comprising a first two-phase structure comprising two distinct stages, designated as first and second stages, joined together by a sealed partition, each of the stages delimiting a sealed enclosure comprising at least one capillary medium for the circulation of a two-phase fluid in liquid phase and a vapor channel for the circulation of the two-phase fluid in vapor phase, the sealed enclosures of each two-phase structure being open at the assembly end, the first and second stages each having a connection end at the assembly end, the first stage of the two-phase structure having, at its end, a salient section which extends in projection from the second stage. State of the art A two-phase heat transfer system comprises a vapor core and a capillary tube. The vapor core and capillary tube are designed to transfer heat energy between a component to be cooled, referred to as the hot source, located at one end of the two-phase system (the hot end), which acts as an evaporator, and a cold source (heat sink or other cooling system) located at the opposite end of the two-phase system (the cold end), which acts as a condenser. This transfer is achieved through the principle of heat transfer by phase transition of a fluid and the principle of capillary circulation. At the hot end of the two-phase system, the fluid, in its liquid state, vaporizes, absorbing thermal energy emitted by the component to be cooled. The vapor then circulates through the vapor core to the cold end of the two-phase system, where it condenses back into a liquid state. Condensation allows thermal energy to be released to the cold source. The liquid then returns to the hot end by capillary action through the capillary tube. A two-phase structure includes, for example, a vapor core formed by a central cavity which extends along an axial or longitudinal direction of the structure, and a capillary arranged for example around said vapor core. Throughout this patent application, the term " heat pipe " will refer to simple, counter-current tubular structures, with the central cavity of the tube corresponding to the heat pipe's vapor core. A heat pipe is generally produced by extrusion. The term " two-phase structure" will be used to refer to any type of two-phase structure. Finally, a two-phase structure that cannot be produced by extrusion will be referred to as a "complex two-phase structure." A complex two-phase structure is, for example, produced by additive manufacturing. Two-phase structures, and in particular heat pipes, are used notably for the thermal control of spacecraft. In the absence of an atmosphere preventing ventilation, heat pipes transfer heat from equipment located inside the satellite to the satellite's exterior walls or to radiators, where the heat can be dissipated by radiation. Extruded heat pipes are also known, having at least one flat outer face, preferably extending along the entire length of the heat pipe, to allow for structural and thermal coupling of said heat pipe either to a radiator panel or to another heat pipe also having a flat outer coupling face. Such a heat pipe may, for example, have a square cross-section (within which a circular cavity is formed) with four flat outer coupling faces. In another example, the heat pipe may be in the form of a circular duct combined with a flat coupling profile (the assembly having a T-shaped cross-section), or with two flat coupling profiles (H-shaped cross-section), or even with an angled coupling profile. Such heat pipes are disclosed in EP 1 031 511 . Extrusion manufacturing of heat pipes allows for the production of any length without limitation. However, configuration options, such as capillary configuration, are limited. For example, it is not possible to manufacture a heat pipe by extrusion where the capillary or vapor core has shapes and/or dimensions that vary along the pipe, or where the capillary is shaped like... lattice for example. Thus, in a heat pipe obtained by extrusion, the capillary is formed by grooves made in the inner face of the tube (vapor core), which grooves necessarily extend along the axial direction of the heat pipe. Conversely, additive manufacturing techniques allow for the design of two-phase structures with varied configurations, particularly 3D capillaries. The term "3D" refers to the ability to manufacture/structure in three directions with additive manufacturing, whereas extrusion is