Two-phase thermal management devices, methods, and systems

Abstract

Devices, methods, and systems for two-phase thermal management are provided in accordance with various embodiments. For example, a two-phase thermal management device is provided that may include two or more containment layers and/or one or more porous layers positioned between at least a portion of each of the two or more containment layers. The portion of each of the two or more containment layers and the one or more porous layers may be bonded with each other. The two or more containment layers and one or more porous layers may be bonded with each other to form an uninterrupted stack of material layers utilizing diffusion bonding. Some embodiments include a method of forming a two-phase thermal management device including arranging multiple materials layers including one or more porous layers positioned with respect to one or more containment layers; and/or bonding the multiple material layers with each other.

1 . A two-phase thermal management device comprising:
 two or more containment layers; and   one or more porous layers positioned between at least a portion of each of the two or more containment layers, wherein the portion of each of the two or more containment layers and the one or more porous layers are bonded with each other.   
     
     
         2 . The device of  claim 1 , wherein the two or more containment layers and one or more porous layers are bonded with each other to form an uninterrupted stack of material layers. 
     
     
         3 . The device of  claim 1 , wherein the two or more containment layers and one or more porous layers are bonded with each other such that a first side of each respective porous layer from the one or more porous layers and a second side of each respective porous layer from the one or more porous layers are each respectively bonded with at least a side of one of the two or more containment layers or a side of one of the other one or more porous layers. 
     
     
         4 . The device of  claim 1 , wherein the two or more containment layers and the one or more porous layers are bonded with each other such that:
 a first side of a first containment layer from the two or more containment layers is bonded with a first side of a first porous layer from the one or more porous layers; and   a first side of a second containment layer from the two or more containment layers is bonded with at least a second side of the first porous layer or a first side of a second porous layer from the one or more porous layers, wherein a second side of the second porous layer is bonded with at least the second side of the first porous layer or one or more additional porous layers from the one or more porous layers such that at least one of the additional porous layers is bonded with the second side of the first porous layer.   
     
     
         5 . The device of  claim 1 , wherein the two or more containment layers and the one or more porous layers are diffusion bonded with each other. 
     
     
         6 . The device of  claim 1 , further comprising a working fluid disposed between the two or more containment layers. 
     
     
         7 . The device of  claim 6 , wherein the working fluid includes at least ammonia, acetone, methanol, water, or ethyl alcohol. 
     
     
         8 . The device of  claim 1 , wherein the two or more containment layers and the one or more porous layers are made from one or more flexible materials. 
     
     
         9 . The device of  claim 1 , wherein the one or more porous layers include at least a first liquid wicking layer and a vapor layer positioned between the first liquid wicking layer and at least one of the two or more containment layers. 
     
     
         10 . The device of  claim 9 , wherein the one or more porous layers includes a second liquid wicking layer positioned such that the vapor layer is positioned between the first liquid wicking layer and the second liquid wicking layer. 
     
     
         11 . The device of  claim 10 , wherein the first liquid wicking layer includes a first mesh, the second liquid wicking layer includes a second mesh, and the vapor layer includes at least a third mesh or a metal foam, wherein the third mesh includes fewer wires per unit length than the first mesh or the second mesh. 
     
     
         12 . The device of  claim 1 , wherein the two or more containment layers include a first copper foil and a second copper foil. 
     
     
         13 . The device of  claim 1 , wherein:
 the two or more containment layers include a first containment layer, a second containment layer, and a third containment layer; and   the one or more porous layers include at least a first porous layer positioned between at least a portion of the first containment layer and a portion of the second containment layer and at least a second porous layer positioned between at least a portion of the second containment layer and at least a portion of the third containment layer.   
     
     
         14 . The device of  claim 13 , wherein the first containment layer, the second containment layer, and the third containment layer are stacked with respect to each other perpendicularly to a main plane. 
     
     
         15 . The device of  claim 13 , wherein the first containment layer and the third containment layer are skewed with respect to each other. 
     
     
         16 . The device of  claim 1 , wherein the one or more porous layers include a first mesh layer, a second mesh layer, a third mesh layer, and a fourth mesh layer wherein:
 the first mesh layer and the third mesh layer include fewer wires per unit length than the second mesh layer and the fourth mesh layer;   at least a portion of the first mesh layer is positioned between the second mesh layer and a first containment layer from the two or more containment layers; and   at least a portion of the third mesh layer is positioned between the fourth mesh layer and a second containment layer from the two or more containment layers.   
     
     
         17 . The device of  claim 16 , further comprising a fifth mesh layer positioned between the second mesh layer and the fourth mesh layer, wherein the fifth mesh layer includes fewer wires per unit length than the first mesh layer, the second mesh layer, the third mesh layer, and the fourth mesh layer. 
     
     
         18 . The device of  claim 16 , further comprising a window aperture positioned between the two or more containment layers. 
     
     
         19 . The device of  claim 1 , wherein the device is configured with one or more evaporator regions and one or more condenser regions. 
     
     
         20 . The device of  claim 6 , wherein the working fluid includes a paraffin. 
     
     
         21 . The device of  claim 1 , wherein the device is configured to maintain its shape when exposed to an internal pressure greater than an external pressure. 
     
     
         22 . The device of  claim 6 , wherein the device is configured to carry an internal vapor pressure of the working fluid greater than an external pressure. 
     
     
         23 . The device of  claim 6 , wherein the device is configured to passively move the working fluid located between the two or more containment layers. 
     
     
         24 . The device of  claim 1 , wherein another portion of a first containment layer from the two or more containment layers and another portion of a second containment layer from the two or more containment layers are bonded with each other to form one or more seals for the device. 
     
     
         25 . The device of  claim 1 , wherein the one or more porous layers include at least two porous layers that partially overlap. 
     
     
         26 . The device of  claim 1 , further comprising a first working fluid and a second working fluid, wherein the device is configured to:
 passively move the first working fluid located between a first containment layer from the two or more containment layers and a second containment layer from the two or more containment layers; and   actively move the second working fluid located between the second containment layer and a third containment layer from the two or more containment layers.   
     
     
         27 . The device of  claim 1 , wherein the two or more containment layers include at least a copper foil, an aluminum foil, a stainless steel foil, or a titanium foil. 
     
     
         28 - 56 . (canceled)