CCI HEAT PIPE DESIGN GUIDE

Rev: D01

Prepared by：CCI RD01 Heat Pipe Team

Date：27. June. 2006

*Contents

z Feature descriptions & Geometry limitation

z Test methodology descriptions

z Screen Mesh

z Groove

z Sintering Powder

z Composite

z Approval sheet

2
*Feature Descriptions
z Dimensions List

Tail

Head

Bend

1.Mass Production Diameter : D= φ4, φ5, φ6, φ8 for Screen Mesh Pipe
D= φ4, φ5, φ6, φ8 for Grooved Pipe
D= φ6, φ8 for Sintering Powder Pipe
D= φ6, φ8 for Composite Pipe

2.Mass Production Length : L= 100 ~ 350 mm

3
 *Test Methodology
‹ Heater: Copper dummy heater , heat source area = 15x W mm
‹ Condenser: Copper fin with fan , cooling length = 60~80mm
‹ Theater (℃): Heater temperature, sensor is embedded between
Heater and evaporator section of heat pipe.
‹ Thp1 (℃): Evaporator temperature of heat pipe, measurement
on heat pipe top side.
‹ Thp2 (℃): Adiabatic temperature of heat pipe, measurement on Heater
Condenser
heat pipe top side. Keep this point at 45oC by Fan speed
control.
‹ Thp3 (℃): Condenser temperature, sensor is embedded
between HP and condenser section of heat pipe.

Thp3
Theater Thp1 Thp2

4
‹ Q(watts) : Input power
‹ Rheat pipe (oC/W)= R(Evaporator Local contact effect) + R(pipe dimension effect) + R(Condenser Local contact effect)
= (Therter– Thp1)/Q + (Thp1-Thp3)/Q + (Thp3-Tsink)/Q
= (Therter-Tsink)/Q
--- Term R(Evaporator contact effect) is concerned about ‘’Local dry out’’ in case of sharp heat flux loading on heat pipe.
--- Term R(Pipe structure effect) is concerned about the capability of dimension and wick structure of heat pipe itself.
--- Term R(Condenser contact effect) is concerned about “Flooding” in case of over cooling on heat pipe.
‹ Qmax(watts) : Thermal resistance Rheat pipe is significant increase when Power input is larger than a certain Power.
‹ Qdryout(watts) : Thermal resistance Rheatpipe is ramp up and almost unsteady when Power input is larger than a
certain Power.

5
*Screen Mesh type
D t t :Tolerance W W:Tolerance Rc Shrinking length
3.0 4.72
2.5 5.02
Head end: 7.0
2.0 5.33
φ4 ±0.05 ±0.1 Rc≧20
1.8 5.43
1.6 5.54
Tail end: 3.5
1.5 5.59
3.0 6.40
2.5 6.64
Head end: 7.5
2.0 6.86
φ5 ±0.05 ±0.1 Rc≧25
1.8 6.95
1.6 7.04
Tail end: 4.0
1.5 7.09
4.0 7.41
3.5 7.66
Head end: 11.0
3.0 7.95
φ6 ±0.05 ±0.1 Rc≧30
2.5 8.23
2.0 8.48
Tail end: 5.0
1.5 8.73
5.0 10.03
4.0 10.59
3.5 10.91
Head end: 14.5
3.0 11.13
φ8 ±0.05 ±0.1 Rc≧40
2.8 11.23
2.5 11.38
Tail end: 8.0
2.0 11.63
1.5 11.88

6
*Grooved type
D t t :Tolerance W W:Tolerance Rc Shrinking length
3.0 6.37
2.8 6.49 Head end: 10.0
φ5 2.5 ±0.05 6.64 ±0.1
Rc≧20
2.0 6.91 Tail end: 3.0
1.8 7.02
4.0 7.40
3.5 7.68
3.0 8.01 Head end: 11.5
φ6 2.8 ±0.05 8.08 ±0.1
Rc≧24
2.5 8.25 Tail end: 3.0
2.0 8.51
1.8 8.61
5.0 10.07
4.5 10.36
4.0 10.65
3.5 10.93 Head end: 15.0
φ8 3.0 ±0.05 11.21 ±0.1 Rc≧32
2.8 11.32 Tail end: 3.0
2.5 11.49
2.0 11.77
1.5 12.05

Remark: All definition of dimension and tolerance is excluded from the Dent of pipe, especially on both
end and bend location of a pipe.

7
*Sintering Powder type
D t t :Tolerance W W:Tolerance Rc Shrinking length
3.0 4.70
2.8 4.83
Head end: 7.0
2.5 4.96
φ4 ±0.05 ±0.1 Rc≧12
2.0 5.25
1.8 5.35
Tail end: 3.0
1.6 5.44
3.0 6.34
2.8 6.45
Head end: 10.0
2.6 6.53
φ5 ±0.05 ±0.1 Rc≧15
2.5 6.6
2.4 6.66
Tail end: 3.0
2.0 6.86
4.5 7.09
4.0 7.39
3.5 7.66 Head end: 11.5
φ6 3.2 ±0.05 7.79 ±0.1 Rc≧18
3.0 7.9 Tail end:3.0
2.8 8.02
2.5 8.15
6.0 9.54
5.5 9.84
5.0 10.11
Head end: 15
4.5 10.37
φ8 ±0.05 ±0.1 Rc≧24
4.0 10.62
3.5 10.89
Tail end: 3.0
3.2 11.02
3.0 11.12

8
*Composite type

Shrinking
D t t :Tolerance W W:Tolerance Rc
length
4.0 7.40
3.5 7.68
3.0 8.01 Head end: 11.5
φ6 2.8 ±0.05 8.08 ±0.1
Rc≧27
2.5 8.25 Tail end: 3.0
2.0 8.51
1.8 8.61
5.0 10.07
4.5 10.36
4.0 10.65
3.5 10.93 Head end: 15.0
φ8 3.0 ±0.05 11.21 ±0.1 Rc≧36
2.8 11.32 Tail end: 3.0
2.5 11.49
2.0 11.77
1.5 12.05

9
* Performance Reference 1: Screen Mesh type
•Orient : Horizontal
•Working Temperature (Adiabatic) : 70 oC

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ4 Round
3.0
0.50 ~ 0.70
0.50 ~ 0.70
20
20
Length:150mm 2.5 0.55 ~ 0.80 18
Straight Pipe 2.0 0.65 ~ 0.90 15

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ5 Round
3.0
0.40 ~ 0.55
0.45 ~ 0.60
25
25
Length:150mm 2.5 0.45 ~ 0.65 22
Straight Pipe 2.0 0.50 ~ 0.80 18

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round
3.0
0.20 ~0.35
0.25 ~0.35
50
50
Length:100mm 2.5 0.25 ~0.40 45
Straight Pipe 2.0 0.35 ~0.60 35

10
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round
3.0
0.20 ~ 0.35
0.25 ~ 0.35
45
45
Length:150mm 2.5 0.25 ~ 0.40 40
Straight Pipe 2.0 0.35 ~ 0.60 35

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round
3.0
0.15 ~0.30
0.20 ~0.30
60
60
Length:100mm 2.5 0.20 ~0.35 55
Straight Pipe 2.0 0.30 ~0.55 50

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round
3.0
0.15 ~0.30
0.20 ~0.30
60
65
Length:150mm 2.5 0.20 ~0.35 50
Straight Pipe 2.0 0.30 ~0.55 45

Note: Increase ~ 50mm of pipe length, Operating max. will drop ≈ 12%

11
* Performance Reference 2: Grooved type
Conditions •Heating / Cooling: Evaporator section Le＝15 ㎜ electric resistance heater,
Condenser section Lc＝60 ㎜ with fin air cooling
•Orient : Horizontal
•Working Temperature (Adiabatic) : 70 oC Tc
Qout

Te
Rpipe＝（Te－Tc）/ Qin
Qin

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ5 Round
3.0
0.02 ~ 0.04
0.03 ~ 0.05
40
40
Length:100mm 2.5 0.03 ~ 0.06 30
Straight Pipe 2.0 0.20 ~ 0.45 5

12
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ5 Round
3.0
0.03 ~ 0.05
0.03 ~ 0.05
35
30
Length:150mm 2.5 0.04 ~ 0.06 25
Straight Pipe 2.0 0.40 ~ 0.70 5
Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
Round 0.02 ~ 0.03 75
3.0 0.02 ~ 0.05 70
φ6 2.8
2.6
0.02 ~ 0.05
0.03 ~ 0.05
60
50
Length:100mm 2.5 0.03 ~ 0.05 45
Straight Pipe 2.4 0.03 ~ 0.05 45
2.2 0.05 ~ 0.10 25
2.0 0.10 ~ 0.32 5

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
Round 0.02 ~ 0.03 65
3.0 0.03 ~ 0.04 60
φ6 2.8
2.6
0.03 ~ 0.05
0.03 ~ 0.05
50
45
Length:150mm 2.5 0.03 ~ 0.05 40
Straight Pipe 2.4 0.04 ~ 0.06 35
2.2 0.10 ~ 0.20 20
2.0 0.40 ~ 0.60 5

13
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round
3.0
0.02 ~ 0.03
0.03 ~ 0.08
45
40
Length:200mm 2.5 0.03 ~ 0.10 35
Straight Pipe 2.0 0.03 ~ 0.70 5

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.007 80
Length:150mm
Straight Pipe 4.5 0.003 ~ 0.015 70

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.007 75
Length:200mm
Straight Pipe 4.5 0.003 ~ 0.015 65

Note: φ6 heat pipe Increase ~50mm of pipe length, Operating max. power will drop ≈ 15%

φ8 heat pipe Increase ~50mm of pipe length, Operating max. power will drop ≈ 7%

14
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) θ: (°)
Rpipe (℃/W) Q (W)
180 0.03 ~ 0.05 40
φ6 150 0.03 ~ 0.08 35
Length:150mm
Rc:18mm 120 0.03 ~ 0.10 35
Flat:2.5mm 90 0.03 ~ 0.12 30

Rc

Note: Through one 90o bend, Operating max. power will drop ≈ 25%.

15
* Performance Reference 3: Sintering Powder type
Conditions •Heating / Cooling: Evaporator section Le＝15 ㎜ electric resistance heater,
Condenser section Lc＝60 ㎜ with fin air cooling
•Orient : Horizontal Tc
Qout
•Working Temperature (Adiabatic) : 70 oC

Rpipe＝（Te－Tc）/ Qin Te

Qin

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ5
Round 0.02 ~ 0.04 40
3.0 0.03 ~ 0.05 40
Length:100mm 2.5 0.03 ~ 0.06 30
Straight Pipe 2.0 0.15 ~ 0.40 5

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ5
Round 0.03 ~ 0.05 35
3.0 0.03 ~ 0.05 30
Length:150mm 2.5 0.04 ~ 0.06 25
Straight Pipe 2.0 0.35 ~ 0.60 5
16
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round 0.02 ~ 0.03 75
Length:100mm 3.0 0.02 ~ 0.04 70
Straight Pipe 2.5 0.03 ~ 0.05 45

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round 0.02 ~ 0.03 65
Length:150mm 3.0 0.03 ~ 0.04 60
Straight Pipe 2.5 0.03 ~ 0.05 40

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round 0.02 ~ 0.03 50
Length:200mm 3.0 0.03 ~ 0.06 45
Straight Pipe 2.5 0.03 ~ 0.08 35

Note: Increase ~50mm of pipe length, Operating max. power will drop ≈ 12%

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.004 80
Length:150mm
Straight Pipe 4.5 0.003 ~ 0.011 70

17
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.004 80
Length:275mm
Straight Pipe 4.5 0.003 ~ 0.012 70

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) θ: (°)
Rpipe (℃/W) Q (W)
φ6 180 0.02 ~ 0.04 40
150 0.02 ~ 0.07 35
Length:150mm
Rc:18mm 120 0.03 ~ 0.08 35
Flat:2.5mm 90 0.03 ~ 0.10 30

Rc

Note: Through one 90o bend, Operating max. power will drop ≈ 25%.

18
* Performance Reference 2: Composive type (Groove Powder)
Conditions •Heating / Cooling: Evaporator section Le＝15 ㎜ electric resistance heater,
Condenser section Lc＝60 ㎜ with fin air cooling
•Orient : Horizontal
•Working Temperature (Adiabatic) : 70 oC Tc
Qout

Te
Rpipe＝（Te－Tc）/ Qin
Qin

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
Round 0.002 ~ 0.003 65
3.0 0.003 ~ 0.004 60
φ6 2.8
2.6
0.003 ~ 0.005
0.003 ~ 0.005
50
45
Length:150mm 2.5 0.003 ~ 0.005 40
Straight Pipe 2.4 0.004 ~ 0.006 35
2.2 0.010 ~ 0.020 20

19
 Pipe Thermal Resistance Operating Max. Power
Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ6 Round
3.0
0.002 ~ 0.003
0.003 ~ 0.008
45
40
Length:200mm 2.5 0.003 ~ 0.010 35
Straight Pipe 2.0 0.03 ~ 0.070 5

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.007 80
Length:150mm
Straight Pipe 4.5 0.003 ~ 0.015 70

Pipe Thermal Resistance Operating Max. Power

Diameter D: (mm) Flat t: (mm)
Rpipe (℃/W) Q (W)
φ8 Round 0.002 ~ 0.007 75
Length:200mm
Straight Pipe 4.5 0.003 ~ 0.015 65

Note: φ6 heat pipe Increase ~50mm of pipe length, Operating max. power will drop ≈ 15%

φ8 heat pipe Increase ~50mm of pipe length, Operating max. power will drop ≈ 7%

20
*Approval List:

ITEM SPECIFICATION
ROUND φ4～φ8
SHAPE
FLAT T = 1.6~3.5 mm
BENDING / SHAPE Drawing
MATERIAL OF CONTAINER C1020
WORKING FLUID DI Water
Grooved / Screen Mesh /
WICK STRUCTURE
Powder / Composite
FAIL TEMP ROUND 300 ℃ Leakage
（No cooling） FLAT 110~140 ℃ Inflation
MAX. HEAT TRANSFER RATE 0～80 W
APPLICATION INCLINATION Horizontal
GUARANTY 3 Years

21
*Quality Control: 1. Sintered Powder and Grooved are good in case of block
high >= 4.0mm
2. Mesh is good in case of all pipe need to flat to >= 1.6 mm
3. Grooved is good in case of all pipe need to flat to >= 2.5
Heat Pipes after bending mm
4. Bending Rc>= 4.5 times of D is good
and flatten 5. Bending θ >= 90o is good

120℃,48hrs Thermal Oven Qmxa Go/NG Test Burst Temp. Test

Accelerated Life (100﹪) (Sampling)
(100﹪)

22