Thermal Shock Chamber With Embedded Channels for Stationary UUTs

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Solution Overview

Problem

Conventional liquid-to-liquid thermal shock tests for units-under-test are cumbersome and inefficient, requiring labor-intensive transfer of UUTs between high and low temperature tanks, and can damage sensitive electrical equipment due to the need for waterproofing, which is prone to failure.

Innovation Solution

A thermal shock testing system with a chamber having embedded channels, a pump, boiler, and chiller, and controlled valves to alternately provide hot and cold liquids directly to the UUT, eliminating the need for physical transfer and protecting sensitive electronics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If liquid-to-liquid thermal shock method is used to achieve high thermal ramp rates, then thermal shock effectiveness is improved, but device complexity and risk of damage increase due to waterproofing requirements

Engineering Contradiction:

Improvethermal ramp rateVSAvoidwaterproofing complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

A transfer chamber serves as an intermediary space between the hot and cold liquid tanks. The UUT remains stationary in this chamber while liquid media are circulated through it via pump systems, eliminating the need for physical transfer and waterproofing while maintaining liquid-to-liquid thermal shock effectiveness

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical hoist system used for physical transfer is replaced with a fluid circulation system. Pumps circulate hot and cold liquids through the UUT via ports in the transfer chamber, substituting mechanical movement with fluid-based thermal delivery

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If physical transfer of UUT between tanks is used, then thermal shock testing can be performed, but productivity decreases due to labor-intensive operations

Engineering Contradiction:

Improvethermal shock test capabilityVSAvoidtesting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables continuous thermal shock testing by circulating liquids through the stationary UUT in the transfer chamber. The pump system alternately delivers hot and cold liquids without requiring interruption for physical transfer, maintaining continuous thermal cycling

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The UUT remains stationary and serves itself by having hot and cold liquids delivered directly to it through the transfer chamber ports. The system automatically cycles temperatures without requiring external manual intervention for transfer operations

Inventive Principle:

Principle #25Self-service

3Reliability

If UUT is physically moved between tanks, then thermal shock can be applied, but loss of time increases due to transfer operations

Engineering Contradiction:

Improvethermal shock effectivenessVSAvoidtransfer time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The UUT is pre-positioned in the transfer chamber at the beginning of the test sequence. This preliminary placement eliminates the need for repeated transfer operations during thermal cycling, saving time while maintaining test effectiveness

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Physical transfer operations are replaced with fluid delivery operations. Pumps deliver hot and cold liquids through ports in the transfer chamber to the stationary UUT, eliminating time-consuming mechanical transfer while maintaining thermal shock effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient and effective thermal shock testing by simulating rapid temperature changes without physically moving the UUT, reducing the risk of damage and enhancing test efficiency.

Implementation Method 1

a pump configured to fluidly connect to the inlet of the chamber and direct a temperature controlled liquid through a channel embedded in the chamber

Methodology Applied

Scientific EffectFluid flow through channels:

Implementation Method 2

a boiler and a chiller fluidly connected to the pump, the temperature of the liquid being controlled by at least one valve configured to alternatively direct hot or cold fluid to the inlet of the chamber

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 4

the temperature of the liquid being controlled by at least one valve configured to alternatively direct hot or cold fluid to the inlet of the chamber

Methodology Applied

Scientific EffectTemperature control through fluid direction:

Implementation Method 5

a chamber having an inlet and an outlet, the chamber being configured to provide a thermal shock to a unit-under-test (UUT)

Methodology Applied

Scientific EffectThermal shock: Thermal Shock

Data Source

PatentUS12411060B2Method and apparatus for delivering a thermal shock

Publication Date: 2025.09.09 GM CRUISE HOLDINGS LLC

AI summary

The subject disclosure relates to a system and method for testing units-under-test (UUT) with a thermal shock. The thermal shock testing system can include a chamber having an inlet and an outlet, the chamber being configured to provide a thermal shock to a unit-under-test (UUT), a pump configured to fluidly connect to the inlet of the chamber and direct a temperature controlled liquid through a channel embedded in the chamber, and a boiler and a chiller fluidly connected to the pump, the temperature of the liquid being controlled by at least one valve configured to alternatively direct hot or cold fluid to the inlet of the chamber.