Thermal Head Fluid Mixing for Rapid Device Temperature Control
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Solution Overview
Problem
Current methods for rapid thermal conditioning of electronic devices during testing are inefficient, as they either heat and cool the test head simultaneously, require energy-intensive air heating and cooling, or involve inefficient mixing of thermal transfer fluids, leading to prolonged testing times and increased costs.
Innovation Solution
An apparatus with a heat transfer system that includes a thermal head with low thermal capacity and high conductivity, coupled with a pump and valve assembly to circulate and control thermal transfer fluid through multiple paths, allowing precise temperature control by mixing hot and cold fluids to maintain thermal equilibrium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If resistive heating is used to control test head temperature, then temperature control is achieved, but thermal efficiency is reduced due to simultaneous heating and cooling
Solution Approach 1:
The thermal control system is segmented into separate heating and cooling paths. The heating path uses a heating element to warm the thermal transfer fluid, while the cooling path uses a cooling element to cool the fluid. This segmentation eliminates the waste of simultaneous heating and cooling by allowing independent control of each thermal path.
Solution Approach 2:
The system dynamically switches between heating and cooling paths based on real-time temperature feedback from the test head. The controller monitors the test head temperature and activates only the necessary thermal path, making the thermal control adaptive and efficient rather than statically maintaining both heating and cooling capabilities simultaneously.
2Temperature
If hot and cold thermal transfer fluids are mixed to control DUT temperature, then temperature control within a temperature band is achieved, but the mixing process is inefficient
Solution Approach 1:
A third, warmer thermal transfer fluid path is introduced as an intermediary between the cold and hot paths. This intermediary path allows for more efficient thermal exchange by reducing the temperature differential that must be bridged through direct mixing, thereby improving overall thermal efficiency while maintaining the ability to control DUT temperature within the desired band.
3Speed
If air is cooled and then heated for thermal conditioning, then rapid heating is achieved, but energy consumption increases
Solution Approach 1:
The system maintains continuous circulation of thermal transfer fluid through optimized path selection, eliminating the energy-intensive cycle of cooling then heating air. By using a closed-loop fluid system with selective path activation, the useful thermal action continues efficiently without repeated heating and cooling cycles of the same medium.
4Stability of the object's composition
If thermal soak step is used to establish test temperature, then temperature stabilization is achieved, but testing time increases
Solution Approach 1:
The system pre-cools or pre-heats the thermal transfer fluid in separate paths before it reaches the test head, so that when the fluid contacts the test head, the desired temperature change occurs rapidly. This preliminary thermal conditioning eliminates the need for prolonged thermal soak steps while achieving stable test temperatures.
Solution Approach 2:
The system changes the temperature parameter of the thermal transfer fluid dynamically by selecting different thermal paths (heating, cooling, or bypass) based on the required test temperature. This allows rapid adjustment of test head temperature by changing the fluid temperature parameter rather than relying on slow thermal conduction during a soak step.
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
This solution enables rapid and efficient temperature control of electronic devices under test, reducing testing time and costs by minimizing energy expenditure and optimizing thermal transfer fluid flow, thus improving the efficiency of the thermal conditioning process.
Implementation Method 1
a heat transfer apparatus... a thermal transfer fluid... allowing precise temperature control by mixing hot and cold fluids to maintain thermal equilibrium
Implementation Method 2
a pump assembly operable to circulate thermal transfer fluid... through one or more of the first, second and third paths
Implementation Method 3
a valve assembly operable to cause predetermined amounts of thermal transfer fluid to flow into one or more of the first, second, and third paths
Implementation Method 4
a first path maintained at a first temperature and connected to the combined path; a second path maintained at a second temperature and connected to the combined path
Data Source
AI summary
Apparatus to control a temperature of a device that includes: a thermal head adapted to be thermally contacted to the device; a combined path to the thermal head; a first path maintained at a first temperature and connected to the combined path; a second path maintained at a second temperature different from the first temperature and connected to the combined path; a third path connected to the combined path; a pump assembly operable to circulate thermal transfer fluid: from the thermal head, through each of the first, second and third paths, from each of the first, second and third paths, through the combined path, and from the combined path, to and through the thermal head; and a valve assembly operable to control amounts of thermal transfer fluid that flow into the first and second paths, thereby controlling the temperature.