A filling rig for liquid and gas working fluids for two-phase thermal management systems

Two-phase cooling devices are used to remove and dissipate heat from high power-density electronic systems to maintain them within their operating temperature limits. The manufacture of these devices, such as heat pipes, thermosyphons or vapour chambers, involves firstly removing any internal air or non-condensable gases before charging with the required volume of working fluid. This paper presents detailed designs and operating instructions for a single bench-top station for use in a laboratory environment for the vacuum evacuation, degassing and charging of these devices. Two configurations allow for the filling of fluids which are either liquids or gases at standard temperature and pressure conditions. For liquids, the dispensed volume can be measured directly on an integrated burette, while the method of vapour transfer is used for gases. The hardware was demonstrated by filling multiple thermosyphon devices with a number of common working fluids used in two-phase systems, including water, acetone and ammonia. It was shown to deliver precise and repeatable filling volumes with average differences compared to target volumes of 1.7% and 10.5% for liquids and gases respectively. The design is intended to be highly customisable where its size can be modified to accommodate filling volume requirements for different applications.