VESSEL CHARGING SYSTEM AND METHOD

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/705,850, filed on Oct. 10, 2024. The disclosure of the above application is incorporated herein by reference in its/their entirety.

GOVERNMENT RIGHTS

This invention was made with government support under FA8650-23-C-5019 awarded by United States Air Force. The government has certain rights in the invention.

FIELD

The present teachings relate to a system and method to of filling a vessel and in particular embodiments to a system and method for charging an OHP device with a working fluid.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Oscillating heat pipe devices, conventional heat pipe devices, vapor chambers, and other hermetic devices having one or more internal channel are typically filled with a working or cooling fluid by adding or forming a tube structure that extends from the device that enables attachment of a sealing system. The sealing system is operable to pull a vacuum, introduce fluid into the device internal channel(s), and then seal the device (not necessarily in that order). The resulting tube structure protrudes from the hermetic device, which is not ideal due to fragility, increased device geometries due to the protruding tube stub, and additional process steps to protect tube structure. These issues are a major problem for complex form-fitting device designs that are possible with heat pipes/hermetic devices such as oscillating heat pipes where a protruding tube structure is difficult to integrate. Additionally, such protrusion tube structures can be subject to damage and therefore present a safety hazard if the working/cooling fluid is toxic or otherwise hazardous and accidental release of fluid can result from damage to the tube structure. Additionally, the multiple manufacturing steps, manufacturing cost and complexity are required to add such protruding tube structures to the device. Furthermore, current heat pipe charging systems are designed for implementation and operation at the device manufacturer's facility and require extensive equipment (e.g., vacuum bakeout systems, ovens, fume exhaust systems, weigh scales, etc.) and considerable capital cost.

SUMMARY

In various embodiments, the present disclosure provides a heat pipe charging system that comprises a work platform structured and operable to have a heat pipe device disposed thereon, wherein the heat pipe device has at least one internal channel formed therein and a connection port formed within an outer wall of thereof. The system additionally comprises a processing head structured and operable to at least partially fill the at least one heat pipe device internal channel with a working fluid, and a plurality of system conduits fluidly connected to the processing head that are structured and operable to provide at least one of a working fluid, a vacuum and a gas to the processing head to at least partially fill the at least one heat pipe device internal channel with the working fluid.

In various other embodiments, the present disclosure provides a method for charging a heat pipe device with a working fluid utilizing a heat pipe charging system comprising a work platform, a processing head and a plurality of system conduits. In various instances the method comprises: a) disposing a heat pipe device on the heat pipe charging system work platform, wherein the heat pipe device comprises at least one internal channel formed therein and a connection port formed within an outer wall of thereof; b) placing a distal end of a multi-function attachment tool of the heat pipe charging system processing head in contact with the heat pipe device connection port such that an inner lumen of the multi-function attachment tool is fluidly connected with the at least one internal channel of the heat pipe device via an evacuation and fille passage of the connection port that extends through an outer wall of the heat pipe device and into the channel least one internal channel of the heat pipe; c) verifying a hermetic seal between the distal end of the multi-function attachment tool and the heat pipe device connection port; and d) at least partially filling at least one internal channel of the heat pipe device with a working fluid via operation of a main operation module of the heat pipe charging system processing head, wherein the multi-function attachment tool extends from the main operation module and an inner lumen of the multi-function attachment tool is fluidly connectable to the plurality of the heat pipe charging system conduits, wherein one of the system conduits is connected to a working fluid source.

This summary is provided merely for purposes of summarizing various example embodiments of the present disclosure so as to provide a basic understanding of various aspects of the teachings herein. Various embodiments, aspects, and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. Accordingly, it should be understood that the description and specific examples set forth herein are intended for purposes of illustration only and are not intended to limit the scope of the present teachings.

BRIEF DESCRIPTION OF DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present teachings in any way.

FIG. 1 exemplarily illustrates an oscillating heat pipe (OHP) charging system, in accordance with various embodiments of the present disclosure.

FIGS. 2A, 2B, 2C, 2D and 2E exemplarily illustrate steps for generating and sealing an evacuation and fill passage in an OHP device utilizing the OHP charging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIGS. 3A, 3B, 3C and 3D exemplarily illustrate steps for generating and sealing an evacuation and fill passage in an OHP device utilizing the OHP charging system shown in FIG. 1, in accordance with various other embodiments of the present disclosure.

FIGS. 4A, 4B and 4C exemplarily illustrate steps for generating and sealing an evacuation and fill passage in an OHP device utilizing the OHP charging system shown in FIG. 1, in accordance with yet other embodiments of the present disclosure.

FIGS. 5A, 5B, 5C and 5D exemplarily illustrate steps for generating and sealing an evacuation and fill passage in an OHP device utilizing the OHP charging system shown in FIG. 1, in accordance with still yet other embodiments of the present disclosure.

FIGS. 6A, 6B and 6C exemplarily illustrate a process for sealing the evacuation and fill passage in an OHP device with a ball plug utilizing the OHP charging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 7 exemplarily illustrates a system and method for disposing the ball plug in the evacuation and fill passage in an OHP device utilizing the OHP charging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 8 exemplarily illustrates the components and structure of the OHP charging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 9 exemplarily illustrates the components and structure of the OHP charging system shown in FIG. 1, in accordance with various other embodiments of the present disclosure.

FIG. 10 exemplarily illustrates the components and structure of the OHP charging system shown in FIG. 1, in accordance with yet other embodiments of the present disclosure.

FIG. 11 exemplarily illustrates the components and structure of the OHP charging system shown in FIG. 1, in accordance with still yet other embodiments of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of drawings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no way intended to limit the present teachings, application, or uses. Throughout this specification, like reference numerals will be used to refer to like elements. Additionally, the embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can utilize their teachings. As well, it should be understood that the drawings are intended to illustrate and plainly disclose presently envisioned embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views to facilitate understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.

As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the appended claims.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises”, “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps can be employed.

When an element, object, device, apparatus, component, region or section, etc., is referred to as being “on”, “engaged to or with”, “connected to or with”, or “coupled to or with” another element, object, device, apparatus, component, region or section, etc., it can be directly on, engaged, connected or coupled to or with the other element, object, device, apparatus, component, region or section, etc., or intervening elements, objects, devices, apparatuses, components, regions or sections, etc., can be present. In contrast, when an element, object, device, apparatus, component, region or section, etc., is referred to as being “directly on”, “directly engaged to”, “directly connected to”, or “directly coupled to” another element, object, device, apparatus, component, region or section, etc., there may be no intervening elements, objects, devices, apparatuses, components, regions or sections, etc., present. Other words used to describe the relationship between elements, objects, devices, apparatuses, components, regions or sections, etc., should be interpreted in a like fashion (e.g., “between” versus “directly between”, “adjacent” versus “directly adjacent”, etc.).

As used herein the phrase “operably connected to” will be understood to mean two are more elements, objects, devices, apparatuses, components, etc., that are directly or indirectly connected to each other in an operational and/or cooperative manner such that operation or function of at least one of the elements, objects, devices, apparatuses, components, etc., imparts or causes operation or function of at least one other of the elements, objects, devices, apparatuses, components, etc. Such imparting or causing of operation or function can be unilateral or bilateral.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. For example, A and/or B includes A alone, or B alone, or both A and B.

Although the terms first, second, third, etc. can be used herein to describe various elements, objects, devices, apparatuses, components, regions or sections, etc., these elements, objects, devices, apparatuses, components, regions or sections, etc., should not be limited by these terms. These terms may be used only to distinguish one element, object, device, apparatus, component, region or section, etc., from another element, object, device, apparatus, component, region or section, etc., and do not necessarily imply a sequence or order unless clearly indicated by the context.

Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, “first”, “second” and so forth are made only with respect to explanation in conjunction with the drawings, and that components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the concept(s) taught herein, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.

In various embodiments, the apparatuses/systems and methods described herein can be implemented at least in part by one or more computer program product comprising one or more non-transitory, tangible, computer-readable mediums storing computer programs with instructions that may be performed by one or more processors. The computer programs may include processor executable instructions and/or instructions that may be translated or otherwise interpreted by a processor such that the processor may perform the instructions. The computer programs can also include stored data. Non-limiting examples of the non-transitory, tangible, computer readable medium are nonvolatile memory, magnetic storage, and optical storage.

As used herein, the term module can refer to, be part of, or include an application specific integrated circuit (ASIC); an electronic circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that performs instructions included in code, including for example, execution of executable code instructions and/or interpretation/translation of uncompiled code; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip. The term module can include memory (shared, dedicated, or group) that stores code executed by the processor.

The term code, as used herein, can include software, firmware, and/or microcode, and can refer to one or more programs, routines, functions, classes, and/or objects. The term shared, as used herein, means that some or all code from multiple modules can be executed using a single (shared) processor. In addition, some or all code from multiple modules can be stored by a single (shared) memory. The term group, as used above, means that some or all code from a single module can be executed using a group of processors. In addition, some or all code from a single module can be stored using a group of memories.

Referring to FIG. 1, the present disclosure provides a heat pipe charging system 10 that is structured and operable to charge (i.e., at least partially fill) an internal volume of one or more heat pipe device 14. More specifically, heat pipe charging system 10 is structured and operable to charge (i.e., at least partially fill) one or more channel 18 (e.g. micro-channel(s)) integrally and internally formed within the heat pipe device(s) 14 with a working or cooling fluid. The heat pipe device(s) 14 can be any heat transfer device such as oscillating heat pipe device(s), vapor chambers, cold plate device(s), pressure vessel(s), hermetically sealed container(s), and other sealed device(s). However, for the purpose of clarity and example, the charging system 10 will be exemplarily described herein with regard to charging of oscillating heat pipe (OHP) devices. Accordingly, the heat pipe charging system 10 and the heat pipe device(s) 14 will be described herein as the OHP charging system 10 and the OHP device(s) 14, and the structure and components of thereof will be described with regard to OHP devices, nevertheless the scope of the present disclosure should not so narrowly interpreted as applying only to OHP devices.

Importantly, the heat pipe charging system 10 of the present disclosure provides a heat pipe device charging system (e.g., an OHP device charging system) that is structured and operable to charge (i.e., at least partially fill) an internal volume of a heat pipe device (i.e., one or more OHP internal micro-channel) with a working or cooling fluid, wherein the system 10 can be efficiently packaged and shipped to a heat pipe device customer's facility to thereby enable charging of heat pipe devices at the customer's facility subsequent to production of the heat pipe device at the heat pipe device manufacturing facility. This allows heat pipe customers to modify non-charged heat pipe devices (e.g., do additional assembly and/or processing of/on the devices) at the customer's facility and then subsequently charge the modified devices. For example, in instances where a charged heat pipe device received from a heat pipe device manufacturer would not survive internal pressures resulting from high temperature processes (e.g., die attachment of integrated circuit chip, adhesive curing, additive manufacturing on the device, etc.) being performed on a charged heat pipe device, the heat pipe customer can receive non-charged heat pipe devices from a heat pipe device manufacturer, perform high temperature processes on the non-charged heat pipe device, then subsequently charge the modified heat pipe devices on-site at the customer's facility using the heat pipe charging system 10, as described herein. Accordingly, in various exemplary embodiments, the present disclosure provides an oscillating heat pipe (OHP) charging system 10 that is structured and operable to charge (i.e., at least partially fill) an internal volume of one or more OHP device 14. More specifically, OHP charging system 10 is structured and operable to charge (i.e., at least partially fill) one or more micro-channel(s) 18 integrally and internally formed within the OHP device(s) 14 with a working or cooling fluid. Although it is envisioned that the OHP charging system 10 described herein can be a fully or partially automated system that is structured and operable to sequentially and consecutively charge a plurality of OHP devices 14 that are automatedly fed into the OHP charging system 10 (e.g., via a conveyor system of the OHP charging system 10), the OHP charging system 10 and a method of use will be exemplarily described below with regard to the charging of single OHP device 14.

Generally, an oscillating heat pipe (OHP) device (e.g., OHP device 14) is a passive heat transfer device that transports heat using two-phase fluid flow within one or more capillary-sized micro-channel(s), or tunnel(s) formed integrally and internally within the OHP device. The micro-channel(s) is/are sized such that it/they has/have a capillary effect on a working or cooling fluid disposed therein, and it/they has/have a meandering path traveling between one or more heat zone of the OHP device and one or more cooling zone of the OHP device. The volume of the micro-channel(s) is/are at least partly filled with the working or cooling fluid and hermetically sealed from the outside environment. The hydraulic diameter of the micro-channel(s) must be small enough and the surface tension of the working or cooling fluid great enough such that the working or cooling fluid disperses itself throughout the micro-channel(s) in discrete liquid “plugs” and vapor “bubbles” (i.e. capillary action). In operation, the OHP device transfer heat from the heat zone(s) to the cooling zone(s) as follows: the working or cooling fluid partially evaporates and expands within the micro-channel(s) at or near the heat zones(s); the associated expansion of the working or cooling fluid vapor forces or drives the working or cooling fluid vapor axially within the micro-channel(s) from the heat zone(s) toward the lower temperature, lower pressure cooling zone(s) where the incoming working or cooling fluid vapor rejects its heat, condenses back to a fluid, and contracts; as a result the working or cooling fluid initially near the cooling zone(s) is dislodged by the incoming fluid and is forced through the micro-channel path toward the heat zone(s); and the cycle repeats as the working or cooling fluid in liquid form and the working or cooling fluid in vapor form oscillates within the micro-channel(s) between the heat zone(s) and the cooling zone(s).

In various embodiments, the charging system 10 comprises a processing head 22, an OHP work platform 24 and plurality of system conduits 26 that are connectable to the processing head 22. The OHP work platform 24 is structured and operable to have an OHP device 14 disposed thereon while the processing head 22 at least partially fills the micro-channel(s) 18 integrally and internally formed within the OHP device 14 with a working or cooling fluid as described below. The processing head 22 comprises a main operation module 28 and a multi-function attachment tool 30 extending from the main operation module 28. The multi-function attachment tool 30 comprises an inner lumen 34 and, as described below, is structured and operable to be attachable to and hermetically sealable with a connection port 38 of an OHP device 14 while the OHP device 14 is disposed on the OHP work platform 24. The system conduits 26 are fluidly connectable to the processing head 22 and are structured and operable to provide a working or cooling fluid, a vacuum, a gas and any other desired liquid, gas, or pneumatic operation to the main operation module 28, the multi-function attachment tool 30, and subsequently to the OHP device 14 during the process of charging of the OHP device 14 as described below. For example, in various embodiments the system conduits can comprise a vacuum conduit 26A that is fluidly connectable to a vacuum source (not shown) and a working or cooling fluid conduit 26B that is fluidly connectable to working or cooling fluid source (not shown). In various instances the charging system 10 can further comprise a leak check conduit 26C that is fluidly connectable to a helium leak detector or a residual gas analyzer (not shown).

Generally, in operation, the OHP device 14 is either manually or automatically (via a conveyor or other automated or robotic conveyance device) placed on the OHP work platform 24. As described above, the OHP device includes the connection port 38 that is formed within an outer wall or exterior surface 46 of the OHP device 14. The connection port 38 is structured and operable to assist in providing a hermetic seal with a distal end 30A of the multi-function attachment tool 30 and to provide a fluid flow connection of the OHP internal micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 when the multi-function attachment tool 30 is connected to the connection port 38 (described below), whereby the OHP device 14 can be charged as described herein. The connection port 38 can be any area of the outer wall or exterior surface 46 of the OHP device 14 that is directly aligned with and adjacent the OHP micro-channel(s) 18 and designated as the connection port 38, or any structure integrally formed within the outer wall or exterior surface 46 that is directly aligned with and adjacent and fluidly connected to or connectable to the OHP micro-channel(s) 18 and designated as the connection port 38.

In various embodiments, to provide the fluid flow connection of the OHP internal micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 when the multi-function attachment tool 30 is connected to the connection port 38, the connection port 38 can comprise an evacuation and fill orifice or passage 42 that extends through the outer wall or exterior surface 46 into the micro-channel(s) 38. In various embodiments, the evacuation and fill orifice or passage 42 can be prefabricated/pre-generated/preformed within the connection port 38 (i.e., fabricated during fabrication or manufacturing of the OHP device 14), whereby the internal volume of the OHP micro-channel(s) 18 are open to and fluidly connected with the ambient environment when the OHP device 14 is initially placed on the OHP work platform 24, and whereby the OHP micro-channel(s) 18 can be charged, (i.e., filled with a working or cooling fluid). Alternatively, in various embodiments the connection port 38 can be sealed (i.e., the evacuation and fille passage 42 is not prefabricated) such that internal volume of the OHP micro-channel(s) 18 is closed and not open to nor fluidly connected with the ambient environment when the OHP device 14 is initially placed on the OHP work platform 24. In such sealed connection port embodiments, the charging system 10 can further include an orifice generating tool 50/90 (e.g., element 50 in FIGS. 2A through 4C, 5D, 6C, 8 and 9, and element 90 in FIGS. 5A through 5C) that is structured and operable to generate or create the connection port evacuation and fill passage 42 when the multi-function attachment tool 30 is connected to the connection port 38 in order to establish the fluid flow connection between the OHP micro-channel(s) 18 and the inner lumen 34 of the multi-function attachment tool 30, whereby the OHP micro-channel(s) 18 can be charged (i.e., filled with a working or cooling fluid).

Once the OHP device 14 is placed on the work platform 38, the distal end 30A of the multi-function attachment tool 30 is placed on or connected to the connection port 38. In various embodiments, the charging system 10 can be structured and operable to create a hermetic seal between the distal end 30A of the multi-function attachment tool 30 and the connection port 38 after the multi-function attachment tool 30 is placed on or connected to the connection port 38. In the embodiments wherein the connection port evacuation and fill passage 42 is prefabricated, the fluid flow connection of the OHP internal micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 is thereby established. However, in the embodiments, wherein the connection port evacuation and fill passage 42 is not prefabricated, once the multi-function attachment tool 30 is placed on or connected to the connection port 38, the connection port evacuation and fill passage 42 is generated (as described below) via the processing head 22, thereby establishing the fluid flow connection of the OHP internal micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30.

Referring now to FIGS. 1, 2A, 2B, 2C, 2D, 2E, 3A, 3B, 3C, 3D, 4A, 4B and 4C, in various embodiments the connection port 38 of the OHP device 14 is structured and operable to assist in locating the multi-function attachment tool 30 on the OHP device in order to properly connect the multi-function attachment tool 30 with the OHP device 14. Moreover, the connection port 38 is structured and operable to assist in providing a hermetic seal between a distal end 30A of the multi-function attachment tool 30 and the OHP device 14 such that a fluid flow connection between the OHP internal micro-channel(s) 18 and the inner lumen 34 of the multi-function attachment tool 30 can be established and the OHP device 14 can be charged as described herein. As described above, in various instances, the OHP device 14 can be fabricated or manufactured such that the connection port 38 is initially sealed. More specifically, in various embodiments, the connection port 38 is formed in or provided by the outer wall or exterior surface 46 of the OHP device 14 and does not comprise the evacuation and fill passage 42. In such instances, in order to evacuate and/or fill the OHP micro-channel(s) 18, the outer wall or exterior surface 46 of the OHP device 14 must be punctured or perforated at the connection port 38 in order to provide the evacuation and fill passage 42 and provide the fluid flow connection between the OHP micro-channel(s) 18 and the inner lumen 34 of the multi-function attachment tool 30 when the multi-function attachment tool 30 is connected to the connection port 38.

In such embodiments, the charging system 10, more particularly the main operation module 28 of the processing head 22, can comprise the orifice generating tool 50 that is structured and operable to puncture, penetrate, bore or otherwise at least partially form an orifice (i.e., the evacuation and fill passage 42) in the outer wall or exterior surface 46 of the OHP device 14. The orifice generating tool 50 can comprise any device, apparatus, system or tool structured and operable to puncture, penetrate, bore or otherwise at least partially form the evacuation and fill port 42 within the OHP device outer wall or exterior surface 46 within an interior space of the connection port 38. For example, the orifice generating tool 50 can comprise a punch or needle (e.g., punch rod 90 shown in FIGS. 6A-6C) that is structured and operable to pierce the OHP device outer wall or exterior surface 46 using a vertical force to form the evacuation and fill passage 42 through the OHP device outer wall or exterior surface 46, or a drill or similar rotating motion device configured to remove or manipulate the material of the OHP device outer wall or exterior surface 46 to form the evacuation and fill passage 42 through the OHP device outer wall or exterior surface 46, or an ablation device or process such as a laser or chemical etching process structured and operable to form the evacuation and fill passage 42 through the OHP device outer wall or exterior surface 46.

For example, as exemplarily illustrated in FIGS. 2A, 2B, 2C and 2D, in various embodiments, the orifice generating tool 50 can comprise a cutting tool (e.g., a milling blade, rotating bit, a laser or other device) that is structured and operable to cut a conical channel, recess or groove 54 partially through a thickness of the OHP device outer wall or exterior surface 46 directly aligned with and adjacent a portion of the OHP micro-channel(s) 18 such that thin amount of the outer wall or exterior surface 46, referred to herein as a thin skin 58 of the OHP device outer wall or exterior surface 46, remains at a distal end of the conical groove 54 between the conical groove 54 and the internal micro-channel(s) 18. More particularly, the orifice generating tool 50 comprises a cutting tool that cuts into the outer wall or exterior surface 46 at an angle and moves in a circle such that the conical groove 54 is generated, as illustrated in FIGS. 2A and 2B. Moreover, the cutting tool (e.g., the orifice generating tool 50) cuts into the outer wall or exterior surface 46 such that the conical groove 54 extends nearly completely through the outer wall or exterior surface 46, thereby forming a cone-shaped plug 62 connected to the skin 58 at an apex 60 of the cone-shaped plug 62 such that the skin 58 is disposed between the apex 60 and the portion of the adjacent OHP micro-channel(s) 18, as illustrated in FIG. 2B.

In such embodiments, the charging system 10, more particularly the main operation module 28 of the processing head 22, can additionally comprise a plug control device 66 that is structured and operable, via an actuator 106 (shown in FIGS. 8, 9, 10 and 11), to push the cone-shaped plug 62 downward (i.e., in the Y direction shown in FIG. 2C) such that the cone-shaped plug 62 is advanced or pushed through the skin 58. As the cone-shaped plug 62 is pushed downward the apex 60 is pushed through the skin 58 such that skin 58 is pierced, perforated or broken. The cone-shaped plug 62 can then be partially or completely withdrawn via the plug control device 66 to thereby form the evacuation and fill passage 42 that extends along and through the conical groove 54, or through the conical-shaped recess provided if the cone-shaped plug 62 is completely withdrawn, and along and through the space between the pierced skin 58 and the cone-shaped plug 62, as shown in FIG. 2C. As described above, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 such that the OHP micro-channel(s) 18 can be charged, (i.e., filled with a working or cooling fluid). Additionally, in various embodiments, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30, whereby the OHP micro-channel(s) 18 can be leak tested, pressure tested and/or evacuated of moisture, residue and/or debris that may be within the internal space of the OHP micro-channel(s) 18 prior to being charged with the working or cooling fluid, as described below. Once the OHP micro-channel(s) 18 has/have been charged, the plug control device 66 can be operated to push the cone-shaped plug 62 further in the Y direction such that the cone-shaped plug 62 closes and at least temporarily seals the evacuation and fill passage 42 (i.e., provides a temporary seal or provides a final seal), as shown in FIG. 2D. Subsequently, the cone-shaped plug 62 can be hermetically sealed within the evacuation and fill passage 42 via any suitable sealing means or process (e.g., torsional ultrasonic welding).

In other embodiments, as illustrated in FIGS. 1, 2E, 3A, 3B, 3C and 3D, as described above, the charging system 10, more particularly the processing head 22, can comprise the orifice generating tool 50 that is structured and operable to puncture, penetrate or otherwise form an orifice (i.e., the evacuation and fill passage 42) in the outer wall or exterior surface 46 of the OHP device 14. As also described above, in various embodiments, the orifice generating tool 50 can comprise a cutting tool (e.g., a milling blade, rotating bit, a laser or other device) that is structured and operable to cut the conical channel, recess or groove 54 partially through a thickness of the OHP device outer wall or exterior surface 46 directly aligned with and adjacent a portion of the OHP micro-channel(s) 18 such that thin amount of the outer wall or exterior surface 46, i.e. thin skin 58, remains at a distal end of the conical groove 54. More particularly, the cutting tool cuts into the outer wall or exterior surface 46 and an angle and moves in a circle such that the conical groove 54 is generated, as illustrated in FIGS. 3A and 3B. Moreover, the cutting tool (e.g., the orifice generating tool 50) cuts into the outer wall or exterior surface 46 such that the conical groove 54 extends nearly completely through the outer wall or exterior surface 46, thereby forming a cone-shaped plug 62 connected to the skin 58 at the apex 60 of the cone-shaped plug 62 such that the skin 58 is disposed between the apex 60 and the portion of the adjacent OHP micro-channel(s) 18, as illustrated in FIG. 3B.

In such embodiments, the charging system 10, more particularly the processing head 22, additionally comprises the plug control device 66 that is structured and operable, via an actuator 106 (shown in FIGS. 8, 9, 10 and 11), to pull the cone-shaped plug 62 upward (i.e., in the Y⁺ direction shown in FIG. 3C) such that the cone-shaped plug 62 is withdrawn or pulled away from the skin 58. As the cone-shaped plug 62 is pulled upward the apex 60 is pulled away from the skin 58 such that skin 58 is broken. The cone-shaped plug 62 can then be partially or completely withdrawn via the plug control device 66 to thereby form the evacuation and fill passage 42 that extends along and through the conical groove 54, or through the conical-shaped recess provided if the cone-shaped plug 62 is completely withdrawn, and along and through the space between the pierced skin 58 and the cone-shaped plug 62, as shown in FIG. 3C. As described above, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 such that the OHP micro-channel(s) 18 can be charged, (i.e., filled with a working or cooling fluid). Additionally, in various embodiments, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30, whereby the OHP micro-channel(s) 18 can be leak tested, pressure tested and/or evacuated of moisture, residue and/or debris that may be within the internal space of the OHP micro-channel(s) 18 prior to being charged with the working or cooling fluid, as described below. Once the OHP micro-channel(s) 18 has/have been charged, the plug control device 66 can be operated to push the cone-shaped plug 62 in the Y-direction such that the cone-shaped plug 62 closes and at least temporarily seals the evacuation and fill passage 42, as shown in FIG. 3D. Subsequently, the cone-shaped plug 62 can be hermetically sealed within the evacuation and fill passage 42 via any suitable sealing means, manner or process (e.g., torsional ultrasonic welding).

In other embodiments, as illustrated in FIGS. 1, 2E, 4A, 4B, and 4C, as described above, the charging system 10, more particularly the processing head 22, can comprise the orifice generating tool 50 that is structured and operable to puncture, penetrate or otherwise at least partially form an orifice (i.e., the evacuation and fill passage 42) in the outer wall or exterior surface 46 of the OHP device 14. As also described above, the orifice generating tool 50 can comprise any device structured and operable to puncture, penetrate or otherwise at least partially form the orifice. For example, in various embodiments, the orifice generating tool 50 can comprise a cutting tool (e.g., a milling blade, rotating bit, a laser or other device) that is structured and operable to bore, cut, mill, burn or otherwise form a truncated cone-shaped recess 70 in the OHP device outer wall or exterior surface 46 directly aligned with and adjacent a portion of the OHP micro-channel(s) 18 such that a thin amount of the outer wall or exterior surface 46, i.e. thin skin 58, remains at a bottom of the truncated cone-shaped recess 70, as illustrated in FIG. 4A.

In such embodiments, the charging system 10, more particularly the processing head 22, additionally comprises the plug control device 66 that is structured and operable, via an actuator 106 (shown in FIGS. 8, 9, 10 and 11), to push a truncated cone-shaped plug 74 downward (i.e., in the Y direction shown in FIG. 4B). In various instances, the truncated cone-shaped plug 74 has an angled base 76 having an apex 78. Therefore, as the truncated cone-shaped plug 74 is pushed downward (i.e., in the Y direction) the apex 78 of the angled base 76 is pushed through the skin 58 such that skin 58 is pierced, perforated or broken.

The truncated cone-shaped plug 74 can then be partially or completely withdrawn via the plug control device 66 to thereby form the evacuation and fill passage 42 that extends between the sidewalls of truncated cone-shaped plug 74 and the sidewalls of truncated cone-shaped recess 70, or through the truncated cone-shaped recess 70 if the cone-shaped plug 62 is completely withdrawn, and through the space between the pierced skin 58 and the truncated cone-shaped plug 74, as shown in FIG. 4B. As described above, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 such that the OHP micro-channel(s) 18 can be charged, (i.e., filled with a working or cooling fluid). Additionally, in various embodiments, the evacuation and fill passage 42 fluidly connects the internal space of OHP micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30, whereby the OHP micro-channel(s) 18 can be leak tested, pressure tested and/or evacuated of moisture, residue and/or debris that may be within the internal space of the OHP micro-channel(s) 18 prior to being charged with the working or cooling fluid, as described below. Once the OHP micro-channel(s) 18 has/have been charged, the plug control device 66 can be operated to push the truncated cone-shaped plug 66 further in the Y direction such that the truncated cone-shaped plug 74 closes and at least temporarily seals the evacuation and fill passage 42, as shown in FIG. 4C. Subsequently, the truncated cone-shaped plug 74 can be hermetically sealed within the evacuation and fill passage 42 via any suitable sealing means, manner or process (e.g., torsional ultrasonic welding).

Referring now to FIGS. 1, 5A, 5B, 5C and 5D, as described above, in various embodiments, to provide the fluid flow connection of the OHP internal micro-channel(s) 18 with the inner lumen 34 of the multi-function attachment tool 30 when the multi-function attachment tool 30 is connected to the connection port 38, the connection port 38 can comprise an evacuation and fill passage 42 that is prefabricated within the connection port 38 (i.e., fabricated during fabrication or manufacturing of the OHP device 14). For example, in various embodiments, the evacuation and fill passage 42 can be small port hole 82 (e.g., a 0.020 to 0.050 inch diameter port hole) that extends at least partially through the thickness of the outer wall or exterior surface 46 of the OHP device 14. In various embodiments where the prefabricated evacuation and fill passage 42/port hole 82 extends completely through the outer wall or exterior surface 46 (FIG. 5A), the internal volume of the OHP micro-channel(s) 18 are open to and fluidly connected with the ambient environment when the OHP device 14 is initially placed on the OHP work platform 24. Alternatively, in various embodiments where the prefabricated evacuation and fill passage 42/port hole 82 does not extend completely through the OHP device outer wall or exterior surface 46, a thin layer or skin 86 of the outer wall remains at a distal end of the evacuation and fill passage 42/port hole 82 (FIG. 5B). In such embodiments, the processing head 22, more particularly, the main operation module 28, is structured and operable to puncture the skin 86 before or after the multi-function attachment tool 30 is hermetically sealed to the connection port 38. For example, in such embodiments, the orifice generating tool 50 can comprise punch rod 90 (FIG. 5D) that is structured and operable, via an actuator 106 (shown in FIGS. 8, 9, 10 and 11), to move or push the punch rod 90 downward (i.e., in the Y direction shown in FIG. 5C) such that outer wall 46 or the skin 86 at the distal end of the evacuation and fill passage 42/port hole 82 is pierced, perforated or broken by the punch rod 90, thereby forming the evacuation and fill passage 42.

As described above, in order to charge the OHP device 14, the multi-function attachment tool 30 is hermetically sealed to the OHP device at the connection port 38. This can be done before or after the evacuation and fill passage 42 is formed or provided. As also described above, the connection port 38 can be any area or structure integrally formed with, formed on, formed in, or connected to the exterior surface of the outer wall or exterior surface 46 directly aligned with adjacent the OHP micro-channel(s) 18 and designated as the connection port 38. For example, in various embodiments, the connection port 38 can comprise a flat surface (e.g., ¼ inch diameter flat surface) on the exterior surface of the OHP device outer wall or exterior surface 46. Generally, in operation, the processing head 22 is connected to the OHP device 14 by connecting and hermetically sealing the multi-function attachment tool 30 to the connection port 38. This can be done in any suitable manner, e.g., via an O-ring, an adhesive, a laser weld, a valve, a quick connect feature, etc.

Once the multi-function attachment tool 30 is connected to, placed in contact with, or otherwise sealed to the connection port 38, and the evacuation and fill passage 42 has been provided or formed, the charging system 10 can perform an internal volume leak check to verify there is no unwanted leaks in the OHP envelope or gas within the OHP channel(s) 18. In various embodiments, where the internal volume is initially under vacuum, this can be done by sensing, via a gas sensor of the processing head 22, whether there is gas within the internal volume of the OHP channel(s) 18 after the evacuation and fill passage 42 is formed, therefore indicating a leak path is present in the OHP envelope causing the unit to be rejected. In various embodiments where the internal volume is fluidly connected to the ambient environment, the internal volume leak test can be done using any suitable method such as detection of gas or air leaking in using RGA, FTIR or CIS, helium or other tracer mass spectrometry gas leak tests, pressure measurement/pressure decay test, vacuum decay, etc.

Additionally, once the multi-function attachment tool 30 is connected to, placed in contact with, or otherwise sealed to the connection port 38, and the evacuation and fill passage 42 has been provided or formed, helium can be introduced into the OHP channel(s) 18 via the multi-function attachment tool inner lumen 34 and a helium source (not shown) that can be connected to the leak check conduit 26C. More specifically, in various instances, the leak check conduit 26C can be selectively fluidly connected to the multi-function attachment tool inner lumen 34 which is fluidly connected to OHP micro-channel(s) 18 when the multi-function attachment tool 30 is connected to the connection port 38. Utilizing standard helium leak detection methods, the helium is used to verify that a hermetic seal has been established between the distal end 30 of the multi-function attachment tool 30 and the connection port 38, and that there are no leaks within the OHP micro-channel(s) 18.

Alternatively, in various embodiments, a vacuum can be utilized to verify the hermetic seal between the distal end 30 of the multi-function attachment tool 30 and the connection port 38, and that there are no leaks within the OHP micro-channel(s) 18. More particularly, the vacuum conduit 26A can be fluidly connected to a vacuum source (not shown). In various instances, the vacuum conduit 26A can be selectively fluidly connected to the multi-function attachment tool inner lumen 34 which is fluidly connected to OPH micro-channel(s) 18. Once the multi-function attachment tool 30 is connected to the connection port 38 a target level or pressure of vacuum can be applied to the OHP micro-channel(s) 18 via the vacuum source for a specific duration of time. The target level or pressure of vacuum is then measured or monitored, via a sensor of the processing head 22, during that duration of time to determine if the target level or pressure of vacuum is maintained. If the target level or pressure of vacuum is maintained the airtightness of the connection between the distal end 30 of the multi-function attachment tool 30 and the connection port 38 is verified, i.e., the hermetic seal between the distal end 30 of the multi-function attachment tool 30 and the connection port 38 is verified, and the hermeticity of the OHP micro-channel(s) is verified.

As described above, in various embodiments, the connection port 38 can comprise an evacuation and fill passage 42 that is prefabricated within the connection port 38 (i.e., fabricated during fabrication or manufacturing of the OHP device 14), whereby the internal volume of the OHP micro-channel(s) 18 are open to and fluidly connected with the ambient environment when the OHP device 14 is initially placed on the OHP work platform 24. Additionally, in various embodiments, the evacuation and fill passage 42 can be fabricated via the main operation module 28 of the processing head 22 as described above prior to, or subsequent to, the multi-function attachment tool 30 being hermetically sealed with the connection port 38. In either of the above scenarios, in various embodiments, once the hermetic seal between the distal end 30 of the multi-function attachment tool 30 and the connection port 38 is established and verified, the OHP micro-channel(s) 18 can be evacuated by pulling a vacuum from the OHP micro-channel(s) 18, via the vacuum source connected to the vacuum conduit 26A. More specifically, as described above, the vacuum conduit 26A can be selectively fluidly connected to the multi-function attachment tool inner lumen 34 which is fluidly connected to OHP micro-channel(s) 18 when the multi-function attachment tool 30 is hermetically sealed to the connection port 38. Accordingly, the vacuum generated by the vacuum source is applied to the OHP micro-channel(s) 18, thereby evacuating the OHP micro-channel(s) 18 of moisture, residue and/or debris

Furthermore, in various embodiments, once the internal volume leak check has been performed, the charging system 10, more specifically the processing head 22, can measure the internal volume of the OHP channel(s) 18. This can be done using any suitable means, manner or process such introducing a known mass of a known gas into the micro-channel(s) 18 and measuring the pressure and temperature of the control volume and calculating the control volume using the ideal gas law or tabulated gas properties and subtracting the known volume of the tool's internal volume. In addition, if two of these properties are unknown, the volume can be calculated by changing one of the values and measuring the properties at each state. Or, by completely filling the OHP channel(s) 18 with working or cooling fluid and correlating that back to the known total volume of the OHP channel(s) 18 using the density of the working or cooling fluid at a specific charging temperature, or via acoustic wave testing, etc. Thereafter, in various embodiments, the charging system 10, more specifically the processing head 22, can perform an internal pressure test on the OHP device 14. Particularly in various instances, a hydraulic pressure test can be performed using the working or cooling fluid. For example, the OHP micro-channel(s) 18 can be filled 100% with a liquid then additional, mechanically driven pressure can be applied to the fluid within the OHP micro-channel(s) to push the OHP device past a fluid saturation curve and to a desired pressure. During pressurization, an external detector of the working or cooling fluid can be used to detect whether leak paths are opened and/or a visual inspection can be completed to verify no permanent deformation of the OHP envelope material. Alternatively, the OHP micro-channel(s) 18 can be depressurized and internally leak checked using the methods described previously.

Once the hermetic seal between the distal end 30 of the multi-function attachment tool 30 and the connection port 38 has been established and verified, the internal volume leak test has been performed, and in various instances, the OHP micro-channel(s) 18 have been evacuated, the OHP micro-channel(s) 18 can be charged with a desired predetermined amount of working or cooling fluid via a working or cooling fluid source (not shown) connected to the working or cooling fluid conduit 26B. More specifically, the working or cooling fluid conduit 26B can be selectively fluidly connected to the multi-function attachment tool inner lumen 34 which is fluidly connected to OHP micro-channel(s) 18 when the multi-function attachment tool 30 is connected to the connection port 38. Accordingly, the desired predetermined amount of working or cooling fluid can be pumped into the OHP micro-channel(s) 18 via the working or cooling fluid source. Once, the OHP micro-channel(s) 18 is/are charged, i.e., filled with the desired amount of working or cooling fluid, the OHP system 10, more particularly the processing head 22, can at least temporarily seal the evacuation and fill passage 42 of the connection port 38 closed, whereafter the multi-function attachment tool 30 can be disconnected and removed from the connection port 38.

Referring now to FIGS. 6A, 6B, 6C and 7, the evacuation and fill passage 42 can be at least temporarily sealed (i.e., at least temporarily hermetically sealed closed) via any suitable means, manner, system, mechanism or device. For example, in various embodiments, the evacuation and fill passage 42 can be sealed closed by plugging a proximal end 42A of the evacuation and fill passage 42 (i.e., the end of the evacuation and fill passage 42 nearest the exterior surface of the OHP device outer wall or exterior surface 46, shown in FIGS. 2D, 3D and 4C) with a ball plug 94 that can be lodged within the proximal end 42A. The ball plug 94 can be disposed in the evacuation and fill passage distal end 42A via any suitable means, manner, system, mechanism or device. Thereafter, a plug ram 98 of the processing head main operation module 28 can push the plug ball 94 downward (i.e., in the Y direction shown in FIG. 6B), via an actuator 106 (shown in FIGS. 8, 9, 10 and 11), to push, wedge, lodge, crush and/or deform the ball plug 94 into the evacuation and fill passage distal end 42A. Consequently, the ball plug 94 at least temporarily seals the evacuation and fill passage 42 (i.e., at least temporarily hermetically seals the evacuation and fill passage 42) and more particularly at least temporarily seals the OHP micro-channel(s) 18 (i.e., at least temporarily hermetically seals the OHP micro-channel(s) 18).

Alternatively, it is envisioned that the charging system (e.g., processing head 22) can be structured and operable to weld the ball plug 94 into the evacuation and fill passage proximal end 42A via a weld material cladding (e.g., via welding of a single alloy plug ball or using a braze/weld material cladded plug ball). Such a sealing process can be provided by the charging system processing head 22 or a separate system structured and operable to provide at least a temporary seal of the evacuation and fill passage 42. Further yet, in various other embodiments, it is envisioned that in place of the ball plug 94, there can be embodiments that utilize a plug or cap that deforms then springs back to seal the evacuation and fill passage 42 after pressed into the evacuation and fill passage proximal end 42A. It is further envisioned that in various embodiments, other variants with other plug shapes and sealing methods (e.g., differences in thermal expansion, welding, press-fit, riveting, etc.) can be implemented to provide at least a temporary seal of the evacuation and fill passage 42 (i.e., provide at least a temporary hermetic seal).

The ball plug 94 can be placed, positioned or otherwise disposed in the proximal end 42A of the evacuation and fill passage 42 using any suitable means, manner, system, mechanism or device. For example, in various embodiments, the main operation module 28 of the processing head 22 can comprise a ball plug input ramp 102 that allows a ball plug 94 to be rolled into place within the evacuation and fill passage proximal end 42A. More specifically, a ball plug 94 can be manually or via automation placed into the ball plug input ramp 102, whereafter the ball plug 94 rolls down and through the ball plug input ramp 102 via gravity and into the inner lumen 34 of multi-function attachment tool 30. The ball plug 94 then falls or rolls through the multi-function attachment tool inner lumen 34 into the evacuation and fill passage proximal end 42A. In various embodiments, the plug ram 98 will then push, wedge, lodge, crush and/or deform the ball plug 94 into the evacuation and fill passage distal end 42A, as described above. Alternatively, as described above, the charging system (e.g., processing head 22) can be structured and operable to weld the ball plug 94 into the evacuation and fill passage proximal end 42A via a weld material cladding (e.g., via welding of a single alloy plug ball or using a braze/weld material cladded plug ball).

If using any means, method, system, mechanism or device described herein for at least temporarily sealing the evacuation and fill passage 42, or any combination of any means, method, system, mechanism or device described herein for at least temporarily sealing the evacuation and fill passage 42 does not provide a hermetic seal that can withstand downstream or customer requirements (e.g., the seal cannot withstand downstream or customer internal pressure, shock, vibration, etc., requirements) an additional final seal can be applied using any suitable sealing process (e.g., torsional ultrasonic welding) to provide the required hermetic seal. Such a final sealing process can be provided by the charging system processing head 22 or a separate system structured and operable to provide the final seal subsequent to charging of the OHP device 14 by the OHP charging system 10. For example, in various embodiments, the charging system 10, more particularly the processing head 22, can perform a final seal prior to disconnecting and removing the multi-function attachment tool 30 from the connection port 38.

Referring now to FIGS. 1 through 11, as described above, the vacuum conduit 16A, the working or cooling fluid conduit 16B and the leak check conduit 16C are selectively connected to the multi-functional attachment tool inner lumen 34 based on the particular operation of the charging system 10, e.g., the OHP micro-channel evacuation operation, the OHP micro-channel charging operation, and the hermetic seal check. More specifically, the vacuum conduit 16A, the working or cooling fluid conduit 16B and the leak check conduit 16C are selectively connected to the multi-functional attachment tool inner lumen 34 via operation of the main operation module 28 of the processing head 22 based on the particular operation of the charging system 10, as described below. Moreover, the processing head 22 and the main operation module 28 of the charging system 10 can have various structures, configurations and functionalities.

For example, with particular reference to FIG. 8, in various embodiments, the processing head 22 main operation module 28 can be a syringe or a piston type module comprising a piston-type actuator 106 that extends into and is at least partially disposed within the internal lumen 34 of the multi-function attachment tool. Additionally, the main operation module 28 can comprise a multi-source feed tube 110 connected at a distal to a sidewall of the multi-function attachment tool 30, and having the system conduits 26 (e.g., the vacuum conduit 26A, the working or cooling fluid conduit 26B and the leak check conduit 26C) connected to a body thereof. The multi-source feed tube 110 comprises an internal bore or lumen such that, via operation of the main operation module, the system conduits 26 are selectively fluidly connectable to the internal lumen 34 of the multi-function attachment tool 30. As described above, in various embodiments, the processing head 22 can include the orifice generating tool 50 that is structured and operable to puncture, penetrate, bore or otherwise at least partially form an orifice (i.e., the evacuation and fill passage 42) in the outer wall or exterior surface 46 of the OHP device 14. In various instances, the orifice generating tool 50 can be a laser device structured and operable to generate or emit a laser beam that is projected through the internal lumen 34 of the multi-function attachment tool 30 to at least partially cut through the OHP device outer wall or exterior surface 46 within the connection port 38 to provide the evacuation and fill passage 42.

As exemplarily illustrated in FIG. 9, in other embodiments, the processing head 22 can comprise rotary-type main operation module 28 comprising a top stator 114 and a bottom stator 118, with a rotatable central body 122 disposed therebetween. The top stator 114 is fluidly connectable to the system conduits 26 (e.g., the vacuum conduit 26A, the working or cooling fluid conduit 26B and the leak check conduit 26C). The bottom stator 118 has the multi-function attachment tool 30 extending therefrom and comprises an orifice or bore fluidly connected to the internal lumen 34 of the multi-function attachment tool 30. The rotatable central body is fabricated, formed or constructed to have various internal channels, tunnels, conduits, and/or passages 126 that fluidly connect the system conduits 26 to the various passages such that the rotatable central body is operable to selectably rotate to align and fluidly connect selected ones of the passages with the bore in the bottom stator and the internal lumen of the neck, and thereby selectably fluidly connect the system conduits 26 to the internal lumen 34 of the multi-function attachment tool 30.

In various instances, the rotatable central body 122 can further include the orifice generating tool 50 that comprises one or more laser port and reflective path guide 130 and one or more laser device (not shown). The laser port and reflective path guide(s) 130 is/are structured and operable to receive a laser beam/signal generated or emitted by the laser device(s) and direct the laser beam(s)/signal(s) through the multi-function attachment tool internal lumen 34 onto the connection port 38 to at least partially cut through the OHP device outer wall or exterior surface 46 within the connection port 38 to provide the evacuation and fill passage 42. More specifically, the rotatable central body 122 can be rotated to align the laser port and reflective path guide(s) 130 so as to direct the emitted laser beam(s)/signal(s) through the multi-function attachment tool internal lumen 34 and onto the OHP device outer wall or exterior surface 46 at the connection port 38 to generate evacuation and fill passage 42. The laser port and reflective path guide(s) 130 can include a mirror that will direct a laser beam onto the connection port 38. Subsequently, the central body 122 can be rotated to align or otherwise fluidly connect one or more of the internal channels, tunnels, conduits, and/or passages 126 with the multi-function attachment tool internal lumen 34 to thereby selectively fluidly connect one or more of the system conduits 26 with the multi-function attachment tool internal lumen 34, and more particularly with the OHP micro-channel(s) 18.

For example, the central body 122 can be rotated to align or otherwise selectively fluidly connect one or more of the internal channels, tunnels, conduits, and/or passages 126 with the leak check conduit 26C and with the multi-function attachment tool inner lumen 34 to thereby selectively fluidly connect the leak check conduit 26C with the OHP micro-channel(s) 18 such that airtightness of the hermetic connection of the multi-function attachment tool 30 with the connection port 38 can be checked and verify, as described above. Thereafter, the central body 122 can be rotated to align or otherwise selectively fluidly connect one or more of the internal channels, tunnels, conduits, and/or passages 126 with the vacuum conduit 26A and with the multi-function attachment tool internal lumen 34 to thereby selectively fluidly connect the vacuum conduit 26A with the OHP micro-channel(s) 18 such that the airtightness of the OHP micro-channel(s) 18 can be tested and verified as described above, and/or the OHP micro-channel(s) 18 can be evacuated of moisture, residue and/or debris, as described above. Next, the central body 122 can be rotated to align or otherwise selectively fluidly connect one or more of the internal channels, tunnels, conduits, and/or passages 126 with the working or cooling fluid conduit 26B and with the multi-function attachment tool internal lumen 34 to thereby selectively fluidly connect the working or cooling fluid conduit 26B with the OHP micro-channel(s) 18. Thereafter, the OHP micro-channel(s) 18 can be charged with working or cooling fluid, as described above.

Finally, the central body 122 can be rotated to align piston rod (e.g., the plug control device 66 described above, the punch rod 90 described above, or the plug ram 98 described above) of an evacuation and fill passage plug insertion device 134 with the multi-function attachment tool inner lumen 34 such that an evacuation and fill passage plug (e.g., a cone-shaped plug 62 described above, or a truncated cone-shaped plug 74 described above, or a ball plug 94 described above) can be inserted and sealed into the evacuation and fill passage proximal end 42A as described above to at least temporarily seal (i.e., can be a temporary seal or the final seal) the evacuation and fille passage 42 as described above. In various embodiments, the central body 122 can subsequently be rotated such that the laser port and reflective path guide(s) 130 is/are positioned to direct a laser beam/signal through the multi-function attachment tool internal lumen 34 onto the connection port 38 to provide or generate a final seal of the evacuation and fill passage plug 62, 74 or 94 within the evacuation and fill passage 42.

As exemplarily illustrated in FIG. 10, in other embodiments, the processing head 22 can comprise an internal moving component 138 disposed within the main operation module 28. In various instances, the internal moving component can include a linear slide 142 which is a tray that holds a first operation head 146 and a second operation head 150. The first and second operation heads 156 and 150 perform the functions/operations of generating the evacuation and fill passage 42, leak checking the seal between the multi-function attachment tool 30 and the connection port 38, the evacuation of moisture, residue and/or debris from the OHP micro-channel(s) 18, the charging of the OHP micro-channel(s) 18 with working or cooling fluid, and the final sealing of the evacuation and fill passage 42 described above. For example, in various embodiments, the first operation head 146 can have a sharp spike disposed on a distal end thereof that is structured and operable to generate or provide the evacuation and fill passage 42, the second operation head 150 can have a blunt boss or post disposed on a distal end thereof that is structured and operable to insert and seal an evacuation and fill passage plug (e.g., a cone-shaped plug 62 described above, or a truncated cone-shaped plug 74 described above, or a ball plug 94 described above) into and within the evacuation and fill passage proximal end 42A as described above to at least temporarily seal (i.e., can be a temporary seal or the final seal) the evacuation and fille passage 42 as described above.

More specifically, the processing head 22 can comprise a slide actuator 154 that is structured and operable to selectively position the linear slide 142 to selectively align the first and second operation heads 146 and 150 with a piston rod 158 of an operation actuator 162 mounted to the main operation module 28 such that piston rod 158 can access and operate on the respective selected first or second operation head d 146 or 150 depending on which function/operation (e.g., of generating the evacuation and fill passage 42, leak checking the seal between the multi-function attachment tool 30 and the connection port 38, evacuating moisture, residue and/or debris from the OHP micro-channel(s) 18, charging of the OHP micro-channel(s) 18 with working or cooling fluid, or final sealing of the evacuation and fill passage 42) is to be carried out. Additionally, the processing head 22 can comprise a multi-source feed tube 166 connected at a distal to a sidewall of the man operation module 28 and fluidly connected to the internal lumen 34 of the multi-function attachment tool 30. The multi-source feed tube 166 has the system conduits 26 (e.g., the vacuum conduit 26A, the working or cooling fluid conduit 26B and the leak check conduit 26C) connected to a body thereof. The multi-source feed tube 166 comprises an internal bore or lumen such that the system conduits 26 are selectively in fluid connection to the internal lumen 34 of the multi-function attachment tool 30.

As exemplarily illustrated in FIGS. 7 and 11, in various embodiments, the processing head 22 can comprise a puncture tool 170 that is structure and operable to at least partially puncture the OHP device outer wall or exterior surface 46 within the connection port 38 to provide the evacuation and fill passage 42. In various instances, the puncture tool 170 is concentrically slidingly disposed within the plug ram 98 (described above with regard to FIG. 7). In such embodiments, the processing head 22 can additionally comprise a puncture tool actuator 174 that is selectively connectable to puncture tool 170 and a plug ram actuator 176 that is selectively connectable to the plug ram 98. The puncture tool actuator 174 and the plug ram actuator 176 are structured and operable to move the respective puncture tool 170 and the plug ram 98 up and down in the Y⁺ and Y⁻ directions.

As described above with regard to FIG. 7, in various embodiments, the main operation module 28 can comprise the ball plug input ramp 102 that allows a ball plug 94 to be rolled into place within the evacuation and fill passage proximal end 42A. More specifically, once the OHP micro-channel(s) 18 have been charged with the desired predetermined amount of working or cooling fluid, a ball plug 94 can be manually or via automation released into the ball plug input ramp 102, whereafter the ball plug 94 rolls down and through the ball plug input ramp 102 via gravity and into the inner lumen 34 of multi-function attachment tool 30. The ball plug 94 then falls or rolls through the multi-function attachment tool inner lumen 34 into the evacuation and fill passage proximal end 42A. The plug ram 98, via operation of the multipurpose actuator 174, will then push, wedge, lodge, crush and/or deform the ball plug 94 into the evacuation and fill passage distal end 42A, as described above. Alternatively, as described above, the charging system (e.g., processing head 22) can be structured and operable to weld the ball plug 94 into the evacuation and fill passage proximal end 42A via a weld material cladding (e.g., via welding of a single alloy plug ball or using a braze/weld material cladded plug ball). Additionally, the processing head 22 can comprise a multi-source feed tube 178 connected at a distal to a sidewall of the man operation module 28 and fluidly connected to the internal lumen 34 of the multi-function attachment tool 30. The multi-source feed tube 178 has the system conduits 26 (not shown) connected to a body thereof. The multi-source feed tube 178 comprises an internal bore or lumen such that the system conduits 26 are selectively in fluid connection to the internal lumen 34 of the multi-function attachment tool 30.

In various embodiments, in operation, the ball plug 94 can be loaded into the ball plug input ramp 102, both the puncture tool actuator 174 and the plug ram actuator 176 are retracted in the in the Y⁺ direction, and the multi-function attachment tool 30 is attached to the OHP device 14 within the connection port 38. Then air is vacuumed out of the main operation module 28 using the vacuum source fluidly connected to the multi-source feed tube 178 via the vacuum conduit 26A (not shown), to thereby verify that the hermetic seal of the multi-function attachment tool 30 with the outer wall or exterior surface 46 of OHP device 14 at the connection port 38. Then both the puncture tool actuator 174 and the plug ram actuator 176 are actuated to lower both the puncture tool 170 and the plug ram 98 in the Y direction such that the puncture tool punctures the OHP device outer wall or exterior surface 46 within the connection port 38 to provide the evacuation and fill passage 42. The puncture tool 170 is then retracted in the Y⁺ direction via the puncture tool actuator 174 allowing the multi-function attachment tool internal lumen 34 to be fluidly connected to the internal OHP channel(s) 18.

Thereafter, the OHP micro-channel(s) 18 are evacuated of moisture, residue and/or debris, and charged with working or cooling fluid, as described above. In various instances, there is a ball catch 182 within the ball plug input ramp 102 that prevents the ball plug 94 from interfering with the puncture and charging process of the OHP device 14. The ball plug 94 is released by the ball catch 182 after the OHP device 14 has been charged and is ready for at least a temporary seal of the evacuation and fill passage 42. In various instances, there is a back-fill prevention O-ring 186 disposed around the puncture tool conduit to prevent the working or cooling fluid from back-filling the space within the main operation module 28 during the charging process. Subsequently, after charging the ball plug ram 98 is lowered in the Y direction via the plug ram actuator 176 to push the ball plug 94 through the back-fill prevention O-ring 186 and into the evacuation and fill passage proximal end 42A to at least temporarily seal the evacuation and fill passage 42.

As described above, all or some of the operations of the charging system 10 described herein can be manual operation and/or automated operations that are controlled by a computer-based controller (not shown but clearly and easily understood by one skilled in the art). In the various automated embodiments, the charging system 10 can be programmed to know where the charging port 38 is on each OHP device 14. Therefore, either the processing head 22 can be moved (as controlled by the computer-based controller) to align the multi-function attachment tool 30 charging port 38, or an automated bed on which each OHP device 14 is disposed can be moved (as controlled by the computer-based controller) to align the multi-function attachment tool 30 charging port 38.

The description herein is merely exemplary in nature and, thus, variations that do not depart from the gist of that which is described are intended to be within the scope of the teachings. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions can be provided by alternative embodiments without departing from the scope of the disclosure. Such variations and alternative combinations of elements and/or functions are not to be regarded as a departure from the spirit and scope of the teachings.