Cold Inflation Tests (CO-OP)

During my co-op term in the spring of 2024, I spent eight months working as an R&D engineer for Mustang Survival. My primary focus was testing the inflation performance of portable flotation devices (PFDs) in cold water environments. Below, I've outlined the typical daily procedures involved in these tests:

Morning Preparation:
Adhering to ISO standards, the PFDs are packed in the morning and placed inside a Thermotron chamber for five hours. This simulates a cold-use scenario where a user might wear the PFD for an extended period before entering the water.


Fig 1. Thermotron Chamber


Fig 2. PFDs are stored in the Thermotron Chamber for five hours

Water Tank Setup:
The water tank is prepared according to ISO requirements, maintaining a temperature close to 0°C to replicate freezing conditions. A water chiller and ice maker are combined to achieve the desired temperature before testing begins.



Fig 3. Water tank for Cold Inflation Testing (Water Chiller on the right)

Testing Process:
After the five-hour conditioning period, the PFDs are removed from the chamber and secured to a metal frame, as shown below. Additional weights are added to the setup following the inherent buoyancy of the PFD. The frame is then partially submerged in the water tank, ensuring it doesn't touch the bottom. Key data such as inflation time, achievement of positive buoyancy, and potential CO2 leakage points are meticulously recorded. These tests are repeated at various Thermotron temperature settings to evaluate the PFDs' performance across multiple conditions. All findings are compiled into a report and shared with the senior engineer.


Fig 4. Strapping the PFD onto the test frame with additional weight


Fig 5. PFD and frame submerged in water (Partial Inflation)


Performance Metrics:
The video below demonstrates a successful test, with the PFD achieving positive buoyancy within the ISO-mandated 10 seconds.


Video 1: Cold Inflation Test (Successful)

This rigorous testing process ensures the reliability and safety of the PFDs in real-world cold-water scenarios.

 







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