Phase change thermal control materials, method and apparatus

• US 5,722,482 A
• Filed: 03/15/1995
• Issued: 03/03/1998
• Est. Priority Date: 07/14/1992
• Status: Expired due to Fees

• Current Assignee: Theresa M. Buckley
• Original Assignee: Theresa M. Buckley
• Inventors: Buckley, Theresa M.
• Primary Examiner(s): Rivell, John
• Assistant Examiner(s): ATKINSON, CHRISTOPHER MARK
• Application Number:
  US08/404,419
• Time in Patent Office: 1,084 Days
• Field of Search: 165/10, 165/46, 428/242, 428/304.4, 428/308.4, 428/311.1, 428/317.9, 252/70
• US Class Current: 165/10
• CPC Class Codes: A41D 13/0056 using evaporative effect
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: A61F 2007/0244 with layers
• CPC Class Codes: A61F 2007/0249 with a layer having low heat transfer capability
• CPC Class Codes: A61F 2007/026 with a fluid absorbing layer
• CPC Class Codes: A61F 2007/0292 using latent heat produced or absorbed during phase change of materials, e.g. of super-cooled solutions
• CPC Class Codes: A61F 7/02 Compresses or poultices for effecting heating or cooling
• CPC Class Codes: A61F 7/034 Flameless
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2266/08 Closed cell foam
• CPC Class Codes: B32B 25/12 comprising natural rubber
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/027 Thermal properties
• CPC Class Codes: C08K 5/0008 Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
• CPC Class Codes: C09K 5/063 Materials absorbing or liberating heat during crystallisation; Heat storage materials
• CPC Class Codes: F28D 20/023 the latent heat storage material being enclosed in granular particles or dispersed in a porous, fibrous or cellular structure
• CPC Class Codes: F28F 2255/02 Flexible elements
• CPC Class Codes: Y02E 60/14 Thermal energy storage
• CPC Class Codes: Y10T 152/10378 Casing enclosed core
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24996 : With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249997 : Encapsulated liquid

Abstract

An apparatus and method for metabolic cooling and insulation of a user in a cold environment. In its preferred embodiment the apparatus is a highly flexible composite material having a flexible matrix containing a phase change thermal storage material. The apparatus can be made to heat or cool the body or to act as a thermal buffer to protect the wearer from changing environmental conditions. The apparatus may also include an external thermal insulation layer and/or an internal thermal control layer to regulate the rate of heat exchange between the composite and the skin of the wearer. Other embodiments of the apparatus also provide 1) a path for evaporation or direct absorption of perspiration from the skin of the wearer for improved comfort and thermal control, 2) heat conductive pathways within the material for thermal equalization, 3) surface treatments for improved absorption or rejection of heat by the material, and 4) means for quickly regenerating the thermal storage capacity for reuse of the material. Applications of the composite materials are also described which take advantage of the composite'"'"'s thermal characteristics. The examples described include a diver'"'"'s wet suit, ski boot liners, thermal socks, gloves an a face mask for cold weather activities, and a metabolic heating or cooling blanket useful for treating hypothermia or fever patients in a medical setting and therapeutic heating or cooling orthopedic joint supports.

Claims

1. An apparatus for metabolic cooling and for insulation of a user in a cold environment having an ambient environmental temperature which is below a comfortable skin temperature, said apparatus comprising a flexible composite material, comprising a flexible matrix material having a thermal storage material capable of storing thermal energy as the latent heat of phase change dispersed therein, said thermal storage material having a phase transition temperature which is equal to or below normal skin temperature and above the ambient environmental temperature, said flexible composite material being in thermal contact with the skin of the user so as to provide a thermal environment at a temperature above said ambient environmental temperature for said user of said apparatus for an extended time period, said thermal storage material further providing a heat sink to absorb metabolic heat of said user, and said metabolic heat serving to recharge said thermal storage material, thereby increasing the duration of said time period for which said thermal storage material provides said thermal environment at a temperature above said ambient environmental temperature.

2. The apparatus of claim 1, wherein said thermal storage material has a thermal mass at least equal to the difference between the heat loss from said thermal storage material to said ambient environment and the metabolic heat absorbed by said thermal storage material during a time period of a predetermined duration.

3. The apparatus of claim 1 further comprising a thermal control layer between said thermal storage material and the skin of the wearer.

4. The apparatus of claim 3, wherein said thermal control layer comprises an insulating material.

5. The apparatus of claim 3, wherein said thermal control layer comprises a thermally conductive material.

6. The apparatus of claim 1 further comprising an insulative layer between said thermal storage material and the ambient environment.

7. The apparatus of claim 1 further comprising a first insulative layer between said thermal storage material and the skin of the wearer and a second insulative layer between said thermal storage material and the ambient environment, said second insulative layer being of greater insulative value than said first insulative layer.

8. The apparatus of claim 1 further comprising a first layer of a thermally conductive material between said thermal storage material and the skin of the wearer and a second insulative layer between said thermal storage material and the ambient environment.

9. The apparatus of claim 1 wherein said apparatus comprises a garment selected from the group consisting of a wetsuit, a boot, a ski boot, a blanket, a facial mask, a hat, a gater, an ear muff, a liner, a shoe insert, a shoe insole, a seating article, a jacket, trousers, a thermal undergarment, an orthopedic support, thermal therapeutic device and biking shorts.

10. A method for metabolic cooling and for insulation of a user in a cold environment having an ambient environmental temperature which is below a comfortable skin temperature, comprising the step of providing a layer containing a phase change material which is in thermal contact with the skin of a wearer, said phase change material having a phase transition temperature which is below normal skin temperature and above ambient environmental temperature, whereby said phase change material provides a thermal environment for said wearer at a temperature above said ambient environmental temperature for an extended time period, and said phase change material further provides a heat sink to absorb metabolic heat of the wearer, and said metabolic heat serves to recharge said phase change material, thereby increasing the duration of said time period for which said phase change material provides said thermal environment at a temperature above said ambient environmental temperature.

11. The method of claim 10, wherein said layer of phase change material has a thermal mass at least equal to the difference between the heat loss from said phase change material to said ambient environment and the metabolic heat absorbed by said phase change material during a time period of a predetermined duration.

12. The method of claim 10 further comprising the step of providing a thermal control layer between said layer of phase change material and the skin of the wearer.

13. The method of claim 10 further comprising the step of providing an insulative layer between said layer of phase change material and the ambient environment.

14. The method of claim 10 further comprising the steps of providing a first insulative layer between said layer of phase change material and the skin of the wearer and providing a second insulative layer between said layer of phase change material and the ambient environment, said second insulative layer being of greater insulative value than said first insulative layer.

15. The method of claim 10 further comprising the step of dispersing said phase change material within a flexible matrix material to form a flexible composite thermal storage material which is flexible at a high energy state above said phase transition temperature and at a low energy state below said phase transition temperature.

16. The method of claim 14 further comprising the step of conducting moisture way from the skin of the wearer through a moisture transport means within said flexible composite thermal storage material.

17. The method of claim 16 wherein said moisture transport means comprises a semipermeable membrane which allows passage of water vapor through said flexible composite thermal storage material, but does not allow passage of liquid water.

18. The method of claim 16 wherein said moisture transport means comprises wicking elements of moisture absorbent material incorporated into said flexible composite thermal storage material, said wicking elements serving to conduct moisture through said flexible composite thermal storage material.

19. The method of claim 10, wherein said phase change material has a thermal mass at least equal to the difference between the heat loss from said phase change material to said cold environment and the metabolic heat absorbed by said phase change material during a time period of a predetermined duration.

20. The method of claim 14 further comprising the step of distributing heat within said layer of phase change material with a thermally conductive material.