Flexible composite material with phase change thermal storage

• US 6,004,662 A
• Filed: 07/14/1992
• Issued: 12/21/1999
• 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): Jones, Deborah
• Assistant Examiner(s): LAM, CATHY FONG FONG
• Application Number:
  US07/913,246
• Time in Patent Office: 2,716 Days
• Field of Search: 428/242, 428/304.4, 428/308.4, 428/311.1, 428/317.9, 428/309.9, 428/321.5, 165/46, 36/3 B, 36/28, 36/30 A, 36/32 R, 152/310, 2/167, 2/168, 2/158, 2/159, 521/76
• US Class Current: 428/304.4
• 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

A highly flexible composite material having a flexible matrix containing a phase change thermal storage material. The composite material 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 composite 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 PCM composite 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 and 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. A flexible composite material, comprising a flexible foam matrix material containing a thermal storage material capable of storing thermal energy as latent heat of phase change, said thermal storage material having a high energy state and a low energy state, said thermal storage material being dispersed within said flexible foam matrix material such that said flexible composite material is flexible when said thermal storage material is in said high energy state and said flexible composite material is flexible when said thermal storage material is in said low energy state.

2. The flexible composite material of claim 1 wherein said flexible foam matrix material comprises a flexible open cell polymer foam.

3. The flexible composite material of claim 1 wherein said flexible foam matrix material comprises a flexible closed cell polymer foam.

4. The flexible composite material of claim 1 wherein said thermal storage material is encapsulated within an encapsulating material.

5. The flexible composite material of claim 1 wherein said thermal storage material is absorbed into an absorbent material.

6. The flexible composite material of claim 5 wherein said absorbent material is a superabsorbent material.

7. The flexible composite material of claim 1 further comprising a moisture transport means for conducting moisture through said flexible composite material, said moisture transport means being incorporated into said composite material.

8. The flexible composite material of claim 7 wherein said moisture transport means comprises a semipermeable membrane which allows passage of water vapor through said flexible composite material, but does not allow passage of liquid water.

9. The flexible composite material of claim 7 wherein said moisture transport means comprises wicking elements of moisture absorbent material incorporated into said composite material, said wicking elements serving to conduct moisture through said flexible composite material.

10. The composite material of claim 1 wherein said thermal storage material is a liquid when it is in the high energy state and a solid when it is in the low energy state.

11. The composite material of claim 1 wherein said thermal storage material is a solid when it is in the high energy state and a solid when it is in the low energy state.

12. The composite material of claim 1 wherein said thermal storage material is a material selected for the group consisting of glycerol, acetic acid, polyethylene glycol, crosslinked polyethylene glycol, camphene, oxasoline wax, d-lactic acid, formic acid, acrylic acid, p-xylene, caprylic acid, jojoba wax, cotton seed oil, coconut oil, rice oil, water, almond oil, beechnut oil, black mustard oil, candlenut oil, castor oil, corn oil, cotton seed stearin, esparto, poppy seed oil, rape seed (canola) oil, pumpkin seed oil, soy bean oil, sunflower oil, walnut oil, white mustard seed oil, beeswax, NH₄ Cl.Na₂ SO₄.10H₂ O, NaCl.NH₄ Cl.2NaSO₄.20H₂ O, NaCl.Na₂.SO₄.10H₂ O, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nanodecane, n-eicosane, n-heneicosane, n-decosane, n-tricosane, trimethylolethane, neopentyl glycol, lithium chloride, calcium chloride hydrate, 1-decanol octadecane, C-16 to C-22 alkyl hydrocarbons, natural rubber, polychloropropene, crystalline alkyl hydrocarbons, pentaerythritol, polyhydric alcohols, acrylate and methacrylate polymers, CaBr₂.6H₂ 0/NaCl, Na₂ SO₄.10H₂ O/NaCl, CaCl₂.6H₂ O, Na₂ SO₄.10H₂ O, and CaBr₂.6H₂ 0.

13. The flexible composite material of claim 6 wherein said superabsorbent material is selected from the group consisting of polyacrylic, carboxy-methyl-cellulose and polyethylene oxide.

14. The flexible composite material of claim 8 wherein said semipermeable membrane is selected from the group consisting of expanded polytetrafluoroethylene membranes and cellulose acetate membranes.

15. A flexible composite material, comprising:

a first layer comprising an flexible insulating foam material,

a second layer comprising a flexible foam matrix material containing a thermal storage material capable of storing thermal energy as latent heat of phase change,

a third layer comprising a thermal control material means for regulating the rate of heat exchange from said thermal storage material through said thermal control material means.

16. The flexible composite material of claim 15 wherein said thermal control material is a thermally insulating foam material which decreases the rate of heat exchange from said thermal storage material through said thermal control material.

17. The flexible composite material of claim 16 further comprising a thermally conductive material which increases the rate of heat exchange from said thermal storage material through said thermal control material.

18. The flexible composite material of claim 17 wherein said thermally conductive material is selected from the group consisting of thermally conductive films, thermally conductive fibers, thermally conductive wires, thermally conductive capsules and metal capsules.

19. The flexible composite material of claim 15 wherein said flexible insulating material is selected from the group consisting of flexible polymers, polymer foams and aerogels.

20. A flexible composite material, comprising:

a first layer comprising an insulating foam material,

a second layer comprising a flexible foam matrix material containing thermal storage material capable of storing thermal energy as latent heat of phase change,

a third layer comprising a thermal control material,

wherein said insulating foam material and said thermal control material are made from the same substance as said foam matrix material and said first, second and third layers are continuous with one another.

21. A garment made from a flexible composite material, comprising a flexible foam matrix material containing a thermal storage material capable of storing thermal energy as latent heat of phase change, said thermal storage material having a high energy state and a low energy state, said thermal storage material being dispersed within said flexible foam matrix material such that said flexible composite material is flexible when said thermal storage material is in at least one of said high energy state or said low energy state.

22. The garment of claim 21 wherein said garment is selected from the group consisting of an exposure suit for underwater diving, a boot liner for cold weather wear, a glove for cold weather wear, a ski mask, a hat, a sock, a mitten and a joint support brace.

23. A blanket made from a flexible composite material, comprising a flexible foam matrix material containing a thermal storage material capable of storing thermal energy as latent heat of phase change, said thermal storage material having a high energy state and a low energy state, said thermal storage material being dispersed within said flexible foam matrix material such that said flexible composite material is flexible when said thermal storage material is in said high energy state and said flexible composite material is flexible when said thermal storage material is in said low energy state.

24. A laminated flexible thermal storage composite material, comprising:

a first layer comprising a first flexible insulating polymer foam material,

a second layer laminated to said first layer and comprising a flexible polymer matrix material having dispersed therein a thermal storage material having a transition temperature and capable of storing thermal energy as latent heat of phase change, and

a third layer laminated to said second layer and comprising a second flexible insulating polymer foam material,

wherein said laminated flexible thermal storage composite material has a sheet configuration, and

wherein said laminated flexible thermal storage composite material is flexible when said thermal storage material is in a high energy state and said laminated flexible thermal storage composite material is flexible when said thermal storage material is in a low energy state.

25. The laminated flexible thermal storage composite material of claim 24, wherein said flexible polymer matrix material comprises a third flexible polymer foam material.

26. The laminated flexible thermal storage composite material of claim 25 wherein first flexible insulating polymer foam material, said second flexible insulating polymer foam material, and said third flexible polymer foam material are made of the same flexible polymer foam material.

27. The laminated flexible thermal storage composite material of claim 24 wherein said thermal storage material is encapsulated in polymeric capsules and said polymeric capsules are dispersed within said flexible polymer matrix material.

28. The laminated flexible thermal storage composite material of claim 24 wherein said first layer further comprises a thermally conductive material to increase a rate of heat exchange from said thermal storage material through said first flexible insulating polymer foam material.

29. The laminated flexible thermal storage composite material of claim 24 further comprising a moisture transport means incorporated into said laminated flexible thermal storage composite material for conducting moisture through said laminated flexible thermal storage composite material.

30. The laminated flexible thermal storage composite material of claim 24 wherein said thermal storage material is absorbed into an absorbent material within said second layer.