Phase change thermal control materials, method and apparatus

• US 6,319,599 B1
• Filed: 03/02/1998
• Issued: 11/20/2001
• 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): Thibodeau, Paul
• Assistant Examiner(s): ZACHARIA, RAMSEY E
• Application Number:
  US09/033,439
• Time in Patent Office: 1,359 Days
• Field of Search: 428/411.1, 428/311.51, 428/321.5, 428/321.1, 428/422, 428/532, 428/317.9, 428/308.4, 524/487, 524/488, 524/489, 524/490, 524/612, 524/560, 2/2.15, 2/93, 2/227, 2/411, 36/83
• US Class Current: 428/308.4
• CPC Class Codes: A41D 13/0056 using evaporative effect
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: A61F 2007/0098 ways of manufacturing heating or cooling devices for therapy
• CPC Class Codes: A61F 2007/0214 Polymers, e.g. water absorbing
• CPC Class Codes: A61F 2007/0244 with layers
• CPC Class Codes: A61F 2007/0246 with a layer having high heat transfer capability
• 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 5/18 characterised by features of a layer of foamed material
• 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: F24V 30/00 Apparatus or devices using heat produced by exothermal chemical reactions other than combustion
• 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: Y02E 60/14 Thermal energy storage
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249962 Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
• CPC Class Codes: Y10T 428/249964 : Fibers of defined composition
• CPC Class Codes: Y10T 428/249972 : Resin or rubber element
• CPC Class Codes: Y10T 428/249981 : Plural void-containing components
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249994 : Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/249995 : Constituent is in liquid form
• CPC Class Codes: Y10T 428/249997 : Encapsulated liquid
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31544 : Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate

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 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 thermal storage composite material, comprising a superabsorbent material and a thermal storage material absorbed into said superabsorbent material, said thermal storage material being capable of storing thermal energy as latent heat of phase change, said superabsorbent material being capable of absorbing more than twenty times its own weight of said thermal storage material and holding said thermal storage material to prevent migration of said thermal storage material within said thermal storage composite material.

2. The composite material of claim 1, further comprising a matrix material enclosing said superabsorbent material and said thermal storage material.

3. The composite material of claim 2, further comprising:

at least one additional layer bonded to said matrix material, said at least one additional layer comprising a thermally conductive material.

4. The composite material of claim 2, wherein said matrix material is a thermoplastic polymer.

5. A process for making the composite material of claim 2 comprising the step of making a layer of said matrix material containing said superabsorbent material having said thermal storage material absorbed therein.

6. The process of claim 5, wherein said matrix material is a polymer.

7. The process of claim 5, wherein said matrix material is an elastomer.

8. The composite material of claim 2 further comprising:

at least one additional layer bonded to said matrix material, said at least one additional layer formed from a thermally insulative material.

9. The composite material of claim 2 further comprising:

at least one additional layer bonded to said matrix material, said at least one additional layer comprising a thermal absorption material.

10. The composite material of claim 2 further comprising:

at least one additional layer bonded to said matrix material, said at least one additional layer comprising a semipermeable membrane of expanded polytetrafluoroethylene.

11. The composite material of claim 2 further comprising:

at least one additional layer bonded to said matrix material, said at least one additional layer comprising a semipermeable membrane of cellulose acetate.

12. The composite material of claim 2, wherein said matrix material is a polymer foam.

13. The composite material of claim 1, wherein said superabsorbent material is crosslinked polyethylene oxide.

14. The material of claim 1 wherein said material is fashioned into a garment selected from the group consisting of a wetsuit, a boot, a facial mask, a hat, a gaiter, an ear muff, a liner, a shoe insert, a shoe insole, a seating article, a jacket, trousers, a thermal undergarment and biking shorts.

15. The material of claim 1 wherein said material is fashioned into an article selected from the group consisting of a blanket, a bed, a mattress, and a comforter.

16. The composite material of claim 1 wherein said thermal storage material is a material selected from the group consisting of Glycerol, Acetic Acid, Polyethylene Glycol 600, Camphene, Oxasoline Wax, d-Lactic Acid, formic acid, acrylic acid, p-Xylene, caprylic acid, Jojoba Wax, Cotton Seed Oil, Coconut Oil, 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, NH₄Cl.Na₂SO₄.10H₂O, NaCl.NH₄Cl.2NaSO₄.20H₂O, NaCl.Na₂.SO₄.10H₂O, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nanodecane, n-eicosane, n-heneicosane, n-decosane, n-tricosane, Trimethlyolethane, Neopentyl Glycol, lithium chloride, Phase Change Material, calcium chloride hydrate, 1-decanol octadecane, C-16 to C-22 alkyl hydroc, natural rubber, polychloropropene, Witco 45A, Witco K-61, Witco K-51, Witco 85010-1, pentaerythritol, polyhydric alcohols, acrylate and methacrylate polymers, CaBr₂.6H₂O/NaCl, Na₂SO₄.10H₂O/NaCl, CaCl₂.6H₂O, Na₂SO₄.10H₂O, CaBr₂.6H₂O, Na₂HPO₄.12H₂O, Parafin Wax, Xylene, Banana Oil, Olive Oil, Anise Oil, Atherosperma Mosechatum, Bay Oil, Bergamot Oil, Bergamot Florence Oil, Birch Bark Oil, Cejeput Oil, Calamus Oil, Caraway Oil, Cascarilla Oil, Cassia Oil, Cedar Oil, Cedrat Oil, Citronella Oil, Clove Oil, Coriander Oil, Cubebs Oil, Dill Oil, Elder Oil, Eucalyptus Oil, Indian Geranium Oil, Lavender Oil, Lemon Oil, Lemon Grass Oil, Melaleuea Oil, Mint Oil, Myrtle Oil, Myrrh Oil, Neroli Oil, Nutmeg Oil, Orange Peel Oil, Parsley Oil, Patchouli Oil, Peppermint Oil, Petit Grain Oil, Rose Oil, Rosemary Oil, Rosewood Oil, Santalwood Oil, Thyme Oil, Turpentine Oil, Verbena Oil, Wintergreen Oil, Wormwood Oil, Gallium Alloy, Sodium, and Naphthol.

17. The composite material of claim 1, wherein said superabsorbent material is polyacrylate.

18. The composite material of claim 1, wherein said superabsorbent material is carboxy-methyl-cellulose.

19. The composite material of claim 1, wherein said superabsorbent material is in the form of superabsorbent particles within a foam matrix.

20. The composite material of claim 19, wherein said superabsorbent particles are swollen by absorption of said thermal storage material to lock said superabsorbent particles within said foam matrix.

21. The composite material of claim 1, wherein said superabsorbent material is in the form of superabsorbent particles within a fibrous matrix.

22. The composite material of claim 21, wherein said superabsorbent particles are swollen by absorption of said thermal storage material to lock said superabsorbent particles within said fibrous matrix.

23. The composite material of claim 1, wherein said superabsorbent material is in the form of an open cell foam.

24. The composite material of claim 1, wherein said superabsorbent material is in the form of superabsorbent fibers.

25. The composite material of claim 1, wherein said superabsorbent material is in the form of a superabsorbent film.

26. A multilayer thermal storage composite material comprising:

a first layer of material,

a second layer including a superabsorbent material and a thermal storage material absorbed into said superabsorbent material, said thermal storage material being capable of storing thermal energy as latent heat of phase change, said superabsorbent material being capable of absorbing more than twenty times its own weight of said thermal storage material and holding said thermal storage material to prevent migration of said thermal storage material within said thermal storage composite material, and

a third layer of material.

27. The multilayer thermal storage composite material of claim 26, wherein said first layer, said second layer and said third layer are bonded to one another.

28. The multilayer thermal storage composite material of claim 26, wherein said second layer is formed with internal spaces within said second layer, and said superabsorbent material is in the form of as superabsorbent particles with said thermal storage material absorbed therein contained within said internal spaces in said second layer.

29. The multilayer thermal storage composite material of claim 28, wherein said superabsorbent particles are swollen within said internal spaces in said second layer by absorption of said thermal storage material.

30. The multilayer thermal storage composite material of claim 26, wherein said second layer contains fibers of said superabsorbent material.

31. The multilayer thermal storage composite material of claim 26, wherein said second layer contains particles of said superabsorbent material within a foam matrix.

32. The multilayer thermal storage composite material of claim 26, wherein said second layer contains particles of said superabsorbent material within a fibrous matrix.

33. The multilayer thermal storage composite material of claim 26, wherein said first layer, said second layer and said third layer comprise a matrix material, and said superabsorbent material with said thermal storage material absorbed therein is contained within said matrix material within said second layer.

34. The multilayer thermal storage composite material of claim 33, wherein said matrix material comprises a polymer foam.

35. The multilayer thermal storage composite material of claim 33, wherein said matrix material comprises a thermoplastic polymer.

36. The multilayer thermal storage composite material of claim 33, wherein said matrix material comprises an elastomer.