U.S. patent application number 12/800482 was filed with the patent office on 2012-09-13 for body temperature control system.
Invention is credited to John Michael Creech, Jason Pauc Drees.
Application Number | 20120227432 12/800482 |
Document ID | / |
Family ID | 46794268 |
Filed Date | 2012-09-13 |
United States Patent
Application |
20120227432 |
Kind Code |
A1 |
Creech; John Michael ; et
al. |
September 13, 2012 |
Body temperature control system
Abstract
In an embodiment, a system is provided. The system includes a
heat exchanger including a compressor and having a pump coupled to
the heat exchanger. The system further includes a personal garment,
the personal garment including an internal bladder with inflow and
outflow fluid tubing. The fluid tubing is coupled to the heat
exchanger.
Inventors: |
Creech; John Michael;
(US) ; Drees; Jason Pauc; (US) |
Family ID: |
46794268 |
Appl. No.: |
12/800482 |
Filed: |
May 14, 2010 |
Current U.S.
Class: |
62/259.3 |
Current CPC
Class: |
A41D 13/0053 20130101;
F25B 21/02 20130101; F25D 2400/26 20130101 |
Class at
Publication: |
62/259.3 |
International
Class: |
F25D 31/00 20060101
F25D031/00 |
Claims
1-30. (canceled)
31. A system, comprising: A cooling device including a heat
exchange chamber, a fluid reservoir and an equipment chamber,
Wherein the heat exchange chamber includes a heat exchanger in
fluid communication with the equipment chamber, Wherein the fluid
reservoir is further in fluid communication with the equipment
chamber, Wherein the equipment chamber includes a pump in fluid
communication with the heat exchange chamber and the fluid
reservoir, Wherein the pump is further in fluid communication with
an inlet port and an outlet port of the cooling device; And A
personal fabric component, the personal fabric component including
fluid passages, the fluid passages in fluid communication with the
inlet port and the outlet port of the cooling device.
32. The system of claim 31, further comprising: A controller
coupled to the pump.
33. The system of claim 32, wherein: the personal fabric component
is a personal garment, including: An inner layer formed from a
wicking material, An internal bladder having a first outer layer
and a second outer layer sealed along a perimeter of the internal
bladder, the internal bladder further having a middle layer
interposed between the outer layer and the inner layer and having
voids therein defining a space in which fluid can circulate within
the internal bladder, the internal bladder further having an inflow
and an outflow tube interposed between the first outer layer and
the second outer layer at the perimeter of the internal bladder,
and An outer layer formed from a wicking material, the outer layer
connected to the internal layer, the outer layer and the inner
layer defining a pocket in which the internal bladder is enclosed,
the pocket having an external opening aligned with the inflow tube
and the outflow tube of the bladder.
34. The system of claim 33, wherein: The heat exchange chamber is
filled with ice.
35. The system of claim 34, wherein: The fluid reservoir is filled
with water.
36. A system, comprising: A cooling device including a heat
exchange chamber, an inlet and an outlet, Wherein the heat exchange
chamber includes a heat exchanger in fluid communication with the
inlet and the outlet, Wherein the heat exchanger is a bundle of
metal tubes, Wherein the metal tubes of the heat exchanger are
mounted to a metal plate of the inlet in an airtight manner,
Wherein the metal tubes of the heat exchanger are mounted to a
metal plate of the outlet in an airtight manner; A blower in fluid
communication with the outlet of the cooling device and in fluid
communication with a helmet; And An air intake port in fluid
communication with the inlet of the cooling device.
37. The system of claim 36, wherein: The blower further includes a
filter interposed between the outlet of the cooling device and the
helmet.
38-45. (canceled)
46. A system, comprising: a cooling device for mounting in an
automobile including a heat exchange chamber, a fluid reservoir and
an equipment chamber, Wherein the heat exchange chamber includes a
heat exchanger in fluid communication with the equipment chamber,
wherein the fluid reservoir is further in fluid communication with
the equipment chamber, wherein the equipment chamber includes a
pump in fluid communication with the heat exchange chamber and the
fluid reservoir, wherein the pump is further in fluid communication
with an inlet port and an outlet port of the cooling device; a
personal garment, the personal garment including fluid passages,
the fluid passages in fluid communication with the inlet port and
the outlet port of the cooling device, the personal garment
including an inner layer formed from a wicking material, a first
internal bladder having a first outer layer and a second outer
layer sealed along a perimeter of the first internal bladder, the
first internal bladder further having a middle layer interposed
between the outer layer and the inner layer and having voids
therein defining a space in which fluid can circulate within the
first internal bladder, the first internal bladder further having
an inflow and an outflow tube interposed between the first outer
layer and the second outer layer at the perimeter of the first
internal bladder, a second internal bladder having a first outer
layer and a second outer layer sealed along a perimeter of the
second internal bladder, the second internal bladder further having
a middle layer interposed between the outer layer and the inner
layer and having voids therein defining a space in which fluid can
circulate within the second internal bladder, the second internal
bladder further having an inflow and an outflow tube interposed
between the first outer layer and the second outer layer at the
perimeter of the second internal bladder, and an outer layer formed
from a wicking material, the outer layer connected to the internal
layer, the outer layer and the inner layer defining a first pocket
in which the first internal bladder is enclosed, the first pocket
having an external opening aligned with the inflow tube and the
outflow tube of the first internal bladder, the outer layer and the
inner layer defining a second pocket in which the second internal
bladder is enclosed, the second pocket having an external opening
aligned with the inflow tube and the outflow tube of the second
internal bladder; and a controller coupled to the pump.
47. The system of claim 33, wherein: the heat exchange chamber is
filled with ice.
48. The system of claim 33, wherein: the personal garment is a
shirt.
49. The system of claim 33, wherein: the personal garment is a
suit.
Description
CLAIM OF PRIORITY
[0001] This application claims priority to U.S. Provisional
Application No. 60/178,066, filed May 14, 2009, which is hereby
incorporated herein by reference. This application claims priority
to U.S. Provisional Application No. 60/285,198, filed Dec. 10,
2009, which is hereby incorporated herein by reference.
BACKGROUND
[0002] Temperature control for human beings can be a very valuable
benefit. While the human body self-regulates body temperature as
much as possible, we tend to expose our bodies to situations where
self-regulation becomes difficult or impossible. In such
situations, performance of tasks becomes less efficient, judgment
can be impaired, and other adverse effects manifest. Thus, it may
be valuable to devise a system which can allow a person to avoid
the worst effects of extreme temperatures by assisting in
regulation of body temperature.
[0003] Regulation of temperature in the torso can provide much
benefit to a person experiencing temperature extremes. One example
of a situation that can cause temperature extremes is a race
(automobile race) set in an extreme temperature environment. Past
attempts to provide a system for controlling body temperature have
focused on overheating and attempts to cool a driver. FIG. 1
illustrates such a system, available from F.A.S.T. of Arlington
Heights, Ill.
[0004] In particular, FIG. 1 illustrates a cool shirt system.
System 100 includes a shirt 110, cooling mechanism 120, connecting
hose 130 and shirt tubing 140. Cooling mechanism 120 operates by
using ice (solid water) to cool liquid water. Cooling mechanism 120
is connected to connecting hoses 130, which in turn are connected
to shirt tubing 140. Water is pumped through connecting hoses 130
and shirt tubing 140 from cooling mechanism 120 using a pump in
cooling mechanism 120 (not shown). The ice in cooling mechanism 120
cools the water, which then circulates to the cool shirt 110,
removing heat from a user of the shirt 110. Also shown is a control
145 which allows a user to control how much water flows through the
shirt 110, thus allowing some modulation of the cooling effect.
Other, similar systems are available from Shafer Enterprises of
Stockbridge, Ga., for example.
[0005] This system allows for basic cooling under hot conditions.
However, it suffers from some potential drawbacks. For example, a
supply of ice is required to provide cooling--if no ice is
available the system does not function. Additionally, in situations
where multiple drivers use the system, conservation of ice to allow
for cooling of later racers can frustrate teammates. Moreover, the
system allows relatively minimal temperature control, providing for
cooling which can only be varied somewhat based on flow rates.
Also, the use of ice means that the system is unlikely to be useful
for warming a person in cold situations. Thus, it may be
advantageous to provide a system which can provide more flexible
temperature control.
[0006] Cooling garments in particular tend to rely on one of four
techniques. One example is freezing--frozen substance packets are
placed in pockets on the garment which continue to absorb heat from
the body until the packet has completely thawed. Another example is
wicking--variable-stitch fabric is used to create shirts which wick
warm moisture away from the wearer's body where it can be more
easily evaporated.
[0007] A third example is phase change--specialized materials are
placed in pockets or under head-wear which resolve to a specific
temperature. One such material resolves to 55 degrees. These
materials continue to absorb heat around them at a specific rate to
achieve an expected surface temperature (such as 55 degrees) until
they are saturated and no longer offer a cooling surface to the
wearer. Note that freezing represents a phase change as well,
typically from solid to liquid. The fourth example technique is
fluid based heat exchange. A cooling fluid, typically water, is
passed over the wearer's body via a network of plastic tubes
wherein the fluid absorbs heat from the wearer and transports it to
some form of cooling system. Each of these techniques has
advantages and disadvantages. However, particularly for techniques
using a cooling fluid, providing improved opportunities to transfer
heat from a wearer of a garment to the associated cooling fluid may
be beneficial.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention is illustrated by way of example in
the accompanying drawings. The drawings should be understood as
illustrative rather than limiting.
[0009] FIG. 1 illustrates an embodiment of a cool shirt system.
[0010] FIG. 2 illustrates an embodiment of a body temperature
control system.
[0011] FIG. 3 illustrates an embodiment of a heat exchanger usable
in a body temperature control system.
[0012] FIG. 4 (collectively FIGS. 4A, 4B and 4C) illustrates an
embodiment of a thermal exchange block such as may be used in a
heat exchanger.
[0013] FIG. 5 illustrates installation of an embodiment of a body
temperature control system in a car.
[0014] FIG. 6 illustrates an embodiment of a process of assembly of
a body temperature control system.
[0015] FIG. 7 illustrates an embodiment of a process of
installation of a body temperature control system.
[0016] FIG. 8 illustrates an embodiment of a fluid transport loop
of a body temperature control system.
[0017] FIG. 9 illustrates an embodiment of a process of operation
of a body temperature control system.
[0018] FIG. 10 illustrates an embodiment of a controller which may
be used in an embodiment of a body temperature control system
installed in vehicle.
[0019] FIG. 11 illustrates another embodiment of a controller which
may be used in an embodiment of a body temperature control
system.
[0020] FIG. 12 illustrates another embodiment of a body temperature
control system.
[0021] FIG. 13 illustrates yet another embodiment of a body
temperature control system.
[0022] FIGS. 14 and 15 illustrate an embodiment of a heat
exchanger.
[0023] FIG. 16 illustrates an embodiment of a fan.
[0024] FIG. 17 illustrates another embodiment of a heat exchange
block, in assembled (FIG. 17A), exploded (FIGS. 17B, 17C), and back
views (FIG. 17D).
[0025] FIG. 18 illustrates another embodiment of a heat exchange
block, in an assembled view (FIG. 18A), and with component views
(FIGS. 18B, 18C and 18D).
[0026] FIG. 19A illustrates another embodiment of a body
temperature control system.
[0027] FIG. 19B illustrates yet another embodiment of a body
temperature control system.
[0028] FIG. 19C illustrates an embodiment of a heat exchange block
in block diagram form.
[0029] FIG. 19D illustrates a perspective view of an embodiment of
a body temperature control system as it may be arranged
physically.
[0030] FIG. 19E illustrates another perspective view of the
embodiment of a body temperature control system of FIG. 19D.
[0031] FIG. 20 illustrates an embodiment of a shirt, in front (FIG.
20A) and back views (FIG. 20B).
[0032] FIG. 21 illustrates an embodiment of a bladder of the front
of the shirt of FIG. 20.
[0033] FIG. 22 illustrates an embodiment of a bladder of the back
of the shirt of FIG. 20.
[0034] FIG. 23 illustrates an exploded perspective view of the
bladder of the back of the shirt of FIG. 20.
[0035] FIG. 24 illustrates an exploded perspective view of the
bladder of the front of the shirt of FIG. 20.
[0036] FIG. 25 illustrates an exploded perspective view of a
bladder such as the bladders of FIGS. 23 and 24.
[0037] FIG. 26 illustrates another embodiment of a garment in the
form of a vest.
[0038] FIG. 27 illustrates a top view of the vest of FIG. 26 as
laid flat.
[0039] FIG. 28 illustrates an exploded view of the vest of FIG.
26.
[0040] FIG. 29 illustrates yet another embodiment of a heat
exchanger.
[0041] FIG. 30 illustrates an embodiment of a shirt that may be
used with various system embodiments.
[0042] FIG. 31 illustrates in FIGS. 31A, 31B, 31C, 31D and 31E,
construction of a bladder for use in the shirt of FIG. 30 and other
garments.
[0043] FIG. 32 illustrates in FIGS. 32A, 32B and 32C, a combination
of a shirt with a bladder in an embodiment.
[0044] FIG. 33 illustrates another embodiment of a bladder.
[0045] FIG. 34 illustrates another embodiment of a cooling
system.
[0046] FIG. 35 illustrates another embodiment of a garment that may
be used with a cooling system.
[0047] FIG. 36A illustrates a back view of an embodiment of a
garment that may be used with a cooling system.
[0048] FIG. 36B illustrates a front view of an embodiment of a
garment that may be used with a cooling system.
[0049] FIG. 36C illustrates a cross-sectional view along a line A-A
of an embodiment of a garment that may be used with a cooling
system.
[0050] FIG. 36D illustrates a cross-sectional view along a line B-B
of an embodiment of a garment that may be used with a cooling
system.
[0051] FIG. 37 illustrates in FIGS. 37A, 37B, 37C and 37D, an
embodiment of a cooling block.
[0052] FIG. 38 illustrates in FIGS. 38A, 38B, 38C and 38D, an
embodiment of an internal cooling block of a cooling block.
[0053] FIG. 39 illustrates in FIGS. 39A, 39B, 39C, 39D, 39E and
39F, an embodiment of an external cooling block of a cooling
block.
[0054] FIG. 40 illustrates an embodiment of a body temperature
control system.
[0055] FIG. 41 illustrates an embodiment of a control interface for
a body temperature control system.
[0056] FIG. 42 illustrates another embodiment of a cooling device
in perspective view.
[0057] FIG. 43A illustrates another view of the cooling device of
FIG. 42 in perspective view with visibility of interior
components.
[0058] FIG. 43B illustrates yet another view of the cooling device
of FIG. 42 in perspective view with a top removed.
[0059] FIG. 43C illustrates another view of the cooling device of
FIG. 42 in a top view with visibility of interior components.
[0060] FIG. 43D illustrates another view of the cooling device of
FIG. 42 in a side view with visibility of interior components.
[0061] FIG. 44A illustrates a view of the heat exchanger of the
cooling device of FIG. 42 in perspective view.
[0062] FIG. 44B illustrates a view of the heat exchanger of the
cooling device of FIG. 42 in a top view.
[0063] FIG. 44C illustrates a view of the heat exchanger of the
cooling device of FIG. 42 in a side view.
[0064] FIG. 45A illustrates another embodiment of a cooling system,
using the cooling device of FIG. 42.
[0065] FIG. 45B illustrates the embodiment of a cooling system of
FIG. 45A.
[0066] FIG. 46A illustrates yet another embodiment of a cooling
device in a top view with an open lid.
[0067] FIG. 46B illustrates the cooling device of FIG. 46A in
perspective view with a closed lid.
[0068] FIG. 46C illustrates the cooling device of FIG. 46A in
perspective view with an open lid.
[0069] FIG. 46D illustrates the cooling device of FIG. 46A in a
side view with an open lid.
[0070] FIG. 46E illustrates the cooling device of FIG. 46A in a
perspective view with an open lid.
[0071] FIG. 46F illustrates another embodiment of a cooling device
in a perspective view with a closed lid.
[0072] FIG. 46G illustrates the cooling device of FIG. 46A in a
cutaway perspective view with an open lid.
[0073] FIG. 46H illustrates the cooling device of FIG. 46A in a top
view with an open lid showing some hidden components in a schematic
illustration.
[0074] FIG. 47A illustrates an embodiment of a cooling device such
as the cooling device of FIG. 46A in a side view.
[0075] FIG. 47B illustrates the cooling device of FIG. 47A in a
side view with flow illustrated.
[0076] FIG. 47C illustrates the cooling device of FIG. 47A in a
cutaway perspective view.
[0077] FIG. 47D illustrates the cooling device of FIG. 47A in a
perspective view.
[0078] FIG. 47E illustrates an embodiment of a cooling device such
as the cooling device of FIG. 47A in a perspective view.
[0079] FIG. 47F illustrates the cooling device of FIG. 47E in a
perspective view with hose connections illustrated.
[0080] FIG. 48 illustrates another embodiment of a cooling device
such as the cooling devices of FIG. 46A or FIG. 46F.
[0081] FIG. 49 illustrates yet another embodiment of a cooling
device such as the cooling devices of FIG. 46A or FIG. 46F.
[0082] The drawings should be understood as illustrative rather
than limiting.
DETAILED DESCRIPTION
[0083] A system, method and apparatus is provided for a body
temperature control system. In one embodiment, the body temperature
control system uses a pump to move a fluid through two heat
exchangers which either a) move heat from a user's body to the heat
exchanger, thereby causing the user to feel cooler or b) move heat
from the heat exchanger to the user's body, thereby causing the
user to feel warmer. The specific embodiments described in this
document represent example embodiments of the present invention,
and are illustrative in nature rather than restrictive.
[0084] In an embodiment, a personal garment is provided. The
personal garment includes an inner layer formed from a wicking
material. The personal garment also includes an internal bladder
having a first outer layer and a second outer layer sealed along a
perimeter of the internal bladder. The internal bladder further has
a middle layer interposed between the outer layer and the inner
layer. The middle layer has voids therein defining a space in which
fluid can circulate within the internal bladder. The internal
bladder further has an inflow and an outflow tube interposed
between the first outer layer and the second outer layer at the
perimeter of the internal bladder. The personal garment also
includes an outer layer formed from a wicking material. The outer
layer is connected to the internal bladder. The outer layer and the
inner layer seal the internal bladder away from surface contact
with ambient atmosphere.
[0085] In another embodiment, a personal garment is provided. The
personal garment includes an inner layer formed from a wicking
material. The personal garment also includes an internal bladder
having a first outer layer and a second outer layer sealed along a
perimeter of the internal bladder. The internal bladder has a
middle layer interposed between the outer layer and the inner
layer. The middle layer has voids therein defining a space in which
fluid can circulate within the internal bladder. The internal
bladder further has an inflow and an outflow tube interposed
between the first outer layer and the second outer layer at the
perimeter of the internal bladder. The personal garment further
includes an outer layer formed from a wicking material. The outer
layer of the personal garment is connected to the inner layer of
the inner layer. The outer layer and the inner layer define a
pocket in which the internal bladder is enclosed, with the pocket
having an external opening aligned with the inflow tube and the
outflow tube of the bladder. Note that while a wicking material has
been described herein, other materials may be used for the
garment.
[0086] In an embodiment, a system is provided. The system includes
a heat exchanger including a thermoelectric cooler. The system also
includes a pump coupled to the heat exchanger. The system further
includes a personal garment. The personal garment includes fluid
tubing. The fluid tubing is coupled to the heat exchanger.
[0087] The system may further include a reservoir coupled to the
heat exchanger. The system may also include a controller coupled to
the heat exchanger. The system may further include a power supply
coupled to the controller. The controller may further be coupled to
the pump.
[0088] In an embodiment, the heat exchanger includes a thermal
exchange block having a top surface and a first thermoelectric
cooler abutting the top surface of the thermal exchanger block. The
heat exchanger further includes a first heat sink thermally coupled
to the first thermoelectric cooler. The system may further include
a first fan thermally coupled to the first heat sink. In another
embodiment, the heat exchanger may be further characterized by the
thermal exchange block further including a bottom surface and the
heat exchanger further including a second thermoelectric cooler
abutting the bottom surface of the thermal exchange block and a
second heat sink thermally coupled to the second thermoelectric
cooler. Likewise, the embodiment may further include a second fan
thermally coupled to the second heat sink.
[0089] In some embodiments, the thermal exchange block includes an
internal fluid channel having an inlet and an outlet. The thermal
fluid channel is disposed adjacent to the first thermoelectric
cooler. The inlet and the outlet are coupled to the pump and the
fluid tubing of the personal garment.
[0090] In some embodiments, the system further includes a user
interface coupled to the controller. In some embodiments, the
controller alters operation of the heat exchanger responsive to
signals from the user interface. In some embodiments, the system is
mounted in an automobile and the power supply is a power supply of
the automobile. In some embodiments, the system is portable.
Moreover, in some embodiments, the power supply is a rechargeable
power supply. Alternatively, in some embodiments, the power supply
receives power from a utility power grid. Additionally, in some
embodiments, the personal garment is a shirt, whereas in other
embodiments the personal garment is a body suit.
[0091] In another embodiment, a system is provided. The system
includes a heat exchanger including a thermal exchange block having
a top surface and a bottom surface. The system further includes a
first thermoelectric cooler abutting the top surface of the thermal
exchanger block and a first heat sink thermally coupled to the
first thermoelectric cooler. The system also includes a second
thermoelectric cooler abutting the bottom surface of the thermal
exchanger block and a second heat sink thermally coupled to the
second thermoelectric cooler.
[0092] The system also includes a pump coupled to the heat
exchanger in fluid communication therewith. The system further
includes a controller coupled to the heat exchanger and the pump.
The system also includes a personal fabric component including
fluid tubing. The fluid tubing of the personal fabric component is
coupled to the heat exchanger in fluid communication therewith.
[0093] In yet another embodiment, a system is provided. The system
includes a heat exchanger including a thermal exchange block having
a top surface. The heat exchanger further includes a first
thermoelectric cooler abutting the top surface of the thermal
exchanger block and a first heat sink thermally coupled to the
first thermoelectric cooler. The system further includes a pump
coupled to the heat exchanger. The system also includes a
controller coupled to the heat exchanger. The system further
includes a personal fabric component. The personal fabric component
includes fluid tubing and the fluid tubing is coupled to the heat
exchanger. In some embodiments, the personal fabric component is a
shirt. In other embodiments, the personal fabric component is a
blanket.
[0094] In still another embodiment, a method is provided. The
method includes installing a gasket on a thermal exchange block.
The thermal exchange block includes an internal fluid transport
channel having an inlet and an outlet. The method further includes
securely connecting a thermoelectric cooler to the thermal exchange
block in contact with the gasket. The method also includes
fastening a heat sink to the thermoelectric cooler in a position
opposite the thermal exchange block. The method further includes
connecting a first tube to the inlet of the fluid transport channel
and connecting the first tube to a fluid tube of a personal
garment. The method also includes connecting a second tube to the
fluid tube of the personal garment and connecting the second tube
to a pump. The method further includes connecting a third tube to
the pump and connecting the third tube to the outlet of the fluid
transport channel.
[0095] In another embodiment, a method is presented. The method
includes flowing fluid through a fluid loop including a heat
exchanger, a personal garment and a pump. The method also includes
adjusting a temperature of the fluid at the heat exchanger through
use of a thermoelectric cooler. The method further includes
receiving control signals from a user interface at a controller.
The method also includes controlling the heat exchanger through
signals from the controller responsive to the signals from the user
interface.
[0096] In another embodiment, a system is provided. The system
includes a heat exchanger. The heat exchanger includes an internal
thermal exchange block having a top surface and a bottom surface. A
first thermoelectric cooler abuts the top surface of the internal
thermal exchanger block. A second thermoelectric cooler abuts the
bottom surface of the internal thermal exchanger block. The heat
exchanger further includes a first external thermal exchange block
having a top surface and a bottom surface. A third thermoelectric
cooler and a fourth thermoelectric cooler abut the bottom surface
of the first external thermal exchange block. A first heat spreader
abuts the third thermoelectric cooler and the fourth thermoelectric
cooler. The heat spreader also abuts the first thermoelectric
cooler. The heat exchanger also includes a second external thermal
exchange block having a top surface and a bottom surface. A fifth
thermoelectric cooler and a sixth thermoelectric cooler abut the
top surface of the second external thermal exchange block. A second
heat spreader abuts the fifth thermoelectric cooler and the sixth
thermoelectric cooler. The heat spreader also abuts the second
thermoelectric cooler.
[0097] The system further includes a first pump coupled to the
internal thermal exchange block in fluid communication. The system
further includes a second pump coupled to the first and second
external thermal exchange blocks in fluid communication. The system
also includes a controller coupled to the heat exchanger and the
first pump and the second pump. The system further includes a
personal fabric component. The personal fabric component includes
fluid passages. The fluid passages are coupled to the internal
thermal exchange block in fluid communication. The system may
further include a radiator coupled in fluid communication with the
second pump and the first and second external thermal exchange
blocks.
[0098] In some embodiments, the first thermoelectric cooler abuts
an internal top surface of the internal thermal exchange block and
the second thermoelectric cooler abuts an internal bottom surface
of the internal thermal exchange block. The third thermoelectric
cooler and the fourth thermoelectric cooler abut an internal bottom
surface of the first external thermal exchange block. The fifth
thermoelectric cooler and the sixth thermoelectric cooler abut an
internal top surface of the second external thermal exchange block.
The first external thermoelectric exchange block abuts the internal
thermoelectric exchange block and the second external
thermoelectric exchange block abuts the internal thermoelectric
exchange block. In some embodiments, the first heat spreader abuts
an internal surface of the first external thermal exchange block
and the second heat spreader abuts an internal surface of the
second external thermal exchange block.
[0099] In some embodiments, the internal thermal exchange block
includes an internal passage in fluid communication with the first
pump. The internal fluid passage is bounded on one side by the
first thermoelectric cooler and on the other side by the second
thermoelectric cooler. The first external thermal exchange block
includes an internal passage in fluid communication with the second
pump. The internal fluid passage of the first external thermal
exchange block is bounded on one side by the third thermoelectric
cooler and the fourth thermoelectric cooler and on the other side
by an internal surface of the first external thermal exchange
block. The second external thermal exchange block includes an
internal passage in fluid communication with the second pump. The
internal fluid passage of the second external thermal exchange
block is bounded on one side by the fifth thermoelectric cooler and
the sixth thermoelectric cooler and on the other side by an
internal surface of the second external thermal exchange block.
[0100] In some embodiments, the personal garment includes an inner
layer formed from a wicking material. The personal garment further
includes an internal bladder having a first outer layer and a
second outer layer sealed along a perimeter of the internal
bladder. The internal bladder further has a middle layer interposed
between the outer layer and the inner layer and having voids
therein defining a space in which fluid can circulate within the
internal bladder. The internal bladder further has an inflow and an
outflow tube interposed between the first outer layer and the
second outer layer at the perimeter of the internal bladder. The
personal garment further has an outer layer formed from a wicking
material. The outer layer is connected to the internal layer. The
outer layer and the inner layer define a pocket in which the
internal bladder is enclosed. The pocket has an external opening
aligned with the inflow tube and the outflow tube of the
bladder.
[0101] In the following description, for purposes of explanation,
numerous specific details are set forth in order to provide a
thorough understanding of the invention. It will be apparent,
however, to one skilled in the art that the invention can be
practiced without these specific details. In other instances,
structures and devices are shown in block diagram form in order to
avoid obscuring the invention.
[0102] Reference in the specification to "one embodiment" or "an
embodiment" means that a particular feature, structure, or
characteristic described in connection with the embodiment is
included in at least one embodiment of the invention. The
appearances of the phrase "in one embodiment" in various places in
the specification are not necessarily all referring to the same
embodiment, nor are separate or alternative embodiments mutually
exclusive of other embodiments. Features and aspects of various
embodiments may be integrated into other embodiments, and
embodiments illustrated in this document may be implemented without
all of the features or aspects illustrated or described.
[0103] Embodiments may solve many of the problems identified above
and provide a system and components that meet many, if not all, of
the identified needs. Further, the system may present all of these
components in a single unified platform, or as a set of separate
components. In an embodiment, five major components are used. These
components include a heat exchange garment, a heat exchanger, a
pump, a reservoir, and a controller. In one embodiment, the system
components are described as follows:
[0104] The heat exchange garment is an item to be worn by, or
placed very near the user which allows the system fluid to pass
near the user's skin. The heat exchange garment allows for thermal
transference between the user and the system. It can be used in
either heating or cooling modes and provides a sealed (non-vented)
portion of the fluid transportation path.
[0105] The heat exchanger warms or cools the system fluid depending
on the user's preference. The warming and cooling is done via
Peltier (thermoelectric) technology. Excess heat is dissipated to
the atmosphere through an outside face of a Peltier device and may
involve an additional heat sink. The heat sink may see increased
efficiency resulting from the use of exhaust fans drawing
atmospheric air over the heat sink. The heat exchanger is a sealed
(non-vented) portion of the fluid transport path as well. The
operation of the heat exchanger (heating or cooling of the system
fluid) is determined by the flow of current through the Peltier
device(s) attached to a thermal exchange block. By reversing the
current polarity, the Peltier device(s) switch thermal flow
direction allowing for heating or cooling.
[0106] One of the following two conditions obtains in such a
situation. Cooling mode--heat is pumped from the fluid as it passes
through the thermal exchange block, thereby cooling the system
fluid and heating the `outside` of the Peltier device(s). The
Peltier device(s) dissipate heat to the atmosphere via the
heat-sink and fan arrangement. Heating mode--heat is pumped into
the fluid as it passes through the thermal exchange block, thereby
warming the system fluid. This cools the `outside` of the Peltier
device(s) which are warmed by the atmosphere via the heat-sink and
fan arrangement, or can be warmed by an optional heater in some
embodiments.
[0107] The pump moves the system fluid through the heat exchanger,
heat exchange garment and the reservoir. The reservoir potentially
serves three functions in the system, though its use is not
necessarily required for the system to operate properly. First, the
reservoir can be used to fill or empty the system of fluid. For
example, in the case of connecting an un-filled heat exchange
garment to the system, the reservoir may provide fluid to fill the
garment. Second, the reservoir allows the venting of gas bubbles in
the system fluid to the atmosphere. Third, the reservoir is a
stabilizing element preventing immediate and drastic changes in
system fluid temperatures.
[0108] The Controller is an electrical (or electromechanical)
device which allows the user to set the desired level of relative
heating or cooling, and adjusts the various electrical outputs to
drive the other components (e.g. appropriate voltage delivery to
the pump and heat exchange block). The controller is operated via
controls located on the controller device or via a user control
panel which is mounted in any desirable position (e.g. a vehicle
dash board, user wrist, hospital bed control panel, tank turret
control panel, or other application-dependent position). The
controller receives power input from a power source (e.g. a vehicle
alternator, battery, fuel cell, solar cell, generator or other AC
or DC voltage source).
[0109] Reference to the embodiment of FIG. 2, which provides an
embodiment of a body temperature control system, may further
illustrate the system. As illustrated, system 200 of FIG. 2
includes a reservoir 220, pump 225, heat exchanger 230, and heat
exchange garment 250 arranged in a fluid loop 210. Thermometers 235
and 245 are provided to monitor temperature of the fluid at entry
and exit points of the heat exchanger 230. Each component of the
loop 210 is coupled to the next component of the loop 210 using
sealed tubing or other fluid carrying components. As illustrated,
the reservoir 220 is vented, allowing for release of gas bubbles
and similar pressure release.
[0110] Controller 260 is illustrated coupled to heat exchanger 230,
providing control signals to heat exchanger 230. Controller 260 is
also coupled to power source 270, and provides power to heat
exchanger 230, user controls 280, and potentially to pump 225
(connection not shown). Alternately, pump 225 may be coupled
directly to power source 270. User controls 280 provide a user
interface for system 200, allowing user adjustment of the
temperature effect delivered by the garment 250. Also, thermometers
235 and 245 may be coupled to controller 260 to provide data to
controller 260 and allow for feedback control of heat exchanger 230
and/or pump 225, for example. Note that the fluid used may be water
or may be a different fluid useful for transport of heat. If water
is used, saline or a disinfectant of some form may be added to
avoid organic contamination in the system.
[0111] Further reference to FIG. 3 and the illustrated embodiment
of a heat exchanger may provide additional insight into the system.
Heat exchanger 300 is shown as a symmetrical design in block
diagram form. Thermal exchange block 340 is provided as a fluid
transport block which may be heated or cooled to heat or cool the
transported fluid. Peltier thermal transducer(s) 330 (a and b) are
provided in contact with thermal exchange block 340 to either
transfer heat into or out of the thermal exchange block 340,
depending on the bias voltage of the transducer 330. Heat sink(s)
320 (a and b) are described as finned, but can take various forms,
and provide a radiating or absorbing surface attached to the
Peltier transducer(s) 330. Fan(s) 310 (a and b) are provided to
increase air flow over heat sink(s) 320, potentially increasing
heat exchange efficiency, and are coupled to or in communication
with heat sink(s) 320.
[0112] Heat exchanger 300 may be built as a single-ended system or
a double-ended system (as shown). The single-ended system may
potentially be more compact, whereas the double-ended system shown
may potentially be more efficient. The various components of heat
exchanger 300 may be controlled separately, such as controlling
electrical bias of the Peltier thermal transducers 330 with a first
signal (or set of signals) and controlling operations of fans 310
with a second signal (or set of signals).
[0113] The heat exchanger 300 may be further understood with
reference to an embodiment of a thermal exchange block as
illustrated in FIG. 4. Note that FIG. 4A illustrates a top view,
FIG. 4B illustrates a front view, and FIG. 4C illustrates a side
view. The back view (not illustrated) is a solid block much like
the side view. The bottom view (and bottom side or surface) may be
implemented as an essentially identical form to that of the top
side (with an open channel) for use in double-ended assemblies, or
in the form of a solid surface without access to the channel for
use in single-ended assemblies.
[0114] Thermal exchange block 400 includes the block 410, fluid
transport channel 440, barbs 430, recess 420, and gaskets (not
shown). Block 410 has embodied therein fluid channel 440, which
allows for transport of fluid through block 410 along a surface or
surfaces (e.g. a top surface and a bottom surface) which may be in
contact with Peltier thermal transducers, for example.
Alternatively, the fluid channel 440 may be open on one or both
surfaces, allowing direct contact between the fluid of the fluid
channel 440 and an associated Peltier device. Recesses 420 are
provided on the surfaces where contact with the transducers is
desired to allow for insertion of gaskets or O-rings, for example,
to facilitate such contact. Barbs 430 are provided at an inlet and
outlet of fluid channel 440, to allow for interface with the rest
of a fluid transport system, such as through connection to a set of
hoses, for example. Note that in some embodiments, the system may
also be fabricated with a barrier between the channel 440 and
components exterior to the block 410, either as a result of not
opening the top and/or bottom surfaces, or as a result of attaching
plates to cover the top and/or bottom surfaces.
[0115] The overall system (body temperature control system) may be
installed in a car for racing purposes, for example. Such an
installation is illustrated in FIG. 5. System 500 represents a
system including a body temperature control system and a car frame.
Other installations may also be useful, and various different
configurations may be used.
[0116] As illustrated, frame 540 may be a cage installed in a race
car, or may represent the available mounting surfaces in a car.
Shirt 510 is provided and may be worn by a driver. It is coupled to
the heat exchange module 520, which is mounted on frame 540, along
with reservoir 530. Reservoir 530 is an optional part of the
system, which is coupled in the illustration to heat exchange
module 520. Not shown is a pump, which may be integrated with heat
exchange module 520. Also shown is a controller 550. Controller 550
is mounted to frame 540. In the illustrated embodiment, controller
550 is mounted in a location convenient for a driver, and includes
a user interface integrated therein. In other embodiments, the
controller may be mounted elsewhere and coupled to a user interface
mounted conveniently for a driver. Controller 550 is coupled to
heat exchange module 520 and controls heat exchange module 520 at
least partially responsive to commands from a driver. Controller
550 may also regulate operation of heat exchange module 520 to
maintain safe operation (e.g. within preset temperature
limits).
[0117] Assembly of the body temperature control system, in one
embodiment, includes building the heat exchanger block, building
the controller (and its sub-system control panel), completing the
fluid transport path between the components and connecting the
electrical wiring for the system. In other embodiments, components
such as the heat exchanger block and controller can be provided in
prepared form.
[0118] Building the heat exchanger may be accomplished by following
the following process, for each side of the heat exchanger.
Reference to FIG. 6 may further illustrate this process. Process
600 begins with milling, cutting, drilling, and tapping a metal
block to form the fluid transport channels and inlet/outlet to form
the thermal exchange block at module 610. In some embodiments, this
block may be pre-made. Next, at module 620, install O-Rings to seal
the thermal exchange block to a Peltier device. Following that, at
module 630, install the Peltier device. Next, install Peltier
device clamping plate(s) with a heat transference compound, or
otherwise affix the Peltier device to the thermal exchange block at
module 640. Note that this assumes contact between the Peltier
devices and the fluid of the thermal exchange block. With no
contact with the fluid, gaskets and the like may not be necessary.
Thereafter, at module 650, install a heat sink and at module 660,
install a cooling fan. The process has been described with respect
to assembly of a single-ended heat exchanger, or a single side of a
double-ended heat exchanger. One may also assemble both sides of a
double-ended heat exchanger as illustrated in FIG. 6.
[0119] The controller can also be assembled from typical
components. The controller may include a processor, for example, or
may be made using analog electrical components or mechanical
components, for example. To create an appropriate controller, one
establishes input voltage based on a source voltage for the
application (e.g. a 12V car battery). One then creates or
integrates a voltage regulation circuit for the heat exchanger
block output(s) including control signals for Peltier device(s) and
exhaust fan(s). One also includes or creates a comparator circuit.
The comparator circuit may accept user input via a control panel
and compare to Peltier device(s) output (e.g. warmer or cooler and
OFF setting). This may include feedback indication (LED's) for the
user. Moreover, the output signals may also come from thermometers
provided in the device, for example. One also installs connectors
for the various device and control panel leads, thereby connecting
or coupling to a user interface and to the heat exchanger (and pump
if separate).
[0120] The fluid reservoir includes a vented vessel containing
sufficient capacity of fluid to replenish the fluid transport
system in the event that an `empty` heat exchange garment is
connected and used in one embodiment. The fluid reservoir is
installed through use of input and output connections leading to
the heat exchange garment and fluid transport pump in one
embodiment. Similarly, the heat exchange garment is assembled using
a suitable article of clothing or surface which will place the
system fluid within proximity of the user's body or specific body
part to be warmed or cooled. The fluid transport system is then
connected, by connecting the various components of the fluid
transport system in a loop. One order may be:
Reservoir->Pump->Heat Exchanger->Heat Exchange
Garment->Reservoir. Assembly of the system also includes
connecting the control system. This includes using suitable wiring
and connectors to make the following connections in one embodiment:
1) Power Source->Controller, 2) Controller->Control Panel(s),
3) Controller->Exhaust Fan(s), 4) Controller->Peltier
Device(s) and 5) Controller->Pump(s). One may further understand
such a process by reference to FIG. 7.
[0121] FIG. 7 illustrates an embodiment of a process for assembling
a system such as the body temperature control systems of various
embodiments. Process 700 initiates with provision of a heat
exchange component such as a heat exchange or thermal exchange
block and associated components at module 710. At module 720, the
heat exchange component is mounted or installed in the area where
it is to operate. At module 730, a controller is connected or
coupled to the heat exchange component, such as through electrical
wiring. At module 740, a fluid transport system is coupled to the
heat exchange component. This may involve connecting tubing for
such a system to the heat exchange component and to other fluid
transport components such as a personal garment with fluid tubing
and a reservoir, for example. At module 750, a user control
interface is connected or coupled to the controller, such as
through electrical wiring or radio coupling. At module 760, a power
source is coupled to the controller, such as through wiring to a
battery or alternator of a vehicle or plugging into an electrical
outlet, for example.
[0122] FIG. 8 illustrates a completed fluid transport loop in such
embodiments. Loop 800 provides for transport of fluid between a
heat exchanger 820 and a heat exchange garment 830. Pump 810
assists transfer of the fluid. In some embodiments, the loop is
completed with pump 810, exchanger 820 and garment 830. Other
embodiments also include reservoir 840 in the loop 800.
[0123] Using the system may be understood with reference to FIG. 9.
After the body temperature control system is assembled and
installed, the user can then don the heat exchange garment and use
the control panel to feel warmer or cooler. When the user selects a
control position to make them cooler, the controller sends an
appropriate voltage and polarity to the pump(s), exhaust fan(s),
Peltier device(s), and control indicators(s) which cause the heat
exchanger to make the system fluid cooler. As the fluid passes
through the heat exchange garment(s), the wearer(s) feels cooler.
Alternatively, when the user selects a control position to make
them warmer, the controller sends an appropriate voltage and
polarity to the pump(s), exhaust fan(s), Peltier device(s), and
control indicators(s) which cause the heat exchanger to make the
system fluid warmer. As the fluid passes through the heat exchange
garment(s), the wearer(s) feel warmer.
[0124] Referring more specifically to FIG. 9, process 900 initiates
at module 910 with initiation of fluid flow. At module 920, a user
command is received. At module 930, a determination is made as to
whether to cool or heat. If to cool, cooling settings are set or
adjusted at module 940. If to heat, heating settings are adjusted
at module 950. At module 960, a determination is made as to whether
a shutdown command was received. If so, at module 970 the fluid
flow and power is shut down, and if not, the process returns to
module 920 to await a user command.
[0125] Further reference to embodiments of a controller which may
be used with various embodiments of the systems may illustrate
additional details. FIG. 10 illustrates an embodiment of a
controller which may be used in an embodiment of a body temperature
control system installed in vehicle. System 1000 provides a
controller which may be mounted in a vehicle and deliver power
based on an associated vehicle power source. Terminals 1005 provide
for reception of power from a power supply, such as a car battery
or alternator. As illustrated, a 13.8 V potential difference is
expected for an embodiment. Other embodiments may be used with
different forms of power, such as other DC power sources or AC
power sources, for example.
[0126] Switch 1010 provides a power switch coupled to a power
supply terminal 1005 in the form of a single pole, single throw
switch in one embodiment. Such a switch may simply supply or
cut-off power to the system. Switches 1015 and 1020 are coupled
between a TEC array 1030 and the power terminals 1005. TEC array
1030 represents a set of thermoelectric coolers which are described
above, such as the TEC devices 330 of FIG. 3. Switches 1015 and
1020 operate collectively to supply power to TEC array 1030 and to
bias TEC array 1030 for either cooling or heating. Thus, a user may
have access to controls coupled to switches 1010, 1015 and 1020 to
control the system (or the user may have direct access to switches
1010, 1015 and 1020).
[0127] Power is also supplied to other components. For example,
pump 1040 is coupled through controller 1000 to the power terminals
1005 to receive power. Similarly, fans 1050 are coupled through
controller 1000 to receive power from terminals 1005. Such a design
requires that the pump 1040 and fans 1050 be adapted to receive the
power available at terminals 1005. However, voltage regulators and
other components can be included as needed in some embodiments.
Note that pump 1040 may correspond to pump 225 of FIG. 2, for
example. Similarly, fans 1050 may correspond to fans 310 of FIG. 3,
for example.
[0128] FIG. 11 illustrates another embodiment of a controller which
may be used in an embodiment of a body temperature control system.
Controller 1100 includes a user interface 1110, thermal regulation
module 1120, pump control module 1130, fan or ventilation control
1140 and power interface 1150. User interface 1110 may be coupled
to an external user interface component or may be part of a user
interface presented to a user. Thermal regulation module 1120 may
be a circuit or other module which supplies power to TEC components
and/or regulates the TEC components and is coupled thereto. This
may include receipt of input from thermometers as well as output of
signals to a TEC component or a set or plurality of TEC components,
for example. This may also include regulation of the TEC components
to maintain temperatures within safety guidelines, for example.
[0129] Pump control module 1130 may supply power to and/or regulate
operation of a pump or pumps coupled thereto. Fan control module
1140 may likewise supply power and/or regulate operation of a fan
or fans coupled thereto. Power interface module 1150 may receive
power from a power source such as a battery or alternator of a car,
or other power source such as a DC or AC electrical source. Power
interface 1150 may regulate such power or simply pass it to
components such as thermal regulator 1120, pump controller 1130 and
fan controller 1140, for example.
[0130] Note that the control systems can be enhanced to include
features which may be useful in various environments. For example,
a user interface may be included with varying types of user
controls and signals (e.g. LEDs, LCD screen, etc.) Additionally,
the power interface of a controller may have a low battery
detection circuit or power fault detection circuit. Such a circuit
can be used to switch to a backup power supply or to shutdown the
system. Likewise, the controller can include detection circuitry
which can detect such conditions as low fluid levels, out of bounds
temperatures, faults in the system generally (e.g. a pump failure)
and other conditions. Moreover, temperature regulation and user
interface components can be used to allow sophisticated temperature
settings, such as a set temperature or a gradient to a set point,
for example. Likewise, the system (e.g. the controller) can detect
such conditions as power startup or ignition in a vehicle, and shut
off to allow for cranking of an engine for example.
[0131] Another embodiment of the system may involve a heat
exchanger dedicated to cooling in hot environments. FIG. 12
illustrates another embodiment of a body temperature control
system. System 1200 is designed to cool a driver in hot
environments, and may be adapted to cooling in general in hot
environments.
[0132] System 1200 includes a cooling garment 1210, heat exchange
block 1290, pump 1225 and a reservoir 1230 in a cool loop. Also
included is another pump 1255 and radiator 1270 in a hot loop with
heat exchanger block 1290. The hot loop may also use a reservoir
1230, which is illustrated as a common reservoir 1230 in FIG. 12,
but may be provided as two separate (hot and cold) reservoirs 1230
in some embodiments. Additionally, blower 1280 may be provided to
bring the ambient air supply to radiator 1270. Heat exchange block
1290 includes a cold loop heat exchanger 1220, a TEC array 1240 and
a hot loop heat exchanger 1250. Thus, TEC array 1240 may transfer
heat from the cold loop (through heat exchanger 1220) to the hot
loop (through heat exchanger 1250), cooling fluid supplied to the
garment 1210, and using radiator 1270 to remove heat from the
system. As illustrated, a single-ended system is provided, with
TECs on one side of each heat exchanger. In an ambient environment
of 115 (degrees) F., one may potentially achieve a drop of 60
(degrees) F. within the system. Driver controls 1260 provide an
option for controlling TEC array 1240, decreasing or increasing the
amount of cooling.
[0133] Other implementations may be provided in similar
embodiments. FIG. 13 illustrates yet another embodiment of a body
temperature control system. System 1300 is likewise designed to
cool a driver in hot environments, and may be adapted to cooling in
general in hot environments.
[0134] System 1300 includes a cooling garment 1310, heat exchange
block 1390, pump 1325 and a reservoir 1330 in a cool loop. System
1300 also includes another pump 1335 and radiator 1370 in a hot
loop with heat exchanger block 1390. The hot loop may also use a
reservoir 1330, which is illustrated as a common reservoir 1330 in
FIG. 13, but may be provided as two separate (hot and cold)
reservoirs 1330 in some embodiments. Additionally, blower 1380 may
be provided to bring the ambient air supply to radiator 1370.
[0135] Heat exchange block 1390 includes a cold loop heat exchanger
1320 (cool blocks), a TEC array 1340 arranged on both sides of cool
blocks 1320 and a hot loop heat exchanger 1350 (hot blocks). Thus,
TEC array 1340 may transfer heat from the cold loop (through cool
blocks 1320) to the hot loop (through hot blocks 1350), cooling
fluid supplied to the garment 1310. Moreover, radiator 1370 removes
heat from the system along with blower 1380. As illustrated, a
double-ended system is provided, with TECs on both sides of the
cool loop heat exchanger (cool blocks 1320). In an ambient
environment of 115 (degrees) F., one may expect to achieve a drop
of 60 (degrees) F. within the system. Controller 1345 controls TEC
array 1340, decreasing or increasing the amount of cooling,
responsive to both driver controls 1360 and electrical system 1355
(which supplies power, etc.).
[0136] One such heat exchanger which may be used in a system such
as system 1200 is illustrated in FIGS. 14 and 15. FIGS. 14 and 15
illustrate an embodiment of a heat exchanger. Heat exchanger 1400
includes a cold cover 1410 (providing a space where cold fluid may
be circulated), a cold plate 1420 and a TEC array 1430, providing
an interface between cold fluid and the TEC array 1430. Thus, TEC
array 1430 may cool a fluid and radiate out heat.
[0137] Such a heat exchanger may be integrated with a hot fluid
heat exchanger, arriving at heat exchanger 1500. Cold cover 1510 is
joined to cold plate 1520, providing a channel for cold fluid
entering through inlet 1560 and exiting through outlet 1565. Cold
plate 1520 is also joined to TEC array 1530. TEC array 1530 is also
joined to hot plate 1590 and to hot cover 1550, providing a channel
for circulation of hot fluid which may enter through inlet 1570 and
exit through outlet 1575.
[0138] To aid in cooling, a fan may be used in various embodiments.
FIG. 16 illustrates an embodiment of a fan. Fan 1600 is suitable
for mounting in places where a secure mount is needed. Fan 1600
includes a housing 1610, fan blades 1620, a mounting component 1630
and a motor and electrical interface (not shown). Fan 1600 may thus
be mounted in an environment such as a vehicle, and powered to blow
ambient air across a TEC array, radiator, or other heat exchanging
surface. Fan 1600 is a relatively conventional component.
[0139] FIG. 17 illustrates an embodiment of a heat exchange block,
in assembled (FIG. 17A), exploded (FIGS. 17B, 17C), and back views
(FIG. 17D). Block 1700 includes a hot block 1710, cold block 1720
and hot block 1710, sandwiched around two TECs 1730. Each TEC 1730
includes leads 1737. Hot blocks 1710 include inlet/outlets 1717 and
cool block 1720 likewise includes inlet/outlets 1727. Cool block
1720 includes channel 1725, for a cooling fluid. Hot blocks 1710
include channels 1715 for fluid circulation as well. TECs 1730 cool
cooling fluid of cold block 1720, and exhaust heat into hot blocks
1710, where fluid therein transports the heat away. TECs 1730 may
seal the channels 1715 and 1725, or the channels may be sealed by
interposed components (e.g. metal sheets).
[0140] FIG. 18 illustrates another embodiment of a heat exchange
block, in an assembled view (FIG. 18A), and with component views
(FIGS. 18B, 18C and 18D). Hot blocks 1810 sandwich a pair of TECs
1830 which in turn sandwich a cold block 1820. Hot blocks 1810
include inlet/outlets 1815 and cold blocks include inlet/outlets
1825. Hot blocks 1810 also include an interior channel 1817 for
fluid circulation, as do cold blocks 1820 with channel 1827.
Alternative hot block 1850 is also provided, with inlet/outlets
1815 and interior channel 1817. TECs 1830 may seal the channels
1817 and 1827, or interposed seals may be used.
Example Embodiment
[0141] In one embodiment, the following describes the particular
features of a cooling system using two loops to cool a garment such
as for use in an automobile. The particular embodiment described
may include features of other embodiments described herein, and
features of this embodiment may be used with those of other
embodiments described herein. Limitations of this particular
embodiment may not apply to other embodiments.
[0142] The cooling system includes two closed loop fluid circuits.
The primary cooling element(s) is a Peltier Device or
thermoelectric cooler (hereinafter TEC) which may be used either
individually or in an array to provide sufficient cooling to the
"cold" fluid circuit. A "hot" fluid circuit is also provided to
wick heat from the TEC array sufficient to allow the unit to
deliver cold-circuit temperatures of between 45 and 65 degrees
Fahrenheit.
[0143] The Cold circuit flow sequence is:
Reservoir->Pump->Heat Exchanger Assembly (containing the TEC
array)->External connections->Cooling Garment->Back to
Reservoir. The Hot circuit flow sequence is:
Reservoir->Pump->Heat Exchanger Assembly (backside of TEC
array)->Radiator->Back to Reservoir.
[0144] Supporting Subsystems include: a blower, controller,
controls, and an enclosure. The blower brings in fresh `ambient`
air to cool the fluid passing through the radiator and force
stagnant hot air out of the enclosure. The controller is an
electronics module (for example) controlling the pump(s),
blower(s), thermocouples, and TEC array. The controls are driver
controls and indicators allowing the (gloved) driver or passenger
to operate the system. The enclosure contains the system components
and may be designed for rapid installation and removal.
[0145] In one embodiment, the TEC array is a collection of Thermo
Electric Coupling devices using the Peltier effect. These devices
may be wired in series or parallel in order to obtain the desired
current draw for the application. An array of multiple devices is
used to increase the surface area through which heat may be
extracted from the cold fluid circuit. When activated, the array
pulls heat from the cold fluid circuit and pushes heat into the hot
fluid circuit. In this way, the TEC array effectively operates as a
large surface area solid state heat pump.
[0146] The heat exchanger assembly, in one embodiment, is a
collection of engineered plates, specific covers, gaskets, and
fittings which allow the TEC array to pump heat from the cold fluid
circuit and move it to the hot fluid circuit. This assembly can be
reconfigured to support a wide variety of TEC arrays. The
components in the heat exchanger assembly include: a cold plate,
cold plate cover, TEC array, hot plate, hot plate cover and
seals.
[0147] The cold plate is an engineered metal plate (typically of
Aluminum or Copper) designed to offer a maximum (essentially)
amount of surface area through which heat is drawn from the cold
fluid circuit. The entire plate is chilled by the TEC array as part
of the assembly. The cold plate cover is an engineered cover for
the cold fluid circuit side of the heat exchanger assembly. This
component may be made of a thermally inert material such as plastic
or lexan. It is configured to accept the cold fluid circuit
fittings. The TEC array is a collection of Peltier devices arranged
for essentially maximum surface area and wired for desired current
draw.
[0148] The hot plate is likewise an engineered metal plate
(typically of Aluminum or Copper) designed to offer a maximum
(approximately) amount of surface area through which heat is drawn
from the TEC array. The plate is warmed by the hot side of the TEC
array and then the heat is drawn into the hot fluid circuit where
it is cooled. This plate may be equipped with the necessary
fittings to integrate into the hot fluid circuit. The hot plate
cover is an engineered cover for the hot fluid circuit side of the
heat exchanger assembly. This component may be made of any material
but will typically be constructed from a thermally inert material
such as plastic or lexan to prevent "heat soaking" the heat
exchanger assembly. The cold and hot fluid circuits are sealed by
way of gaskets or O-rings between the plates and their covers.
[0149] Supporting components include pump(s)--e.g. two pumping
units propel the cold and hot fluid circuits. Flow should be
approximately 2.5 e10-5 M 3/S. Multiple motors or an external
driving source may be used to rotate the pumping assemblies.
Additionally, radiator(s) such as finned fluid channels are used
within the hot fluid circuit to exchange heat to a charge of
ambient air being passed through the enclosure by the blower. The
surface area of the finned surface should be sufficient to keep the
hot fluid circuit within ten degrees (10) F of the ambient
temperature. Moreover, blower(s), such as high-velocity fan
assemblies may be used for moving sufficient volumes of ambient air
through the enclosure so that the radiator achieves its desired
level of heat dissipation and so the enclosure will not rise in
temperature as a result of operating in a hot environment. Typical
inlet/outlet dimensions are between 1.5'' and 4'' diameters with
flow rates between 120 and 240 cubic feet per minute.
[0150] External connectors provide interfaces between the system
and the cooling garment and may be provided using leak resistant
quick disconnects. For additional operator safety, these
connections may become disconnected if a suitable force is applied
to the connection without the need to actively disengage them via a
button or spring release. In one particular embodiment, this force
is approximately fifty pounds (50 lbs) of linear pull on the long
axis of the connector. A sufficient volume of fluid may be
contained within the unit, in a reservoir, to fill depleted cooling
garments, vent gas bubbles from the fluid circuits, and provide a
thermal balance to prevent rapid temperature swings. Also, an
electrical control circuit can be included to receive power from
the primary source and parse it out to the various system
components including the TEC array, pumps, blowers, and controls
and indicators. The unit may be equipped with adequate external
connections to allow for wire and cable replacement without
completely removing the system and/or controller.
[0151] Sufficient switch gear and indicators, either via lights or
displays, allow the operator to activate the system and set a
desired level of cooling. Additional functionality may include
service modes, fluid level indications, and sufficient illumination
to operate the system in low-light environments. The controls may
be a panel or may be individually mounted within reach and view of
the system operator and are connected back to the controller via an
electrical umbilical carrying the control and feedback signals. The
system components are contained within an enclosure (excepting the
controller and controls and potentially the blower(s)) which
provides protection from the environment and accidental damage to
the system. The enclosure is typically thermally inert and offers
thermal, shock, and fluid protection to the system components. The
enclosure may include a method for rapidly installing and removing
it from the operating environment--it may be designed for such
installation and removal.
[0152] Other embodiments of similar systems may also be used. FIG.
19A illustrates another embodiment of a body temperature control
system. System 1900 uses a compressor for heat exchange and
cooling. System 1900 includes a cooling loop coupling a garment
1910, compressor 1920, pump 1930 and reservoir 1940. The compressor
is further coupled to a radiator 1950 to assist in shedding excess
heat. Compressor 1920 may be powered from an electrical system of a
car, for example, or from other conventional power sources.
Additionally, a control component (not shown) may be integrated to
control operation of compressor 1920, and thus to vary the
temperature of a fluid circulated in the cooling loop. The various
components may be coupled through use of tubes or hoses, for
example, and may operate to circulate cooled water to garment 1910,
and then to cool water circulated from garment 1910. Compressor
1920 in conjunction with radiator 1950 provides a heat exchanger
function in this particular embodiment, and may provide advantages
in terms of power draw, for example.
[0153] In another embodiment, cool and hot loops are used. FIG. 19B
illustrates yet another embodiment of a body temperature control
system. System 1990 includes the components of system 1900 as
described with respect to FIG. 19A. However, a hot loop is
provided, with an additional pump 1930 and reservoir 1940 provided
in a loop with compressor 1920 and radiator 1950--all of which are
coupled together through use of hoses or tubes, for example. System
1990 may provide more efficient cooling in systems where the
additional components may be incorporated effectively. System 1990
may also incorporate control and power supply components (not
shown), for example. Compressor 1920 provides a heat exchanger
function in this embodiment in conjunction with the cold and hot
loops.
[0154] One may also implement a heat exchanger through use of a
compressor in conjunction with a TEC or Peltier device. FIG. 19C
illustrates an embodiment of a heat exchange block in block diagram
form. Heat exchanger block 1925 includes compressor 1970, fluid
line 1975 and TEC 1980. Compressor 1970 is coupled to a fluid
transfer line 1975 to cool line 1975. TEC 1980 is also coupled to
line 1975, and may operate to oppose compressor 1970. Thus, TEC
1980 may provide for fine tuning of the temperature imparted to
line 1975 in some embodiments.
[0155] The embodiments of FIGS. 19A, 19B and 19C may have various
physical forms. FIG. 19D illustrates a perspective view of an
embodiment of a body temperature control system as it may be
arranged physically. System 1901 includes a compressor 1920,
controller 1957 (controlling the compressor 1920, e.g.), condenser
1967, heat exchanger 1947, shell 1937, suit connections 1927, air
inlet 1917, and exhaust air slats 1907. Compressor 1920 is mounted
on shell 1937 and is controlled by controller 1957. Compressor
receives air from inlet 1917 via condenser 1967, and provides
cooled refrigerant to heat exchanger 1947. Heat exchanger 1947
receives and sends coolant fluid through suit connections 1927
(e.g. barbs provided in through-holes of shell 1937). Exhaust air
slats 1907 allow for cooling of compressor 1920. Coolant fluid may
be entirely separate from refrigerant, for example, such that a
typical refrigerant may be used with compressor 1920, for
example.
[0156] FIG. 19E illustrates another perspective view of the
embodiment of a body temperature control system of FIG. 19D. Note
that pump 1930 is also illustrated, providing a mechanism to cause
fluid flow between heat exchanger 1947 and a garment (not shown).
Additionally, reservoir 1940 is illustrated, attached to shell
1937--reservoir 1940 may be used with the coolant fluid, for
example. Also, fan 1917 may be provided as part of inlet 1917 (the
fan may be an integral part of the inlet). Moreover, controller
1957 may be an interface between compressor 1920 and such systems
or components as an electrical system of a car and/or a driver
control component, for example.
[0157] Various garments may be used with the systems described.
FIG. 20 illustrates an embodiment of a shirt, in front (FIG. 20A)
and back views (FIG. 20B). Shirt 2000 provides one such example.
Shirt 2000 includes fabric layers 2010 and a bladder 2100. Bladder
2100 includes, in one embodiment, die cut foam 2020 (providing a
relatively incompressible layer with space for fluid flow),
barriers 2030 (which may provide structural stability, isolation,
and/or direction to fluid flow), tube 2040, inlet 2050 (coupled to
tube 2040) and outlet 2060 (provided at the bottom of bladder 2100
in this embodiment). Bladder 2100 allows for fluid flow within a
confined part of shirt 2000, and is either encased in fabric layers
2010 or attached to a fabric layer 2010.
[0158] FIG. 20A illustrates an embodiment with a single inlet 2050
and outlet 2060, with coverage for most of the torso. FIG. 20B
illustrates an embodiment with multiple inlet 2050/outlet 2060
pairs, associated with two regions separated by barriers 2030. In
one embodiment, FIG. 20A illustrates the front of a shirt and FIG.
20B illustrates the back of a shirt.
[0159] FIG. 21 illustrates an embodiment of a bladder of the front
of the shirt of FIG. 20. Likewise, FIG. 22 illustrates an
embodiment of a bladder of the back of the shirt of FIG. 20. FIG.
21 illustrates an embodiment where valves 2050 and 2060 are coupled
to tubes 2040 further away from bladder 2100. Additionally, a tube
2040 for outlet purposes is provided in an outlet portion of die
cut polyurethane 2020. FIG. 22 likewise illustrates an embodiment
in which tubes 2040 lead to inlet and outlet components not shown,
through passages in die cut polyurethane 2020.
[0160] FIG. 23 illustrates an exploded perspective view of the
bladder of the back of the shirt of FIG. 20. FIG. 24 illustrates an
exploded perspective view of the bladder of the front of the shirt
of FIG. 20. FIG. 25 illustrates an exploded perspective view of a
bladder such as the bladders of FIGS. 23 and 24. Reference to FIG.
25 makes it apparent that such a bladder (e.g. bladder 2500) may be
constructed as part of a shirt, with an outer shirt layer 2510
attached to a thermoplastic polyurethane layer 2520. A die cut
polyurethane layer 2530 is then provided, with tubes or hoses 2535
also provided in appropriate locations for fluid distribution. The
die cut polyurethane layer 2530 is sized to be thick enough to
allow for fluid flow within voids in the layer, and is dense enough
to be relatively incompressible, even under pressure such as that
created by a seat harness in a car. Die cut polyurethane layer 2530
is sonic welded to layer 2520 and also to layer 2540, providing a
sandwich that seals any fluid separately from the surrounding shirt
layers. Inner shirt layer 2550 is attached to layer 2540, and is a
wicking layer which takes moisture from a wearer of the garment in
some embodiments.
[0161] FIG. 23 illustrates a similar structure, with thermoplastic
polyurethane layers 2310 and 2320 of bladder 2200 welded on both
sides of die cut polyurethane 2020. Welding occurs along weld area
2025. Tubing 2040 is placed within the voids of polyurethane 2020,
providing for distribution of fluid. FIG. 24 illustrates yet
another similar structure. Layers 2410 and 2420 provide the outer
thermoplastic polyurethane layers for bladder 2100. In FIG. 23, the
bladder 2200 may be useful for a back of a shirt, whereas in FIG.
24, the bladder 2100 may be useful for the front of a shirt in one
embodiment. Other materials may provide a relatively incompressible
space for fluid flow in a bladder of a garment. Moreover, other
assembly methods may be useful, such as simply containing a bladder
within a sewn or otherwise enclosed portion of fabric of a garment,
for example.
[0162] Another option for a garment is a vest or similar garment
with a bladder contained therein. FIG. 26 illustrates another
embodiment of a garment in the form of a vest. Vest 2600 includes
an outer layer 2610 (which may be an insulating layer), and inner
layer 2630 (which may be a wicking layer, for example) and
inlet/outlet ports 2620. Not shown is a bladder which may be
provided using a bladder layer. FIG. 27 illustrates a top view of
the vest of FIG. 26 as laid flat. It is apparent that the
inlet/outlet ports are relatively far from each other on the vest
2600 in this view.
[0163] FIG. 28 illustrates an exploded view of the vest of FIG. 26.
Vest 2800 corresponds to vest 2600, with an inner layer 2830,
bladder layer 2820 and outer layer 2810. Inner layer 2830 is a
wicking layer useful in removing heat and moisture from the skin of
a wearer. Outer layer 2810 is an insulating layer which keeps
excess heat out. Bladder layer 2820 provides a relatively
incompressible bladder which allows for fluid flow even under some
compressing forces or loads (e.g. a harness in a car, or a person
lying on the material). In one embodiment, bladder layer 2820 is
provided using a plastic mesh available from Kuchofuku of Japan.
The plastic mess is relatively incompressible, and can be attached
to wearable outer and inner layers 2810 and 2830. Outer layer 2810
may be made of various materials, such as rip-stop nylon, leather,
vinyl, and potentially a treated cotton product, for example. Inner
layer 2830 may be a wicking material such as Wicker's brand fabric
or a cotton or polyester blend material. It may be preferable to
treat inner layer 2830 with a flame retardant chemical or process,
such as Akwatek.
Example Embodiment
[0164] In one embodiment, the following describes the particular
features of a garment which may be used in a cooling system. The
particular embodiment described may include features of other
embodiments described herein, and features of this embodiment may
be used with those of other embodiments described herein.
Limitations of this particular embodiment may not apply to other
embodiments.
[0165] The human body's natural mechanism for maintaining body
temperature, and particularly, cooling the core temperature is a
two phase process. In part one; warm blood is circulated to the
extremities (hands, ears, and feet) to promote the radiation of
heat into the environment. In part two; sweat is produced to wick
heat away from the body via an evaporative effect. Existing cooling
garments ignore the second component (part) of the body's cooling
process. While they absorb and remove heat from the surface of the
skin, the existing garments do not allow surface moisture to
evaporate. This leaves the wearer uncomfortably moist and
sweaty--and no cooler from their perspiration. Thus, it may be
useful to produce a garment which complements the body's natural
mechanisms by: 1) providing a cooler fluid into which heat may be
radiated as well as 2) providing a mechanism to remove moisture
from and around the body.
[0166] One option is to provide a garment that creates a gap or
airspace around the body through which conditioned air or another
fluid may be circulated and eventually exhausted. This will provide
a cooler (assuming a cooling mode) fluid into which the body may
radiate excess heat and will provide a mechanism for stripping the
wearer's body and undergarments of moisture. The airspace is
created by placing a suitable mesh between two layers of fabric or
material which is: relatively incompressible under the forces of
normal use while simultaneously allowing air or another cooling
fluid to circulate through the mesh, in contact with both the inner
and outer layers of the garment.
[0167] Ambient air is passed through an air cooling device, such as
those described with respect to various embodiments above. This
filtered and chilled air is then passed to the garment via
insulated hoses. The hoses connect to the garment via
positive-locking or magnetic-retention, for example. The chilled
air enters the garment and passes through the middle layer. The
Inner layer wicks heat and moisture from the wearer's body and
passing it to the middle layer. As the chilled air circulated
around the garment, it carries the heat and moisture with it until
it is exhausted. This warm and moist air is now exhausted via
pre-determined exit points in the garment, taking the heat and
moisture into the ambient air outside of the wearer and garment. In
the case of a cooling fluid, moisture can be absorbed in other
ways, such as in a reservoir or ducted out separately.
[0168] The Garment which makes this possible includes an inner
layer, a middle layer and an outer layer. The inner layer (against
the body) includes a wicking fabric which is comfortable, flexible,
has elastic qualities, and which pulls moisture from the wearer's
skin toward the middle layer (the airspace). Potential materials
include: Wicker's brand flame resistant fabric and a number of
cotton and polyester blends which may be treated with Akwatek or a
similar chemical process. This layer may also be flame resistant
and may not emit noxious fumes when charred.
[0169] The middle layer (airspace) Is filled with a `plastic mesh`
which is not crushable and allows for air to flow through the
middle layer even when the garment is compressed, twisted, and
folded as part of normal use. Other materials providing a similar
set of properties may be used. This layer may be made of a light
weight material which does not readily decompose or have its
physical or chemical properties significantly altered in the
presence of sweat and moisture. An example of this layer would be
plastic mesh available from Kuchofuku of Japan.
[0170] The outer layer (furthest from the body) is a non-vapor
permeable and durable exterior shell which protects the interior of
the garment, provides fastening for patches, connections, and is a
surface for branding and design elements. Potential materials for
this layer include: rip-stop nylon, vinyl, leather, and a number of
treated cotton products.
[0171] A further note on the plastic mesh. The product available
from Kuchofuku is a plastic mesh of interlocking open-sided cubes
which are linked via small tabs. The cubes themselves are capable
of supporting the weight of a man when that weight is spread over
sufficient area. The open sides of the cubes allow air to flow
through the fabric in the X and Y planes without the air having to
exit the fabric via the Z plane (air can flow laterally without
penetrating the side walls of the mesh). The mesh is flexible in
twisting and folding making it comfortable to wear as it conforms
to the body's natural curves. However, it is able to withstand
compression as long as the user's weight is distributed across a
sufficient area. Fresh air is motivated through the middle layer,
where it absorbs heat and moisture, and is then exhausted via an
exit point in the product.
[0172] Other embodiments of various components may be used in the
systems described above. FIG. 29 illustrates yet another embodiment
of a heat exchanger. Heat exchanger 2900 may be useful with the
systems of FIGS. 19A-19E, for example. FIG. 29 provides a top view
(FIG. 29A), perspective view (FIG. 29B), side view (FIG. 29C) and
front view (FIG. 29D). Other views are omitted to avoid
unnecessarily obscuring details of the component.
[0173] Exchange block 2900 includes fluid channels 2910, fluid
barbs 2920, a suction line and cap tube 2930, and a copper block
2940. Fluid channels 2910 are formed within copper block 2940. In
one embodiment, fluid channels 2910A is formed in a top portion of
copper block 2940, and is connected to fluid barbs 2920 to provide
for inlet and outlet connections. Fluid channel 2910A is used with
coolant fluid (such as water) which is circulated to and from a
garment. Fluid channel 2910B is formed in a lower portion of copper
block 2940, adjacent to fluid channel 2910A. Fluid channel 2910B is
used with suction and cap lines/tubes 2930 to exchange refrigerant
fluid with a compressor, for example (e.g. as an expansion area for
refrigerant fluid). Refrigerant fluid in channel 2910B cools copper
block 2940, which in turn cools coolant fluid in channel 2910A. A
fluid cap 2950 is placed over fluid channel 2910A (potentially
covering and sealing channel 2910A), and fluid cap 2950 may be
plastic or another inert material, for example. Evaporator cap 2960
is placed beneath fluid channel 2910B (potentially covering and
sealing channel 2910B). Evaporator cap 2960 may be copper, for
example, to support brazing. Note that other materials may be
useful in this heat exchanger, for example.
[0174] Additional embodiments may be used with a different garment
design as shown and described. In one embodiment, a personal
cooling garment is provided. The personal cooling garment is
designed to work with both specific predetermined cooling systems
such as those described in the embodiments above, and with other
cooling systems designed to extract heat from the human body by
passing a cooled fluid near the surface of the skin.
[0175] In one embodiment, a fluid-based heat exchange system which
puts the cooling fluid in much more intimate and broader contact
(or proximity) with a wearer's body than other systems is provided.
In addition, a garment used in the system leverages wicking
techniques to move warm moisture away from the wearer. Moreover,
the construction of the garment potentially lends itself to easier
maintenance, reduced wear and tear on the product, improved comfort
in automobile racing environments and similar compressed or
confined environments, and offers superior thermal exchange when
compared to current liquid based solutions available on the market
today.
[0176] Some of the features of the garment used in the system in
some embodiments include use of a bladder, foam standoffs, high
performance fabric and high efficiency tubing. Each of these
features will be discussed in turn. The bladder system involves
passing cooling fluid across the wearer's body via a bladder
system, as opposed to flowing through plastic tubing. The bladders
can be constructed of multiple layers of TPU (thermoplastic
polyurethane) film, between which the cooling fluid is passed and
routed. Relative to other systems, such a system can provide
greatly increased surface area. When compared to tube options, the
bladder provides as much as 20 times the surface area for thermal
exchange. Moreover, this can provide more intimate contact.
Single-layer TPU film is used to place the cooling fluid as close
to the wearer's skin as possible while providing greater
flexibility to conform to the wearer's body shape.
[0177] Additionally, such a construction can provide for force
distribution. For those who would wear the garment while seated or
in a compressed situation, the broad surface of the bladder more
evenly distributes force loads. This reduces the likelihood of
developing uncomfortable pressure points and increases the overall
comfort for the wearer when exposed to situations such as being
strapped into a racing seat, constantly jostled as in off-road
racing, for prolonged periods of time as a heavy-machine operator,
or when lying for prolonged periods of time on the back or stomach.
Moreover, such force distribution potentially decreases or
eliminates pinch-off effects and similar fluid flow blockages.
[0178] The garment construction can be anti-microbial in nature as
well. As the film used to create the bladder system discourages the
growth of bacteria, the product better copes without being drained,
and is less likely to clog itself or supporting systems after
extended periods of non-use. The garment as illustrated (see, e.g.
FIGS. 20A and 20B, 30, 32, etc.) also provides for a gravity-drain
feature. When hung from a designated draining point on the bladder,
the bladder will tend to drain, with the outlets at the lowest
point(s) of the bladder. This potentially encourages proper
maintenance and simplifies purging the bladder. The bladder has a
multi-channel arrangement. Cooling fluid is allowed to flow
throughout the bladder via a large number of potential paths. This
potentially allows for maximum surface area and promotes optional
routing around any potentially pinched or obstructed paths where
fluid flow may be restricted. Also, the bladder provides breathing
holes. An arrangement of holes through the bladder promote and
allow for the natural escape of heat and offer a chance for the
wicking material of which the garment is constructed, to operate
within the footprint of the bladders. These features potentially
reduce the weight of the bladder system as well.
[0179] In some embodiments, the bladder is removable and placed in
a pocket within a garment (see, e.g. FIGS. 30 and 32). In other
embodiments, the bladder is integrated within the garment. In such
garments, fabric may penetrate the holes of the bladder (e.g.
joining layers from opposite sides of the bladder through the
holes), and thereby further promote wicking and heat transfer, for
example.
[0180] The bladders discussed are supported by foam standoffs--a
network of foam standoffs which provide a number of additional
features. The foam standoffs can be made of a relatively
incompressible celled foam, such as LD45 foam (a low density
polyethylene foam, for example) available from a variety of
manufacturers. The foam standoffs can provide thermal insulation,
further isolating the cooling fluid contained within the bladder
from external heat sources, and rendering the garment and cooling
system more effective. The foam standoffs also provide flow
protection, as arranged in the illustrated embodiments. The
arrangement of the standoffs serves to keep the bladder channels
open and flowing during compression of the garment thereby
preventing or reducing blockage of flow.
[0181] Additionally, the foam standoffs can provide shock
absorption. The foam offers padding and shock relief to loads which
would affect the wearer. This is accomplished via the offset of two
force loads. Loads perpendicular to the surface of the foam
standoffs are partially absorbed and normalized via the
compressible qualities of the foam. Shearing loads parallel to the
surface of the foam standoffs are partially mitigated allowing the
wearer to experience reduced chaffing and rubbing when the outer
surface of the garment may be enduring these loads in a greater
magnitude.
[0182] Some embodiments of the garments also use high-performance
fabric construction. The garments are constructed primarily of
wicking fabric which encourages warm moisture to travel to the
outer surface of the garment where it can be evaporated,
contributing to wearer cooling. One example of such a fabric is
available from Wickers of Commack, N.Y. Additionally, the fabric is
flame retardant and does not easily ignite, melt, or burn
continuously. Rather it chars while releasing a non-toxic smoke.
Moreover, the fabric is particularly elastic, allowing the garment
to accommodate many body types while encouraging the bladder system
to be in intimate contact (proximity) with the wearer's body
profile. In addition, the intimate contact of the material with the
skin further enhances the wicking qualities of the garment. Other
fabric can be used which may include some or all of these features.
In particular, fabric may be used that has wicking properties, but
may not have fire-retardant properties, for example. The garments
may also be made using Aries Micro Plus Polyester available from
Bone (Bushnell of Overland Park, Kans.).
[0183] Some embodiments of the garments and bladders also use high
efficiency tubing. An arrangement of tubing is used to transport
the cooling fluid from the cooling system to the bladder system (as
with the system of FIG. 5, for example. The use of highly insulated
tubing allows for the delivery of appropriately cool fluid to the
bladder system. This promotes efficiency of the system, as the cool
fluid can then absorb heat from the wearer. Multiple routing
options may also be used. The tubes may be routed in one of many
ways to promote cooling to the wearer's preference. Potential
routing options include: front to back, back to front, split
front/back (as illustrated in FIG. 30, for example), front only and
back only.
[0184] Such tubing and associated connectors allow for effective
disconnection. The tubing arrangement may be disconnected allowing
for the removal of the bladders from the garment for replacement,
maintenance, or laundering. These disconnect points may be
user-serviceable, requiring no specialized tools or processes to
disconnect and reconnect the tubing arrangement. Moreover, these
disconnect points, the fluid inlet and outlet interfaces of the
garment, are provided via `quick disconnect` fittings. Such
fittings can be managed with single-handed operation and seal upon
disconnection to avoid or limit leakage and drainage of fluid.
Moreover, such fittings allow for emergency break-away from a
system (such as when a wearer in a racing vehicle needs to make a
quick exit) without requiring a button press, for example.
Additionally, such fittings may smooth the process of attachment to
other cooling systems.
[0185] Reference to specific figures may further illuminate
features of various embodiments. FIG. 30 illustrates an embodiment
of a shirt that may be used with various system embodiments. Shirt
3000 includes an actual garment 3010, having a pocket 3020 with an
overlapping fabric seam through which a bladder 3030 is visible.
Inlet tube 3060 and outlet tube 3065 are connected to and part of
bladder 3030, providing for inflow and outflow of temperature
control liquid (e.g. cooling liquid). Another bladder (not shown)
is provided in the back of shirt 3000, to which inflow tube 3040
and outflow tube 3045 are attached. Inflow connector 3050 provides
a connection from a temperature control system such as that of FIG.
5, for example, to inflow tubes 3040 and 3060. Likewise, outflow
connector 3070 provides a connection to such a system for outflow
tubes 3045 and 3065. Thus, both bladders can be supplied
simultaneously with temperature controlled fluid, allowing for
temperature regulation.
[0186] FIG. 31 illustrates in FIGS. 31A, 31B, 31C, 31D and 31E,
construction of a bladder for use in the shirt of FIG. 30 and other
garments. FIG. 31A illustrates the bladder 3100 starting with
die-cut foam 3110. Foam 3110 may be LD45 foam, for example, which
is relatively incompressible and may be an open-cell polyethylene
foam, for example. FIG. 31B illustrates bladder 3100 with foam 3110
mounted on layer 3120. Layer 3120 may be TPU, for example, which
may be attached to foam 3110 in a variety of ways. FIG. 31C further
illustrates bladder 3100, showing through-holes 3125 aligned
between layer 3120 and foam 3110. Such through-holes 3125 may allow
for communication of heat or fluids through bladder 3100.
[0187] FIG. 31D illustrates bladder 3100 with layer 3130 attached
on top of foam 3110 and sealed along an exterior edge to layer
3120. Through-holes 3125 extend through layer 3130 as well. Also
shown are inflow tube 3140 and outflow tube 3150. FIG. 31E shows
bladder 3100 from the back (showing layer 3120). Also visible is
seam 3160, which seals a portion of the internal channels of
bladder 3100. Seam 3160 has the effect of forcing temperature
regulated liquid from inflow tube 3140 to circulate through at
least part of bladder 3100 before returning to an external system
through outflow tube 3150. Bladder 3200, which may be used for a
different portion of a garment, is also partially visible.
[0188] A bladder such as bladder 3100 of FIG. 31 may be used with a
garment to provide a temperature controlled-portion of such a
garment. FIG. 32 illustrates in FIGS. 32A, 32B and 32C, a
combination of a shirt with a bladder in an embodiment. Illustrated
in FIG. 32A is shirt 3250, including garment 3210 and bladder 3100.
FIG. 32B shows shirt 3250 with the bladder 3100 inserted into
pocket 3230 through opening 3220. Opening 3220 is provided through
two overlapping pieces of fabric. FIG. 32C illustrates a closeup
view of shirt 3250, with a portion of bladder 3100 visible through
an opened opening 3220.
[0189] Other bladder designs may also be used. FIG. 33 illustrates
another embodiment of a bladder. Bladder 3200 may be used in a back
pocket of a shirt, for example. Bladder 3200 is shown with a top
TPU layer 3330, seam 3360, inflow tube 3340 and outflow tube 3360.
Seam 3360 constrains circulation to force some circulation through
bladder of internal fluid. Not shown is a bottom TPU layer attached
to layer 3330, or the internal material, which may be similar LD45
foam. Interstitial spaces 3335 are solid covers of holes in the
internal foam. In this embodiment of a bladder, there are no
through-holes as there are in bladder 3100 of FIG. 31.
[0190] As may be apparent, shirts such as shirt 3250 and bladders
such as bladders 3100 and 3200 may be used with a cooling system.
FIG. 34 illustrates another embodiment of a cooling system. System
3400 includes connective tubing 3410, pump 3425, heat exchanger
3430 and garment 3450 provided in a fluid communication loop.
Reservoir 3420 is also provided, which may allow for expansion of
circulating liquid or replacement of lost fluid. Heat exchanger
3430 may be a heat exchanger such as that illustrated in FIGS. 3
and 4 or one such as that illustrated in FIG. 29, for example.
Controller 3490 controls heat exchanger 3430, and may be coupled to
or include sensors, a power supply, and a user interface (not
shown), for example. Pump 3425 pumps fluid through the fluid
communication loop. Garment 3450 may be a garment such as shirt
3250 or shirt 510, for example. As illustrated, garment 3450 has a
single inlet and a single outlet, but this may involve branches
within garment 3450, or may involve a series connection of multiple
bladders, for example, in garment 3450.
[0191] FIG. 35 illustrates another embodiment of a garment that may
be used with a cooling system. Garment 3500 is a shirt which
includes two bladders (front and back) through which cooling liquid
(or generally temperature-controlled liquid) may be circulated.
Illustrated is bladder pocket 3510 and coolant hoses 3520, which
couple to a bladder (not shown) through a slot in bladder pocket
3510. Not shown is a bladder pocket on the other side of the shirt,
with a corresponding slot in the fabric for coolant hoses 3520.
[0192] Coolant hoses 3520 are shown with quick-release connectors
3530, which are fittings that allow for easy disconnection from a
temperature control system which circulates fluid through coolant
hoses 3520. Such fittings may be fittings available from Colder of
St. Paul, Minn., such as the PLC series of fittings for example.
These fittings may work with tubing such as Norprene or Tygon
tubing available from Saint-Gobain of France to provide a
relatively incompressible fluid pathway. Other tubing and fittings
may also function appropriately. Additionally, the fittings are
generally open (allow fluid flow) when pressed by connected to a
central system (and the appropriate fitting) and generally closed
when only fluid on the inside of bladders of garment 3500 is
present (and the appropriate fitting is not connected), for
example. These fittings and hoses (tubing) may allow for use of the
garment with systems other than those described in this document as
well.
[0193] Bladder pocket 3510 is a pocket in the fabric of shirt 3500
which holds a bladder in place. In one embodiment, bladder pocket
3510 is sewn shut with the bladder contained therein. This may have
the advantage of providing better support for a bladder than other
designs may provide, for example. In other embodiments, the bladder
may be accessed through a zipper or other fastener, for
example.
[0194] A similar embodiment to that of FIG. 35 is illustrated in
FIG. 36 (as FIGS. 36A, 36B, 36C and 36D). FIG. 36A illustrates a
back view of an embodiment of a garment that may be used with a
cooling system. FIG. 36B illustrates a front view of an embodiment
of a garment that may be used with a cooling system. Garment 3600
includes a front bladder pocket 3610 and a back bladder pocket
3620. Contained therein are front bladder 3630 and back bladder
3640, respectively. Coolant hoses 3670 are coupled to bladders 3630
and 3640 through slots in pockets 3610 and 3620. Bladder pocket
3610 is sewn on to shirt front 3660 and bladder pocket 3620 is sewn
on to shirt back 3650 in this embodiment. Other methods of forming
the pocket may also be appropriate, such as through use of a pocket
such as that shown in FIGS. 30 and 32C, for example.
[0195] FIG. 36C illustrates a cross-sectional view along a line A-A
of an embodiment of a garment that may be used with a cooling
system. As is apparent, the two bladders 3630 and 3640 are
contained in the pockets 3610 and 3620, respectively. This
arrangement can be used to effectively support the bladders 3630
and 3640 through use of the fabric of the garment 3600. FIG. 36D
illustrates a cross-sectional view along a line B-B of an
embodiment of a garment that may be used with a cooling system. As
can be seen, coolant hoses 3670 are coupled to the bladders (not
shown) through slots in each of bladder pockets 3610 and 3620,
allowing for coolant to be circulated from a central system through
the garment 3600.
[0196] The bladders and garments described above may be used in
other systems and other applications, and may be used for both
heating and cooling a wearer. Additionally, bladders may be formed
in various different shapes and from various different materials,
depending on the application. Thus, one may create a bladder
suitable for use in a pant leg or for use in blanket, for
example.
[0197] As another example, other materials may be used for a
garment. Garment materials may include fabric with thermally
conductive material weaved in or otherwise incorporated. Use of,
for example, conductive material stitched into fabric may have
beneficial effects. Likewise, natural fibers or synthetic materials
of various sorts may be useful in such a garment in various
applications. Other aspects of the embodiments illustrated and
described may also be varied in keeping with the invention.
[0198] Another embodiment of a cooling block may also be
incorporated in various systems. FIG. 37 illustrates in FIGS. 37A,
37B, 37C and 37D, an embodiment of a cooling block. Cooling block
3700 may be used for both cooling or heating a fluid that may be
circulated through a garment such as a shirt. Block 3700 includes
an internal cooling block 3710, heat spreaders (3740, 3770),
external cooling blocks (3760, 3790), internal TECs (3720, 3730),
and external TECs (3750A, 3750B, 3780A, 3780B). Cooling block 3700
thus provides for an inner and outer fluid loop which may be used
to achieve two-stage fluid-based cooling. FIG. 37A provides an
exploded perspective view of cooling block 3700. FIG. 37B provides
a back view of block 3700. FIG. 37C provides a side view of block
3700 and FIG. 37D provides another exploded perspective view of
block 3700.
[0199] Internal cooling block 3710 is provided as a center portion
of cooling block 3700, and may be implemented as is shown in FIG.
38, for example. Coupled to internal cooling block 3710 are direct
fluid contact TECs 3720 and 3730, with one in a lower position
(below a channel of block 3710) and one in an upper position (above
the channel of block 3710). Upper heat spreader 3740 covers TEC
3730 and the top of block 3710, providing a heat spreader that is
thermally conductive, such as a plate of brazed copper, for
example. Similarly, lower heat spreader 3770 covers the bottom of
both TEC 3720 and the lower surface of block 3710, providing a heat
spreader similar to heat spreader 3740 on the bottom of block
3710.
[0200] Connected to heat spreader 3740 are upper TECs 3750A and
3750B. Upper external cooling block 3760 covers and encloses TECs
3750A and 3750B and upper heat spreader 3760 (in one embodiment).
Likewise, connected to heat spreader 3770 are upper TECs 3780A and
3780B. Upper external cooling block 3790 covers and encloses TECs
3780A and 3780B and upper heat spreader 3790 (in one embodiment).
Block 3760 and block 3790 may be implemented as blocks such as
those shown in FIG. 39, for example. Note that cooling block 3700
may be used for heating or cooling of fluid, with a simple switch
in polarities of the TECs, for example.
[0201] FIG. 38 illustrates in FIGS. 38A, 38B, 38C and 38D, an
embodiment of an internal cooling block of a cooling block. Block
3800 of FIG. 38 may be a cooling block such as internal cooling
block 3710 of cooling block 3700 of FIG. 37, for example. FIG. 38A
provides a top view of block 3800. Cooling block 3800 includes an
internal chamber or passage 3820 contained within a block 3810.
Block 3800 may be made from Delrin plastic, for example, providing
an insulating block of material. Passage 3820 includes an inlet
3830 and an outlet 3840, both of which may be connected to tubes
through use of barbs or other connecting components.
[0202] FIG. 38B provides a perspective view of block 3800. Shown
here are shelf 3850 surrounding passage 3820 and providing a
resting place for a TEC, which may be contained within chamber 3860
which is in turn contained within the top portion of block 3810.
Likewise, shelf 3870 provides a resting place or boundary for a TEC
which may be held in chamber 3880 at the bottom of block 3810,
directly below passage 3820. Thus, two TECs may be placed in
proximity to or in contact with fluid circulating through passage
3820. FIG. 38C shows a back view of block 3800 and FIG. 38D shows a
side view of block 3800. Not shown are mounting bolts and
associated apertures or through-holes, or spaces for leads of a TEC
or other contact points, which may be placed in positions
appropriate to specific devices used in various embodiments.
[0203] Providing an additional stage of temperature differential
are additional TECs placed in external cooling blocks. FIG. 39
illustrates in FIGS. 39A, 39B, 39C, 39D, 39E and 39F, an embodiment
of an external cooling block of a cooling block. Cooling block 3900
may be used to provide external cooling blocks 3760 and 3790 of
block 3700, for example. Block 3900 is made up of block 3910 which
includes channels 3920A and 3920B, which are used for circulation
of fluid. Shelf 3950 provides a shelf for a heat spreader such as
heat spreaders 3740 and 3770 of block 3700, for example.
[0204] Shelves 3980A and 3980B provide shelves (or upper surfaces)
for TECs which may be placed within block 3900 and held in place by
a heat spreader, for example. TECs on shelves 3980A and 3980B may
be in communication with (e.g. in contact with) passages 3920A and
3920B, or may be in contact with a wall of such passages (in the
case of sealed passages), for example. Chambers 3990A and 3990B
define the spaces in which such TECs may be held. Channels 3920A
and 3920B also include inlet/outlets 3930A, 3930B, 3940A and 3940B,
which may be used to connect the channels 3920A and 3920B to
external portions of a fluid loop, for example.
[0205] FIG. 39A provides a bottom view of block 3900. FIG. 39B
provides a perspective view of block 3900. FIG. 39C provides a back
view and FIG. 39D provides a side view of block 3900. FIG. 39E
provides a top view and FIG. 39F provides another perspective view
of block 3900. Note that in some embodiments, channels 3920A and
3920B have wider passage widths on one end of the channel than on
the other end of the channel. This may provide a Venturi effect,
cooling or heating circulating fluid as a result of increasing or
decreasing volume, in some embodiments.
[0206] Block 3700 and similar cooling blocks may be used in a
system such as those described and illustrated in Figs. Xxx, for
example. FIG. 40 illustrates another embodiment of a body
temperature control system. System 4000 includes a cold loop 4010
and a hot loop 4070. Cold loop 4010 links a garment 4030 (or other
object to be temperature regulated) to a reservoir 4050, pump 4020
and cooling block 4040 (a heating/cooling block) in a fluid loop,
with each component in fluid communication with the next. Hot loop
4070 links cooling block 4040 with pump 4075 and reservoir 4050 in
a fluid loop as well. Radiator 4080 may also be used in hot loop
4080 to achieve additional cooling.
[0207] Block 4040 may be a block such as that of FIG. 37. Block
4040 thus has a cold portion which is linked to cold loop 4010 and
a hot portion which is linked to hot loop 4070. For a situation
where cooling is desired, cool fluid circulates through cold loop
4010, bearing heat away from garment 4030. Warmer fluid circulates
through hot loop 4070, taking heat from cold loop 4010 via block
4040 and radiating that heat through radiator 4080, for example.
Fan 4090 may be employed to increase efficiency, for example.
[0208] Also shown is control/power module 4060. Control module 4060
receives power from a power supply 4065 and provides that power to
block 4040, pump 4020, pump 4075 and fan 4090, for example. The
power supplied to block 4040 may be supplied to included TECs in
block 4040, for example. Control module 4060 may vary the amount of
power supplied or may provide control signals to components as
well, to control the system. Thus, pumps 4020 and 4075 may be
regulated by speed or power, for example. Moreover, TECs in block
4040 may be regulated to increase or decrease an associated thermal
differential. Control module 4060 receives control signals from
control interface 4055, which may include both a user control
interface (e.g. a driver interface in a car) and other control
settings, such as switched settings internal to a system, for
example. Control module 4060 receives power from power supply 4065,
which may be a power supply of various types, including an
automotive power supply (e.g. a 13.8V power supply), a building
power supply (e.g. a 120V or 240V power supply, for example), or
various other power supplies. In some embodiments, battery, solar,
thermoelectric, piezoelectric, IR (infrared), magnetic, wind,
chemical, static electricity, electrolysis, fuel cell, biological,
and kinetic including motor and user/operator powered options may
be used as a power supply.
[0209] Note that reservoir 4050 is illustrated as a single
component with an internal division into reservoir 4050A (cold
loop) and 4050B (hot loop). Reservoir 4050 may be fully or
partially divided, allowing for use of a single reservoir of fluid
for both loops. In some embodiments, this can allow for additional
heat exchange. With a reservoir container which is sufficiently
thermally insulating, the two loops may be kept distinct.
[0210] Controlling a system such as system 4000 may be done in a
variety of ways. FIG. 41 illustrates an embodiment of a control
interface for a body temperature control system. Control interface
4100 includes a power supply 4110, fuse 4120, switch 4130, circuits
4140 and 4150, and a common terminal 4160. In one embodiment,
switch 4130 is a single pole, triple throw switch available from
Carling Technologies of Plainville, Conn. In one embodiment, the
2GG series of switches from Carling Technologies is used. These
switches allow for a series of settings, with a first setting of
off, a second setting of circuit 1 (subcircuit 4140) on and a third
setting of circuits 1 and 2 (subcircuit 4150) on. Thus, one may
regulate the system such that only some or all of the available
cooling capacity is used with such an interface.
[0211] As is illustrated, circuit 1 (subcircuit 4140) includes a
TEC array 4165, cold pump 4170, hot pump 4175 and blower 4180. All
of the components of subcircuit 4140 receive power when switch 4130
is activated. When switch 4130 is placed such that both circuits
are active, subcircuit 4150 (a second TEC array) also receives
power, increasing cooling capacity. Not shown is a switch
configuration for switching from cooling to heating, which may be
accomplished by reversing polarity of voltage inputs to TEC Array
4165 and TEC array 4150, for example. Moreover, not shown are
additional safeguards such as temperature sensors, monitoring
processor(s) or other components which may be incorporated.
[0212] In some embodiments, other options may be used for cooling
or heat exchange. For example, one may choose to provide a heat
exchanger which is used for fluids such as air, rather than water
or a similar liquid. One may use a heat exchanger and a cooling
device (or heating device) in various different configurations.
Additionally, one may choose to provide temperature control for a
shirt or garment as mentioned above, or for a helmet, for
example.
[0213] In one embodiment, a product is designed to address a
primary source of racing car driver overheating; the intake and
respiration of abnormally hot air during the race. The breathing
air available to a racing driver is often hot, polluted, and in
relatively short supply when compared to standard conditions in a
home, for example. This is the result of a few effects such as:
restricted airflow in and out of the cockpit in racing cars,
restricted airflow in and out of the driver's helmet, air intakes
which are generally located close to the racing surface, air
intakes passing near heated structures, and the generally hot and
polluted conditions experienced when closely following another
vehicle at high speeds.
[0214] The potential effects of drivers breathing this hot and
polluted air can manifest in a number of ways ranging from simple
discomfort and displeasure with the temperature and smell of the
air to exacerbated and accelerated levels of driver dehydration and
overheating. In an attempt to ameloriate these conditions, an
embodiment was developed to reduce the temperature of the breathing
air delivered to the driver, to increase the general flow and
availability of fresh air to a driver wearing a safety helmet, and
to filter contaminants in the breathing airflow. In one embodiment,
the system generally consists of three components: a cooling
module, a blower, and interconnecting hoses and interfaces.
[0215] The general arrangement of system components in order from
air intake into the system to delivery at the driver's helmet is:
duct/Inlet location->primary intake hose->cooling module
intake->heat exchanger->cooling module outlet->secondary
intake hose->filter element and blower->driver connection
hose->helmet intake connection.
[0216] These components, in an embodiment, can be described as
follows in the following paragraphs. A duct/inlet location is
provided. This is the point at which outside air is taken into the
system. In an embodiment, a NACA duct with a 3'' diameter port is
exposed to the fresh air surrounding the vehicle. This component is
designed to introduce a large volume of air into the system in a
manageable way, without too much of an adverse affect on the
aerodynamic characteristics of the vehicle. Most such ducts will
have some affect on aerodynamics, but placement can be chosen based
on vehicle design to reduce such an effect.
[0217] A primary intake hose, in an embodiment, is a 3'' diameter
hose or duct cut to length appropriate to move the air from the
inlet location to the blower. Its typical characteristics include
resistance to deformation and failure at required thermal loading,
wound reinforcement throughout its length to maintain a consistent
cross-sectional diameter, and a coating of relatively soft and
flexible material thereby allowing for more versatile routing and
easier installation. It may be secured to the duct and blower at
either end by means of fasteners such as zip-ties, hose clamps,
adhesives, tape, or screws, for example.
[0218] The cooling module, in an embodiment, is an insulated
enclosure and sealed cavity which allows for the installation of a
heat exchanger in a way which puts the heat exchanger in direct
contact with ice or ice-water. The cooling module includes a main
body and a lid which is secured with rubber/elastic T-handled
fasteners in one embodiment. The construction of the module is
generally a plastic (e.g. polyethylene) shell which is filled with
expanding foam to provide a highly insulating enclosure for the ice
cavity. The cooling module may be formed using roto-molding, for
example. In one embodiment, the module has an inlet and outlet port
located on opposite sides to allow air in/out of the heat exchanger
mounted within. In some embodiments, the cooling module itself may
be secured to the vehicle by the use of straps routed through slots
and reliefs on the module such that the lid may be removed without
necessitating the removal or loosening of the strapping system.
This feature allows for rapid re-filling of the ice cavity as the
cooling module may remain firmly mounted to the vehicle. The
cooling module further includes a cooling module intake, heat
exchanger and cooling module outlet in one embodiment.
[0219] The cooling module intake, In one embodiment, is a 3''
diameter intake port on the cooling module sufficient to accept the
primary intake hose and offer some feature for securing the hose to
this port. Actual size may be slightly smaller to accommodate 3''
interior diameter hoses, for example. The heat exchanger, in an
embodiment, is suspended within the ice cavity of the cooling
module and is intended to move heat from the air-stream to the ice.
In this way, air moving through the heat exchanger exits the
exchanger significantly cooler as it passes out of the cooling
module outlet. The exchanger, in an embodiment, is provided as an
array of copper or aluminum tubes arranged in a dense circular
array, fastened at either end to a copper or aluminum plate. The
copper or aluminum plate has through-holes that correspond to the
tubes, allowing air or fluid to pass through the plate. As air
enters the cooling module intake location, it is pulled through one
of the many passages (tubes) of the heat exchanger via suction
developed by the blower. As the air moves through a tube passage
within the heat exchanger, it is exposed to the walls of the tube
and rejects heat through the tube wall. The exterior of the tube
wall is in contact with ice/ice-water, which offers the thermal
delta (significantly cooler) to motivate the heat rejection from
the air. The cooled air or fluid is then collected at the cooling
module outlet into a single 3'' passage for delivery to the filter
and blower element.
[0220] The cooling module outlet, in an embodiment, is a 3''
diameter male outlet port on the cooling module sufficient to
accept a secondary intake hose and offer features sufficient to
fasten the hose securely to the port. Actual diameter may be
slightly smaller to accommodate 3'' interior diameter hoses, for
example. A secondary intake hose, In an embodiment, is another 3''
interior diameter hose connected to the cooling module outlet port
and to the filter/blower inlet. It is flexible and designed to
allow for easy and varied placement of the blower/filter
element.
[0221] The blower/filter element, in an embodiment, motivates air
through the system using an axial fan (blower) powered by the
vehicle's electrical system at approximately 13.8 VDC. This
air-stream itself will be modified by both the blower and the
filter. For the blower, in an embodiment, this device may have a
3''O.D. inlet and a 1.5''O.D. outlet to support the ingestion of
air from the cooling module outlet, its
acceleration/pressurization, and delivery to the driver's helmet
via a 1.5'' diameter flexible hose. Air speed may be varied by the
driver using a rotary knob or multi-position switch which affects
simple circuitry related to the voltage supplied to the electrical
motor of the blower. For the filter, in such an embodiment, this
component will be located at or near the blower inlet and is
intended to remove large and small particulate matter and may
further condition the air through the offset, alteration, or
removal of vapors and other chemicals such as carbon monoxide and
fuel or exhaust fumes. The filter element can be of a disk or wafer
shape having dimensions of approximately 3-4'' in O.D. with a
thickness of approximately 1'' in some embodiments.
[0222] Also provided is a driver connection hose. In an embodiment,
this is a 1.5'' interior diameter flexible hose which carries the
cooled and filtered air to the driver helmet intake port. It may be
chosen to be flexible to allow for easy routing and attachment. A
spiral wound or accordion-style hose may be used, for example.
[0223] Reference to the figures may provide a greater understanding
of various embodiments. FIG. 42 illustrates another embodiment of a
cooling device in perspective view. Cooling device 4200 is intended
for use with fluids such as air (or potentially fluids in liquid
form). As illustrated, cooling device has a lid 4210, body
(enclosure) 4220, inlet 4230 and outlet 4240. In one embodiment,
lid 4210 and body 4220 collectively provide an essentially airtight
container. Inlet 4230 and outlet 4240 allow for flow of air into
and out of the cooling device 4200.
[0224] FIG. 43A illustrates another view of the cooling device of
FIG. 42 in perspective view with visibility of interior components.
As can be seen, heat exchanger 4250 is provided inside of cooling
device 4200, mounted between inlet port 4230 and outlet port 4240.
FIG. 43B illustrates yet another view of the cooling device of FIG.
42 in perspective view with a top removed. As can be seen, internal
void or cavity 4260 is provided, with heat exchanger 4250 placed
within the space of void 4260. Ice, or another cooling or phase
change material, can be placed into void 4260 to extract heat out
of (or put heat into) heat exchanger 4250. As is apparent, heat
exchanger 4250 is a bundle of tubes or pipes mounted on plates at
each end (inlet port 4230 and outlet port 4240). In a situation
where ice is used, ice may interstitially occupy space between
tubes, and water may likewise occupy such spaces, resulting in
thermal conduction to/from the heat exchanger 4250.
[0225] FIG. 43C illustrates another view of the cooling device of
FIG. 42 in a top view with visibility of interior components. FIG.
43D illustrates another view of the cooling device of FIG. 42 in a
side view with visibility of interior components. Note that slots
4270 are provided which may be used for securing top 4210 to body
4220, or for routing of mounting straps, for example.
[0226] The heat exchanger 4250 has been discussed above, and is
further illustrated in FIGS. 44A-C. FIG. 44A illustrates a view of
the heat exchanger of the cooling device of FIG. 42 in perspective
view. FIG. 44B illustrates a view of the heat exchanger of the
cooling device of FIG. 42 in a top view. FIG. 44C illustrates a
view of the heat exchanger of the cooling device of FIG. 42 in a
side view. Copper or aluminum tubes may be used, for example, to
provide a transport mechanism for a fluid such as water or other
coolants passing through a cooling medium such as ice. The
conductive nature of the tubes allows for transfer of heat out of
the heat exchanger and into a cooling medium (or in the opposite
direction for heating). As mentioned above, metal plates can be
used at the interface between the tubes and the larger ports 4240
and 4250, providing an essentially air/water-tight seal. Such
plates (discussed above) will be understood to one having skill in
the art from the context of the illustrations and discussion.
[0227] The cooling device of FIGS. 42-44 can be used in various
embodiments. FIG. 45A illustrates another embodiment of a cooling
system, using the cooling device of FIG. 42. System 4500 includes
an intake duct 4510 (shown in a cutaway perspective view) coupled
to cooling device 4200, blower/filter 4520 and helmet 4530. This
system takes in outside air at duct 4510, cools it through cooling
device 4200, forces the air to flow as a result of blower/filter
4520 (and filters the air) and then delivers the cooled, filtered
air to a driver via helmet 4530. Vents in helmet 4530 may allow for
exhausting of air into the environment (and potentially may provide
secondary cooling/conditioning in a closed environment). FIG. 45B
illustrates the embodiment of a cooling system of FIG. 45A in
schematic form. Note that other components can be used to provide
the functions of intake, heat exchange, blowing/filtering, and
delivery (helmet).
[0228] In one embodiment, which has been tested, the exterior
dimensions of the lid and enclosure are approximately
17''.times.10''.times.9.5'' with an empty weight of 8 lbs (3.6 kg).
This allows for an ice capacity of 4 lbs (1.8 kg). The power draw
can range from 0.5-2.5 A in a typical 13.8 V system. An air filter
is also provided for optional installation.
[0229] In this embodiment, a system is provided which delivers a
temperature drop of 40+ degrees (F.). Such temperature drops can be
sustained over a period of 3 hours from 4 pounds of ice in such an
embodiment. A flow rate of the air can be selected by a driver
through use of a control adjusting operation of the blower in such
an embodiment. Air tight seals and rubber T-handles are used to
lock the lid in place in such an embodiment. Additionally, the
enclosure design insulates and increases ice life relative to prior
systems in such an embodiment. These features result in lower power
draw than prior systems in such embodiments as well.
[0230] In another embodiment, cooling of fluids is provided with a
focus on a water or liquid-based system. Whether water itself, or a
coolant fluid such as glycol is used, the system may be designed
with a heat exchanger and overall system which improves upon
performance of systems currently in the market. In one embodiment,
a system is provided to address the primary drawback of
conventional ice-chest based systems deployed for race car driver
cooling. This drawback is the relatively short timeframe in which
the system delivers sufficiently cool water to the driver,
typically 45 minutes under racing conditions. The system may be
expected to extend the amount of time which an ice-based driver
cooling system could be used without significant changes to the
packaging weight and exterior dimensions of prior systems. To
accomplish the goal above, the system in some embodiments exchanges
potential cold fluid temperatures for run-time. In one embodiment,
the system delivers slightly warmer temperatures for greatly
extended periods of time, potentially 1.5 hours or more using a
similar or smaller quantity of ice to prior systems.
[0231] A system flow description (flow through a loop) in one
embodiment can be provided as: First, water flows vertically down
from the reservoir cavity through a first port to fill the fluid
system as air is purged via a second port from the fluid system
into the reservoir cavity via the double-T. Next, water flows via
the fluid system to the pump inlet. Water then flows from the pump
outlet to the heat exchanger Inlet via the system plumbing and
interface barbs described below. Next, the water loses heat while
it is pumped through the heat exchanger. The heat exchanger is
covered/submerged by ice/ice water.
[0232] Thereafter, the water flows out of the system via the
panel-mount quick-disconnect fittings to the cooling garment where
it is passed over the driver. The water then absorbs heat from the
driver and flows back into the system via the panel-mount
quick-disconnect fittings where it is delivered to the inlet of the
double-T. The process is repeated in this closed-loop system
wherein water continues to be cooled via the heat exchanger, any
air in the system is purged via the double-T. Deficiencies in water
volume are filled via the double-T, and heat continues to be wicked
off of the driver via the cooling garment.
[0233] Primary system components in one embodiment include a system
enclosure, enclosure lid, ice cavity, reservoir cavity, systems
cavity, heat exchanger, pump, electrical control system, and a
mounting system. The system enclosure resembles an ice chest,
though it contains multiple cavities (described below). It is
designed with a primary focus on thermal isolation and is typically
constructed of polyethylene with voids filled with expanding
two-part foam. The enclosure lid is designed to allow easy access
to the `Ice` and `reservoir` cavities. It can be completely
removable, and may be secured with rubber `pull` fasteners which
provide shock absorption while maintaining a water-tight seal with
the system enclosure.
[0234] The ice cavity is a void within the system enclosure and is
the primary holding area for system ice. The cavity is constructed
with baffles in place to discourage `sloshing` of the ice or water
during the course of a race. At its bottom, the cavity offers a
mounting area for the heat exchanger and barbed fittings to
accommodate system plumbing. The cavity is made water-tight by the
enclosure lid and is accessed from the top of the enclosure. The
reservoir cavity is another void within the system enclosure and is
the primary holding area for system fluid used as the thermal
transfer medium between the cooling system (particularly the heat
exchanger) and driver cooling garments. It has sufficient capacity
to completely fill multiple cooling garments and is easily filled
by the user when the enclosure lid is removed. When the enclosure
lid is in place, this cavity is also water-tight and is accessed
from the top of the enclosure. There are two ports at the bottom of
this cavity which allow the fluid, typically water, to fill the
fluid loop and to purge air from the fluid system. The cavity is
shaped in a manner which promotes the pooling of fluid near the
ports at the bottom of the cavity to encourage proper system
filling.
[0235] The systems cavity is yet another void in the enclosure,
located and accessed via a side of the system enclosure. The
systems cavity houses the fluid pump, double-T, external plumbing
fittings, internal plumbing fittings, and the electrical
connections for the system. It includes two ports on the top face
which allow for fluid passage up to the reservoir cavity. It
includes two ports on the interior face which allow for fluid
passage in/out of the heat exchanger. It includes two panel mount
fittings which allow for fluid passage in/out of the system to the
cooling garment. It includes one wiring port to allow for power and
control circuit wiring in/out of the system. It is enclosed via a
removable service panel. This service panel may be ported/drilled
or otherwise fashioned to promote air-exchange around the pump
housing under racing conditions.
[0236] The heat exchanger may be a coil or array of metal channels,
typically of copper or aluminum. The heat exchanger allows for the
flow of system fluid through the ice cavity where heat is drawn
from the fluid through the heat exchanger. The heat exchanger is
generally in direct contact with the ice/ice water (typically a
mixture of ice and water); typically being completely submerged
and/or covered by ice during operation. The exchanger provides for
sufficient surface area such that the system fluid leaves the
exchanger at a useful temperature, often above 0 degrees Celsius,
but cold enough to promote driver cooling. A typical range of 5-13
degrees Celsius is measured in one embodiment.
[0237] Also provided is a pump. A single pump can be employed to
motivate fluid flow throughout the system. It is driven using a
single or variable voltage derived from a vehicle's 13.8 VDC
alternator/battery power source. It is turned on/off and modulated
via an electrical control system. An electrical control system is
also typically provided. Various systems can be used, to provide
the following features:
[0238] Driver control of the system--achieved through the use of
switches or potentiometers whereby the state (on/off) of the system
and its performance is designated by the operator.
[0239] Safety mechanisms--includes fusing, rollover-detection, pump
failure, and other safety triggers based on fluid and ice
capacities, cooling garment connectivity, under/over voltage
situations, and any other scenario under which system performance
may be compromised or harmful to the racing platform, operator, or
any crew interacting with the racing platform or cooling
system.
[0240] Power connections--wiring, connectors, and associated
hardware sufficient to connect the cooling system to the racing
platform's power supply including alternator, battery, solar cell,
or any other source of the required DC voltage.
[0241] Also included is a mounting system. A system of straps and
receivers integrated into the system enclosure allows for the
positive mounting of the cooling system to the vehicle such that it
will pass relevant technical specifications for the series (racing
series, e.g.) and will provide a measure of containment and safety
should the system be installed in a vehicle which is involved in an
impact, rollover, or other abnormal circumstance whereby the
cooling system may become moved from its intended mounting
position. The straps may typically be constructed of a Nylon
material and are often terminated and attached to the vehicle using
steel hardware sufficient to support the loads which the system may
generate in any impact. This may be expected to keep the cooling
system firmly installed in its intended location.
[0242] More details may be understood with reference to the
drawings. FIG. 46A illustrates yet another embodiment of a cooling
device in a top view with an open lid. Cooling device 4600 includes
a lid 4610, enclosure (body) 4620, fluid reservoir 4650 and heat
exchange chamber 4660, among other features. Inlet (4630) and
outlet (4640) ports are shown on one side of the enclosure 4620.
Also shown are ports 4655 of the fluid reservoir 4650 and internal
dividers 4670 of the heat exchange chamber 4650. Not shown is a
heat exchanger in the heat exchange chamber 4660, among other
items.
[0243] FIG. 46B illustrates the cooling device of FIG. 46A in
perspective view with a closed lid. FIG. 46C illustrates the
cooling device of FIG. 46A in perspective view with an open lid.
FIG. 46D illustrates the cooling device of FIG. 46A in a side view
with an open lid. FIG. 46E illustrates the cooling device of FIG.
46A in a perspective view with an open lid. Note that plate 4680 is
provided to block access to internal components of the cooling
device 4600, in this embodiment with a ventilated portion of the
plate allowing for air circulation in a void behind plate 4680.
[0244] FIG. 46F illustrates another embodiment of a cooling device
in a perspective view with a closed lid. This embodiment of cooling
device 4600 is functionally the same as that of FIGS. 46A-E.
However, also shown are pump 4685 and double-T 4695, which are
provided in cavity 4675. Double-T may be expected to mate with or
be coupled to the pump 4685, to the ports 4655 of fluid reservoir
4650 and to one of inlet port 4630 or outlet port 4640, for
example. Also shown are a handhold indent and slots for securing
the system 4600.
[0245] FIG. 46G illustrates the cooling device of FIG. 46A in a
cutaway perspective view with an open lid. In this embodiment, a
single divider 4670 is provided in heat exchange chamber 4660 in
the form of a metal plate. Additionally, a heat exchanger 4690 is
provided in the form of a metal tube or pipe which is in contact
with divider 4670. Divider 4670 in this instance may provide
additional thermal conductivity. Also shown are locking T-handles
4615 on lid 4610 and a different configuration of inlet (4630) and
outlet (4640) ports. Note that such ports may be interchangeable in
some embodiments.
[0246] FIG. 46H illustrates the cooling device of FIG. 46A in a top
view with an open lid showing some hidden components in a schematic
illustration. Included in this illustration is a schematic
representation of a heat exchanging coil 4690, with inlet and
outlet pipes which mate with ports in the side of heat exchange
chamber 4660 (ports not shown to avoid further obscuring the
illustration). Heat exchanger 4690 may take on a variety of
different forms or types. For example, a more complex topology
winding through more of the heat exchange chamber 4660 may be
used.
[0247] FIG. 47A illustrates an embodiment of a cooling device such
as the cooling device of FIG. 46A in a side view. FIG. 47B
illustrates the cooling device of FIG. 47A in a side view with flow
illustrated. Device 4700 is a similar embodiment to cooling device
4600, and features of one such embodiment may be incorporated in
the other. As shown, double-T 4710 mates with ports 4655 of fluid
reservoir 4650, allowing air to travel upward into reservoir 4650
and replenishing fluid to travel downward into double-T 4710 (and
thus into the coolant fluid stream). Fluid transport is motivated
by pump 4720, which is coupled to double-T 4710 and to port 4730
(serving as an inlet in this embodiment to a heat exchanging
chamber). Another port 4730 serves as an outlet from the heat
exchanging chamber and is coupled to an outlet 4640 (not shown).
Likewise, an inlet 4630 brings fluid in from the external loop of
the system and to the double-T 4710.
[0248] FIG. 47C illustrates the cooling device of FIG. 47A in a
cutaway perspective view. FIG. 47D illustrates the cooling device
of FIG. 47A in a perspective view. Here, the relationship of the
various components is somewhat more clear.
[0249] FIG. 47E illustrates an embodiment of a cooling device such
as the cooling device of FIG. 47A in a perspective view. FIG. 47F
illustrates the cooling device of FIG. 47E in a perspective view
with hose connections illustrated. Cooling system 4750 uses
essentially the same components as cooling systems 4700 and 4600.
However, a smaller fluid reservoir 4750 is shown. Additionally, the
hose connections further illustrate the fluid flow previously
described with respect to cooling system 4700.
[0250] FIG. 48 illustrates another embodiment of a cooling device
such as the cooling devices of FIG. 46A or FIG. 46F. Cooling system
4800 is schematically represented to provide a general
understanding of the cooling systems of other embodiments. Cooling
device 4600 is used, with an internal pump 4840, heat exchanger
4820 and reservoir 4810 coupled together as part of an open loop.
This open loop is closed through connections (couplings) to a
personal heat exchange garment, such as the shirts discussed
previously.
[0251] FIG. 49 illustrates yet another embodiment of a cooling
device such as the cooling devices of FIG. 46A or FIG. 46F. In
particular, device 4990 may be implemented as any of devices 4600,
4700 or 4750, among other devices. System 4900 includes device 4990
and a personal garment 4960. Device 4990 includes a panel fitting
(inlet) 4970, coupled to a double-T 4920. Double-T 4920 is coupled
to a reservoir 4910 allowing for air purge and fluid
fill/replenishment, and is also coupled to a pump 4930. Pump 4930
is further coupled to a heat exchanger 4940, which in turn is
coupled to a panel fitting (outlet) 4950. Fitting 4950 and 4970 are
coupled to personal garment 4960, completing the cooling loop.
[0252] In an embodiment, a system has been implemented and tested
based on components and features as described above. This system
provide an efficient ice-based driver cooling system, and may be
used for other applications as well. The system delivers two or
more hours of essentially constant driver cooling, eliminating a
need to conserve ice in hot conditions. The dual-chambered design
separates ice from driver cooling fluid. This allows use of other
cooling media and of other heat transport media (e.g. glycol,
saltwater, etc.) An external fluid reservoir may also be included
in the system. A temperature control can be included with a
controller which senses temperature and adjusts operation of the
pump.
[0253] Other features include the integrated vertical baffles
(dividers) which reduce sloshing of liquid in the heat exchange
chamber. In one embodiment, the enclosure and lid are roto-molded
polyethylene with an expanding plastic interior which insulates the
heat exchange and reservoir chambers from external conditions. Air
tight seals are provided as a result of precision molded parts in
some embodiments, although gaskets can also be used. Rubber
T-handles can be used to lock the lid in place in some embodiments.
This insulation and highly specific design may increase and
maximize ice life. Additionally, a high pressure pump may be used
to enhance flow in high temperature conditions.
[0254] In one embodiment, the outer dimensions of the cooling
device are 14.5''.times.11''.times.11.5'' with an empty weight of
16 lbs (7.3 kg). This provides for an ice capacity of 9 lbs (4.0
kg) and a reservoir capacity of 22 fluid oz (650 ml). The system in
such an embodiment has been operated with a 1A power draw at a
typical 13.8 VDC supply.
[0255] Note that aside from heat exchangers and cooling
technologies described above, systems may also be implemented
through use of Stirling engines as heat exchangers.
[0256] The entire system as described can be implemented in various
different embodiments. An embodiment has been tested under a
variety of conditions. It has performed well in keeping a driver
cool in an automobile race under hot conditions. Likewise, it has
performed well in keeping a driver warm in an automobile race under
cold conditions. Another embodiment of the system designed for
cooling has likewise been tested in a variety of conditions and has
performed well.
[0257] One skilled in the art will appreciate that although
specific examples and embodiments of the system and methods have
been described for purposes of illustration, various modifications
can be made without deviating from the present invention. For
example, embodiments of the present invention may be applied to
many different types of applications, such as vehicles, personal
use, stationary use, temporary or permanent installations, or other
environments. Moreover, features of one embodiment may be
incorporated into other embodiments, even where those features are
not described together in a single embodiment within the present
document.
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