Temperature and PCM Control System and Methods for Controlling Temperature

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority, under 35 U.S.C. § 119, of copending U.S. Provisional Patent Application Nos. 63/645,087, filed May 9, 2024, 63/651,756, filed May 24, 2024, and 63/657,920, filed Jun. 9, 2024; the prior applications are herewith incorporated by reference herein in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

FIELD OF THE INVENTION

The present disclosure relates generally to a cooling and heating system for managing temperature and temperature sensing for use in clothing, body gear, coats, jackets, blankets, pads, and other devices having performance requirements where it is beneficial to manage a desired temperature.

BACKGROUND OF THE INVENTION

To exert temperature changes in the environment around the body or directly against the skin, cold packs, heat packs, or ice are well understood in the prior art. For example, U.S. Pat. No. 2,907,173 to Robbins discloses a cooling or refrigerating package with a compartment or inner envelope and an outer bag, such that when the inner compartment is broken, the contents of the outer and inner mix, creating a chemical reaction. U.S. Pat. No. 8,402,772 to Duval et al. discloses a thermal treatment device for contact with the skin and two compartments separated by a temperature actuated gate such that the gate opens at a set temperature and the two compartments mix to create a chemical reaction. U.S. Pat. No. 9,644,880 to Mastaneh Paul discloses a cooling device with two compartments for wrapping about a body part. The two compartments contain different substances, such as urea and water, such that a rupture between compartments mixes the contents of the two compartments. US9879897B2 to Leavitt et al. discloses various cooling agents for cold packs, evaporative cooling, and cold pack construction. US20110022137 A1 to Ennit-Thomas et al. disclose a tubing matrix in the form of a waffle design for the distribution of cooling from cooling packs within garments. Individual water storage packages can be broken to initiate cooling. Also discussed is saturation cooling whereby the temperature of the water changes the reaction and provides more cooling.

US20110034887 A1 to Forden et al. discloses a cooling product for contact with the skin such that the cooling element cannot directly contact the skin, hydrogels for cooling applications, and sleeve wraps and gauntlets using a gel to cool the skin. US 20150253057 to Leavitt et al. discloses sold particulate compounds that undergo endothermic reactions when mixed with water and improved compounds. US20170016664 A1 to Leavitt et al. discloses endothermic agents that are non-toxic when mixed with water and can be recycled.

As the prior art discloses, all the chemical reactions occur as a single time event. When the liquid and powder mix, the reaction occurs creating a change in rapid change in temperature. Once the reaction is complete, the endothermic or exothermic energy change is also complete, which can create extreme temperature changes. There is no ability to control the final temperature or release of energy.

Thus, a need exists to overcome the problems with the prior art systems, designs, and processes as discussed above.

SUMMARY OF THE INVENTION

The present systems, apparatuses, and methods provide for a heating, cooling, distribution, and monitoring system to maintain a desired clothing-to-human interface temperature to make a more comfortable environment for the wearer.

A cooling and heating system is designed to work with a multiple component chemical system whereby at least one chemical compound is isolated from a second chemical compound and at least one chemical compound and second chemical compounds are mixed over time. The amount by volume or weight of the first chemical compound introduced into the second chemical compound can be at a constant rate, but is preferred to be variable based on needed cooling or heating. The reaction of two or more chemicals either takes in heat from the surroundings or releases heat into the surroundings. Chemical form of the components can be powder, pellets, liquid, gas, or any suitable form. More than two chemicals can be mixed to create or moderate the reaction.

By controlling the mixing rate, the endothermic or exothermic reaction can be controlled. This allows direct control over the change in temperature (ΔT) from the initial starting condition to the desired human interface temperature and maintaining the desired temperature. As the mixing rate is preferred to be variable, this allows for increases or decreases in ΔT as needed. For example, 5 grams of the first chemical component introduced into 50 grams of the second component may create a p66 T of 10 degrees. 10 grams of the first chemical component introduced into 50 grams of the second component may create a ΔT of 20 degrees. However, the ΔT can be but is not necessarily linear. This is due to the chemical reaction rate, dissolution rate of two or more components, the energy it takes to cool the container or system holding the chemical components, and/or mixing chamber from the started temperature. By monitoring the temperature output, the amount of the first chemical compound introduced into the second chemical compound can be kept the same, sped up, or slowed down to keep the temperature at the desired temperature.

By controlling the change in temperature over time, the immediate and high energy endothermic and exothermic reactions that occur from combining the chemicals in one short period can be avoided. For example, a normal two-part ice pack can drop the temperature down to near freezing, and certain reactions can dip below freezing. Controlling the mixing rate controls the rate of the energy released or absorbed.

For Urea, this is approximately 15 kj/mol. Ammonium Nitrate is higher, at approximately 25 kj/mol; however, the weight per mol is also higher. Barium Hydroxide Octahydrate and dry Ammonium Thiocyanate or Ammonium Chloride in crystal form create a two chemical dry mixture that creates an endothermic reaction of approximately 47 kj/mol. For releasing heat and creating an exothermic reaction, magnesium sulfate, calcium chloride, and iron are commonly used. Magnesium sulfate or calcium chloride are combined with water, while iron reacts with oxygen from the air to form iron (III) oxide. Some chemicals are available in different forms, such as powder or pellets. This can effect dissolution rates.

As an example, in a two-part reaction, the maximum amount of cooling or heating energy available is based on the amount of chemical one and chemical two in a ratio whereby chemical one and chemical 2 are completely used up in the reaction, or as close as possible based on temperature and atmospheric pressure. For Urea/Water, this is approximately 545 grams per liter. This example applies to any combination of two or more chemicals.

Controlling the reaction by only allowing enough of the chemicals to mix to reach a set temperature creates a potential and kinetic energy system that is more efficient to use and can control and keep the temperature within a set range. Rather than starting at freezing temperatures of a normal ice pack, the reaction allows for an initial temperature to be set at any desired point below the initial or prior to reaction starting temperature. For example, the initial starting temperature could be set at 70 degrees, and only enough of the chemicals are mixed to achieve this result. The remaining unmixed chemicals are then used to maintain the temperature at the desired set temperature, mixing at the rate required. Enough of the chemicals need to be present to allow the reaction to occur over the time period needed. When this approach is used for cooling the human body, if exertion is increasing and the cooling rate needed to maintain the set temperature is increasing, the mixing rate increases, using up the chemicals faster.

For a reaction created by mixing a liquid and solid together, it is simpler to place the powder into a container and meter the fluid into the powder by the use of a fluid pump, such as a peristaltic pump. Peristaltic pumps are capable of flows as low as 0.01 ml/minute to over 500 ml per minute. This allows extremely good control over the reaction. For the reaction of water and Urea:

The reaction gives carbon dioxide and ammonia. In addition, the reaction absorbs heat from the surroundings, which causes cooling of the surroundings. By controlling how much H2O enters the reaction, the reaction is controlled, which allows direct control of the cooling rate. The mass of one molecule of H2O=

18.02 g 1 ⁢ mol × 1 ⁢ mol 6.02 × 10 23 = 2.99 × 10 - 2 ⁢ 3 ⁢ grams

where 6.02×10²³ is Avogadro's number.

As one milliliter of water weighs 1 gram, a pump with a rate of 0.01 ml/min allows the water to enter at a rate of 0.01 grams per minute, or 3.3×1020 molecules of H2O per minute. In comparison, 110 grams of water, which is approximately enough to release the available energy in 1 mol of Urea contains 2.2×1025 molecules of H2O. By using a peristaltic pump with a stepper motor, the rate of water per minute can be controlled in even smaller increments, allowing precise control of the amount of H2O entering the reaction. However, there is a practical limitation, as the amount of energy absorbed during a single molecular reaction of Urea and H2O is very small and a significant number of reactions are needed to occur for a cooling effect to be achieved. This is an example of only one of many possible endothermic and exothermic reactions. As another example, a pump can also be used to meter oxygen in the same manner to control the reaction with iron powder to create iron oxide, which releases significant amounts of heat. Liquid/powder combinations can also occur with less control by isolating the powder in packs constructed from material that is dissolved over time intervals by the liquid. Two Powder combinations can be metered together in different ways, such as by removable dividers, dissolvable dividers, or venturi air pressure/vacuum mixing.

To take advantage of the heating and cooling created by the reaction, the reaction occurs in a chamber. In an exemplary embodiment, at least a portion which has a thermally conductive surface. This thermally conductive surface can be machined in, molded in, or be a separate component that is press-fit, mechanically attached, or bonded by adhesive or welding. The chamber can also be metallic to increase surface area. In addition, the chamber can be thermally conductive metal or polymer and overmolded with a polymer to expose only a portion of the thermally conductive area while insulating the rest. In an alterative embodiment, the heat exchanger fits within the chamber. As an example, a coiled heat conducting tube can be placed within the chamber such that chemical reaction pulls heat or adds heat to the tube. The ends of the tube exit the chamber to create a input and exit that allows a fluid or gas to flow through the tube without leaking into the contents of the chamber.

In an exemplary embodiment, the chamber is part of a cartridge which contains the reaction chemicals within. When the cartridge is inserted into a receiver, the thermally conductive surface of the chamber comes in contact with the thermally conductive surface within the receiver, allowing for heat transfer between the two thermally conductive surfaces. This allows the cartridge to be replaceable as the chemicals are used up and the reaction is no longer sufficiently capable of keeping the required heating or cooling rate.

The receiver has an opening for receiving the cartridge, a heat exchanger with a thermally conductive surface, and a retention mechanism for holding the cartridge in place such that the thermally conductive surfaces of the cartridge and receiver are in direct contact when the cartridge is seated. The receiver heat exchanger has an input for receiving a fluid, a passageway for the fluid to pass through, and an exit for exiting of the fluid. When a fluid is pumped through the passageway, heat is added or removed from the fluid via the heat exchange between the chemical reaction in the cartridge and the liquid flowing through the heat exchanger.

As an alternative embodiment, a tube running through at least part of the reaction chamber and an input and output to the tube as previously described. When the cartridge is inserted into the receiver, connections at the input and output of the tube seal to connections in the receiver, creating a watertight system for the flow of liquids or gas. Flow through the tube is regulated by a pump and the heat exchange rate is controlled by the reaction in the cartridge and flow rate through the tubing.

A garment, such as a vest, jacket, shirt, pants, or other piece of clothing, ice chest, pad in a kennel or cat carrier, or other device that needs cooling has at least one tube that has an input and an exit for the movement of fluid through the tube by a pump. The heat exchanger in the receiver controls the temperature in the fluid passing through the tubing by adding or removing heat created by the reaction, or holding the temperature stable. By placing at least one temperature sensor in the item that needs cooling, a control system can monitor the temperature in the tubing, clothing, or item, and use the data to control the rate of reaction.

For example, a vest having a single tube fifty to over 100 feet in length is formed to fit within the vest and contact the front, back, and sides of the wearer. The vest can be in direct contact with the skin or a liner. As the fluid runs through the tubing, it also circulates through the heat exchanger. Feedback from at least one temperature sensor in the vest provides data via a wired or wireless connection to a controller or central processor unit within the receiver. The feedback can be used to control the rate of reaction in the chamber as well as the speed of the pump moving fluid through the tubing. Thus, the amount of heating or cooling can be controlled by combining two separate systems working at independent rates. Programming interprets the data and determines the reaction and flow rates and can adjust either system accordingly. This approach uses the least amount of reaction in the chamber possible to maintain the desired temperature in order to extend the cooling or heating as long as possible before the cartridge is expended. Of course, when the cartridge is expended, it can be removed and another new cartridge inserted in its place.

As another example, a vest or piece of clothing can have multiple sections of tube of equal or different lengths connected by pressure sensitive bypass valves. When the pressure in one section reduces below a set point, indicating leakage, or above a set point, indicating blockage, the section of tubing experiencing the issue is bypassed and flow directed to a normally functioning section. The valves can be electromechanical, such as solenoid or motor controlled, such that pressure sensors indicate to the control system whether the valve should be in the open position or closed position, or mechanical.

A filter can be placed in the system to prevent any contaminates or debris from entering the tubing in the vest and damaging the pump. It is preferable that the filter be readily replaceable and part of the cartridge system, such that when the cartridge is replaced, a new filter is automatically connected. Small membrane filters are inexpensive and allow for control of contaminates down to micron sizes.

A compliance chamber can also be placed in the system to remove any air that enters the system during connection of the vest to the heat exchanger pump cartridge system. Air is separated from the water by allowing the air and water to enter a chamber whereby the air flows to the top of the chamber and is removed from the fluid. Alternatively, an air porous membrane in contact with the fluid allows air to exit the chamber.

To assist in maintaining a more constant temperature and more efficient system in certain applications, the cartridge cooling system can be used in conjunction with a phase change material. Phase changing materials (PCMs) are substances that can absorb or release large amounts of heat energy when they change from one phase (solid, liquid, or gas) to another, such as melting or freezing. These materials are capable of regulating temperatures at specific set points, such that when a set temperature is reached, the material begins to phase change from a solid to a liquid, absorbing or releasing heat, effectively acting as a near constant temperature battery until the phase change is complete.

In an exemplary embodiment, a water tight first container has a chamber with a high thermally conductive surface or heat exchanger on at least one face and the remaining faces formed from less thermally conductive material. The solid form of the endothermic reagent is placed within the first container. Water or another fluid is placed within a second container. A metering pump, such as a peristaltic pump, transfers fluid from the second container to the first container at a desired volume over time. As the fluid enters the first container, the fluid mixes with the solid, creating the endothermic reaction. The endothermic reaction pulls heat from the high thermal conductive surface or heat exchanger, which cools the thermally conductive surface.

In another exemplary embodiment, a first chamber is formed from a tube that is sealed on the bottom. At least a portion of the first chamber has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. The first chamber contains the first chemical compound. When the second chemical compound is introduced into the first chamber, a chemical reaction is started such that the temperature of the heat exchanger bottom surface reaches a set temperature. As the temperature changes, more of the second chemical compound is added to maintain the temperature of the heat exchanger bottom surface. The tube construct allows for the chemicals to be contained within a cartridge to allow cartridges can be exchanged during use. Thus, when the chemical reaction is finally expended, the system allows for cartridge swap.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube that is sealed on the bottom. The tube may be round, square, oval, rectangular, or any shape. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum, copper, or thermally conductive polymer. The first container contains the first chemical compound. The second container contains the second chemical compound. When the first chemical compound is introduced into the second container, a chemical reaction is started such that the temperature of the heat exchanger bottom surface reaches a set temperature. As the temperature changes, more of the first chemical compound is added to maintain the temperature of the heat exchanger bottom surface. The tube construct allows for the chemicals to be contained within a cartridge to allow cartridges to be exchanged during use. Thus, when the chemical reaction is finally expended, the system allows for cartridge swap.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one hole for receiving a small diameter hollow tube. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube extends through the hole in the cap into the space between the cap and the heat exchanger inner surface. The first container contains the first chemical compound. The first chemical compound is introduced into the second container through the small diameter tube, starting a chemical reaction such that the temperature of the heat exchanger bottom surface reaches a set temperature range. As the temperature changes, more of the first chemical compound is added to maintain the temperature of the heat exchanger bottom surface.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one hole for receiving a small diameter hollow tube. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end and extends through the hole in the cap such that the first end is disposed within the space between the cap and the heat exchanger inner surface. The first end is either flat, angled, or sealed with multiple perimeter holes such that the inner bore allows for a chemical to pass through with sufficient velocity and direction(s) to enhance mixing of the two chemicals. The second end of the small diameter tube is connected to a valve normally in the closed position. When the first chamber is pressurized, the chemical in the first chamber is forced into the second chamber to cause mixing of the two chemicals.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one hole for receiving a small diameter hollow tube. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end and extends through the hole in the cap such that the first end is disposed within the space between the cap and the heat exchanger inner surface. The first end is either flat, angled, or sealed with multiple perimeter holes such that the inner bore allows for a chemical to pass through with sufficient velocity and direction(s) to enhance mixing of the two chemicals. The second end of the small diameter tube is connected to a pump. The pump has an inlet for receiving the chemical in the first container. The chemical from the first chamber is metered into the second chamber to cause mixing of the two chemicals.

In another exemplary embodiment, a first container is suspended within a second container. The first chamber is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one hole for receiving a small diameter hollow tube. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end and extends through the hole in the cap such that the first end is disposed within the space between the cap and the heat exchanger inner surface. The first end is either flat, angled, or sealed with multiple perimeter holes such that the inner bore allows for a chemical to pass through with sufficient velocity and direction(s) to enhance mixing of the two chemicals. The second end of the small diameter tube is connected to a valve normally in the closed position and the valve is connected to a pump. The pump has an inlet for receiving the chemical in the first chamber. The chemical from the first container is metered into the second container with sufficient pressure to open the valve, allowing the chemical from the first container to enter the second container and cause mixing of the two chemicals.

In another exemplary embodiment, a first container is suspended within a second chamber. The first chamber is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one opening for allowing the chemical in the first chamber to enter the second chamber under pressure. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end and extends through the hole in the cap such that the first end is disposed within the space between the cap and the heat exchanger inner surface. A ring having an inner bore and an outer diameter slides over the first chamber such that the inner bore seals to the outside of the first container and the outer diameter seals to the inner diameter of the second container. The ring slides while maintaining both seals. The first chemical is placed in the second container and the ring is pressed downwards against the first chemical. The second chemical is introduced into the first container. As the second chemical is forced into the second container, the pressure forces the ring to slide upwards.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one opening for allowing the chemical in the first container to enter the second container under pressure. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end and extends through the hole in the cap such that the first end is disposed within the space between the cap and the heat exchanger inner surface. A ring having an inner bore and an outer diameter slides over the first container such that the inner bore seals to the outside of the first chamber and the outer diameter seals to the inner diameter of the second chamber. The ring slides while maintaining both seals. The first chemical is placed in the second container and the ring is pressed downwards against the first container. The second chemical is introduced into the first container and the space above the ring. As the second chemical is forced into the second container, the pressure forces the ring to slide upwards.

In another exemplary embodiment, a tube is divided into a first container and a second container by a sliding divider. The divider has an inner bore, tube, or valve for connection with a metering pump and an outer diameter that forms a movable seal to the inside of the tube. As the chemical in the second container is pumped into the first container, the divider moves to compensate for the volume increase in the first chamber.

In another exemplary embodiment, a tube has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap has a hole for receiving a thermally conductive component. At least a portion of the thermally conductive component extends through the end cap.

In another exemplary embodiment, a tube has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers. At least a portion of the thermally conductive material extends through to the top face of the end cap.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers. At least a portion of the thermally conductive material extends through to the top face of the end cap.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers. At least a portion of the thermally conductive material extends through to the top face of the end cap. A first chemical is introduced against the thermally conductive material. A second chemical is added to the first chemical by controlled increments to create a chemical reaction which causes cooling or heating of the thermally conductive material.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap that seals the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers. At least a portion of the thermally conductive material extends through to the top face of the end cap. A temperature sensor measures the temperature of the thermally conductive end cap portion. The temperature sensor is connected to a control system. The control system also controls the output rate of a second chemical. A first chemical is introduced against the thermally conductive material. The output rate of the second chemical is metered by the control system in increments to create a chemical reaction which causes the temperature of the thermally conductive material to reach a set temperature point and maintain a set point within a set range.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap. The end cap has a bottom face and top face and seals the inner bore of the tube. The side of the hollow component is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers or assembled to have a section that is thermally conductive. At least a portion of the thermally conductive material extends through to the inside of the hollow component. A temperature sensor measures the temperature of the thermally conductive portion. The temperature sensor is connected to a control system. The control system also controls the output rate of a second chemical. A first chemical is introduced against the thermally conductive material. The output rate of the second chemical is metered by the control system in increments to create a chemical reaction which causes the temperature of the thermally conductive material to reach a set temperature point and maintain a set point within a set range.

In another exemplary embodiment, a hollow construct in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end that seals the inner bore. The end is press-fit, welded, or bonded to seal the inner bore. A section of the hollow component is at least partially constructed from thermally conductive material, such as metals and thermally conductive polymers or assembled to have a section that is thermally conductive. At least a portion of the thermally conductive material has a surface that is open to the inside of the hollow component. A temperature sensor measures the temperature of the thermally conductive portion. The temperature sensor is connected to a control system. The control system also controls the output rate of a second chemical. A first chemical is introduced against the thermally conductive material. The output rate of the second chemical is metered by the control system in increments to create a chemical reaction with the first chemical which causes the temperature of the thermally conductive material to reach a set temperature point and maintain a set point within a set range.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube that is sealed on the bottom. The tube may be round, square, oval, rectangular, or any shape. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. The first container contains the first chemical compound. The second container contains a series of dividers with the second chemical contained between the dividers. The distance between the dividers forms a cavity that holds a volume of the second chemical. The volume can be equal between dividers or different, such that the initial volume is higher to increase initial cooling rate. When the first chemical compound is introduced into the second container by removing a divider, a chemical reaction is started such that the temperature of the heat exchanger bottom surface reaches a set temperature range. Additional dividers are removed to release more of the first chemical into the second chemical.

In another exemplary embodiment, a first container is suspended within a second container. The first container is formed from a tube with a cap that seals the bottom. The tube may be round, square, oval, rectangular, or any shape. The cap has at least one opening for allowing the chemical in the first chamber to enter the second chamber under pressure. The second container has a bottom with at least a portion that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A small diameter tube having an inner bore has a first end and a second end extends such that the first end is disposed within the space between the cap and the heat exchanger inner surface. A ring having an inner bore and an outer diameter slides over the first container such that the inner bore seals to the outside of the first chamber and the outer diameter seals to the inner diameter of the second container. The ring slides while maintaining both seals. The first chemical is placed in the second container and the ring is pressed downwards against the first chemical. The second chemical is introduced into the first container and the space above the ring. As the second chemical is forced into the second container, the pressure forces the ring to slide upwards.

In an exemplary embodiment, a small tube extends into the space within the reaction chamber. A first end is either flat, angled, or sealed with multiple perimeter holes such that the inner bore allows for a chemical to pass through with sufficient velocity and direction(s) to enhance mixing of the two chemicals. The second end of the small diameter tube receives the flow of the second chemical.

In an exemplary embodiment, a small tube extends into the space within the reaction chamber. A first end is either flat, angled, or sealed with multiple perimeter holes such that the inner bore allows for a chemical to pass through with sufficient velocity and direction(s) to enhance mixing of the two chemicals. The second end of the small diameter tube connects to a valve normally in the closed position and the valve is connected to a pump. The pump has an inlet for receiving the chemical in the first chamber. The chemical from a first chamber is metered a second container with sufficient pressure to open the valve, allowing the chemical from the first container to enter the second container and cause mixing of the two chemicals.

In an exemplary embodiment, a container containing a reaction chamber has a first face, second face, and an internal bore. The container has at least a portion which is thermally conductive. A rotating cylinder has a first face and a second face, and a series of holes radially distributed about a central axis that extend at least through the first face. A plate having a first face and a second face has a thru hole at the same distance from the central axis as the rotating cylinder such that at certain rotational positions a hole in the cylinder aligns with the thru hole in the plate. A first chemical is placed in the container and the second chemical is loaded into the holes in the rotating cylinder. The cylinder fits within the container. When the cylinder rotates, a hole in the cylinder aligns with a hole in the plate, allowing the second chemical in that hole to be released into the first chemical. When the reaction is complete or software indicates the need for more of the second chemical to achieve a desired temperature, a gear motor rotates the cylinder to the next position, aligning the next hole to release more of the second chemical into the reaction chamber.

In another exemplary embodiment, a first container is formed from a sealed tube a portion of the tube or that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A second container formed form from a tube has a piston which slides within the second tube and is actuated by a motor. At least one chemical is placed within the first container and at least one second chemical is placed within the second container. When the piston motor is actuated, the piston pushes the at least one second chemical into the first container.

In an exemplary embodiment, a container containing a reaction chamber has an internal bore for receiving a heat exchanger. A first chemical is placed within the first container. A second container has an internal bore for receiving a second chemical. The first chemical is transferred by a pump to create a chemical reaction which changes the temperature of the heat exchanger.

In another exemplary embodiment, a container is formed from a tube with a cap that seals the bottom and a portion of the tube or cap that has a heat exchanger surface with a high heat transfer rate, such as one constructed from aluminum or copper. A first chemical is placed within fluid dissolvable packets. The packets are constructed from soluble cellulose or other soluble material. Each packet has a specific wall thickness that allows for dissolution of the packet and exposure of the interior chemical to create an endothermic or exothermic reaction. By having packets with different wall thicknesses or composition, the dissolution of the packets occurs at different times, allowing for an extended reaction.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a surface which contacts the chemical reaction within the container, a second plate a distance from the first plate creating a volume between the two plates, and a phase change material at least partially filling the volume.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate a distance from the first plate creating a volume between the two plates, and a phase change material at least partially filling the volume.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate having a first surface and a second surface, the first surface having fins or pins, and a phase change material at least partially filling the volume between the fins.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate having a first surface and a second surface, the first surface having fins or pins that fit within the fins or pins on the first plate, and a phase change material at least partially filling the volume between the fins.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate having a first surface and a second surface, the first surface having fins or pins that fit within the fins or pins on the first plate, and a phase change material at least partially filling the volume between the fins. The fins or pins on the first plate do not contact the second plate, and the fins or pins on the second plate do not contact the first plate.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate and a volume of phase change material between the first and second plate, and at least one tube disposed within the volume of phase change material for the flow of fluid or gas within.

In another exemplary embodiment, a first container is formed from a tube with one end containing a heat exchanger having two plates. The first plate has a first surface which contacts the chemical reaction within the container and a second surface with fins or pins to enhance heat transfer, a second plate and a volume of phase change material between the first and second plate, and at least one tube disposed within the volume of phase change material for the flow of fluid or gas within to allow for fluid to be pumped through to an external cooling loop.

In another exemplary embodiment, a container is formed from a tube with a cap that seals the bottom and a portion of the tube or cap that has a thermally conductive surface with a high heat transfer rate, such as one constructed from aluminum or copper. A heat exchanger in a receiver contacts the thermally conductive surface of the container when the container is inserted into the receiver. The heat exchanger has a first plate and a second plate with a phase change material between the two plates.

In another exemplary embodiment, a container is formed from a tube with a cap that seals the bottom and a portion of the tube or cap that has a thermally conductive surface with a high heat transfer rate, such as one constructed from aluminum or copper. A heat exchanger in a receiver contacts the thermally conductive surface of the container when the container is inserted into the receiver. The heat exchanger has a first plate with a first surface and a second plate with a phase change material between the two plates and at least one tube disposed within the volume of phase change material for the flow of fluid or gas within to allow for fluid to be pumped through to an external cooling loop.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap has an inlet and outlet for receiving a thermally conductive tube that coils within the inner bore. The inlet and outlet seal to matching tube connectors in a receiver. A pump moves fluid through the tube to an external heat exchanger.

In another exemplary embodiment, a hollow component in the shape of a round, square, rectangular, hexagonal, or other geometric shape has an inner bore and an end cap that fits within the inner bore. The end cap has a bottom face and top face and a section that fits within the tube inner bore and seals to the inner bore of the tube. The end cap has an inlet and outlet for receiving a thermally conductive tube that coils within the inner bore. The inlet and outlet seal to matching tube connectors in a receiver. A pump moves fluid through the tube to an external heat exchanger whereby the external heat exchanger contains a phase change material.

In another exemplary embodiment, the phase changing heat exchanger is constructed with a series of hollow rectangular tubes coated with phase change material or contained within a block of phase change material.

In another exemplary embodiment, the phase changing heat exchanger is constructed with a series of hollow rectangular tubes formed from fabric and coated with a phase change material or contained within a block of phase change material.

In another exemplary embodiment, the phase changing heat exchanger is constructed with a series of hollow rectangular tubes formed from fabric with an internal stent to keep the tubes open during phase change while compensating for the change in volume during phase change.

In another exemplary embodiment, heat transfer components have a surface for contacting the skin or fabric against the skin, a portion for retaining the components in a fabric or material layer, a receiver for retaining phase change material within and in contact with a heat exchanging tube, and a cap for retaining the phase change material within.

In another exemplary embodiment, heat transfer components have a surface for contacting the skin or fabric against the skin, a portion for retaining the components in a fabric or material layer, a receiver for retaining phase change material within and in contact with a heat exchanging tube, and a flexible cap for retaining the phase change material within such that the cap flexes during phase change of the phase change material to allow for expansion and contraction of the phase change material.

In another exemplary embodiment, heat transfer components have a surface for contacting the skin or fabric against the skin, a portion for retaining the components in a fabric or material layer, a receiver for retaining phase change material within and in contact with a heat exchanging tube, a sensor for sensing the temperature of the phase change material, and a cap for retaining the phase change material and sensor within.

In another exemplary embodiment, heat transfer components are attached to a panel in an array to maximize surface contact area for contacting the skin or a fabric liner against the skin, a series of receivers for retaining phase change material within and each in contact with at least a portion of a heat exchanging tube.

In another exemplary embodiment, heat transfer components are attached to a panel in an array to maximize surface contact area for contacting the skin or a fabric liner against the skin, a series of receivers for retaining phase change material within and each in contact with at least a portion of a heat exchanging tube, and at least some of the heat exchanger tubes connected to flexible couplers that allow for the panel to flex while preventing leakage of fluid through the heat exchanger tubing.

In another exemplary embodiment, heat transfer components are attached to a panel in an array to maximize surface contact area for contacting the skin or a fabric liner against the skin, a series of receivers for retaining phase change material within and each in contact with at least a portion of a heat exchanging tube, and at least some of the heat exchanger tubes connected to flexible couplers that allow for the panel to flex while preventing leakage of fluid through the heat exchanger tubing, and at least one sensor in the panel for detecting temperature of the phase change material.

Provided within is a new temperature control system for controlling and altering the temperature within clothing, such as a shirt, a jacket, a coat, a pair of pants, or person-coverable clothing such as a poncho, a scarf, a shawl, a cloak, blanket, or other goods, such as an ice chest or other device. As used herein, clothing or apparel are defined to include any wearable cloth-like item that is body-shaped or draped over the body; a number of different pieces of clothing and draped items are listed as examples herein. The temperature control system directly controls a rate of reaction from at least two chemicals to enable heating or cooling through respective exothermic or endothermic reactions. The heating or cooling is transferred from the reaction to the clothing or device by a fluid transfer system by way of a heat exchanger. A fluid is forced through tubing or chambers in the apparel or device by a pump, such as a peristaltic, gear head, or diaphragm pump and through the heat exchanger. This way, the reaction chemicals are isolated and do not enter the tubing running through the clothing or device. The pump motor can be preferably direct current brush or brushless, stepper, or servo motor. When the reaction is controlled by a separate pump, the reaction pump motor can be preferably direct current brush or brushless, stepper, or servo motor ideally with an encoder to determine the exact rotation of the shaft of the pump motor.

In the preferred embodiment, the apparel temperature control system can monitor the external air, inside temperature, and internal heat rise rate to determine the best reaction rate and flow rate through the clothing or device. This dual control system allows for control of the flow conditions to create a constant internal temperature, or one that declines or increases according to a program or user set level or pattern. Thus, the control system, with a built-in controller, microcontroller, or CPU can react and adjust to real time conditions as they occur. An electrical connection is made between the electronic components, such as the controller, the pumps, and any sensors. The collected data can be stored or transmitted via wired or wireless connection. This allows for external monitoring of personnel for safety reasons.

The present systems, apparatuses, and methods provide a temperature control system whereby the temperature is controlled by the rate of chemical introduction of at least one chemical into at least one other chemical.

The present systems, apparatuses, and methods provide a temperature control system whereby the temperature is controlled by pumping a liquid into at least one solid.

The present systems, apparatuses, and methods provide a temperature control system whereby the temperature is controlled by dispensing one or more solids into at least one solid.

The present systems, apparatuses, and methods provide a temperature control system whereby the temperature the solid in the reaction is in powder, pellet, tablet, or other form.

The present systems, apparatuses, and methods provide a temperature control system whereby a heat exchanger is part of a chamber wherein the chemical reaction occurs.

The present systems, apparatuses, and methods provide a temperature control system whereby part of a heat exchanger comes in contact with the chemical reaction.

The present systems, apparatuses, and methods provide a temperature control system and a reaction chamber with a thermally conductive component having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component.

The present systems, apparatuses, and methods provide a temperature control system and a sealed tube with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive surface having a first face for contact with the chemical reaction, a second external face for conducting heat or cooling through the thermally conductive component, and a first chemical placed within the container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction, a second surface for conducting heat or cooling through the thermally conductive component.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction, and a second container suspended within the first container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction, and a divider suspended within the first container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction and at least one chemical placed within, and a second isolated section containing at least one other chemical within.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction and at least one chemical placed within, and a second isolated section containing at least one other chemical within, and a pump for moving the contents of the second section into the container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction and at least one chemical placed within, and a second isolated section containing at least one other chemical within, and a pump with a control system for controlling the pump output volume.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, and a second container suspended within the first container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, a second container suspended within the first container, and a pump for moving the contents of the second container into the first container.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, a second container suspended within the first container, a pump for moving the contents of the second container into the first container, and a nozzle for enhancing the mixing of the two or more chemicals.

The present systems, apparatuses, and methods provide a container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, a second container suspended within the first container, a divider which fits within the space between the inner wall of the first container and the outer wall of the second container, at least one chemical on one side of the divider and at least one second chemical on the other side of the divider and in the second container.

The present systems, apparatuses, and methods provide a flexible container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, a second container suspended within the first container, a divider which fits within the space between the inner wall of the first container and the outer wall of the second container, at least one chemical on one side of the divider and at least one second chemical on the other side of the divider and in the second container.

The present systems, apparatuses, and methods provide a first container with a thermally conductive surface having a first face for contact with the chemical reaction and a second external face for conducting heat or cooling through the thermally conductive component, a second container suspended within the first container, a divider which fits within the space between the inner wall of the first container and the outer wall of the second container, at least one chemical on one side of the divider and at least one second chemical on the other side of the divider and in the second container such that a pump for moving the contents of the second container and the contents above the divider into the first container and moves the divider away from the first face as the combined volume of the chemicals increases in the first container.

The present systems, apparatuses, and methods provide a first container with a thermally conductive surface having a first face for contact with the chemical reaction, a divider which fits within the first container and movably seals to the outer wall of the container, at least one chemical on the side of the divider facing the thermally conductive surface and at least one second chemical on the opposite side of the divider and a pump for moving the contents on the outside the divider to the inside of the divider.

The present systems, apparatuses, and methods provide a container with a thermally conductive surface having a first face for contact with the chemical reaction, a divider which fits within the first container and movably seals to the outer wall of the container, at least one chemical on the side of the divider facing the thermally conductive surface and at least one second chemical on the opposite side of the divider and a pump for moving the contents on the outside the divider to the inside of the divider to maintain contact of the reaction chemicals against the thermally conductive surface regardless of the angle of rotation of the container.

The present systems, apparatuses, and methods provide a first container with a thermally conductive surface within a portion of the container and having a surface contact the chemical reaction.

The present systems, apparatuses, and methods provide a first container with a thermally conductive structure such as a coiled tube within a portion of the container and having a surface contact the chemical reaction.

The present systems, apparatuses, and methods provide a first container with a thermally conductive structure such as fins within a portion of the container and having a surface contact the chemical reaction.

The present systems, apparatuses, and methods provide a first container with a thermally conductive surface having a first face for contact with the chemical reaction and a second face for contacting a second thermally conductive surface.

The present systems, apparatuses, and methods provide a receiver for receiving a container with a thermally conductive surface such that upon insertion of the container, the thermally conductive container surface contacts a second thermally conductive face within the receiver.

The present systems, apparatuses, and methods provide a receiver for receiving a container with a thermally conductive surface and a heat exchanger within the receiver having a surface for contact with the thermally conductive surface on the container and an internal cavity for fluid to pass through.

The present systems, apparatuses, and methods provide a receiver for receiving a container with a thermally conductive surface and a heat exchanger within the receiver having a surface for contact with the thermally conductive surface on the container and an internal cavity for fluid to pass through and a pump for forcing fluid through the internal cavity to allow for heat to be removed or added to the fluid.

The present systems, apparatuses, and methods provide for a cartridge with a heat exchanger within having a passageway leading from a first port to a second port.

The present systems, apparatuses, and methods provide for a cartridge having a heat exchanger within having a passageway leading from a first port to a second port and a receiver having a first port and a second port such that upon positioning of the cartridge within the receiver, the matching ports of the cartridge align with the ports of the receiver.

The present systems, apparatuses, and methods provide for a cartridge having a heat exchanger within having a passageway leading from a first port with a check valve to a second port with a check valve and a receiver having a first port and a second port such that upon positioning of the cartridge within the receiver, the matching ports of the cartridge align with the ports of the receiver.

The present systems, apparatuses, and methods provide for a cartridge having a heat exchanger formed from thermally conductive tubing, the tubing ends forming an inlet and an exit, and a receiver having a first port and a second port such that upon positioning of the cartridge within the receiver, the inlet and exits of the tubing align with the correct ports of the receiver.

The present systems, apparatuses, and methods provide for a cartridge for containing at least two chemicals and an inlet and exit port.

The present systems, apparatuses, and methods provide for a cartridge for containing at least two chemicals, a first port and a second port, and a receiver having a first port and a second port such that upon positioning of the cartridge within the receiver, the ports of the cartridge align with the correct ports of the receiver.

The present systems, apparatuses, and methods provide a temperature control system and a container with a thermally conductive component having a first surface for contact with the chemical reaction, a second surface for conducting heat or cooling through the thermally conductive component, and a temperature sensor mounted in contact with the thermally conductive component.

The present systems, apparatuses, and methods provide a receiver for receiving a container with a thermally conductive surface such that upon insertion of the container, the thermally conductive container surface contacts a second thermally conductive face within the receiver, and a temperature sensor is placed in contact with the receiver thermally conductive face.

The present systems, apparatuses, and methods provide a receiver having a thermally conductive portion with an inlet and exit to allow for flow from a pump to move fluid through the inlet port and exit port, apparel with a closed circuit for receiving the flow from the pump, and a removable cartridge with at least two chemicals within, such that when the at least two chemicals are mixed, an endothermic or exothermic reaction occurs and the resulting energy is removed or transferred to the fluid moving through the apparel.

The present systems, apparatuses, and methods provide a receiver having a thermally conductive portion with an inlet and exit to allow for flow from a pump to move fluid through the inlet port and exit port, apparel with multiple closed independent circuits for receiving flow from at least one pump, and a removable cartridge with at least two chemicals within, such that when the at least two chemicals are mixed, an endothermic or exothermic reaction occurs and the resulting energy is removed or transferred to the fluid moving through the apparel.

The present systems, apparatuses, and methods provide a receiver having a thermally conductive portion with an inlet and exit to allow for flow from a pump to move fluid through the inlet port and exit port, apparel with multiple loops connected by pressure sensing valves for receiving flow from at least one pump, and a removable cartridge with at least two chemicals within, such that when the at least two chemicals are mixed, an endothermic or exothermic reaction occurs and the resulting energy is removed or transferred to the fluid moving through the apparel.

The present systems, apparatuses, and methods provide a receiver having a thermally conductive portion with an inlet and exit to allow for flow from a pump to move fluid through the inlet port and exit port, a device with a closed circuit for receiving the flow from the pump, and a removable cartridge with at least two chemical within, such that when the at least two chemicals are mixed, an endothermic or exothermic reaction occurs and the resulting energy is removed or transferred to the fluid moving through the device.

The present systems, apparatuses, and methods provide a receiver having at least one thermally conductive portion with an inlet and exit to allow for flow from a pump to move fluid through the inlet port and exit port, a device, apparel, pad, blanket or other with a closed circuit for receiving the flow from the pump, and a first removable cartridge with at least two chemical within, such that when the at least two chemicals are mixed, an endothermic reaction occurs and a second removable cartridge such that when the at least two chemicals are mixed and exothermic reaction occurs, and a control system that controls the cooling or heating of the device, apparel, pad, blanket or other to maintain a constant temperature range.

The present systems, apparatuses, and methods provide a fabric consisting of two outer layers and a pocket for receiving a phase change material within, and a tube suspended within the phase change material.

The present systems, apparatuses, and methods provide a fabric consisting of two outer layers for receiving a phase change material within, and a tube suspended within the phase change material.

The present systems, apparatuses, and methods provide a fabric consisting of two outer layers for receiving two different phase change materials within, and a tube suspended within the phase change materials.

The present systems, apparatuses, and methods provide a non-woven fabric consisting of two outer layers for receiving phase change material within, and a tube suspended within the phase change materials.

The present systems apparatuses, and methods provide a woven fabric consisting of two outer layers for receiving phase change material within, and a tube suspended within the phase change materials.

The present systems, apparatuses, and methods provide a fabric consisting of two outer layers for receiving phase change material within, a tube suspended within the phase change materials, and a heat meltable surface on the inside of at least one fabric to permit sealing of the two fabric layers around the phase change material.

The present systems, apparatuses, and methods provide a two outer layers for receiving phase change material within, a tube suspended within the phase change materials, and a heat meltable surface on the inside of at least one fabric to permit sealing of the two fabric layers around the phase change material.

The present systems, apparatuses, and methods provide a two outer layers for containing multiple pockets for phase change material within, phase change material in each pocket, and a tube suspended within at least some of the phase change material.

The present systems, apparatuses, and methods provide a two outer layers for containing a pocket for receiving phase change material within, a tube suspended within the phase change material, and a temperature sensor having a tip suspended within a portion of the phase change material.

The present systems, apparatuses, and methods provide a fabric consisting of two outer layers for receiving phase change material within, a tube suspended within the phase change materials, and an adhesive on the inside of at least one fabric to permit sealing of the two fabric layers around the phase change material.

The present systems, apparatuses, and methods provide a fabric consisting of a woven three-dimensional tube for receiving individual phase change material nodules within, and a tube suspended within the phase change material nodules.

The present systems, apparatuses and methods provide cooling modules consisting of a thermally conductive component having a bottom surface and an upper portion that extends through a flexible layer, a cap that extends over the upper portion and reaches a locking position such that the bottom of the locking cap contacts the flexible layer, a thermally conductive tube extending through at least a portion of the module, phase change material contained within the thermally conductive component and contained within the module by the construct.

The present systems, apparatuses and methods provide cooling modules consisting of a thermally conductive component having a bottom surface and an upper portion that extends through a flexible layer, an at least partially flexible cap that extends over the upper portion and reaches a locking position such that the bottom of the locking cap contacts the flexible layer, a thermally conductive tube extending through at least a portion of the module, phase change material contained within the thermally conductive component and contained within the module by the construct.

The present systems, apparatuses and methods provide cooling modules consisting of a thermally conductive component having a bottom surface and an upper portion, an at least partially flexible cap that can expand and contract when the phase change material changes phases, a thermally conductive tube for carrying fluid, and a phase change material within the component that is always in contact with the conductive tube.

The present systems, apparatuses and methods provide cooling modules arranged in an array such that the lower thermally conductive surfaces provide ample surface area to transfer body heat from the thermally conductive surface to the phase change material within.

The present systems, apparatuses and methods provide cooling modules arranged in an array such that the lower thermally conductive surfaces provide ample surface area to transfer body heat from the thermally conductive surface to the phase change material within, and the array is fixed to a flexible material consisting of a fire retardant material such as Nomex or other similar material.

The present systems, apparatuses and methods provide cooling modules consisting of a thermally conductive component having a bottom surface and an upper portion, an at least partially flexible cap that can expand and contract when the phase change material changes phases, a thermally conductive tube for carrying fluid, a temperature sensor, and a phase change material within the component that is always in contact with the conductive tube.

The present systems, apparatuses and methods provide cooling modules consisting of a thermally conductive component having a bottom surface and an upper portion, an at least partially flexible cap that can expand and contract when the phase change material changes phases, a thermally conductive tube for carrying fluid, a temperature sensor for determining the temperature of the phase change material within, and a phase change material within the component that is always in contact with the conductive tube.

The present systems, apparatuses and methods provide cooling modules arranged in an array such that the lower thermally conductive surfaces provide ample surface area to transfer body heat from the thermally conductive surface to the phase change material within, and the array is fixed to a flexible material consisting of a fire retardant material such as Nomex or other similar material, and the individual cooling modules are connected by flexible tubes or couplings that allow for the panel to flex while maintaining fluid flow.

With the foregoing and other objects in view, there is provided a self-contained apparel, blanket, pad, and device temperature control system comprising a cartridge containing at least two chemicals, a control system for controlling the rate of reaction from the mixing effect of the at least two chemicals and a receiver for securing the cartridge and transferring the thermal effects of the cartridge to a fluid isolated and independent from the cartridge The cartridge can be constructed from a tube formed from a metal or polymer, for example aluminum, polycarbonate, ABS, or others and having an end that is sealed. A portion of the cartridge acts as a thermally conductive surface and the remaining portion acts as an insulator to minimize energy loss. To provide for insulation, the part of the tube not designed to be thermally conductive can be double walled, with a vacuum between the walls, constructed from an insulating polymer, or overmolded with a insulating polymer layer. The geometric shape of the cartridge can be square, rectangular, round, rectangular with curvate faces, or other geometric shape.

The cartridge can be sealed by a cap, which can be fixed by adhesive or welding, or removable to make cleaning the inside of the cartridge easier for recycling. The cap can be manufactured by molding or machining. The end cap can be a solid plug when the side of the cartridge is used for thermally transferring the reaction, or the entire end cap surface area is needed for thermal transfer, but it is preferred that the end cap have a surface to seal the cartridge to prevent leaking and a through hole for receiving a thermally conductive plate or heat exchanger. The thermally conductive plate or heat exchanger has an internal surface for contact with the chemical reaction and an external surface. The thermally conductive plate or heat exchanger surface can be flat, smooth or rough, or have fins or pins that extend into the cartridge to increase heat transfer surface area. In addition, the thermally conductive component or heat exchanger can be recessed into the end cap such that the heat exchanger face outside the chamber is protected from damage by the surrounded edges of the end cap. The cartridge can also be molded as one piece with the end cap part of the molding or manufactured from deep drawn metal, such as aluminum.

With the objects in view, there is provided a cartridge has at least two cavities for holding at least two different chemicals whereby at least one chemical is always in contact with the thermally conductive component regardless of the orientation of the cartridge.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed crate a thermal reaction, and a starting condition whereby the cartridge is inserted prior to the reaction occurring.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, a receiver for accepting the cartridge within, and a starting condition whereby the cartridge is inserted prior to the reaction occurring.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, and receiver for accepting the cartridge having a thermally conductive surface such that upon insertion of the cartridge, the two thermally conducted surfaces are in direct contact.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive heat exchanger within and a passage through the heat exchanger having a first opening and a second opening, a receiver for accepting the cartridge such that the first opening and second opening of the cartridge heat exchanger align with ports in the receiver and seal and allow fluid flow through the receiver ports to enter the cartridge heat exchanger without leaking.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive component, a receiver for receiving the cartridge and connected with the thermally conductive component, apparel with a closed structure for allowing the flow of fluid within without leaking, and a pump for moving fluid through the apparel and receiver such that the thermally conductive component transfers or removes heat from the fluid.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, and a receiver for receiving the cartridge and a connection between the receiver and the cartridge such that the pump for moving the second chemical to the first chemical is contained within the receiver.

With the objects in view, there is provided a cartridge having an internal bore and a thermally conductive portion, a piston having a first face, second face, and a hole, a first chemical disposed between the thermally conductive face and the piston first face, a second chemical place ed within the space about the piston second face, an end cap sealing the cartridge, and a direct current geared motor for moving the piston such that moving the piston towards the end cap forces the chemical above the piston second face to move through the hole in the piston into the first chemical.

With the objects in view, there is provided a cartridge having an internal bore and a thermally conductive portion, a first chemical within the cartridge and a second chemical in a chamber with an electrically controlled valve such that the valve can be directed to open and close to release a measure amount of the second chemical into the first chemical.

With the objects in view, there is provided a cartridge having an internal bore and a thermally conductive portion, a first chemical within the cartridge and a second chemical separated within, and a venturi tube such that pressure through the venturing tube creates a vacuum to move the second chemical into the first chemical to create mixing and a chemical reaction.

With the objects in view, there is provided a cartridge containing a powder and liquid separate within, at least one temperature sensor, a control system, and a metering pump for controlling the amount of liquid entering the powder in increments from 0.01 ml per minute to 100 ml per minute.

With the objects in view, there is provided a cartridge containing a powder and liquid separate within, at least one temperature sensor, a control system, and a metering pump for controlling the amount of liquid entering the powder in increments from 0.01 ml per minute to 1000 ml per minute.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface, at least two chemicals that when mixed create a thermal reaction, and a battery built into the cartridge.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having an internal flexible bladder containing at least one chemical, a second compartment separated from the first compartment by a divider, and a valve that can be electrically opened and closed to meter the contents within the flexible bladder into the second compartment.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having an internal flexible bladder containing at least one chemical filling and expanding the bladder to create pressure within the bladder, a second compartment separated from the first compartment by a divider, and a valve that can be electrically opened and closed to meter the contents withing the flexible bladder into the second compartment.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having an internal flexible bladder containing at least one chemical filling and expanding the bladder to create pressure within the bladder, a second compartment separated from the first compartment by a divider, a valve that can be electrically opened and closed to meter the contents withing the flexible bladder into the second compartment, and a thermally conductive surface on at least a portion of the cartridge.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, a receiver mounted to the side of a box for receiving at least one cartridge, and a connection between the receiver and the box such that the fluid moving through the receiver heat exchanger can be accessed from the inside of the box.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, a receiver mounted to the side of a box for receiving at least one cartridge, and a connection between the receiver and the box such that the tubing from the receiver heat exchanger connects to self-sealing quick disconnects that can be accessed from inside of the box.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, a receiver mounted to the side of a box for receiving at least one cartridge, a connection between the receiver and the box such that the tubing from the receiver heat exchanger connects to self-sealing quick disconnects that can be accessed from inside of the box, and a mat containing tubing that when connected to the disconnects allows for the fluid moving through the receiver heat exchanger to enter the mat and cool or heat the mat.

With the objects in view, there is provided a self-contained temperature control system with electronic display and controls on the front of the box comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, a receiver mounted to the side of a box for receiving at least one cartridge, a connection between the receiver and the box such that the tubing from the receiver heat exchanger connects to self-sealing quick disconnects that can be accessed from inside of the box, and a mat containing tubing that when connected to the disconnects allows for the fluid moving through the receiver heat exchanger to enter the mat and cool or heat the mat.

With the objects in view, there is provided a self-contained temperature control system with electronic display and controls on the front of the box comprising a cartridge having a first section for receiving a first chemical, a second section for receiving a second chemical, a receiver mounted to the side of a box for receiving at least one cartridge, a connection between the receiver and the box such that the tubing from the receiver heat exchanger connects to self-sealing quick disconnects that can be accessed from inside of the box, and a mat containing tubing and at least one temperature sensor that when connected to the disconnects allows for the fluid moving through the receiver heat exchanger to enter the mat and cool or heat the mat and transmits the temperature of the mat to the receiver via wire or wireless connection.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface, at least two chemicals that when mixed create a thermal reaction, and a battery built into the cartridge such that replacing the cartridge also replaces the discharged battery with a charged battery.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface, at least two chemicals that when mixed create a thermal reaction, and a drain for draining the fluid from the cartridge after the reaction is complete.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having an exit port, at least two chemicals that when mixed create a thermal reaction, and a piston or pump to create pressure in the cartridge, such that the force causes the mixed fluid in the cartridge through the exit port for remote cooling.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having at least one port, at least two chemicals that when mixed create a thermal reaction, a piston or pump, such that the piston or pump causes the mixed fluid in the cartridge to exit, and a filter to prevent unmixed chemicals from exiting the cartridge.

With the objects in view, there is provided a self-contained apparel temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed crate a thermal reaction, and a starting condition whereby the cartridge is inserted prior to the reaction occurring, and a phase change material such that the cooling or heated created by the thermal reaction is transferred to the phase change material.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed crate a thermal reaction, and a starting condition whereby the cartridge is inserted prior to the reaction occurring, and a phase change material such that the cooling or heated created by the thermal reaction is transferred to the phase change material over time.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, and a phase change material such that the cooling or heat created by the thermal reaction is transferred to the phase change material and the cartridge removed after energy storage is complete.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, and a phase change material such that the cooling or heat created by the thermal reaction is transferred to a phase change material when the phase change material changes from a solid to a liquid.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, and a phase change material such that the cooling or heat created by the thermal reaction is transferred to a phase change material when the phase change material changes reaches a set temperature.

With the objects in view, there is provided a self-contained temperature control system comprising a cartridge having a thermally conductive surface and at least two chemicals that when mixed create a thermal reaction, and a phase change material such that the cooling by the thermal reaction is transferred to a phase change material when the phase change material changes reaches a set temperature and using only enough of the thermal reaction to change the phase change material back to its original state.

In accordance with yet a further feature, at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface and a level sensor to determine the level of at least one chemical in the cartridge,

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface and a level sensor to determine the level of a divider in the cartridge.

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface, a level sensor to determine the location of a divider in the cartridge, and an internal apparel temperature sensor.

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface, and a motor rotation encoder to determine the shaft location of at least one DC motor.

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface, and a motor rotation encoder to determine the shaft location of at least one DC pump motor.

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface, and a motor rotation encoder to determine the shaft location of at least one DC pump motor, and a control system to control the speed of the DC pump motor to control the mixing and reaction rate of at least two chemicals.

In accordance with yet a further feature, the at least one temperature sensor comprises a cartridge temperature sensor to measure the temperature of the thermally conductive surface, a motor rotation encoder to determine the shaft location of at least one DC motor, and a control system to control the speed of the DC motor to control the mixing and reaction rate of at least two chemicals.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising an apparel temperature sensor to measure the temperature of the inside of the apparel, a motor rotation encoder to determine the shaft location of at least one DC motor, and a control system to control the speed of the DC motor to control the mixing and reaction rate of at least two chemicals.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising an apparel temperature sensor to measure the temperature of the inside of the apparel, least one DC motor, and a control system to control the speed of the DC motor to control the mixing and reaction rate of at least two chemicals, and a transmitter to transmit temperature and cartridge use or remaining projected reaction time to an external monitor.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising an apparel temperature sensor to measure the temperature of the inside of the apparel, least one DC motor, and a control system to control the speed of the DC motor to control the mixing and reaction rate of at least two chemicals, and an indicator or readout on the receiver showing temperature and cartridge use or remaining projected reaction time to an external monitor.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising an apparel temperature sensor to measure the temperature of the inside of the apparel, least one DC motor and a piston, and a control system to control the speed of the DC motor to control the movement of the piston to force the movement of at least one chemical into at least one second chemical to create a chemical reaction.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising a temperature sensor to measure the temperature of the inside of a blanket or pad, least one DC motor and a piston, and a control system to control the speed of the DC motor to control the movement of the piston to force the movement of at least one chemical into at least one second chemical to create a chemical reaction.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising a temperature sensor to measure the temperature of the inside of a cooling module, the cooling module consisting of phase change material sandwiched between two sheets of material, in which a thermally conducting tube passes through the middle of the phase change material.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising a temperature sensor to measure the temperature of the inside of a cooling module, the cooling module consisting of phase change material sandwiched between two sheets of material, in which a thermally conducting tube passes through the middle of the phase change material, whereby the sensor tip is aligned with the center of the thermally conductive tube.

In accordance with yet a further feature, a temperature control system having at least one temperature sensor comprising a temperature sensor to measure the temperature of the inside of a cooling module, the cooling module consisting of phase change material sandwiched between two sheets of material, in which a thermally conducting tube passes through the middle of the phase change material, whereby the sensor tip is offset from the center of the thermally conductive tube.

In accordance with yet a further feature, a temperature control system having at least one cooling module consisting of phase change material sandwiched between two sheets of material, in which a thermally conducting tube passes through the middle of the phase change material.

In accordance with yet a further feature, a temperature control system having at least one an array of cooling modules with at least one cooling module with a temperature sensor, and similar modules without a sensor, the modules sandwiched between two sheets of material, in which a thermally conducting tube passes through the middle of the phase change material and connecting the array for allowing fluid to pass through all the modules.

In accordance with yet a further feature, a temperature control system having at least one cooling module consisting of a thermally conductive component, a cap that is at least partially flexible, a thermally conductive tube, and a phase change material that is sealed within the module when the components are assembled.

In accordance with yet a further feature, a temperature control system having at least one cooling module consisting of a thermally conductive component, a cap that is at least partially flexible, a thermally conductive tube, and a phase change material that is sealed within the module when the components are assembled, and a sensor that extends into the cavity of the cooling module.

In accordance with yet a further feature, a temperature control system having at least one cooling module consisting of a thermally conductive component which is inserted through a preferably flexible material, and a cap that is at least partially flexible, such that sliding the cap over the cooling module to the proper location locks the cap in position, which compresses a portion of the cooling module and surface of the cap against the preferably flexible material to lock the assembly in position.

In accordance with yet a further feature, a temperature control system having at multiple cooling modules consisting of a thermally conductive component, a cap that is at least partially flexible, a thermally conductive tube, and a phase change material that is sealed within the module when the components are assembled, and at least one sensor that extends into the cavity of at least one cooling module.

In accordance with yet a further feature, a temperature control system having at multiple cooling modules consisting of a thermally conductive component, a cap that is at least partially flexible, a thermally conductive tube, and a phase change material that is sealed within the module when the components are assembled, and at least one sensor that extends into the cavity of at least one cooling module to create a panel that can be connected to other panels to build a vest or other piece of apparel.

With the foregoing and other objects in view, there is provided, a self-contained temperature control system comprising a cartridge having a thermally conductive surface, a chamber disposed above the thermally conductive surface, a first chemical disposed within the chamber, at least one additional compartment, at least one additional chemical disposed within the at least one additional compartment, and a pump configured to move at least one chemical from the at least one additional compartment into the chamber to change a temperature of the thermally conductive surface.

With the objects in view, there is also provided a temperature control system comprising a first container suspended within a second container, the first container having a sealed end, an opening in the sealed end for receiving a hollow tube, a first chemical disposed within the first container, a piston movable within the first container, and an actuator configured to move the piston from a first position to a second position to displace contents of the first container into the second container.

With the objects in view, there is also provided a temperature-regulating fabric comprising a top flexible layer, a phase change material, a flexible tube suspended within the phase change material, and a bottom flexible layer.

With the objects in view, there is also provided a temperature-regulating construct comprising a thermally conductive component, an at least partially flexible cap covering and secured to the thermally conductive component, a phase change material disposed within the thermally conductive component, and a thermally conductive tube suspended within the phase change material and extending through, and held in position by, the flexible cap.

With the objects in view, there is also provided a temperature control system comprising a heat exchanger comprising a housing defining an internal cavity, the housing having a fluid inlet and a fluid outlet, a heat exchange cartridge removably in contact with the heat exchanger, the cartridge comprising a chemical reaction configured to absorb thermal energy from a circulating fluid, a pump configured to circulate the fluid through the heat exchanger and a fluid pathway, and a temperature-regulating textile in fluid communication with the heat exchanger via the fluid pathway, the textile comprising one or more fluid conduits configured to receive the circulating fluid and transfer thermal energy between the circulating fluid and a body in contact with the textile.

In accordance with another feature, the cartridge is configured to fit within a receiver, the receiver containing a heat exchanger surface such that insertion of the cartridge into the receiver creates surface contact between the thermally conductive surface of the cartridge and the heat exchanger surface of the receiver.

In accordance with a further feature, a temperature of an internal environment is controlled by regulating a volume of at least two chemicals introduced into the chamber.

In accordance with an added feature, the at least two chemicals are mixed at a rate between 0.01 mL and 100 mL per minute.

In accordance with an additional feature, there is provided a heat exchanger having an internal passageway for the movement of fluid, the heat exchanger having an inlet and outlet and a pump configured to control flow of fluid through the heat exchanger through the inlet and outlet.

In accordance with yet another feature, there is provided a receiver having a cavity configured to receive the cartridge, the receiver comprising a heat exchanger for contacting the thermally conductive surface of the cartridge, the heat exchanger having a fluid passageway and a second pump configured to move fluid through the fluid passageway.

In accordance with yet a further feature, there is provided a receiver having a cavity for receiving the cartridge and a first connection to the cartridge for receiving fluid from the cartridge.

In accordance with yet an added feature, there is provided a receiver having a cavity for receiving the cartridge, the receiver comprising a heat exchanger for contacting the thermally conductive surface of the cartridge, and a phase change material disposed within the heat exchanger.

In accordance with yet an additional feature, there is provided a pump for moving fluid through the heat exchanger, a series of modules at least partially containing a phase change material through which the fluid passes, and a closed-loop system configured to return the fluid from the modules to the heat exchanger.

In accordance with again another feature, there is provided a sensor in contact with the phase change material.

In accordance with again a further feature, multiple nodes are disposed on a flexible panel and are interconnected to allow for fluid flow through the nodes.

In accordance with again an added feature, at least one node in the panel contains a sensor.

In accordance with again an additional feature, the phase change material is in a solid phase below a set temperature.

In accordance with a concomitant feature, there is provided a second lower-temperature phase change material disposed within the thermally conductive component, a cartridge, chemicals in the cartridge, fluid in the cartridge, a heat exchanger, a first and a second phase change material having different transition temperatures, both initially in a solid phase below a set temperature, a processor configured to control the cartridge and the heat exchanger to mix the chemicals and change temperature of the fluid to return the lower-temperature phase change material to solid state before the higher-temperature phase change material transitions, and a sensor configured to detect partial liquefaction of the lower-temperature phase change material and to transmit data to the processor.

Although the systems, apparatuses, and methods are illustrated and described herein as embodied in the adaptive temperature control system, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments will not be described in detail or will be omitted so as not to obscure the relevant details of the systems, apparatuses, and methods.

Additional advantages and other features characteristic of the systems, apparatuses, and methods will be set forth in the detailed description that follows and may be apparent from the detailed description or may be learned by practice of exemplary embodiments. Still other advantages of the systems, apparatuses, and methods may be realized by any of the instrumentalities, methods, or combinations particularly pointed out in the claims.

Other features that are considered as characteristic for the systems, apparatuses, and methods are set forth in the appended claims. As required, detailed embodiments of the systems, apparatuses, and methods are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the systems, apparatuses, and methods, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the systems, apparatuses, and methods in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the systems, apparatuses, and methods. While the specification concludes with claims defining the systems, apparatuses, and methods of the invention that are regarded as novel, it is believed that the systems, apparatuses, and methods will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which are not true to scale, and which, together with the detailed description below, are incorporated in and form part of the specification, serve to illustrate further various embodiments and to explain various principles and advantages all in accordance with the systems, apparatuses, and methods. Advantages of embodiments of the systems, apparatuses, and methods will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:

FIG. 1 is an isometric view of an exemplary embodiment of a cartridge having a thermally conductive component;

FIG. 2 is a perspective view of an exemplary embodiment of a cartridge internal structure;

FIG. 3 is a front perspective view of an exemplary embodiment of a cartridge internal structure with a partially extended actuating piston;

FIG. 4 is perspective view of an exemplary embodiment of a cartridge end cap;

FIG. 5 is an exploded view of an exemplary embodiment of a cartridge end cap;

FIG. 6 is a cut-away view of an exemplary embodiment of a cartridge;

FIG. 7 is a cut-away side perspective view of an exemplary embodiment of a cartridge;

FIG. 8 is a perspective view of an exemplary embodiment of a cartridge;

FIG. 9 is a perspective view of an exemplary embodiment of a cartridge;

FIG. 10 is a cut-away of an exemplary embodiment of a cartridge;

FIG. 11 is a exploded view of an exemplary embodiment of a receiver heat exchanger;

FIG. 12 is an internal view of an exemplary embodiment of a cartridge and receiver temperature control system;

FIG. 13 is a perspective view of an exemplary embodiment of a cartridge and receiver temperature control system with fluid loop;

FIG. 14 is a section view of an exemplary embodiment of an alternative cartridge;

FIG. 15 is an exploded view of an exemplary embodiment of a phase changer material heat exchanger;

FIG. 16 is an isometric view of an exemplary embodiment of an alternative phase change material heat exchanger.

FIG. 17 is an exploded view of an exemplary embodiment of a fabric and phase change material assembly.

FIG. 18 is an isometric view of an exemplary embodiment of a fabric and phase change material assembly.

FIG. 19 is an isometric view of an exemplary embodiment of a fabric and multiple phase change material assembly.

FIG. 20 is an isometric view of an exemplary embodiment of a fabric and phase change material assembly with sensor.

FIG. 21 is an isometric view of an exemplary embodiment of a fabric and multiple phase change material assembly with sensor.

FIG. 22 is an isometric view of an exemplary embodiment of a thermally conductive component.

FIG. 23 is an isometric view of an exemplary embodiment of a thermally conductive component, thermally conductive tube, and temperature sensor.

FIG. 24 is an isometric view of an exemplary embodiment of a thermally conductive assembly, consisting of a thermally conductive component, thermally conductive tube, temperature sensor, and at least partially flexible cap.

FIG. 25 is an exploded view of an exemplary embodiment of a thermally conductive assembly, consisting of a thermally conductive component, thermally conductive tube, and at least partially flexible cap.

FIG. 26 is an isometric top view of an exemplary embodiment of a thermally conductive array, consisting of a thermally conductive components, thermally conductive tubes, at least one, temperature sensor, and at least partially flexible caps arranged on a panel.

FIG. 27 is an isometric bottom view of an exemplary embodiment of a thermally conductive array, consisting of a thermally conductive components, thermally conductive tubes, at least one, temperature sensor, and at least partially flexible caps arranged on a panel.

DETAILED DESCRIPTION OF THE EMBODIMENTS

As required, detailed embodiments of the systems, apparatuses, and methods are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the systems, apparatuses, and methods, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the systems, apparatuses, and methods in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the systems, apparatuses, and methods. While the specification concludes with claims defining the features of the systems, apparatuses, and methods that are regarded as novel, it is believed that the systems, apparatuses, and methods will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the systems, apparatuses, and methods will not be described in detail or will be omitted so as not to obscure the relevant details of the systems, apparatuses, and methods.

Before the systems, apparatuses, and methods are disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “comprises,” “comprising,” or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The terms “a” or “an”, as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments.

The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact (e.g., directly coupled). However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other (e.g., indirectly coupled).

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The description may use perspective-based descriptions such as up/down, back/front, top/bottom, and proximal/distal. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments. Various operations may be described as multiple discrete operations in tum, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.

As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. As used herein, the terms “substantial” and “substantially” means, when comparing various parts to one another, that the parts being compared are equal to or are so close enough in dimension that one skill in the art would consider the same. Substantial and substantially, as used herein, are not limited to a single dimension and specifically include a range of values for those parts being compared. The range of values, both above and below (e.g., “+/−” or greater/lesser or larger/smaller), includes a variance that one skilled in the art would know to be a reasonable tolerance for the parts mentioned.

It will be appreciated that embodiments of the systems, apparatuses, and methods described herein may be comprised of one or more conventional processors and unique stored program instructions that control the one or more processors to implement, in conjunction with certain non-processor circuits and other elements, some, most, or all of the functions of the systems, apparatuses, and methods described herein. The non-processor circuits may include, but are not limited to, signal drivers, clock circuits, power source circuits, and user input and output elements. Alternatively, some or all functions could be implemented by a state machine that has no stored program instructions, or in one or more application specific integrated circuits (ASICs) or field-programmable gate arrays (FPGA), in which each function or some combinations of certain of the functions are implemented as custom logic. Of course, a combination of these approaches could also be used. Thus, methods and means for these functions have been described herein.

The terms “program,” “software,” “software application,” and the like as used herein, are defined as a sequence of instructions designed for execution on a computer system or programmable device. A “program,” “software,” “application,” “computer program,” or “software application” may include a subroutine, a function, a procedure, an object method, an object implementation, an executable application, an applet, a servlet, a source code, an object code, any computer language logic, a shared library/dynamic load library and/or other sequence of instructions designed for execution on a computer system.

Herein various embodiments of the systems, apparatuses, and methods are described. In many of the different embodiments, features are similar. Therefore, to avoid redundancy, repetitive description of these similar features may not be made in some circumstances. It shall be understood, however, that description of a first-appearing feature applies to the later described similar feature and each respective description, therefore, is to be incorporated therein without such repetition.

Described now are exemplary embodiments of the present systems, apparatuses, and methods. Referring now to the figures of the drawings in detail, there is shown a first embodiment of the air distribution system, illustrated generally at 100, as shown in FIG. 1. The cartridge has an end cap 1 with a first face 1a, bottom face 1b, an outer lip 1d, edge 1e, a bore 1h, and a chamfer 1k. The thermally conductive insert 2 has a bottom face 2b, a portion 2j to fit within the bore 1h, and a blend radius 2m to avoid a sharp edge, The surface 2b is generally lower than end cap surface 1b to protect the surface 2b of the thermally conductive insert from being scratched. The outer tube 3 has an outer surface 3a, bottom surface 3b, and upper surface 3c. End cap 1, thermally conductive component 2, and tube 3 are sealed by sealant, adhesive, threading, mechanical fastening, and/or o-rings to prevent leaking of the contents. The outer shape is shown round but can be any other shape, including square, rectangular, oval, or other geometric shapes. In this example, a powered piston 4 is used and has a outer gear sleeve 7a and end 7c.

In FIG. 2, the cartridge assembly 100 is shown in more detail. Outer tube 3 is not shown to show the inside components. End cap 1 has a recessed portion If that fits within outer tube to provide a sealing surface. A bore 1c into face 1a is larger than bore 1h, which creates a step for seating the thermally conductive component. The thermally conductive component 2 has an internal lower face 2c, an internal side face 2e, and a chamfer 3f. The thermally conductive component is relatively thin walled to minimize the thermal mass of the heat transfer surface. The quicker heat transfer occurs, the more reactive the assembly can be to thermal changes. Preferably, thermally conductive component 2 is formed from aluminum by machining, additive manufacturing, casting, or a combination of approaches. It can also be made from copper, or thermally conductive polymers. The surface of the thermally conductive component can also be treated by coatings such as anodizing or plating to increase resistance to scratching. In this embodiment, an inner tube 4 is provided having a outer surface 4a, a top end 4c, and an inner diameter 4d. Partition ring 5 has a outer surface 5a, bottom surface 5b, top surface 5c, an inner bore 5d, and a sealing portion 5e. Partition ring 5e slides along inner tube 4 and the inner bore 5d slidably seals against tube outer diameter 4a. Sealing portion 5e seals to outer tube 5 inner surface. A retention ring 6 has a top surface 6a, bottom surface 6b, outer surface 6c and inner bore 6d. The retention ring 6 holds the inner tube assembly suspended within outer tube 3 and is sealed or bonded to inner tube 4 and the inside of outer tube 3. Retention ring 6 can also be molded or machined as a one-piece assembly with inner tube 4. A small DC powered piston has an outer rotating cylinder 7 with an outer sleeve 7a, lower surface 7b, upper surface 7c, keyway 7d, and a gear 7e molded or machined into the outer sleeve 7a. A first piston 8 is located within and has an outer surface 8a, and lower surface 8b. Inner shaft 9 engages with keyway 7d. A small DC gearhead motor 10 has a pinion gear 10a for engaging gear 7e. It is preferred that the DC motor have an encoder for closed loop feedback to determine the number of rotations of the motor which directly correlate to the position of piston 20. Piston 20 has a top surface 20a and outer surface 20c. Outer surface 20c slidably seals with inner surface 4d of inner tube 4 such that as piston 8 advances, piston 20 is forced further into tube 4. Mixing tube 12 connects to nozzle 12a. The mixing tube and nozzle can be machined or molded from one piece, or the nozzle and tube can be separate components that are assembled. As piston 20 is compressed downward, tube 12 allows for fluid within tube 4 to be forced into the powder or fluid held in the cavity formed within outer tube 3 and end cap 1, thermally conductive component 2, partition ring 5, and the bottom of inner tube 4.

In FIG. 3 the cartridge assembly 100 is shown in more detail by a section view. Inner tube end 26 seals the bottom of inner tube 4 and has a top surface 26a, bottom surface 26b, side wall 26c, and a recess 26d. The recess provides maximum volume of the contents in the interior chamber, shown as 22, while maintaining sufficient edge thickness of sidewall 26c to seal to inner tube bore 4d, but can be removed. Inner tube end 26 can be adhesively bonded, attached by ultrasonic welding, threaded and screwed into matching threads in inner tube 4, or sealed in such a manner that it can be removed to clean the inner bore after usage. Mixing tube 12 has a nozzle 12a and this embodiment, and angled face to direct the flow from inside the mixing tube to create sufficient turbulence to help mix the two or more chemicals. While a separate motor and mixer can be added, having the pressure through the mixing tube do the mixing, it reduces complexity. The DC motor powered piston 7 is shown with the piston partially extended. As pinion gear 10a turns gear 7e, threaded sections advance, forcing piston 20 downwards. Central threaded shaft 9 is keyed to piston outer sleeve 7a. Rotating gear 7e rotates threaded shaft 9, which matches to threads inside threaded section 14. Threads on the outside of threaded section 14 mate to threads on the inside of threaded section 16. External threads on threaded section 16 match with internal threads on piston 8. Friction and pressure between the face 18b of piston 18 and top surface 20a of piston 20 create sufficient resistance that the threaded sections advance. Multiple threaded sections can be used to extend the cylinder active length. Although not visible, the external threaded portions have a small section that does not have threads. For example, threaded section 14 in the fully extended state has a section that extends below threaded section 16 top surface 16a, and threaded section 16 in the fully extended state has a section that extends below section 18 top surface 18a. This prevents the threaded sections from becoming separated at the end of travel. A check valve 24 has a top opening 24a and a bottom surface for connection with mixing tube 12. The check valve prevents fluid from leaving interior chamber 22 unless sufficient pressure is generated from the piston against the fluid to overcome the check valve cracking pressure. As more fluid is moved into the interior chamber, the partition ring 6 moves upwards to compensate for more volume.

In FIG. 4, the end plate assembly of assembly 100 is shown in more detail. The thermally conductive component 2 inner surface 2c can be smooth, textured, finned, or have other features to increase surface area for better thermal transfer. The bore 2e has a small blend radius 2d. Chamfer 2f is provided to allow for better flow of powder or pellets against face 2c.

In FIG. 5, the exploded view of end plate assembly 100 is shown. The thermally conductive component 2 has an outer lip 2h and an undercut 2j, which forms lip 2k. The lower surface 2b is blended into face 2j by blend radius 2m to avoid sharp edges. End cap 1 has an internal bore 1h and a counterbore 1c. The thermally conductive component 2 fits within end cap 1 and seats such that lip 2k sits against lip 1m formed by where bore 1c and 1h meet. The two components are sealed by adhesive, sealant, o-rings, or other mechanical attachment. They also may be molded together or molded from a thermally conductive material. Creating a cup shaped thermally conductive component helps nozzle 12a form a vortex within a restricted space to enhance mixing of the chemicals. The thermally conductive component can also be a flat plate countersunk within the end cap.

In FIG. 6, an alternative cartridge assembly 200 is shown in a cut-away view. While similar to the previous cartridge assembly, assembly 200 does not use an inner tube. End cap 1 with thermally conductive component 2 seal one end of tube 3. The other end is sealed by plug 30. Plug 30 has a top surface 30a, lower surface 30b, side surface 30c, a first hole 30d and a second hole 30e. The plug can be mechanically attached, threaded into position, sealed with an o-ring or adhesive, or have a form of end cap 1 without the thermally conductive component. Inlet tube 32 has a top surface 32a and bore 32c. The bottom of the inlet extends past surface 30b. Injection tube 34 has a top surface 34a, side wall 34b, and bore 34c. The injection tube connects with check valve 24. The check valve prevents fluid from the tube length above the valve from exiting the tube unless the crack pressure is high enough to open the valve. The location of check valve 24 can vary according to requirements, such as be closer to the tip. A smaller length of tube 35 has an external surface 35a and connects to check valve 24 and injection tip 38. Injection tip 38 has an external surface 38a, and an exit port 38b. The exit port 38b can be a single hole, angled hole, series or holes, or a jet designed to enhance mixing of at least two chemicals. Partition 36h has a top surface 36a, bottom surface 36b, side surface 36c, a slidable seal, such as an o-ring or lip 36d, a recess 36e which forms inner side wall 36f. In place or in conduction with an o-ring, a lip 36h can provide additional sealing. This can be an angled face that is compressed into a cylindrical form when inserted into internal bore 3b. The recess is optional; however, it allows for a larger side surface 36c while reducing the volume of partition 36. A hole 36g extends through partition 36 and slidably seals to injection tube 34. For example, powder, pellets or a solid form of reactant is placed in the space between partition 36 and the end cap 1 and thermally conductive component 2. This area is defined as the reaction chamber. Liquid is contained in the area above partition 36, between the partition and plug 30. Liquid is pumped from inlet tube 32, where the end of inlet 32 is disposed within the liquid, and through the injection tube assembly and out the exit port 38b. This mixes the liquid and solid directly against the thermally conductive plate. As the liquid is moved from above the partition to below it, the partition moves to accept the increased volume. This also keeps the combined chemicals against the thermally conductive component even if the cartridge is inverted. It is preferred that inlet tub 32 and injection tube 34 connect to quick disconnects.

In FIG. 7, the cartridge assembly 200 shown in FIG. 6 is shown in an angled cut-away view. Inlet tube 32 has an end 32b that extends into the chamber formed between the bottom 30d of plug 30 and the top 36a of partition 36. Pump 40 has a pump end 40a, input end 40b, output end 40c, and motor 40d. The pump transfers fluid from inlet tube 32 to injection tube 34. In this example, the pump is a peristaltic pump, which is capable of metering fluid rates from 0.01 ml to 500 ml per minute. In general, metering rates should be between 1 ml and 20 ml per minute, but can be higher or lower as needed to control the chemical reaction rate.

In FIG. 8, alternative cartridge assembly 300 is shown. The cartridge has a upper cap 50, having a top face 50a, lower face 50b, front face 50c, side faces 50d and 50f, and back face 50e. Upper cap 50 has a first hole 50g with chamfer 50h and a second hole 50j with chamfer 50k. The main cartridge body 52 has a front wall 52a, back wall 52e, top face 52c, bottom face 52b. and side faces 52d and 52f. The lower end cap 54 has a lower face 54b, front face 54c, side faces 54d and 54e, a radius or chamfer 54f, and back face 54g.

In FIG. 9, alternative cartridge assembly 300 is shown in more detail. Lower end cap 54 has an opening 54k for receiving thermally conductive component 56 within. Chamfer 54k runs around the intersection of opening 54k and bottom face 54b. Thermally conductive component 56 has a contact face 56a, back face 56b, first side face 56c. second side face 56d, third side face 56e, and fits within end cap 54. When increase surface contact area is required, the end cap can be completely thermally conductive and form the entire end cap. It is preferred to inset the thermal conductive component such that the face 56a of the thermally conductive component is below the surface of end cap 54 to reduce the risk of scratching.

In FIG. 10, alternative cartridge assembly 300 is shown in more detail with main cartridge body 52 sectioned. A recessed portion of upper cap 50 has a front face 50r, a first side face 50t, second side face 50u, and lower face 50s. A tube 50m extends inwards from face 50s and has an end 50n. The tube preferably has a check valve built into it and is connected to hole 50g to allow fluid to flow through. Hole 50J connects to injection tube 34 and can have an additional check valve at the top of the tube. The check valves at the top of the assembly prevent fluid or chemicals from leaking out of the cartridge once the cartridge is disconnected from the receiver. End cap 54 has a recessed portion which forms front wall 54m, a first side wall 54n, and second side wall 54p. The extended side walls allow for good sealing area, which is recessed to maximize the inner volume of the space for chemicals. The recess has a first side face 54q, back face 54r, front face 54s, and second side face 54t. Injection tube extension 60 has a tube portion 60a and a tip 60b having peripheral holes connected to the internal injection tube bore to allow the fluid to be directed outwards in a circular pattern to enhance mixing of two or more chemicals. Partition 60 slidably seals with injection tube 34 and the internal walls of the main cartridge body 52. The partition has an upper face 62a, lower face 62b, a first side face 62c. second side face 62e, front face 62d, and back face 62f.

In FIG. 11, the receiver heat exchanger of assembly 300 is shown in detail. The receiver heat exchanger has a base having a top face 72a, bottom face 72b, front face 72c, a first side face 72d a second side face 72e, and back face 72f. holes 72g accept screws 74 and can be counterbored to sink the screw heads. Two tubing connectors attach to the bottom face 72b. Cylindrical section 72h a lower face 72j and a smaller cylindrical section 72k. At least one barb 72m is provided to hold flexible tubing and a bore 72j connects with the inside of base 72. A second cylindrical section 72p a lower face 72q and a smaller cylindrical section 72r. At least one barb 72s is provided to hold flexible tubing and a bore 72t connects with the inside of base 72. The tubing connectors provide an inlet and separate exit for fluid. The lower section is preferable molded, 3d printed, or machined from a thermally insulating material, such as plastics or polymers. Thermally conductive plate 70 has a top surface 70a, bottom surface 70b, front face 70c, back face 70d, side face 70e and second side face 70f. Fins 70h extend from the surface to create turbulence and more surface area for heat transfer with the fluid passing within the heat exchanger. The fins have a groove 70k in the middle running lengthwise for accepting a gasket. Threaded holes 70g accept the threads 74a from screws 74. A gasket 71 has a top surface 71a, bottom surface 7ab, front surface 71c, back surface 71d, side surface 71e and second side surface 71f. The inside of the gasket is divided into two sections. The first section has a side wall 71h and the second section has a side wall 71j. Base 72 also has a divider that runs the length of the inside of base and separates the two tubing connects. At the opposite end of the divider from the tubing connectors, an opening in the divider allows for fluid to flow from one tubing connector through the divider and to the other tubing connector. The center 71m of gasket 71 seals the divider in base 72 to thermally conductive lower face 70b, and fits within groove 70k. The gasket can be formed from silicone, Nitrile, Neoprene, EPDM rubber, or other compressible materials. When screws 74 are tightened, the assembly seals, creating a water tight assembly with a flow path from one tubing connector to another. There are multiple flow patterns that can be created by changing or adding dividers within the flow stream.

In FIG. 12, assembly 300 is shown with the receiver absent the cover. The receiver 92 has a top 92a, bottom 92b, side 92c, and second side 92d. Internally, the receiver is divided into three compartments, with the top compartment having a top internal wall 92f, a first side 92j, second side 92h, and a divider 93. A lower compartment has a second divider 92g and a top surface 92j, side surface 92k and second side surface 92k, and bottom surface 92n. Divider 92g has a rectangular through hole to allow heat exchanger 72 to linearly slide within. A support bar 92p supports spring 76. This allows heat exchanger assembly, including top 70, and base 72 to move downwards when the cartridge is inserted and then back up to compress the heat exchanger top surface against the thermally conductive surface of the cartridge. Top divider 93 has a top surface 93a, bottom surface 93b, and two tubing connectors extending from surface 93a. The top divider can be molded or 3d printed as one piece with receiver 92. Two cylinders with o-rings and fluid passageways extend from the bottom surface 93b and match the hole locations of cartridge top plate 50a. One cylinder extends inside hole 50j and the other within 50g. The o-rings seal the cylinders to their perspective holes. When the cartridge is inserted, the heat exchanger moves against the spring and allows sufficient motion downwards for the cartridge to clear the two cylinders with o-rings. When the cartridge is fully inserted, the spring returns the heat exchanger to the proper position while pushing the cartridge upwards to engage the two cylinders and seal the fluid passageways. Pump 40 has an inlet 40a and outlet 40b which connect by tubes 90 and 92 to the tubing connectors on divider 93. Printed circuit board 94 and rechargeable batteries 96 sit above divider 93. The batteries can alternatively be included in the cartridge such that replacing cartridge replaces the discharged batteries with charged batteries. A second pump 88 having a dc motor 88a connects to quick disconnects 84 and 86 by respective tubes 78 and 80. Temperature sensors (not shown) monitor the temperature of the heat exchanger and fluid running through pump 88. The temperature sensor(s) for monitoring the flow from pump 88 are preferably placed remotely in the apparel, blanket, pad, device, equipment, or other to directly monitor temperature at the desired cooling or heating location.

In FIG. 13, assembly 300 is shown with an example of an external flow loop. Receiver 92 has a cover 96 having a top surface 96a, bottom surface 96b, side 96c, second side 96d, and in this example, a small extension to compensate for the overall length of the pump. A lower cover panel 100 has a front face 100a, bottom surface 100b, top edge 100c, a side face 100d, and a second side face 100e. a hinged cover 98 has a hinge assembly 98d that attaches to the receiver side 92e. The hinged door has a front face 98a top face 98c, and bottom face 98b. A latch 98e holds the door closed and sealed against the receiver edges to insulate the interior of the receiver. There are multiple ways to cover the receiver and insulate the interior, of which this is just an example. Also cover 96 and cover 100 can be one piece with the door sliding or hinged from another direction. Tubing 106 forms a closed loop such that fluid from the pump travels through quick disconnect 104 through quick disconnect 102. Heat is added or removed from the tubing by the reaction by the speed of pump 88 and the speed of the reaction of at least two chemicals.

In FIG. 14, assembly 400 is shown in a cut-away view. Powder, pellets, or solid material 88 is separated into compartments by dividers 84. The dividers slidably seal to inner tube inner wall 4c and slidably seal to injection tube 34. As piston assembly 7 is rotated, the piston advances, pushing internal piston 80 downwards to force the solid material down into the reaction chamber 86. The powder, pellets, or solid react with the chemical in reaction chamber 86 to cool or heat the thermally conductive component 3. Dividers 84 are thin enough to stack within chamber 36. Alternatively, the dividers are at least partially made from a dissolving material such as cellulose. As the dividers and solids move downwards, the volume increases and partition 5 moves upwards to compensate. When the first chemical within the reaction chamber is liquid, the space between inner wall 3d and outer wall 4a of the inner tube can also be filled with liquid. As partition 5 rises, pressure forces the liquid in the space through hole 91d in inner tube retainer 91. Retainer 91 has a top surface 91a, bottom surface 91b. Center piston 95 has a top surface 95a for engaging the piston, a lower surface 95b, and channels 955 for channeling fluid under the piston to injection tube 34.

In FIG. 15, assembly 500 is shown in an exploded view. The heat exchanger assembly can be part of the receiver for contact with the cartridge or built into the bottom the cartridge. The heat exchanger has a top plate having a top surface 110a, bottom surface 100b, side face 110c and a second side face 110d, a back face 110e and front face 110f. Fins 110j have a first face 110g, second face 110m, and a lower face 110k. The fins, which can also be pins, allow for better heat distribution from the top plate and the number and spacing can be adjusted according to the requirements. The phase change material container has a top face 114a, bottom face 114b, a front face 114c, back face 114d, a first side face 114e, a second side face 114f, and internal faces 114p, 114k, 114m, and 114n. In this example, the container is sealed and has a bottom inside face. Fins 114j extend upwards from the bottom inside face. As an alternative, the fins can be machined or manufactured through additive manufacturing to a plate, such as plate 70 in FIG. 11 and a box attached to the top of the plate to create a sealed box. Fin bottom 110k can contact the bottom inner face of container 114, or have a gap to create a thermal gap. As the container is mostly filled with phase change material, this creates an initial thermal layer that has to melt before the fins of 110 started absorbing heat. Fins 114j and the fins 110j are spaced such that the fins fit within the gaps between the fins, so there is overlap of the heat transfer structure. The shorter fin 110j, the more phase change material needs to melt before the cooling from the cartridge starts. As the fins 110j extend down below the surface of fins 114j, both sets of fins are always in contact with the phase change material regardless of whether or not the material is in the solid or liquid phase.

In FIG. 16, assembly 600 is shown in an isometric view. An outer case 116 has a top surface 116a, bottom surface 116b, a side surface 116c, a second side surface 116d, a front surface 116e and a back surface 116f. The box has a thin wall with inner front face 116j, inner back face 116g, and inside side faces 116g and 116h. Openings 116p accept heat transfer tubes 118. The inside bottom face 116k with the sides of the inside of the box create a cavity for fitting heat transfer elements within. Tube connectors 118f connect to a second heat exchanging element and have a front face 118h and a tubing barb 118g. In this embodiment, rectangular tubes 118 are aligned in the box such that at least the interior of the tube is open to the outside environment. Tubes 118 have a first face 118a, inside face 118b, side faces 118c and 118d, and top face 118e. These tubes can be constructed from a variety of thermally conductive materials, and can be rigid or flexible material. A second tube heat exchanger portion fits within box 116 and has a tube portion 120a that connects to tubing connects 118f. These connectors are shown molded into box 116 as one piece, but can be separate and bonded, welded, or sealed to the box. The second tube heat exchanger can also be constructed from tubes that bend down and are interspersed between tubes 116. Box 116 is filled approximately 80-90% with a phase changing material, such as long chain or short chain paraffin, with or without nanoparticles, such as aluminum, carbon tubes, or other elements to increase the heat transfer speed rate. When tubes 118 are at least partially flexible, the flex can compensate for the expansion of the phase change material during phase change and the box can have an increased volume of phase change material. The second heat tube 120 allows for cooling or heating fluid from the cartridge or receiver to enter box 116 while being isolated from heat exchanger tubes 118. A temperature probe 122 is preferably suspended within the box. When the probe determines that the temperature of the phase change material has reached the point that the material is sufficient to cause the phase change, flow through the second heat exchanger tube 120 can be automatically started by sending a signal to a controller in the receiver. This allows for the secondary loop to change the temperature of the phase change material back to its initial state. In cooling, this is from a liquid back to a solid. The tubes can be of a variety of shapes and sides from capillary thin-walled tubing to larger diameter to allow for more flow without creating large pressure drops through the tubing. Tubes 118 can also be constructed from metals, or a fabric where the pore size is insufficient to allow the phase change material to enter during the liquid phase. The fabric can be woven or nonwoven and allow the phase change material to partially enter the pores in the fabric, as long as the phase change material does not penetrate completely to the inside of the fabric. There are a variety of fabrics, such as nylons, polyester, as well as other polymer-based fabrics. For a lightweight construct, using thin fabric has application for forming lightweight long tubes to create large heat transfer surfaces for applications such as cooling respiration.

In FIG. 17, assembly 700 shows a flexible fabric construct for containing a single element of phase change material with a cooling tube interface. A first layer 140 of fabric, woven, or unwoven material has a top surface 140a and bottom surface 140b. A second layer 142 of fabric, woven, or unwoven material has a top surface 142a and bottom surface 142b. A tube 144, preferably thin-walled flexible tubing, has an outer wall 144a, a first tube end 144b and second end 144c, and inner bore 144d. The tube is placed between first layer 140 bottom surface 140b and second layer 142 top surface 142a. The phase change material is formed around tube 144. In this exemplary embodiment, the phase change material is formed from two separate sections, each of which can be the same or different phase change material or having different phase change properties. The top portion 146 of phase change material has an outer surface 146a and an interface surface 146b. The lower portion 148 has an outer surface 148a and interface surface 148b. The phase change material can also be formed from a uniform single phase change material. The surface contact of phase change material at the interface defines a boundary layer. This is a theoretical plane when the phase change material is a uniform single piece or both sides are molded from the same material. The tubing can be manufactured of a variety of metallic or non-metallic materials, but is preferred to be manufactured from flexible materials such as PTFE, FEP, OR ETFE with a wall thickness between 0.005 and 0.020 inches. The diameter can vary from micro to macro sizes in excess of 0.125 inches. However, flow rate and pressure drop are key factors in the selection of tubing diameter and length. The fabric can be of a solid thin polymer or woven from a variety of fibers, organic and non-organic, and include polyesters, aramids, and others, and may be coated for various applications, including fire resistance.

In FIG. 18, assembly 700 shows the flexible fabric construct of FIG. 17 as an assembly. The first layer 140 is compressed and sealed to second layer 142 to contain the phase change material and tubing within. When formed in this manner via adhesive, heat sealing, sewing, or weaving, pocket 140e is formed around the phase change material and a cylindrical sections 140f and 140g are formed around the tubing. When the phase change material turns from solid to liquid, it is contained by the construct. The pockets and cylinder can also be preformed in the fabric or plastic sheets. As phase changing material changes volume with the change in phase, either the fabric, flexible tube, or both can change shape sufficiently to absorb the volume increase. This keeps the phase change material in contact with the tube for maximum heat transfer capability. An alternative way to add the phase change material is to create the pocket(s) and inject the phase change material through at least one of the layers to fill the pocket around the tube. Another alternative is to force encapsulated micro beads into the pocket around the tube. A further alternative is to weave fiber in a pattern of sufficient density around the phase change material and tubing to contain the material within, such as in three-dimensional weaving.

In FIG. 19, assembly 700 shows the flexible fabric construct of FIG. 18 where a series of the individual constructs are connected. Tubing 144 rubs through multiple phase material elements, which are defined herein as nodes. The number of nodes per inch can vary, as can the size of each node. This provides for customizing thermal heat absorption based on the application. Cooling through the tubes is only need when the phase change material is partially liquified. Even without cooling running through the tubes, the node combination provides significant cooling based on the combined thermal mass of the nodes.

In FIG. 20, a construct with a temperature sensor 150 is shown. Temperature sensor 150 has a tip 150a disposed within the phase change material at the boundary layer. As discussed above, the boundary layer is a transition zone. When the phase change material reaches the melt temperature at the boundary layer, the sensor can detect this and provide feedback to the cooling control system. As an alternative, when the phase change material node is made from two phase change materials or layers with different melting temperatures, the sensor can detect the rise in temperature at the transition or boundary layer between the two materials. This provides direct feedback to the cooling system. The second layer can absorb heat from the first layer and partially melt before cooling is needed to resolidify at least part of the phase change material.

In FIG. 21, a section of layered fabric or plastic is shown with nodes and tubing contained within. The fabric 160 has a top face 160a, bottom face 160b, and while this can be a large sheet with a high number of nodes, this exemplary embodiment shows a panel having a first edge 160f, second edge 160g, third edge 160h, and fourth edge 160j. Pockets 160e contain the phase change material and the fabric is sealed around the tubing at locations 160d. Lower layer 162 has a upper face 162a for contact with fabric 160 bottom face 160b, a bottom face 162b, and edges 162c, 162d, a62e, and 162f. Tubing 155 has an outer diameter 155a inner diameter 1155d, and runs from input face 155b to output face 155c. Smooth bends 155e in the tubing allow for one tube to connect multiple rows of nodes within the fabric. In this example, one temperature sensor 150 is provided per panel. Of course, more than one sensor can be provided. Also, panels with nodes containing only phase change material and no tubing can be mixed with nodes with tubing, to create a mixed construct to maximize cooling without having tubing run through all the nodes. This is helpful to increase node density. The nodes without tubes also contain more thermal mass of phase change material. This creates at least six node options that can be mixed together, including a node with one phase change material, a node with two phase change materials, a node containing one phase change material and tubing, a node containing two change materials and tubing, a node with one phase change material and a sensor, and a node with two phase materials and a sensor.

With fluid flowing through the tubing, the phase change of the material in each node can be controlled based on the flow rate and temperature of the cooling fluid. In addition, the cooling temperature of the fluid, which in this application is colder than the phase change temperature, is effectively buffered from the body until the phase change material turns back to its original form. This helps even the temperature throughout all the nodes and minimizes or eliminates cold spots on the surface of the fabric, which can be in contact with the skin or a shirt or liner.

By metering the chemical reaction rate and controlling the flow of liquid to the apparel, device, equipment, pad, blanket, or environment, the rate of cooling or heating can be directly controlled. The expandable piston described within uses a small gear motor that has a very low power draw. The gear ratio of the motor combined with pinion gear and gear on the piston and threads provide high torque, which is effective as motor speed is less important in this application. The number of rotations and threads per inch or millimeter directly control the amount of one chemical mixing with another. As an example, 1 mm thread pitch allows for very fine control of the piston advancement. Encoders allow for closed loop monitoring of the motor rotation to ensure the piston is advancing to the required position.

For the pump embodiments, the flow from the pump controlling the introduction and mixing of one chemical within another can be accurately controlled. Pumps can also be provided with DC motors with encoders for verification that the number of rotations needed to force the required amount of fluid into the reaction are verified, and if needed, compensated for. Peristaltic, gear, and diaphragm pumps are available in very small sizes to fit this application and very capable of working with onboard small battery packs.

An alternative embodiment uses a spring under compression in place of the threaded piston. For example, in FIG. 3, the threaded piston is replaced with a spring which presses downwards on piston 20. For this to work effectively, the check valve is replaced with a electrically controlled metering valve to control the flow of fluid from cavity 22 into the reaction chamber and second chemical above the thermally conductive surface.

By placing multiple temperature sensors within the apparel, an accurate map can be made to control and set the desired temperature and control proper cooling via fluid flow through the tubing in the apparel, device, blanket, pad, or other item. Of course, one sensor can be used, but more than one sensor can provide more accurate temperature mapping. In an exemplary embodiment the output voltage of the temperature sensor(s) varies according to the temperature of the environment in which the sensor resides. A controller of the temperature control unit 1, 20 (e.g., a CPU) can read each sensor and come up with an average, or the software can adjust the result by weighting the value of a particular sensor to come up with a weighted average. The adjustment(s) can be automatic, or the user can make adjustments as needed.

Sensors for temperature and humidity are readily available. Examples include DHT22 by Aosong, TMP36 by TMP, DS18B20, by Dallas, and a series of sensors by SENSIRION AG, including SHT11, SHT40, and SHT85 among others. Some of the SENSIRION AG sensors are also water resistant to the IP67 standard. This allows for the sensor to be submerged up to 1 meter in water for up to 30 minutes, allowing the sensors to remain in place in the jacket or apparel for the purposes of washing or exposure to rain. When used herein, measuring a temperature or a temperature value means that a reading is taken that corresponds directly or indirectly to the temperature of the particular environment, e.g., the outside or inside. A given sensor may return a voltage value, for example, which may not be equal to a temperature but it is a value that can correspond to a temperature value that the controller can receive (wired or wirelessly) and interpret as a particular temperature. For measuring temperature for the phase change modules, micro-sensors such as Negative Temperature Coefficient thermistors can be used. For smaller sensors, sensors can be placed at the phase change material boundary plane. For miniaturization, the sensors can be constructed from nanometric partially-depleted complementary metal-oxide-semi-conductors, which are extremely small and low power.

The novel invention described herein has significant value when cooling or heating is required for various applications. Cooling in particular is more challenging than heating. For applications, such as wearers in high temperature environments, cooling can reduce the risk of heat induced injury as well as increase performance. Extended high heat exposure increases fatigue. In other applications, such as firefighters in extreme temperatures, the system within can be active when the cartridge is inserted, or come on at a set temperature to act as a safety life support system in case of emergency. It can also be tied into another safety system, such that when it is triggered, it also triggers temperature monitoring and cooling.

As the reaction only occurs at the rate needed, the cooling can be extended for long periods, which is based on the heat or cooling required. In addition, the reaction can be started when needed, and the cartridge can remain inactive until then. When a cartridge is expended, it is readily replaced with another. This allows for rapid replacement of the cartridge. As the cartridge reaches its end life, a signal is sent to warn the user that that a new cartridge will be required. In addition, the programming via artificial intelligence and/or machine learning can predict the rate of reaction, cooling rate or heating used and predicted to be used, and life of the cartridge remaining in order to give the user information on the use of the cartridge and advanced warning in advance of the cartridge being expended. This information can also be wirelessly transmitted to an external receiver along with any acquired temperature data so conditions can be monitored remotely. Information can also be displayed visually on the receiver.

The cartridges are designed to work in any position. Thus, if the cartridges are tilted or inverted, the reacting chemicals will still remain in contact with the cartridge thermally conductive surface and add or remove heat from the receiver heat exchanger. In addition, they are sealed to prevent leakage. It is preferred that the cartridges be recyclable, such that the chemical contents be safely disposed of and refilled with fresh contents. Batteries are shown in the receiver but can also be built directly into the cartridge such that replacing the cartridge replaces the expended batteries with charged batteries. For extreme temperature applications, a portion of the cooled fluid can be diverted to the batteries for safety, should maximum operating temperature be reached.

As the cooling and heating cartridges are interchangeable, they can be selected without changing the receiver. The receiver can also include space for multiple cartridges. For applications, whereby the environment is variable and may be cold or hot, a receiver can select a heating or cooling cartridge, or combine the cooling cartridge with a heating element in the apparel, blanket, pad, or other device. The correct cartridge is only used when needed.

The receiver and cartridge size vary according to the chemicals needed and the amount of cooling or heating required over a projected use rate per time, but is small enough to be worn on a belt, or directly attached to the side of a box or container.

To assist in maintaining a more constant temperature and more efficient system in certain applications, the cartridge cooling system can be used in conjunction with a phase change material. Phase change materials (PCMs) are substances that can absorb or release large amounts of heat energy when they change from one phase (solid, liquid, or gas) to another, such as melting or freezing. These materials are capable of regulating temperatures at specific set points, such that when a set temperature is reached, the material begins to phase change from a solid to a liquid, absorbing or releasing heat, effectively acting as a near constant temperature battery until the phase change is complete.

When the phase change is complete and no additional energy can be absorbed or released, change in temperature within the PCM occurs. This is detectable as a change in temperature over a time period. A temperature sensor then provides a signal to the control system to trigger the cartridge to activate to add or remove heat to the PCM, thereby forcing the phase change material from liquid back into a solid. With sufficient initial thermal mass, the PCM can extend the life of the cartridge significantly, as the cartridge only activates when a phase change is near completion or at completion, and deactivates once the initial PCM state is restored.

The PCM module can be interchangeable based on the temperature needs and personal requirements of the user. As an example, paraffin wax based PCMs can be altered to have difference melting points based on the length of the molecular chain. Modules can be provided with different compositions to create a customizable solution. To increase heat transfer rates of the material, the PCM can be a nanostructured PCM. Nanostructured PCMs leverage the unique properties of nanomaterials to enhance the performance of phase change materials. These materials typically consist of PCM nanoparticles dispersed within a matrix material, which may be organic, inorganic, or hybrid in nature. The nanoscale dimensions of the PCM particles offer advantages such as increased surface area, improved thermal conductivity, and enhanced heat transfer characteristics. Nanoparticles can be a variety of materials, including Carbon Nanotubes, Graphene, Metal Nanoparticles, or, Nanostructured Oxides. Aluminum nanoparticles provide an inexpensive way of increasing thermal transfer of a material such as paraffin. In addition, Nanostructured PCMs provide enhanced stability and durability, and the ability to adjust the matrix to optimize temperature and thermal properties.

To transfer or absorb heat from the PCM module, the PCM can be in direct contact with the thermally conductive face of the cartridge. As PCM materials change volume during phase change, sufficient space is required for the expansion, which is approximately eight to fifteen percent. As an example, the PCM material is sandwiched between two thermally conductive plates. The space between the thermally conductive plates contains the PCM material and an air gap to compensate for the phase change expansion. As a gap between the PCM material and the top plate would affect the heat transfer rate, heat fins extend from at least the top face, but preferably both plates to assure that the PCM is always in direct contact with both heat exchanging surfaces or fins. The higher the density of fins, the faster the heat transfer rate. As a sealed PCM changes volume during phase change, this creates a pressure vessel as the air gap space is compressed. To compensate, the space can have a vacuum, or having a floating platen, whereby the top plate is directly against the PCM material, but is elastically sealed to the sides of the PCM module, such that the platen can move up or down as phase change occurs. A spring outside of the PCM module pushes against the module to assure the PCM module is against the cartridge regardless of the phase change condition.

An alternative way to optimize heat transfer of the cartridge into the PCM is the use of heat pipes or tubes that run through the PCM. These tubes are small diameter thermally conductive tubes that allow for fluid or gas to flow through. This provides excellent heat transfer to the PCM as the tubes have 360 degrees of contact with the PCM. In addition, the tubes can have fins for additional surface area and heat transfer capability. The heat tubes can be constructed from metallic materials, such as aluminum or copper, thermally conductive polymers, or fabrics of woven or non-woven structure having a pore size that does not allow the PCM to fully penetrate to the inner diameter. A flexible tube structure also helps to compensate for the volume change pressure, as the fabric or polymer tube can alter shape by compression or expansion, such as from round to oval. Furthermore, the fabric can be formed from a stiff material or formed with an internal stent to maintain the shape while being elastic. These tubes can be connected directly with the inside of the cartridge, such that the cold fluid flows directly through the tubes. It is preferred that in this example, a filter be user to prevent any undissolved solids from entering the tubes. Alternatively, the PCM module can be in contact with the cartridge thermally conductive surface and fluid to the external cooling or heating loop can run through the PCM tubing. As another alternative, the cooling from the cartridge can be directed to a remote PCM module.

For certain applications, it is ideal to have a PCM module wherein respiration from a user flows through the PCM to aid in providing cooling to the body by cooling the air going into the lungs. The PCM has multiple tubes for maximum surface area for respiration to contact and be constructed as described above. For maximum air flow and light weight, the tubes are elongate, creating large surface areas for transferring the incoming respiration heat to the PCM matrix. This module can then be in direct contact with the cartridge, such that when the PCM matrix rises above the phase change temperature, at a desired point, the cartridge cools the PCM back to at least a partially solid form. The PCM matrix can also have a second set of tubes that cooling flow from the cartridge runs through to internally cool the matrix. As an alternative, a heat exchanger, such as shown in FIG. 11 and PCM can be placed remotely.

In various applications, particularly those involving thermal management, it is ideal to have a fabric that combines the benefits of phase change materials (PCMs) with active cooling capabilities. PCMs work by absorbing heat as they transition from a solid to a liquid state, maintaining a stable temperature during the phase change process. This allows for effective heat transfer and regulation of temperature within a specific range.

However, there are limitations to using PCMs alone. Once the PCM has fully melted and the phase change is complete, its capacity to absorb additional heat is exhausted, and the temperature of the surrounding environment can begin to rise again. This poses a challenge in situations where prolonged or intense heat exposure is expected. For example, in the case of an undergarment situated between the body and an external layer, the effectiveness of PCMs is constrained by the initial starting temperature and the duration of heat exposure. Once the PCM reaches its melting point and transitions to a liquid state, it no longer absorbs heat, which can lead to a rise in temperature and potential discomfort and health risks.

To address these challenges, integrating active cooling systems with PCM fabrics can provide a more comprehensive solution. Active cooling systems, such as those utilizing thermoelectric coolers or circulating chilled fluids, can help maintain a lower temperature and extend the cooling duration beyond the limits of the PCM alone. This combination enhances thermal regulation, ensuring that the wearer remains comfortable and protected from excessive heat over extended periods.

PCMs absorb and release thermal energy during the process of melting and freezing (phase change) to provide useful heat or cooling. The material absorbs heat as it melts, maintaining a constant temperature until the entire material has changed phase. When the surrounding temperature drops, the PCM solidifies, releasing the stored latent heat. This characteristic makes PCMs effective for applications requiring temperature control and energy storage.

Overall, while PCMs offer significant benefits in thermal management, their integration with active cooling technologies can overcome their inherent limitations, providing a more effective and sustainable solution for applications requiring reliable and prolonged heat control.

To overcome the limitations, an innovative fabric structure combining a PCM is disclosed herein. A lightweight fabric construct effectively forms a five-layer system with two types of nodes. The primary cooling node is a construct of two layers of PCM with a small diameter thin-walled tube suspended between the two layers, creating a boundary layer (layer 3) at the tube and two-layer interface. The three layers are contained within two layers of fabric, forming the five-layer construct. As the temperature in the first layer exceeds the phase change temperature, the PCM begins to liquify, passing through the first to the second layer of PCM. As the temperature of the boundary layer changes to a melt condition, cooling is sent through the flexible tubing to maintain the boundary layer and convert the first layer back to a solid. As the second PCM layer is absorbing heat, it is expected that the second PCM layer will partially phase change at the interface prior to re-solidification. Thus, the boundary layer is also expected to shift. To monitor the boundary layer, a second node having a nano partially-depleted complementary metal-oxide semiconductor temperature sensor is interspersed between the primary nodes. Sensors can also be other temperature sensors, such as micro sensors. As the phase change temperature can be set by the material, the temperature sensors only need a very limited range to function in this application. The nodes can also be a single node combining a temperature sensor, PCM, and tube. Not all nodes need a temperature sensor, and it is preferred to intersperse a limited number to minimize the complexity and transmission of temperature sensor data to a collection point. Cooling nodes can also be interspersed with PCM containing nodes without tubing. These nodes contain only phase changing material. Temperature sensors measuring the temperature of the fluid flowing through the nodes can be used for simplified measuring of the combined temperature changes of multiple nodes.

The structure above can be formed in a simplified way where the PCM material is injected, formed, or molded around the tubing in a single piece. Thus, the first layer can be defined as the layer or amount of material on one side of the tubing centerline and the second layer defined as the amount of material on the other side of the tubing centerline. The boundary layer is a shifting layer created by the phase changing temperature conditions as the phase change material heats and cools.

The PCM layers, or volume of material on each side of the tubing centerline can be uniform or non-uniform. Thus, the thermal mass of material can be greater on the side exposed to direct heat, and less on the opposite side, or the same thickness. The phase change material layers can also be of different materials or compositions, such that the heat transfer properties are not exactly the same. This allows for the first layer to phase change and the second layer to phase change only when a set temperature is reached, creating a step-like approach. For example, if the phase change first layer phase changes to liquid at 70 degrees F., the second layer will only phase change at 72 degrees F. Thus, the first layer must rise to 72 degrees before further heat absorption by the second layer of PCM, delaying any phase change of the second layer. Of course, more than two layers of phase change materials can be used to accomplish different results.

The primary node PCM with cooling tubes are connected to the endothermic metered chemical reaction to maintain a relatively constant temperature regardless of high temperature environmental conditions. Feedback from the temperature sensors provide the control system with information to control the reaction. This combination reduces the amount of endothermic reaction needed while the PCM buffers the cooling to create an even temperature distribution through the fabric, apparel, or other application.

The fabric nodes can be of any size or shape, including round, hexagonal, oval, octagonal, or others, and of sufficient thickness to contain enough mass of the PCM to create the desired effect. By creating multiple small nodes, the overall fabric weight can be kept low. In addition, the nodes can create a pattern such that the nodes touch the skin or underlayer surface, but the fabric in between the nodes is suspended above, creating small channels for air and perspiration to move throughout the fabric. Nodes containing only PCM can be interspersed between nodes with tubing to allow for tighter packing of nodes. By using nodes, the fabric construct remains light and flexible.

Phase change materials used in this application can vary according to requirements, and various forms absorb or release energy at phase transition from solid to liquid. This includes organic or inorganic, paraffins, water-based, salt hydrates, and organics without or without suspended particles.

Phase change materials (PCMs) used in thermal management applications can vary widely based on specific requirements. These materials absorb or release energy during the phase transition from solid to liquid and vice versa, effectively stabilizing temperatures within a designated range. The selection of PCMs depends on factors such as the desired phase change temperature, latent heat capacity, thermal conductivity, and chemical stability. Various forms of PCMs are utilized, including organic, inorganic, paraffin-based, water-based, salt hydrates, and organics with or without suspended particles.

For example, paraffins are the most commonly used organic PCMs. Paraffins are hydrocarbons with a general formula of CnH2n+2. They are favored for their high latent heat storage capacity, chemical stability, and non-corrosiveness. Examples include n-octadecane and n-eicosane. Another example are fatty acids, which are organic PCMs, such as capric acid and lauric acid. They have a high latent heat capacity and are biodegradable, making them environmentally friendly. Inorganic PCMs can be made from Salt Hydrates, which are salts that incorporate water molecules into their crystalline structure, such as sodium sulfate decahydrate and calcium chloride hexahydrate. Salt hydrates have a high latent heat capacity and good thermal conductivity, but they can suffer from phase separation and supercooling issues. Although less common, metals and metal alloys can be used as PCMs due to their high thermal conductivity and substantial latent heat capacity. Examples include gallium and eutectic alloys of bismuth and tin. To enhance the thermal conductivity and performance of PCMs, nanoparticles (e.g., aluminum, copper, carbon nanotubes, or graphene) can be suspended in the PCM matrix. These nanocomposites exhibit improved heat transfer characteristics, enabling faster and more efficient thermal regulation. PCM particles can also be microencapsulated, which involves encapsulating PCM particles within a protective shell to form microcapsules. This technique enhances the stability and durability of PCMs, preventing leakage during the phase transition. The ability to select PCMs based on specific phase change temperatures and thermal properties allows for precise thermal management in various applications and helps maintain stable thermal transfer rates. Bio-based waxes are also used.

Phase change materials may also be micro-encapsulated and distributed within the node. It is preferred that the phase change material be organic and contain nanoparticles, such as aluminum or carbon to increase effective thermal conductivity of the construct. For the fabric layers, the fabric can be constructed from a variety of organic and inorganic materials. For fire resistance, it is preferred that the fabric be manufactured from materials such as meta-aramids, and para-aramids, synthetic fire-resistant fabrics, and materials with fire-resistant coatings. The fabric can be woven or unwoven, or a combination of both. It can also be a sandwich of polymer sheets.

By combining the fabric phase change material structure with cooling tubes, the temperature output can be more uniform. The phase change material acts as a temperature buffer and can be set at specific temperatures. Temperatures can be set base on the material, which is often adjusted based on changing the chemical composition or chemical chain length. Examples of temperatures that can be set that are beneficial to the human body are 70 degrees F. and 85 degrees F., but can be adjusted as needed. This allows for cooling from the endothermic reaction to be below the phase change material transition temperature.

In FIG. 22, a thermally conductive component of assembly 900 is shown. This component can be machined from aluminum, copper, or other material, or 3D printed or molded. If machined, 6063 aluminum is preferred for its heat transfer capability combined with low weight. The thermally conductive component 170 has a top surface 170a, bottom surface 170b, upper cylindrical surface 170c, and a lower recessed area 170d. Surface 170e acts as a flange and 170f extends from the cylindrical surface to form a lip 170g. An optional chamfer 170h slopes the top surface of the flange. An opening 170j runs through the part. While it can be just a bore, in this example opening 170j is a rounded slot, leaving a flat portion 170k. The outer edge 170m of flange 170e is radiused 170r to avoid sharp edge. A second opening 170n is machined or formed in the part.

In FIG. 23, the thermally conductive component is shown as part of assembly 900. A thermally conductive tube 180 sits within at least a portion of opening 170j. Tube 180 has a first end 180a, send end 180b, outer surface 180c, and bore 180d. A temperature sensor 176 has a top 176a and connectors 176b. Sensor 176 sites within opening 170n.

In FIG. 24, the thermally conductive component assembly 900 with sensor is shown. A cap 182 is pressed over the thermally conductive component 170 until in the proper position. The cap 182 has a top surface 182a, bottom surface 182b, outer surface 182c, extension 182d, outer face 182e of extension 182d, and a bore 182f for receiving temperature sensor 176. An optional blend radius 182f avoids sharp edges where 182d and 182c surfaces join. Face 182j and 182k have a bore 182m that extends through to allow tube 180 to pass through while sealing to cap 182. When the cap is pressed into position, there is a gap between 182b and 170e, which is thickness of the fabric minus enough to create sufficient force to hold the assembly in position on a panel, which is preferably flexible fabric, but can be a rigid or semi-rigid panel.

In FIG. 25, thermally conductive component assembly 950 without sensor is shown. It is not necessary for every assembly to have a sensor, as the results from one sensor can be extrapolated to provide an estimated result for multiple assemblies. As can be seen in the figure, the thermally conductive component 174 does not have a hole or feature to accept a sensor. Of course, it is possible to use component 170 for all the assemblies. However, removing the hole reduces the part cost. The thermally conductive component 174 has a top surface 174a, bottom surface 174b, surface 174c, recess 174d, a flange face 174e, and outer edge of the flange 174f, lip 174g, and a chamfer leading from surface 174c to lip 174g. The lip creates a locking feature for cap 172. The top surface 174a is blended to surface 174c with a radius to avoid a sharp edge. A slot for thermally conductive tube 180 has a radiused lower surface 174m and side wall 174n. When thermally conductive tube 180 fits within the slot, the tube does not contact surface 174m or 174m, and is suspended by the location of opening 172f in cap 172. This avoids heat transfer of thermally conductive component 174 directly to tube 180. This allows the heat transfer of the assembly to occur only by the phase change material contact within component 174 to the tube and the fluid flowing through the tube. An optional radius 174p at the bottom of component 174 blends the internal bore 174k with the internal bottom surface (not shown). Wall thickness of the assembly is preferably between 0.010 and 0.020 inches and manufactured from a thermally conductive material. For cost and weight purposes, aluminum 6063 is a good material. However, other alloys of aluminum, copper, graphene, pyrolytic carbon, thermally conductive polymers, and others are possible. Cap 172 has a top surface 172a, bottom surface 172b, other surface 172c, an extension 172d to provide enough surface area to seal the cap against the surface 180c of tube 180. Extension 172d has a face 172e and a bore that extends through face 172e to face 172j. Internal bore 172k has a groove 172g for receiving the lip 174g and chamfer 174h within to positionally lock the two components together.

In FIG. 25, an example of a thermally conductive component array 1000 is shown. A series of assemblies without sensors is combined with a assembly with a sensor to create a single panel. The number of components and size of the panel can vary greatly, and more than one sensor assembly can be used per panel. The assemblies are connected by flexible connectors 210 which allow the entire panel to flex. Lower surfaces of the caps, 172b and 182b contact panel 200 to press against panel top face 200a. Tubes 190 connect one row of components to the next row, to create a continuous loop to allow for fluid to flow from one end to the other. Multiple panels can be connected in this manner to create a very large continuous array. While shown as individual tubes and caps, this assembly can also be molded as a complete assembly. When this is done, small tube segments of tube 180 can be inserted into the molded assembly prior to inserting the thermally conductive components 170 and 174.

In FIG. 25, the thermally conductive component array 1000 is shown from the bottom. Thermally conductive components 170 and 174 are inserted through holes in the fabric or flexible panel, which sandwich the material between 172e and cap surface 172b and 182b. This creates a large thermally conductive surface for transferring heat from the body into the array. This allows for heat transfer from the thermally conductive components to the phase change material contained within, to tube 180, and then to the fluid flowing through the tube and visa versa. When the panel is below the phase change temperature of the phase change material, the phase change material remains solid, as phase change occurs and the temperature changes, the phase change material turns to liquid, and the sensor detects the change and can direct the system to direct cold fluid through the tubing to cool the phase change material and return it back to a solid or semi-solid phase. As the phase change material changes characteristics during phase change from solid to liquid, the at least partially flexible cap allows the assembly to expand and contract to maintain the maximum phase change material volume within the assembly. In addition, this volume change can be detected by alternate pressure sensors, which can be substituted for the temperature sensors. Thus, pressure change will determine the rate of fluid flow through the tubing to the array. The location of the sensor can also be adjusted based on the desired response time to phase change. As the system takes time to send cool fluid to each thermally conductive component, and the phase change material has a response time to turn from solid to liquid, the sensor position can be moved closer to the thermal face in contact with the heat source to speed up the response or further away to slow the response time.

For the components shown herein, there are multiple materials and manufacturing approaches possible to construct the components. As discussed in the embodiments, one ideal way to manufacture the components is by additive manufacturing. This allows for the elimination of molds and creates material possibilities and easier changes and modifications which may be needed depending on the apparel or item. 3D printing is readily available and allows for complex part manufacture. Various polymers, including ABS, ASA, PETG, carbon-fiber-reinforced materials, polycarbonate, acrylic, PEEK, PLA, metals, and others are available. Titanium and aluminum are lightweight metals that can be used for this application. Materials and colors can be combined to create unique structures. Water soluble support materials allow for support of the printing structure for complex shapes and can be easily removed after printing. Standard manufacturing techniques can be used, such as molding and machining, and making the embodiments herein in multiple pieces to make such manufacturing processes possible. The fabric, as discussed herein, can be constructed from woven or non-woven materials, such as cotton, polyester, aramid, Nomex, and other organic and inorganic fibers of various diameters. The fabric can be flash proof and/or fire retardant.

It is noted that various individual features of the inventive processes and systems may be described only in one exemplary embodiment herein. The particular choice for description herein with regard to a single exemplary embodiment is not to be taken as a limitation that the particular feature is only applicable to the embodiment in which it is described. All features described herein are equally applicable to, additive, or interchangeable with any or all of the other exemplary embodiments described herein and in any combination or grouping or configuration. In particular, use of a single reference numeral herein to illustrate, define, or describe a particular feature does not mean that the feature cannot be associated or equated to another feature in another drawing figure or description. Further, where two or more reference numerals are used in the figures or in the drawings, this should not be construed as being limited to only those embodiments or features, they are equally applicable to similar features or not a reference numeral is used or another reference numeral is omitted.

The foregoing description and accompanying drawings illustrate the principles, exemplary embodiments, and modes of operation of the systems, apparatuses, and methods. However, the systems, apparatuses, and methods should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art and the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the systems, apparatuses, and methods as defined by the following claims.

The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present systems, apparatuses, and methods are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention can be practiced otherwise than as specifically described.