System, method, and device for temperature management

Abstract

Systems, methods, and devices for temperature management are disclosed. The temperature management system may include a multilayered thermal barrier system. The thermal barrier system includes a thermally reflective material layer, a material having a low thermal conductivity layer, and a phase change material. The layers may be applied as a fluid.

Description

SYSTEM, METHOD, AND DEVICE FOR TEMPERATURE MANAGEMENT RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 611,653, filed December 18, 2023, and U.S. Provisional Patent Application No. 63 / 561,688, filed March 5, 2024, both titled “System, Method, and Device for Temperature Management,” the entirety of both disclosures are hereby incorporated by reference. TECHNICAL FIELD

[0002] This document relates generally to systems, methods, and devices for temperature management. Specifically, the disclosed embodiments relate to a thermal barrier system. BACKGROUND

[0003] Thermal barriers for roofs and attics include localized repairs, complete roof replacements, and blown-in insulation. The above elements can contribute significantly to a home’s energy efficiency, indoor air quality, and overall livability. SUMMARY

[0004] According to some embodiments, a thermal barrier system has three layers. In some embodiments, a thermal barrier system includes a thermal reflective layer, a low thermal conductivity layer having a silica-based aerogel, and a thermal energy storage layer having a phase change material. In some embodiments, each of the materials is applied as a fluid.

[0005] In some embodiments, the thermal reflective layer is a top layer, the thermal energy storage layer is a bottom layer, and the low thermal conductivity layer is disposed between the thermal reflective layer and the thermal energy storage layer. The thermal energy storage layer may be applied on the surface of a substrate. The substrate may be the exterior surface of a building.

[0006] The thermal reflective layer may be configured to reflect at least 80% of the infrared heat exposed to the thermal reflective layer. In some embodiments, the low thermal conductivity layer is configured to achieve insulative values surpassing R-3. In some embodiments, the low thermal conductivity layer has a thickness of 2 mm. The thermal energy storage layer may have an energy storage capacity of 5 British Thermal Units per square foot. In some embodiments, the thermal energy storage layer has a thickness of 1 mm.

[0007] In some embodiments, the thermal energy storage layer is a top layer, the low thermal conductivity layer is a bottom layer, and the thermal reflective layer is disposed between the low thermal conductivity layer and the energy storage layer.

[0008] In some embodiments, the low thermal conductivity layer is applied on the surface of a substrate. In some embodiments, the surface of the substrate is an interior surface of a building, and the top layer faces the interior of the building.

[0009] According to some embodiments, a method of applying a thermal barrier system to a building includes fluidly applying a phase change material on an exterior surface of a substrate of the building to form a first layer of the thermal barrier system. The method may also include fluidly applying a material having a low thermal conductivity over the phase change material to form a second layer of the thermal barrier system. In some embodiments, the method includes fluidly applying a thermally reflective material over the material having low thermal conductivity to form a third layer of the thermal barrier system. In some embodiments, fluidly applying means applying by spraying. In some embodiments, fluidly applying means applying with a roll-on application.

[0010] In some embodiments, a method of applying a thermal barrier system on a building includes fluidly applying a material having a low thermal conductivity on a surface facing an interior of the building to form a first layer of the thermal barrier system. The method may also include fluidly applying a thermally reflective material over the material having low thermal conductivity to form a second layer of low thermal conductivity. The method may also include fluidly applying a phase change material over the thermally reflective material to form a third layer of the thermal barrier system. In some embodiments, fluidly applying means spraying. In some embodiments, fluidly applying means roll-on applications.

[0011] In some embodiments, a thermal barrier system includes a thermal reflective layer, a low thermal conductivity layer, and a thermal energy storage layer. In some embodiments, the thermal reflective layer includes one of reflective pigments, aluminum oxide particles, and glass-polymer hybrid metamaterial. In some embodiments, the thermal barrier system includes a weather barrier.

[0012] A thermal barrier system, according to some embodiments, includes films disposed between the thermal reflective layer, the low thermal conductivity layer, and the thermal energy storage layer. In some embodiments, the thermal barrier system’s low thermal conductivity layer includes low thermal conductivity particles. In some embodiments, the low thermal conductivity particles include silica-based aerogels suspended in resins. In some embodiments, the thermal energy storage layer comprises a phase-change material. In some embodiments, the thermal energy storage layer or the low thermal conductivity layer includes solid particles.

[0013] According to some embodiments, a method of applying a thermal barrier system includes applying a first layer to a substrate and a second layer to the first layer. In some embodiments, one of the first and the second layers is a thermal energy storage layer and one of the first and the second layers is a low thermal conductivity layer. In some embodiments, the first and the second layers are different.

[0014] The foregoing and other aspects, features, and advantages will be apparent from the DESCRIPTION and DRAWINGS, and from the CLAIMS. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Implementations will hereinafter be described in conjunction with the DRAWINGS, where like designations denote like elements, and:

[0016] FIG. 1 shows a schematic of a thermal barrier system according to some embodiments;

[0017] FIG. 2 shows a schematic of a thermal barrier system according to some embodiments;

[0018] FIG. 3 shows an isometric view of the thermal barrier system of FIG. 2;

[0019] FIG. 4 shows a schematic of a thermal barrier system according to some embodiments;

[0020] FIG. 5 shows a schematic of a thermal barrier system according to some embodiments;

[0021] FIG. 6 shows a schematic of a thermal barrier system according to some embodiments;

[0022] FIG. 7 shows a schematic of a thermal barrier system according to some embodiments;

[0023] FIG. 8 shows a graph of temperatures over time of a control and thermal barrier systems according to some embodiments;

[0024] FIG. 9 shows a graph of temperatures over time of a control and thermal barrier systems according to some embodiments;

[0025] FIG. 10 shows a graph of temperatures over time of a control and thermal barrier systems according to some embodiments; and

[0026] FIG. 11 shows a graph of temperatures over time of a control and thermal barrier systems according to some embodiments. DETAILED DESCRIPTION

[0027] Detailed aspects and applications of the disclosure are described below in the following drawings and detailed description of the technology. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts.

[0028] In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the disclosure. It will be understood, however, by those skilled in the relevant arts, that embodiments of the technology disclosed herein may be practiced without these specific details. It should be noted that there are many different and alternative configurations, devices, and technologies to which the disclosed technologies may be applied. The full scope of the technology disclosed herein is not limited to the examples that are described below.

[0029] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a step” includes reference to one or more of such steps.

[0030] The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

[0031] When a range of values is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. All ranges are inclusive and combinable.

[0032] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, mean “including but not limited to”, and are not intended to (and do not) exclude other components. 

[0033] As required, detailed embodiments of the present disclosure are included herein. It is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limits, but merely as a basis for teaching one skilled in the art to employ the present invention. The specific examples below will enable the disclosure to be better understood. However, they are given merely by way of guidance and do not imply any limitation.

[0034] The present disclosure may be understood more readily by reference to the following detailed description taken in connection with the accompanying figures and examples, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific materials, devices, methods, applications, conditions, or parameters described and / or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed inventions. The term “plurality”, as used herein, means more than one.

[0035] Embodiments of the present disclosure relate to systems, methods, and devices for temperature management. Specifically, the disclosed embodiments relate to thermal barrier systems. The thermal barrier systems can be used in interior or exterior applications.

[0036] According to some embodiments, a thermal barrier system is a multilayered system. As discussed herein, the thermal barrier system is used to reduce the amount of heat transfer across a surface. For example, the thermal barrier system may be used to reduce the rate of heat transfer from a warm outdoor environment to a cooler inside environment across an exterior wall. This may be the case with a thermal barrier system applied to the roof of a building.

[0037] The use of layering allows for better insulation. A benefit of the present invention is the customization of the thermal barrier system to the application. For example, when the thermal barrier system is used on a roof in a hot environment, the thermal barrier system may include layers that reflect the radiant heat away from the roof, and layers that store the heat so that the heat does not penetrate to the surface of the roof (and, from there, into the living spaces of the building that an operator is trying to cool). The features of the thermal barrier system will be described with reference to the accompanying figures.

[0038] FIG. 1 shows a thermal barrier system 100 according to some embodiments. Thermal barrier system 100 has three layers. Thermally reflective layer 110 is disposed on alternating layers of low thermal conductivity layers 120 and thermal energy storage layers 130. FIG. 1 shows a representative number of layers, but the use of more or fewer layers is contemplated. In some embodiments, the thermal barrier system comprises between two and forty layers (e.g., 2, 5, 6, 8, 10, 15, 20, 25, 30, 35 layers). For example, in some embodiments, the thermal barrier system comprises three layers. In some embodiments, more than forty layers are used. Additionally, the layers may be organized in a variety of ways. For example, thermally reflective layer 110 may be disposed on a low thermal conductivity layer 120, as shown in FIG. 1. Or, thermally reflective layer 110 may be disposed on a thermal energy storage layers 130. In some embodiments, thermally reflective layer 110 is absent altogether.

[0039] Thermally reflective layer 110 may include reflective pigments or other reflective material to reduce and mitigate the amount of radiant heat that initially penetrates the outermost or exposed surface of thermal barrier system 100. Thermally reflective layer 110 may use any material or combination of materials useful to reflect heat. For example, the thermally reflective layer may be a thin film product made of a highly reflective, low-emittance material, such as aluminum foil. Thermally reflective layer 110 may also include a membrane using IR-reflective pigments, aluminum oxide particles, and other spherical or non-spherical particles dispersed in a resin matrix, which may further include ceramic particles, metal oxides, silicates, carbon-based materials, or polymer composites engineered to achieve equivalent functional properties, polymer microspheres, or other reflective or insulative particles. The particulate additives may include materials with one or more of the following properties: high reflectivity to solar radiation, low thermal conductivity, high resistance to UV degradation, and mechanical stability under extreme weather conditions. The system comprises particles may reflect infrared radiation, reduce heat transfer, and provide a barrier to environmental wear, wherein the particles are uniformly dispersed within a polymeric matrix to enhance the thermal and weather-resistant properties of the coating. The particulate materials may provide reflective, insulative, and protective properties, reducing the thermal load on the substrate and enhancing the longevity of the coating system

[0040] These components reflect light across both the visible and IR bands of the spectrum. Other materials may be used that reflect radiant heat rather than absorbing it. In some embodiments, the thermally reflective layer 110 comprises a glass-polymer hybrid metamaterial. For example, glass microspheres may be sandwiched between a bottom silver film layer and a top polymer film layer. In some embodiments, thermally reflective layer 110 comprises Mylar.

[0041] In some embodiments, thermally reflective layer 110 may also be a top layer of thermal barrier system 100. In some embodiments, the top layer includes additional functions. For example, when thermal barrier system 100 is used as a coating for an exterior roof for a building, the top layer may also be a weather barrier. For example, one or more films may be used as the top layer to reduce air infiltration and increase water resistance. In some embodiments, the top layer may block water from permeating to the layers below the top layer but may permit water to escape from the layers below the top layer. This allows for the transport of water vapor away from the thermal barrier system 100, which may improve adhesion, facilitate layer drying, and reduce the risk of mold on the surface under thermal barrier system 100. A thermal barrier system 100 of some embodiments may also include additional weather barriers specifically for the management of airflow and moisture. In some embodiments, for example, the weather barrier comprises asphalt-impregnated paper, micro-perforated cross-lapped films, and films laminated to spun-bound non-woven materials. In some embodiments, using a multilayered structure allows for optimum optical, thermal, air, moisture, and mechanical properties.

[0042] Examples of the thermal barrier system 100 at work include a layer comprising a base material and particulate materials selected to enhance reflectivity and weather resistance. The particulate materials are selected from ceramics, metal oxides, or other low-thermal-conductivity materials. The particulate materials may comprise aluminum oxide, titanium dioxide, or silicon dioxide.

[0043] FIG. 2 shows a detailed cross-sectional schematic of thermal barrier system 100 according to some embodiments. FIG. 2 shows low thermal conductivity layers 120 sandwiching thermal energy storage layers 130. In the embodiment shown in FIG. 2, low thermal conductivity layers 120 and thermal energy storage layers 130 are disposed between films 102.

[0044] Low thermal conductivity layer 120 provides a thermal break using a highly porous or low thermal conducting material like aerogel. FIG. 2 shows low thermal conductivity layers 120 with low thermal conductivity particles 122. Low thermal conductivity particles 122 may be any number of substances with a low thermal conductivity. For example, the low thermal conductivity particles 122 may comprise a silica-based aerogel suspended in a resin. For example, an aerogel with a thermal conductivity of λ<0.08 W / mK may be used. Aerogels, known for their exceptional insulating properties, trap significant amounts of air within their structure. When appropriately dispersed in the resin, these nano-sized particles form a network of air pockets that effectively retard heat transfer through the layer.

[0045] Low thermal conductivity layers 120 may allow heat stored in thermal energy storage layers 130 to radiate back out into the environment and away from the object to be cooled when an ambient temperature has fallen. For example, at night, heat stored in thermal energy storage layers 130 may radiate out into the night. Low thermal conductivity layers 120 permit the heat transfer from thermal energy storage layers 130 to the environment.

[0046] For the low thermal conductivity layers 120 a layer composition may comprise a base material, an optional binder, and particulate additives engineered to enhance thermal insulation, solar reflectance, durability, or environmental resistance. The particulate additives may include materials with one or more of the following properties: ultra-low thermal conductivity, high porosity, lightweight structure, high thermal stability, and excellent optical scattering or reflective capabilities. The particulate additives may include, but are not limited to, aerogels, silica-based materials, polymeric foams, porous carbon structures, or composite materials engineered to achieve equivalent thermal or insulative properties. The particulate materials are configured to provide superior thermal insulation, reduce heat transfer, and enhance the energy efficiency of the coated substrate, while maintaining a lightweight and durable structure. The layer comprises particles with high porosity and ultra-low density, designed to reduce heat transfer, increase infrared scattering and reflectivity for heat management and provide a thermal barrier, provide hydrophobicity to increase moisture resistance, wherein the particles are uniformly dispersed in a polymer matrix to enhance thermal insulation and weather resistance.

[0047] For example, a low thermal conductivity layer may comprise one or more of: (i) a polymer base and particulate materials selected to enhance thermal insulation and environmental durability; and (ii) the particulate materials including aerogels, silica aerogels, carbon aerogels, polymer-enhanced aerogels, porous silicates, or other ultra-low-density materials.

[0048] In some embodiments, the multi-layer system also comprises one or more layers of high-conductive materials (e.g., graphene, λ>1000 W / mK), which may also be in alternating layers. High-conductive materials may be useful to direct heat flow. For example, a layer of high-conductive materials may be used to direct heat from an exhaust port across a wider surface. The high-conductive materials may also move heat to another structure, such as a heat sink. In some embodiments, high-conductive material may move heat to thermal energy storage layers 130.

[0049] As mentioned, thermal energy storage layers 130 store energy to prevent the energy from reaching the insulated object or area. Thermal energy storage layers 130 may store energy in a variety of ways. For example, thermal energy storage layer 130 may include a single or combination of thermal energy storage materials like phase-change materials (PCMs) with different phase transition temperatures. For example, a phase-change material of ΔH>120j / g may be used. The phase change materials phase-change transition temperature (PCT) may be selected based on the system application. For example, a building located in Phoenix, Arizona will require a different phase change temperature than a jacket used in Antarctica. In some embodiments, a blend of phase-change materials with different phase-change temperatures may be used in an individual layer or across multiple layers. The layers may have a variety of thicknesses. The phase change temperature of the phase change material of the thermal energy storage layer may be different in different embodiments. The phase change temperature may be selected for maximizing thermal performance.

[0050] In some embodiments, the phase-change material is a microencapsulated organic material. Microencapsulated organic materials can maintain their latent heat storage across numerous thermal cycles and avoid susceptibility to supercooling. The incorporation of phase-change materials into a membrane requires consideration of factors such as transition temperature and each thermal energy storage layer 130’s capacity. The optimal phase-change transition temperature is application-specific, contingent on the expected temperature fluctuations the phase change material layer will encounter. The goal is to design the transition temperature effectively, such that phase change materials can actively charge and discharge, providing optimal heat flux control.

[0051] FIG. 2 shows thermal energy storage layers 130 with phase change material 132. The combination of low thermal conductivity layers 120 and thermal energy storage layers 130 may be described as an engineered metamaterial (EMM). In some embodiments, the order and number of layers in the EMM may be designed for certain applications. In some embodiments, the low thermal conductivity layer(s) and the thermal energy storage layer(s) are made up of deposited particles. In some embodiments, each layer is comprised of 50-90% volume of solid particles. In some embodiments, the layer thickness is dependent on the particle size. In some embodiments, such as the one shown in FIG. 2, each layer may be separated by film 102 (e.g., a thermoplastic film). Film 102 acts as a substrate on which to deposit the particles. Adhesive 150 may be used for depositing the particles on the film.

[0052] Film 102 may be any number of films configured to receive components of thermal barrier system 100. In some embodiments, adhesive 150 is applied to film 102. In some embodiments, the substrate on which each layer is deposited (for example, the film discussed above) comprises plastic sheeting, which may be 0.3-0.5 mil plastic sheeting. In some embodiments, recycled plastic may be used to make the substrate (e.g., leftover plastic grocery bags). In some embodiments, the substrates may have perforations disposed therein, such as micro perforations, or be porous (e.g., to allow for water vapor permeability).

[0053] Adhesive 150 may adhere components of low thermal conductivity layers 120 and thermal energy storage layers 130 to films 102. Adhesive 150 may be any number of adhesives. In some embodiments, professional spray adhesive (e.g. LOCTITE) may be used on each plastic layer to adhere particles of the alternating layers. In some embodiments, a non-flammable, low toxic, sustainable spray adhesive is used.

[0054] FIG. 3 shows an embodiment of thermal barrier system 100. Thermal barrier system 100 shows thermal energy storage layers 130 sandwiched between low thermal conductivity layers 120. This layering creates an EMM composite system. Smart weather barrier 101 may be composed of breathable / micro-porous polymer films that prevents air and moisture penetration, but allows for vapor transmission.

[0055] As explained above, the multilayer insulation systems disclosed herein use PCM particles having high latent heat capacities (~180 J / g) and aerogel particles having very low thermal conductivities (~0.012 W / mK) in between thin sheets to provide spacing between the layers of thin sheets to prevent the layers from touching one another. In some embodiments, these particles, with a median particle size between 10-20 mm, serve as micro-spacers between the layers and thereby function as a thermal break, even at low volumes, leading to higher efficiency at lower costs. By forcing the heat transfer to occur between the particle-film interface instead of relying on random dispersion of these particles within a matrix (as in the case of traditional building products), the EMM can now be engineered to a specific application. The low thermal conductivity of aerogel within the layer reduces the amount of conduction that can occur between the layers, while PCM’s high latent heat capacity causes a time-delayed heat transfer to occur. This delayed heat transfer is unique to PCMs given their ability to store and release heat at specific PCTs.

[0056] FIGS. 4 and 5 show low thermal conductivity layers 120 and thermal energy storage layers 130, respectively, according to some embodiments. As previously discussed, each layer may defined by an upper film 102 and a lower film 102. Adhesive 150 may be applied to the films. As shown in FIG. 4, low thermal conductivity particles 122 are adhered to films 102 by adhesive 150. FIG. 5 shows phase change material 132 are adhered to films 102 by adhesive 150.

[0057] FIGS. 6 and 7 show thermal barrier system 100 according to some embodiments. The notations on each surface (the curved arrows on thermally reflective layer 110, the straight arrows on low thermal conductivity layers 120, and the battery symbol on thermal energy storage layers 130) are included for clarity. However, the notations are not necessarily indicative of the direction of the heat flow. For example, thermally reflective layer 110 may be configured to reflect heat in either direction.

[0058] FIG. 6 shows an exemplary thermal barrier system 100 for use to keep heat away from surface 200. As shown, thermal barrier system 100 includes thermal energy storage layers 130 disposed on surface 200. Low thermal conductivity layers 120 are disposed on thermal energy storage layers 130. Finally, thermally reflective layer 110 is disposed on thermal energy storage layers 130. This layering may be useful for an exterior roof that is exposed to the heat of the sun. In this embodiment, surface 200 may be a roof, or other exterior surface of a building. Heat is reflected from the roof by thermally reflective layer 110 of thermal barrier system 100. The heat that is not reflected passes through the low thermal conductivity layers 120 and is stored in thermal energy storage layers 130. This minimizes the amount of heat that reaches surface 200.

[0059] FIG. 7 shows an embodiment of the present disclosure used to keep heat in a structure. This embodiment may be used, for example, in regions with cold climates where keeping heat in the interior improves energy efficiency and comfort. In this embodiment, surface 200 may be a ceiling, for example, the ceiling in an attic. In the embodiment shown in FIG. 7, the heat from the interior of the structure is stored by thermal energy storage layers 130. The heat that is not stored by thermal energy storage layers 130, is reflected back to thermal energy storage layers 130 by 110.

[0060] FIG. 8 shows a graph of time compared to temperature. The TEMP axis shows the temperature of an area that is separated from a heat source by various substrates. The “substrate” temperature is the temperature of the area when only the substrate, without thermal barrier system 100, is used. As shown, the heat diffuses in the area in a relatively linear fashion, and the temperature rises quickly. “HR” shows the same setup except that the area is separated from the heat source by a substrate having a thermal barrier system 100. In the “HR” embodiment, thermal barrier system 100 only uses thermally reflective layer 110. FIG. 8 shows that, while the temperature increases, it does so at a lower rate than when no thermal barrier system 100 with thermally reflective layer 110 is present.

[0061] Similarly, “HR + LTC” shows the temperature of the area separated from the heat source by the substrate with thermal barrier system 100 having thermally reflective layer 110 and low thermal conductivity layers 120. As shown, the rate of heat transfer into the area is reduced when low thermal conductivity layer 120 is used in conjunction with thermally reflective layer 110. Finally, “HR + LTC + TES” shows the temperature of the area separated from the heat source by the substrate with thermal barrier system 100 having thermally reflective layer 110, low thermal conductivity layers 120, and thermal energy storage layers 130.

[0062] FIGS. 9 – 11 shows various testing data of thermal barrier system 100 in various configurations. The testing was carried out using a “hot-box” experimental setup. The “hot-box” operates by locating a heat lamp above a barrier. The temperature on the opposite side of the barrier is then monitored. FIG. 9 shows the experimental results of the “hot-box” test using three different barriers. The first barrier substrate is 22-gauge steel (0.76mm thick). The second barrier substrate tested is the 22-gauge steel coated with 6mm of low thermal conductivity layers 120. The third barrier substrate tested is the 22-gauge steel coated with 6mm of low thermal conductivity layers 120 and 1mm of thermally reflective layer 110. Notably, the steel sample gets significantly hotter very quickly and attains a peak temperature of 60°C in about 10 minutes, whereas the rate of heat gain of all other samples is much slower. It can be observed that the temperature profile of the second sample (with the 6mm of low thermal conductivity layers 120) is much lower than that of the uncoated steel sample. Further, adding a 1mm thermally reflective layer 110 to the 6mm low thermal conductivity layers 120 lowers the temperature and reduces the rate of heat transfer.

[0063] The tested formulations consist of nearly 20% by volume of fillers, 50-60% by volume of the polymer resin, with the rest being composed of other pigments and additives. The thermally reflective layer 110 layer consists of spherical aluminum oxide particles which have a high reflectivity in the infrared (IR) spectrum. The low thermal conductivity layers 120 consist of silica-based aerogel particles, which have very low thermal conductivity in the range of 0.010 W / mK as compared to traditional insulation materials such as fiberglass and Rockwool. This is due to their highly porous network with a gel-like structure which minimizes the solid material through which heat can be conducted. The thermal energy storage layers 130 consists of phase-change materials, which are designed to have a phase transition temperature. These phase change materials act as a barrier to heat flow because of their high latent heat capacity in the range of 200 J / g to 300 J / g. In a thin layer, these materials can lead to a reduction in peak temperatures by 15-20% and offset peak temperatures by 30 minutes or more, which can translate to energy and cost savings.

[0064] In some embodiments, the layers of thermal barrier system 100 are organized to limit or prevent the delamination of the layers. This is particularly important given the constant temperature changes of thermal barrier system 100. When arranged in a strategic layering sequence, these technologies collaborate synergistically to mitigate the rapid exchange of heat, either entering into or escaping from a given surface. The temperature is significantly reduced when a combination of the three different layers is added on the substrate. This superiority stems from the fact that each individual technology exhibits inherent limitations. For instance, thermally reflective layer 110 may be susceptible to the accumulation of dust and algae, compromising its reflective capabilities. Meanwhile, a layer designed for thermal energy storage layers 130 may face challenges related to saturation due to radiant heat exposure. Similarly, low thermal conductivity layer 120 may be prone to accelerated degradation when exposed to intense ultraviolet (UV) radiation.

[0065] FIG. 10 shows the results of another “hot-box” experiment. Each barrier sample was steel. Rigid polyisocyanurate insulation (commonly referred to as “poly-iso insulation”) was adhered to the steel using a standard structural adhesive. The poly-iso insulation was either 0.5” or 1” thick. The poly-iso insulation has an R-value of 3.25 ft2·°F·h / BTU (0.57 K·m2 / W) at a thickness of 0.5”. And the poly-iso insulation has an R-value of 6.5 ft2·°F·h / BTU (1.14 K·m2 / W) at a thickness of 1”. Additional samples were prepared by adding low thermal conductivity layers 120 in different thicknesses to the steel with the poly-iso. The results of the testing of the steel with the various thermal barrier systems 100 are presented in FIG. 10. As FIG. 10 shows, the thicker the low thermal conductivity layers 120, the lower the rate of heat transfer, and therefore, the lower temperature.

[0066] FIG. 11 shows the results of another “hot-box” experiment. The samples are again steel with poly-iso. This time, each sample includes 4mm of low thermal conductivity layers 120. The second and third samples show experimental temperature results when 1mm and 2mm of thermal energy storage layers 130 are added to thermal barrier system 100. The experimental results show that the greater the thickness of thermal energy storage layers 130, the less heat is transferred across the sample.

[0067] A variety of methods of applying the layers may be used, including, but not limited to chemical vapor deposition, physical deposition, layer-by-layer assembly, etc. In some embodiments, each layer is applied to the surface to which the system will be providing a thermal barrier (e.g., a building roof) one at a time. In some embodiments, the entire thermal barrier system is assembled layer by layer and then the entire system is applied to the surface to which the system will be providing a thermal barrier (e.g., a building roof) all at once. In some embodiments, the layers discussed above are applied, contained, or sandwiched between a different material, such as a foil face or sticker paper. In some embodiments, each layer is comprised of 50-90% volume of solid particles. In some embodiments, the layer thickness is dependent on the particle size.

[0068] In some embodiments, the thermal barrier system as a whole may be in a variety of forms, including, but not limited to a tape, a house wrap, a sticker, a board, a panel, a roll, a sheet, a coating, a film, one or more liquids that can be applied, etc. In some embodiments, the thermal barrier system includes transparent aerogel particles. For example, the thermal barrier system may be used to adhere to existing windows, making them more energy efficient. In some embodiments, the thermal barrier system includes an electrochromic layer within the system to tint the window and act as a privacy shade.

[0069] In some embodiments, the thermal barrier system comprises a hybrid PCM-aerogel metamaterial (e.g., which may be used, for example, to enhance the thermal performance of buildings and other structures such as enclosures for equipment such as switchgear boxes, fluid transport conduits within large systems such as aircrafts and power plants, and food storage containers). Rather than integrating aerogels and / or PCMs as dispersed particles within commercial products (e.g., wallboards, insulation blankets / batts, and paints / coatings), these materials (aerogels and PCMs) may each be arranged as a layer, thus providing an innovative and engineered hybrid PCM-aerogel metamaterial, implementing a whole system design approach. In some embodiments, each layer of PCM or aerogel is separated by layers of a thin polymer. Each layer is essentially an enhanced void where heat transfer occurs by means of conduction through the particle-film interface between the layers. The low thermal conductivity (~0.012 W / m.K) of aerogel particles reduces this heat transfer effect and the high TES capacity (~180 J / g) of the PCM particles induces a time-dependent heat transfer effect. In some embodiments, the combination of these effects in this engineered metamaterial may be designed and optimized for climate specific applications where enhanced thermal performance is significant or critical.

[0070] In some embodiments, the engineered metamaterial comprises a thin film technology utilizing micron-scale metamaterials to replace existing films or insulation material. The material microstructure itself (e.g., each individual layer) and the combination of layers (combining materials and systems) may be optimized to enhance thermal protection in a variety of applications. As one example, enhancing the thermal performance of existing building materials by using the engineered metamaterial provides an efficient way to reduce the energy consumption and carbon emissions associated with existing approaches. Given the number of buildings that may be retrofitted with the engineered metamaterial, this represents an opportunity to drastically reduce the energy consumption, energy-related imports, and energy-related emissions in the U.S. As another example, in the utilities space, there is a major heat management problem within substations and switchgear enclosures which contain heat-sensitive electronic equipment. Rising external temperatures can cause these electronics to fail and the failure of a single switchgear box could lead to loss of power to an entire neighborhood, whereas failure of a single substation could lead to the loss of power to several switchgear enclosures. An EMM applied to the exterior of substations and switchgears can help reduce internal operating temperatures which in turn can lead to an increase in the reliability, resilience, and security of U.S. energy infrastructure.

[0071] In some embodiments, the hybrid PCM-aerogel metamaterial (EMM) solution directly integrates in new construction and as an easy to implement retrofit solution in residential and commercial buildings. At scale, the EMM technology has the potential to reduce the energy consumption of buildings directly and reduce carbon emissions. Further, EMM radiant barriers could be directly applied onto the exterior of utility’s infrastructure to reduce external temperature loads which would lead to reductions in internal operating temperatures. This could lower the cost of heat-induced electric power outages and would increase the resilience, reliability, and security of U.S. energy infrastructure. Conventional single film products have been widely used throughout the building construction industry for decades due to their simplistic design, and ease of use. The proposed EMM solution, however, meets the demand for more sustainable and energy-efficient products by providing tunable temperature regulation ability from the PCMs, in addition to performing the typical functionalities such as reducing radiant heat and / or acting as a weather barrier. In some embodiments, the EMM comprises an easy-to-apply film. In some embodiments, these EMMs are manufactured using roll-to-roll fabrication, which may facilitate rapid commercialization and deployment onto buildings and other structural enclosures.

[0072] The low thermal conductivity layer consisting of silica-based aerogel achieves insulative values surpassing R-3 in a 2 mm thick layer, while the thermal storage PCM layer exhibits an energy storage capacity of 5 BTUs per square foot over a 1 mm thick layer within a designed temperature range. The reflective layer can reflect over 90% of the infrared heat and can be used for exterior roofing in hotter climates, or interior attic applications for colder climates. When combined in the proper arrangement, these different technologies position this system as a superior alternative to existing retrofit solutions. The different technologies embedded in the proposed multi-layered system allow roofs to maintain a high degree of thermal resilience even with surface contamination and indirect solar exposure.

[0073] As noted above, the systems disclosed herein may be manufactured using roll-to-roll processing. Roll-to-roll (R2R) processing is a continuous manufacturing technique used for producing large quantities of flexible materials. In some embodiments, the process involves feeding materials in roll form from one roll to another through a series of processing steps. This continuous material handling enables efficient, high-volume production. In the context of thermal shields, reflective or emissive coatings may be applied using coating stations. These coatings contribute to the thermal properties of the material. Methods such as physical vapor deposition (PVD) or chemical vapor deposition (CVD) may be employed to deposit thin films onto the material. After coating, the material may pass through drying chambers to remove solvents or moisture. In some embodiments, curing processes may be applied to ensure the coatings adhere properly.

[0074] Thermal shields (such as the thermal barrier system discussed above) may include multiple layers. Roll-to-roll processing allows for the continuous lamination of layers, creating a cohesive multilayer structure. In some embodiments, automated systems ensure the precise alignment of layers as they are laminated together. Once the multilayer structure is formed, slitters may be used to cut the continuous material into the desired widths. This is crucial for obtaining the final dimensions of the thermal shields. In some embodiments, automated cutting systems help achieve precision in cutting, ensuring consistency in the final product.

[0075] Once the material has undergone all necessary processing steps, it may be wound into rolls and may be packaged for storage or further transportation. Roll-to-roll processing is advantageous for its high throughput, cost-effectiveness, and suitability for flexible materials. It enables the continuous production of thermal shields with consistent quality and can accommodate various materials and coatings to meet specific thermal performance requirements. The automation in this process contributes to efficiency and scalability in manufacturing.

[0076] As noted above, thermal barrier systems may be used in a variety of other applications. Additional non-limiting examples are provided below.

[0077] Examples of using a thermal barrier system include building surfaces (roofs or attics for more energy-efficient and comfortable living spaces, roofing membranes, structural insulated panels, etc.), an automotive surface (e.g., engine components to withstand high temperatures, a car’s exterior, etc.), a clothing surface (e.g., industrial protective clothing, athletic wear, etc.), food packaging surfaces, a greenhouse surface, or a surface in a number of other applications. Examples also include batteries (e.g., lithium-ion batteries / solar and battery storage) for automobiles, aircraft, and spacecraft. Example applications include, but are not limited to, environments with extreme temperature variations (e.g., in industrial settings where equipment is exposed to fluctuating temperatures), cryogenic applications (e.g., storage and transportation of liquefied gases or materials at extremely low temperatures), electronic systems (e.g., high- performance electronics, electronic components that generate significant heat), aerospace and aviation, research and laboratory equipment (e.g., where maintaining specific temperature conditions is crucial for experiments, for sensitive equipment), transportation of temperature-sensitive goods, medical applications (e.g., for devices or equipment that require precise temperature control, medical imaging systems, cryopreservation units), energy storage (e.g., high-capacity energy storage systems), automotive applications (e.g., engine components, electric vehicle batteries, exterior surfaces), high-performance building insulation, refrigeration and cold storage, solar energy systems, industrial processes, oil and gas industry (e.g., for insulating pipelines, storage tanks, or equipment), transportation of hazardous materials, advanced materials manufacturing, greenhouses and controlled agriculture, military and defense applications, and textile and fabrics (e.g., cold-weather apparel, thermal blankets, sleeping bags, extreme sportswear, space suits, medical devices, industrial protective clothing, transportation, insulated tents and shelters, thermal undergarments, energy-efficient curtains and window coverings, automotive interiors, outdoor recreation equipment, and others.

[0078] In some embodiments, the multilayer insulation (MLI) system may be applied to textiles and fabrics, particularly in industries where thermal management and insulation are significant or critical. Potential applications related to textiles and fabrics include: Cold-Weather Apparel (e.g., incorporating MLI into winter clothing, jackets, and outerwear to enhance insulation and keep individuals warm in extremely cold conditions); Thermal Blankets and Sleeping Bags (e.g., designing thermal blankets and sleeping bags with MLI to improve heat retention, making them more effective in outdoor activities, camping, and emergency situations); Extreme Sportswear (e.g., developing sportswear for extreme conditions, such as mountaineering or arctic expeditions, where maintaining body temperature is crucial); Space Suits (e.g., enhancing the thermal insulation of space suits to protect astronauts from temperature extremes during extravehicular activities or extended space missions); Medical Devices (e.g., incorporating MLI into medical textiles used in devices for temperature- sensitive applications, such as warming or cooling blankets in healthcare settings); Industrial Protective Clothing (e.g., creating high-performance protective clothing for workers in industries with extreme temperatures or thermal hazards, providing both insulation and flexibility); Transportation (e.g., integrating MLI into textiles for automotive or aerospace applications, such as insulating seats, interiors, or components exposed to varying temperatures); Insulated Tents and Shelters (e.g., designing insulated tents and shelters for camping or emergency relief situations, providing improved thermal comfort for occupants); Thermal Undergarments (e.g., developing thermal undergarments for everyday use or specific activities, providing enhanced insulation without adding bulk); Energy-Efficient Curtains and Window Coverings (e.g., creating curtains or window coverings with MLI to improve thermal insulation in homes or commercial buildings, helping to regulate indoor temperatures); Automotive Interiors (e.g., applying MLI to automotive interiors, such as seats and headliners, to contribute to temperature control and comfort within vehicles); Outdoor Recreation Equipment (e.g., integrating MLI into various outdoor gear, such as gloves, boots, or gear bags, to enhance insulation for adventurers and outdoor enthusiasts. Factors such as flexibility, comfort, and durability are considered when incorporating MLI into textiles.

[0079] Potential applications related to applying MLI in high-performance building insulation include: Passive House Construction (e.g., MLI could be integrated into the construction of passive houses, where the goal is to achieve extremely low energy consumption. MLI’s high thermal resistance would contribute to maintaining comfortable indoor temperatures with minimal reliance on active heating or cooling systems); Arctic or Desert Dwellings (e.g., in regions with extreme climates, such as the Arctic or deserts, MLI could be used to insulate residential and commercial buildings. Its ability to provide effective insulation against both extreme cold and heat makes it suitable for structures in challenging environments); Green Roof Systems (e.g., green roofs, which incorporate vegetation for insulation and energy efficiency, could benefit from MLI as an additional layer of thermal protection. This could enhance the overall insulation of the building and contribute to sustainable design practices); Historical Building Preservation (e.g., MLI could be employed in the insulation of historical buildings, where preserving the integrity of the structure is crucial. Its thin profile and flexibility would allow for insulation without compromising the architectural features of the building); High-Rise Buildings in Urban Environments (e.g., high-rise buildings in urban environments often face challenges related to temperature regulation and energy efficiency. MLI could be incorporated into the building envelope to mitigate heat loss or gain, reducing the overall energy demand for heating and cooling); Data Centers (e.g., data centers generate significant heat from servers and electronic equipment. MLI could be used to insulate data center facilities, helping to manage the heat generated and maintain optimal operating temperatures, thus improving energy efficiency); Energy-Efficient Retrofitting (e.g., MLI could play a role in retrofitting existing buildings to enhance their energy efficiency. By adding MLI to walls, roofs, or floors, older structures could benefit from improved insulation without major alterations to the existing architecture); Temperature-Sensitive Facilities (e.g., buildings housing temperature-sensitive facilities, such as laboratories or pharmaceutical manufacturing plants, could leverage MLI for insulation. This would be particularly relevant in scenarios where precise temperature control is significant or critical for the operation of sensitive equipment or processes); Sustainable and Net-Zero Buildings (e.g., MLI could be integrated into the construction of sustainable and net-zero energy buildings, helping to minimize the energy required for heating and cooling. This aligns with the goal of reducing the environmental impact of buildings); Vacation Homes in Extreme Climates (e.g., vacation homes located in extreme climates, such as mountainous regions or tropical islands, could benefit from MLI as insulation to ensure comfort for occupants during varying weather conditions). Potential applications related to applying MLI in military and defense contexts include: Satellite and Spacecraft Insulation (e.g., MLI may be used for insulating military satellites and spacecraft, protecting sensitive electronic components from extreme temperatures in orbit); Aircraft Components (e.g., MLI might be integrated into specific components of military aircraft, such as avionics systems or equipment housed in the wings or fuselage, to shield them from temperature extremes during flight); Ground Vehicles (e.g., military vehicles, including tanks and armored personnel carriers, could benefit from MLI insulation to protect significant or critical electronics and equipment from temperature variations in diverse operational environments); Missile Systems (e.g., MLI could be incorporated into missile systems to ensure that onboard electronics and guidance systems remain within optimal temperature ranges during storage, transport, and launch); Field Equipment (e.g., portable military equipment, such as communication devices, sensors, and surveillance systems, could be insulated with MLI to maintain functionality and protect against extreme temperatures during field operations); Aerospace and Defense Infrastructure (e.g., MLI may be used to insulate significant or critical infrastructure in aerospace and defense facilities, ensuring that electronic systems, control rooms, and communication centers are shielded from temperature fluctuations); Military Shelters and Tents (e.g., MLI could be integrated into military shelters or tents to provide thermal insulation for personnel and equipment, creating a more comfortable and controlled environment in diverse climate conditions); Submarine Systems (e.g., MLI might find applications in submarine systems, insulating significant or critical equipment from the temperature variations experienced in underwater environments); Unmanned Aerial Vehicles (UAVs) (e.g., UAVs used for military reconnaissance or surveillance could incorporate MLI to protect their electronic payloads from temperature extremes during prolonged missions); Specialized Equipment Storage (e.g., MLI could be used to insulate storage containers for sensitive and specialized military equipment, ensuring that items remain in operational condition even when stored for extended period).

[0080] Potential applications related to applying MLI in electric vehicle (EV) batteries include: Battery Pack Insulation (e.g., MLI could be integrated into the design of the battery pack to provide efficient insulation, helping maintain a consistent temperature within the pack. This can contribute to improved battery performance, longevity, and safety); Thermal Management Systems (e.g., MLI could be part of the thermal management system, helping to regulate the temperature of individual battery cells. This is crucial for preventing overheating and ensuring optimal operating conditions, especially during charging and discharging cycles); Fast Charging Stations (e.g., MLI could be incorporated into the insulation of fast charging stations, aiding in maintaining stable temperatures during rapid charging processes. Efficient thermal management is vital for preventing battery degradation and enhancing charging efficiency); Electric Vehicle Thermal Blankets (e.g., MLI could be designed as thermal blankets or wraps specifically for electric vehicle batteries. These blankets could be applied during extreme temperature conditions to provide additional insulation and protect the battery from temperature-related stress); Battery Modules in Electric Aircraft (e.g., in electric aircraft, MLI could find applications in insulating battery modules. Ensuring stable temperatures during flight is significant or critical for the safety and efficiency of electric propulsion systems); Electric Commercial Vehicles (e.g., MLI could be employed in the battery systems of electric commercial vehicles, such as electric buses or delivery trucks. Maintaining optimal battery temperature is essential for the reliable operation of these vehicles during frequent start-stop cycles); Battery Electric Marine Propulsion (e.g., In electric marine propulsion systems, MLI could contribute to the thermal insulation of batteries used in electric boats and ships. This ensures reliable performance, especially in marine environments where temperature variations can be significant); Electric Off-Road Vehicles (e.g., MLI could be applied in electric off-road vehicles, including electric motorcycles, ATVs, or electric off-road trucks. These applications often encounter varying environmental conditions, and effective thermal management is crucial for battery efficiency); Electric Race Cars (e.g., MLI might find applications in electric race cars, where batteries experience rapid charge and discharge cycles and high-performance demands. Maintaining optimal temperature conditions could enhance the overall performance and lifespan of the batteries); Emergency Response Electric Vehicles (e.g., Electric vehicles used in emergency response applications, such as electric ambulances or fire trucks, could benefit from MLI to ensure that the battery systems remain operational under various environmental conditions). Potential applications related to applying MLI in solar energy applications include: Solar Water Heaters (e.g., solar water heating systems use sunlight to heat water for residential or commercial purposes. MLI could enhance the insulation of the water storage tanks, minimizing heat loss and improving overall system efficiency); Solar Desalination (e.g., solar desalination processes use solar energy to convert seawater into freshwater. MLI could play a role in insulating components of these systems, helping to maintain optimal operating temperatures for improved efficiency); Solar Cooking Systems (e.g., solar cookers utilize sunlight for cooking food. MLI could be integrated into the design to enhance insulation, improving heat retention and cooking performance); Solar-Powered Air Conditioning (e.g., solar cooling systems use sunlight to power air conditioning units. MLI could contribute to the insulation of components, reducing energy consumption and enhancing the overall efficiency of the system); Solar-Powered Refrigeration (e.g., solar refrigeration systems, used for cooling in remote areas, could benefit from MLI to improve the insulation of refrigeration units, ensuring efficient temperature control); Solar-Powered Pumps (e.g., solar pumps, used for water extraction in agriculture or remote locations, could incorporate MLI to enhance the insulation of components, ensuring reliable operation in varying environmental conditions); Solar-Powered Ventilation Systems (e.g., solar-powered ventilation systems utilize sunlight to power fans for air circulation. MLI could be employed to insulate components, improving the overall efficiency of ventilation systems); Solar-Powered Lighting (e.g., solar lighting systems, including solar streetlights or garden lights, could benefit from MLI to enhance the insulation of energy storage components, optimizing performance in various weather conditions); Solar-Powered Vehicles (e.g., solar electric vehicles or solar-assisted vehicles could utilize MLI to enhance the insulation of energy storage systems, improving the efficiency of solar energy conversion for propulsion); Solar-Powered Communication Systems (e.g., in remote or off-grid areas, solar-powered communication systems could integrate MLI to improve the insulation of components, ensuring reliable operation in diverse environmental conditions); Solar-Powered Water Treatment (e.g., solar-driven water treatment systems could utilize MLI to enhance the insulation of components, maintaining optimal temperatures for water purification processes).

[0081] Potential applications related to applying MLI in refrigeration and cold storage applications include: Refrigerated Trucks and Containers (e.g., MLI could be integrated into the insulation of refrigerated trucks and shipping containers used for transporting perishable goods. This would enhance thermal resistance and contribute to maintaining stable temperatures during transportation); Refrigeration Unit Insulation (e.g., within refrigeration units, MLI could be employed to insulate significant or critical components such as evaporators, condensers, and storage compartments. This application would help reduce heat transfer and improve overall energy efficiency); Cold Storage Warehouses (e.g., cold storage facilities that store items requiring specific temperature conditions could benefit from MLI insulation. The material could be applied to walls, ceilings, and doors to minimize heat ingress and maintain consistent cold storage environments); Food Processing Equipment (e.g., in food processing facilities, where precise temperature control is essential, MLI could be used to insulate equipment like refrigeration chambers, blast freezers, and other units involved in food preservation and processing); Medical and Pharmaceutical Cold Storage (e.g., MLI might find application in cold storage units for storing vaccines, pharmaceuticals, and medical supplies that require strict temperature control. This would ensure the integrity of temperature-sensitive medications); Specialized Cold Rooms (e.g, for applications requiring extremely low temperatures, such as research laboratories or facilities dealing with cryopreservation, MLI could be applied to the insulation of specialized cold rooms); Refrigerated Display Cases (e.g., MLI could enhance the insulation of refrigerated display cases in supermarkets and retail environments, contributing to energy efficiency and temperature consistency for products like fresh produce, dairy, and meats); Ice Cream and Frozen Dessert Manufacturing (e.g., MLI insulation could be incorporated into equipment used in the production of ice cream and frozen desserts, such as freezing tunnels and storage areas, ensuring optimal temperatures for product quality); Breweries and Beverage Production (e.g., breweries and beverage production facilities could use MLI to insulate fermentation tanks, cold storage areas for ingredients, and other equipment requiring precise temperature control during the brewing and fermentation processes); Seafood Processing (e.g., seafood processing plants, which often require strict temperature control for the storage and processing of seafood products, could benefit from MLI insulation in cold storage areas and processing equipment).

[0082] Potential applications related to applying MLI in the oil and gas industry, include: Pipelines (e.g., MLI could be applied to insulate pipelines, especially in regions with extreme temperatures. This insulation would help maintain the desired temperature of the transported fluids, preventing heat loss or freezing); Storage Tanks (e.g, MLI could be used to insulate storage tanks for crude oil, refined products, or liquefied gases. This insulation would reduce heat transfer and minimize temperature fluctuations, preserving the quality and properties of stored substances); Offshore Platforms (e.g., offshore platforms often face harsh environmental conditions, including temperature variations. MLI could be utilized to insulate significant or critical equipment, structures, or piping on offshore platforms to ensure operational stability and prevent issues related to temperature extremes); LNG Facilities (e.g., MLI could contribute to the insulation of liquefied natural gas (LNG) facilities, including storage tanks and transportation containers. This application would help maintain the low temperatures required for LNG storage and transportation); Downhole Tools (e.g., some downhole tools used in oil and gas exploration and production may operate in extreme temperature environments. MLI could be incorporated into the design of these tools to provide effective thermal insulation, ensuring their proper functioning); Refinery Equipment (e.g., various equipment in refineries, such as heat exchangers, reactors, and distillation columns, could benefit from MLI insulation. This would contribute to energy efficiency by minimizing heat loss and optimizing process temperatures); LNG Liquefaction and Regasification (e.g., MLI might be employed in LNG liquefaction and regasification facilities to insulate equipment involved in these processes. Maintaining specific temperatures is significant or critical for efficient LNG handling and processing); Drilling Equipment (e.g., drilling equipment used in oil and gas exploration, especially in extreme climates, could be insulated with MLI to ensure proper functioning and longevity, even in temperature-challenging environments); Oil and Gas Transportation (e.g., vehicles or containers used for the transportation of oil and gas could benefit from MLI insulation. This could be particularly valuable for overland transportation through regions with variable climates); Instrumentation and Control Systems (e.g., delicate instrumentation and control systems that are sensitive to temperature variations could be insulated with MLI, ensuring their reliable performance in diverse operating conditions).

[0083] Potential applications related to applying MLI in various industrial processes include: Glass Manufacturing (e.g., in the glass industry, where high-temperature processes are involved, MLI could be used to insulate equipment like furnaces and kilns. This insulation can enhance energy efficiency and maintain consistent temperatures for glass production); Steel and Metal Production (e.g., industries involved in steel and metal production often utilize processes with extreme temperatures. MLI could insulate equipment such as crucibles, furnaces, or casting molds to optimize thermal management and reduce heat loss); Semiconductor Manufacturing (e.g., semiconductor fabrication processes often require precise temperature control. MLI could be employed to insulate equipment involved in wafer manufacturing, ion implantation, and other semiconductor production stages); Chemical Processing (e.g., MLI may find applications in chemical processing facilities where maintaining specific temperature conditions is significant or critical. Insulating reactors, distillation columns, or storage tanks could improve process efficiency and safety); Plastics Extrusion and Molding (e.g., industries involved in plastics extrusion and molding could benefit from MLI insulation in equipment like extruders and molds. This could help control temperatures and improve the quality of molded products); Ceramic Production (e.g., ceramic manufacturing involves high-temperature kilns and furnaces. MLI could be applied to insulate these kilns, reducing heat loss and improving energy efficiency in ceramic production processes); Food Processing (e.g., certain food processing operations, such as those involving heat treatment or drying, could benefit from MLI insulation. This might be applicable to ovens, drying chambers, or other equipment where precise temperature control is essential); Pharmaceutical Manufacturing (e.g., in pharmaceutical manufacturing, processes like crystallization or sterilization often require specific temperature conditions. MLI could be used to insulate equipment, ensuring consistent and controlled temperatures for pharmaceutical production); Textile Industry (e.g., textile manufacturing processes involve various temperature-sensitive stages, such as dyeing and finishing. MLI could contribute to energy efficiency by insulating equipment used in these processes); Paper and Pulp Industry (e.g., MLI might be applied in the paper and pulp industry to insulate components like digesters and dryers, helping to optimize the temperature conditions during pulp processing and paper production).

[0084] This disclosure, its aspects, and embodiments, are not limited to the specific material types, components, methods, or other examples disclosed herein. Many additional material types, components, methods, and procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and / or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

[0085] It will be understood that implementations of the thermal barrier system include but are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of various thermal barrier system may be utilized. Accordingly, for example, it should be understood that, while the drawings and accompanying text show and describe particular thermal barrier system implementations, any such implementation may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and / or the like consistent with the intended operation of thermal barrier system.

[0086] The concepts disclosed herein are not limited to the specific thermal barrier system shown herein. For example, it is specifically contemplated that the components included in particular thermal barrier system may be formed of any of many different types of materials or combinations that can readily be formed into shaped objects and that are consistent with the intended operation of the thermal barrier system. For example, the components may be formed of: rubbers (synthetic and / or natural) and / or other like materials; glasses (such as fiberglass), carbon-fiber, aramid-fiber, any combination therefore, and / or other like materials; elastomers and / or other like materials; polymers such as thermoplastics (such as ABS, fluoropolymers, polyacetal, polyamide, polycarbonate, polyethylene, polysulfone, and / or the like, thermosets (such as epoxy, phenolic resin, polyimide, polyurethane, and / or the like), and / or other like materials; plastics and / or other like materials; composites and / or other like materials; metals, such as zinc, magnesium, titanium, copper, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, spring steel, aluminum, and / or other like materials; and / or any combination of the foregoing.

[0087] Furthermore, thermal barrier system may be manufactured separately and then assembled together, or any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously, as understood by those of ordinary skill in the art, may involve 3-D printing, extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and / or the like. If any of the components are manufactured separately, they may then be coupled or removably coupled with one another in any manner, such as with adhesive, a weld, a fastener, any combination thereof, and / or the like for example, depending on, among other considerations, the particular material(s) forming the components.

[0088] In places where the description above refers to particular thermal barrier system implementations, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other implementations disclosed or undisclosed. The presently disclosed thermal barrier system are, therefore, to be considered in all respects as illustrative and not restrictive.CLAIMSWhat is claimed is:1. A thermal barrier system comprising:a thermal reflective layer;a low thermal conductivity layer comprising a silica-based aerogel; anda thermal energy storage layer comprising a phase change material,wherein material for each layer is applied as a fluid.2. The system of claim 1, wherein the thermal reflective layer is a top layer, the thermal energy storage layer is a bottom layer, and the low thermal conductivity layer is disposed between the thermal reflective layer and the thermal energy storage layer.3. The system of claim 1 or claim 2, wherein the thermal energy storage layer is applied on a surface of a substrate.4. The system of any one of claims 1 – 3, wherein the surface of the substrate is an exterior surface of a building.5. The system of any one of claims 1 – 4, wherein the thermal reflective layer is configured to reflect at least 80% of infrared heat exposed to the thermal reflective layer.6. The system of any one of claims 1 – 5, wherein the low thermal conductivity layer is configured to achieve insulative values surpassing R-3.7. The system of any one of claims 1 – 6, wherein the low thermal conductivity layer has a thickness of 2 mm.8. The system of any one of claims 1 – 7, wherein the thermal energy storage layer exhibits an energy storage capacity of 5 British Thermal Units per square foot.9. The system of any one of claims 1 – 8, wherein the thermal energy storage layer has a thickness of 1 mm.10. The system of any one of claims 1 – 9, wherein the thermal energy storage layer is a top layer, the low thermal conductivity layer is a bottom layer, and the low thermal reflective layer is disposed between the low thermal conductivity layer and the thermal energy storage layer.11. The system of any one of claims 1 – 10, wherein the low thermal conductivity layer is applied on a surface of a substrate.12. The system of any one of claims 1 – 11, wherein the surface of the substrate is an interior surface of a building and the top layer is facing an interior of the building.13. A method of applying a thermal barrier system on a building, the method comprising:fluidly applying a phase change material on an exterior surface of a substrate of the building to form a first layer of the thermal barrier system;fluidly applying a material having low thermal conductivity over the phase change material to form a second layer of the thermal barrier system; andfluidly applying a thermally reflective material over the material having low thermal conductivity to form a third layer of the thermal barrier system.14. The method of claim 13, wherein fluidly applying comprises spraying.15. The method of any one of claims 13 and 14, wherein fluidly applying comprises a roll-on application.16. A method of applying a thermal barrier system on a building, the method comprising:fluidly applying a material having low thermal conductivity on a surface facing an interior of the building to form a first layer of the thermal barrier system;fluidly applying a thermally reflective material over the material having low thermal conductivity to form a second layer of the thermal barrier system; andfluidly applying a phase change material over the thermally reflective material to form a third layer of the thermal barrier system.17. The method of claim 16, wherein fluidly applying comprises spraying.18. The method of claim 16 or claim 17, wherein fluidly applying comprises a roll-on application.19. A thermal barrier system comprising:a thermal reflective layer;a low thermal conductivity layer; anda thermal energy storage layer.20. The thermal barrier system of claim 19, wherein the thermal reflective layer comprises one of reflective pigments, aluminum oxide particles, and glass-polymer hybrid metamaterial.21. The thermal barrier system of any of claims 19 – 20, further comprising a weather barrier.22. The thermal barrier system of any of claims 19 – 21, further comprising films disposed between the thermal reflective layer, the low thermal conductivity layer, and the thermal energy storage layer.23. The thermal barrier system of any of claims 19 – 22, wherein the low thermal conductivity layer comprises low thermal conductivity particles.24. The thermal barrier system of any of claims 19 – 23, wherein the low thermal conductivity particles comprise a silica-based aerogel suspended in a resin.25. The thermal barrier system of any of claims 19 – 24, wherein the thermal energy storage layer comprises a phase-change material.26. The thermal barrier system of any of claims 19 – 25, wherein the thermal energy storage layer or the low thermal conductivity layer comprise solid particles.27. A method of applying a thermal barrier system, the method comprising:applying a first layer to a substrate; andapplying a second layer to a first layer,wherein one of the first and the second layers comprise a thermal energy storage layer,wherein one of the first and the second layers comprises a low thermal conductivity layer; andwherein the first and the second layers are different.  ABSTRACTSystems, methods, and devices for temperature management are disclosed. The temperature management system may include a multilayered thermal barrier system. The thermal barrier system includes a thermally reflective material layer, a material having a low thermal conductivity layer, and a phase change material. The layers may be applied as a fluid. 

Claims

1. A thermal barrier system comprising:a thermal reflective layer;a low thermal conductivity layer comprising a silica-based aerogel; and a thermal energy storage layer comprising a phase change material, wherein material for each layer is applied as a fluid. 2. The system of claim 1, wherein the thermal reflective layer is a top layer, the thermal energy storage layer is a bottom layer, and the low thermal conductivity layer is disposed between the thermal reflective layer and the thermal energy storage layer. 3. The system of claim 1 or claim 2, wherein the thermal energy storage layer is applied on a surface of a substrate. 4. The system of any one of claims 1 – 3, wherein the surface of the substrate is an exterior surface of a building. 5. The system of any one of claims 1 – 4, wherein the thermal reflective layer is configured to reflect at least 80% of infrared heat exposed to the thermal reflective layer. 6. The system of any one of claims 1 – 5, wherein the low thermal conductivity layer is configured to achieve insulative values surpassing R-3. 7. The system of any one of claims 1 – 6, wherein the low thermal conductivity layer has a thickness of 2 mm. 8. The system of any one of claims 1 – 7, wherein the thermal energy storage layer exhibits an energy storage capacity of 5 British Thermal Units per square foot. 9. The system of any one of claims 1 – 8, wherein the thermal energy storage layer has a thickness of 1 mm. 10. The system of any one of claims 1 – 9, wherein the thermal energy storage layer is a top layer, the low thermal conductivity layer is a bottom layer, and the low thermal reflective layer is disposed between the low thermal conductivity layer and the thermal energy storage layer. 11. The system of any one of claims 1 – 10, wherein the low thermal conductivity layer is applied on a surface of a substrate. 12. The system of any one of claims 1 – 11, wherein the surface of the substrate is an interior surface of a building and the top layer is facing an interior of the building. 13. A method of applying a thermal barrier system on a building, the method comprising:fluidly applying a phase change material on an exterior surface of a substrate of the building to form a first layer of the thermal barrier system;fluidly applying a material having low thermal conductivity over the phase change material to form a second layer of the thermal barrier system; andfluidly applying a thermally reflective material over the material having low thermal conductivity to form a third layer of the thermal barrier system. 14. The method of claim 13, wherein fluidly applying comprises spraying. 15. The method of any one of claims 13 and 14, wherein fluidly applying comprises a roll-on application. 16. A method of applying a thermal barrier system on a building, the method comprising:fluidly applying a material having low thermal conductivity on a surface facing an interior of the building to form a first layer of the thermal barrier system;fluidly applying a thermally reflective material over the material having low thermal conductivity to form a second layer of the thermal barrier system; andfluidly applying a phase change material over the thermally reflective material to form a third layer of the thermal barrier system.  17. The method of claim 16, wherein fluidly applying comprises spraying. 18. The method of claim 16 or claim 17, wherein fluidly applying comprises a roll-on application. 19. A thermal barrier system comprising:a thermal reflective layer;a low thermal conductivity layer; anda thermal energy storage layer.  20. The thermal barrier system of claim 19, wherein the thermal reflective layer comprises one of reflective pigments, aluminum oxide particles, and glass-polymer hybrid metamaterial. 21. The thermal barrier system of any of claims 19 – 20, further comprising a weather barrier. 22. The thermal barrier system of any of claims 19 – 21, further comprising films disposed between the thermal reflective layer, the low thermal conductivity layer, and the thermal energy storage layer. 23. The thermal barrier system of any of claims 19 – 22, wherein the low thermal conductivity layer comprises low thermal conductivity particles. 24. The thermal barrier system of any of claims 19 – 23, wherein the low thermal conductivity particles comprise a silica-based aerogel suspended in a resin. 25. The thermal barrier system of any of claims 19 – 24, wherein the thermal energy storage layer comprises a phase-change material. 26. The thermal barrier system of any of claims 19 – 25, wherein the thermal energy storage layer or the low thermal conductivity layer comprise solid particles. 27. A method of applying a thermal barrier system, the method comprising:applying a first layer to a substrate; andapplying a second layer to a first layer,wherein one of the first and the second layers comprise a thermal energy storage layer,wherein one of the first and the second layers comprises a low thermal conductivity layer; andwherein the first and the second layers are different. 

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