Oxygen starting heater in cold weather

Abstract

The heater system includes a first heater and a second heater, each containing a metal and an electrolyte solution that exothermically react with oxygen to generate heat, the first heater superimposed on the second heater. The heater system also includes an air-impermeable package enclosing the metal and the electrolyte solution, the air-impermeable package configured to be openable to allow air to enter the metal and the electrolyte solution. The heater system also includes a spacer that is gas permeable and is disposed between the first heater and the second heater in a direction in which the first heater overlaps the second heater. The first heater at least partially covers the second heater.

Description

BACKGROUND OF THE INVENTION

[0001] In products across various industries, the need for portable "anytime, anywhere" instant heating is evident. One example is the need for heat in an environment where the air temperature is below 5 degrees Celsius (41 degrees Fahrenheit). For certain objects, it may be necessary to heat or maintain a certain temperature for a period of time under cold conditions. For example, in a cold environment, a fluid that needs to be maintained at 23 degrees Celsius (73 degrees Fahrenheit) for several hours can benefit from a heater system. Another example is the instant, portable heat required to prevent hypothermia.

[0002] An air-activated heater with a sealed package is described in U.S. Patent Application No. 14 / 058,719, the text of which is incorporated herein by reference. However, in known heater systems, there is actually a desire to improve the time extension for providing the required heat while reliably fixing the heating device to the desired object. SUMMARY OF THE INVENTION

[0003] According to one aspect, a heater system includes a first heater and a second heater. Both the first heater and the second heater include a metal and an electrolyte solution that undergoes a thermal reaction with oxygen to generate heat, and the first heater is superimposed on the second heater. The heater system further includes at least one airtight package. The at least one airtight package encloses the metal and the electrolyte solution included in the first heater and the second heater, and the airtight package is configured to be opened to allow air to enter the metal and the electrolyte solution. The heater system further includes a breathable spacer disposed between the first heater and the second heater along the direction in which the second heater is superimposed on the first heater. The first heater at least partially covers the second heater.

[0004] The above heater system further includes a plurality of heaters and a plurality of spacers. The plurality of heaters includes the first heater, the second heater, and a third heater, and the second heater is superimposed on the third heater such that the second heater is disposed between the first heater and the third heater and separates the first heater and the third heater. The plurality of spacers includes the spacer, which is a first spacer. The plurality of spacers includes the first spacer disposed between the first heater and the second heater, and a second spacer disposed between the second heater and the third heater along the direction in which the second heater is superimposed on the third heater.

[0005] The heater system mentioned in the previous paragraph or the paragraph before the previous paragraph further includes a heat insulation layer made of a breathable material, the heat insulation layer being deployed on the first heater, on the side of the first heater opposite to the second heater, wherein the heat insulation layer, the first heater, the spacer, and the second heater are configured to be applied to an object to heat the object so that the first heater at least partially covers the second heater relative to the object.

[0006] Any one of the above-mentioned spacers has a thickness and a porosity and is configured to convey ambient air to at least one of the corresponding heaters located beside the corresponding spacer.

[0007] Any one of the above-mentioned spacers may be made of a heavy non-woven fabric. The outer edge of any one of the above-mentioned spacers may be exposed to the ambient air between at least two corresponding heaters. Any one of the heaters may include a breathable membrane or fabric within the airtight package, and if desired, one heater may include a breathable membrane or fabric having a higher air permeability relative to the breathable membrane or fabric associated with another heater.

[0008] Each heater includes a corresponding electrolyte solution, which may be different between multiple heaters. For example, the first heater includes a first electrolyte solution, the second heater includes a second electrolyte solution, and the minimum operating temperature of the first electrolyte solution is lower than that of the second electrolyte solution. Different electrolyte solutions may include at least one of isopropyl alcohol, propylene glycol, ethanol, ethylene glycol, and potassium hydroxide in different proportions. For example, the first electrolyte solution includes at least one of isopropyl alcohol, propylene glycol, ethanol, ethylene glycol, and potassium hydroxide and in a proportion greater than that of the second electrolyte solution.

[0009] The above-described heater may be formed entirely of a mixture of activated carbon, zinc, and polytetrafluoroethylene disposed on a porous fabric carrier. The at least one airtight package may enclose the porous fabric carrier of each heater, such as the first and second heaters when two heaters are provided, and / or multiple heaters when more than two heaters are provided. Alternatively, the at least one airtight package may enclose the porous fabric carrier of a particular heater. For example, a first airtight package may enclose the porous fabric carrier of the first heater, and a second airtight package may enclose the porous fabric carrier of the second heater. In some embodiments, each heater includes a mixture having at least 4% by weight of activated carbon, at least 41% of zinc, and at least 5% of polytetrafluoroethylene, a saturated solution of sodium bromide added to the mixture of the carbon, zinc, and polytetrafluoroethylene, wherein the saturated solution weighs at least 15% of the mixture of the carbon, zinc, and polytetrafluoroethylene, and a porous material layer, wherein the mixture of the carbon, zinc, and polytetrafluoroethylene including the saturated solution is added to one side of the porous material layer.

[0010] In one embodiment of the above-described heater system, the spacer operates as a thermal insulation layer that forms a strip configured to wrap around an object to be heated such that when the strip wraps around the object, the first heater at least partially covers the second heater relative to the object. In this embodiment, the first heater and the second heater may be part of a larger heater and are separated by the spacer in a direction in which the first heater overlays the second heater, or the first heater and the second heater are independent and are separated by the spacer in a direction in which the first heater overlays the second heater. Optionally in this embodiment, the strip includes a first strip intersecting a second strip, wherein the position where the first strip intersects the second strip is closer to the first end of the second strip than to the second end of the second strip, the position where the second strip intersects the first strip is closer to the first end of the first strip than to the second end of the first strip, the first strip defines an opening offset from the second strip, and the opening is closer to the first end of the second strip than to the second end of the second strip. In this alternative embodiment, the fixing member is connected to the second strip at a position closer to the first end of the second strip than to the first end of the second strip, the fixing member is configured to fix the strip wrapping around the object, and the first heater and the second heater are disposed on the second strip.

[0011] A method of heating an object includes: providing a first heater and a second heater, wherein both the first heater and the second heater include a metal and an electrolyte solution, and the electrolyte solution undergoes a thermal reaction with oxygen to generate heat, so that the first heater at least partially covers the second heater by means of a spacer, the spacer is breathable and is deployed between the first heater and the second heater along the direction in which the second heater is stacked on the first heater. The method further includes: opening at least one airtight package to allow air to enter the metal and the electrolyte solution, the at least one airtight package enclosing the metal and the electrolyte solution included in the first heater and the second heater. The method can be used for any of the above heater configurations. Description of the Drawings

[0012] Figure 1 is a schematic diagram of a heater system, which includes a heater and a heat insulation layer, located on the object to be heated.

[0013] Figure 2 and Figure 2A is a schematic diagram of a heater system, including a first heater, a second heater and a spacer, disposed on the object.

[0014] Figure 3 is a schematic diagram of a heater system, including a plurality of heaters and a plurality of spacers, arranged in an alternating pattern.

[0015] Figure 4 is a table showing the results of the first set of tests.

[0016] Figure 5 is a graph showing the results of the first test in the second set of tests.

[0017] Figure 6 is a graph showing the results of the second test in the second set of tests.

[0018] Figure 7 is a graph showing the results of the third test in the second set of tests.

[0019] Figure 8 is a graph showing the results of the fourth test in the second set of tests.

[0020] Figure 9 is a perspective view of the first heater configuration and the second heater configuration in the third set of tests.

[0021] Figure 10 is an enlarged perspective view of the first heater configuration.

[0022] Figure 11 is another perspective view of the first heater configuration and the second heater configuration.

[0023] Figure 12 is an enlarged perspective view of a second heater configuration.

[0024] Figure 13 is a graph of a third set of test results.

[0025] Figure 14 is a graph of the average results of a third set of tests.

[0026] Figure 15 is a top perspective view of a heater system and an object to be heated.

[0027] Figure 16 is a top perspective view of a heater system and an object, wherein a first end portion of a first strip wraps around the object.

[0028] Figure 17 is a top perspective view of a heater system and an object, wherein a second end portion of the first strip wraps around the object.

[0029] Figure 18 is a perspective view of a heater system and an object, wherein a second strip wraps around the object.

[0030] Figure 19 is a perspective view of a heater system and an object, wherein a fixing member fixes the second strip and the first strip around the object. DETAILED DESCRIPTION

[0031] Referring now to the drawings, where like numerals refer to like parts throughout the several views, Figure 1 there is shown a portable, self - contained, air - activated heater system 100 that, when deployed, is configured to generate heat through an exothermic chemical oxidation process. The heater system 100 includes a heater substrate 102 having an air - impermeable peripheral wrapper 104, and a breathable or air - permeable thermal insulation assembly, referred to as thermal insulation layer 110. The heater substrate 102 contains metal and an electrolyte solution, and some examples will be described in more detail below, which will react exothermically with oxygen to generate heat. The assembly of the heater substrate 102 with or without the peripheral wrapper 104 may be collectively referred to as the heater 112. The thermal insulation layer 110 is located on at least one side of the heater 112 and may be made of polyethylene terephthalate (PET) or other synthetic or natural materials, open - cell foams, and felts.

[0032] The heater system 100 can heat an object 114 to a specific temperature for a specific time according to the arrangement of the components of the heater system 100. This time / temperature combination is achieved through the arrangement of the physical structure (e.g., by stacking, or laminating the heater 112 and its associated breathable thermal insulation layer 110 together or placing them adjacent to each other) and by managing the heat output of the heater 112 itself.

[0033] At temperatures of 0 degrees Celsius and above, a single heater 112, when uninsulated and once exposed to ambient air, can start an exothermic reaction. Under cold weather conditions (e.g., below 0 degrees Celsius), the layers of the heater 112 and the thermal insulation layer 110 can be used for: 1) assisting in heating startup, 2) maintaining heating.

[0034] The heater system 100 can be used in a variety of ways. Figure 1 One heating implementation is shown. According to the definitions here and in all examples, the thermal insulation layer 110 can include thermal insulation materials of various thicknesses and may include various materials. The peripheral package 104 is an airtight package that encloses the heater substrate 102. The peripheral package 104 is opened to allow air to enter the heater substrate 102 to initiate heating. The peripheral package 104 may include a removable label that can be removed to allow air to enter the heater substrate 102. The peripheral package 104 may include a removable laminated film layer that can be removed to allow air to enter the heater substrate 102. The peripheral package 104 may be an interlocking mechanism that can prevent air from entering when closed but allows air to enter the heater substrate 102 when opened.

[0035] To improve the performance of the heater system 100 in terms of peak temperature and duration, at least one additional heater substrate 102 can be employed, as Figure 2 shown. Referring to Figure 2 , the heater system 100 includes a first heater 120 and a second heater 122 that have similar characteristics and functions and are similar to the heater 112. The first heater 120 is stacked on top of the second heater 122 such that when the heater system 100 is applied to the object 114, the first heater 120 at least partially covers the second heater 122 relative to the object 114. As Figure 2 shown, the first heater 120 substantially covers the second heater 122 relative to the object 114.

[0036] The heater system 100 includes a spacer 124 located between the first heater 120 and the second heater 122 in the direction in which the first heater 120 is stacked on the second heater 122, which is herein referred to as the stacking direction. The spacer 124 is breathable so that the second heater 122 can still obtain the oxygen it needs for its continued exothermic reaction from the surrounding air.

[0037] To this end, the spacer 124 is formed of a thick non-woven fabric and is laminated between the first heater 120 and the second heater 122. The spacer 124 has a porosity and a thickness in the stacking direction, and is configured to deliver ambient air from the outer edge 130 of the spacer 124 to the inner portions 132 of the first heater 120 and the second heater 122, which would otherwise be covered by ambient air. In one embodiment, the spacer 124 is made of a metalized polyester material and is configured to retain heat between the first heater 120 and the second heater 122. More specifically, the spacer 124 can be made of a thermal insulation material sold under trademarks such as "Insul-Bright" and "Thinsulate". In one embodiment, the thermal insulation layer 110 and the spacer 124 are made of the same material, and each can have reflective properties.

[0038] The spacer 124 extends between the inner portions 132 of the first heater 120 and the second heater 122, toward the outer edges 134 of the first heater 120 and the second heater 122. Thus, the outer edge 130 of the spacer 124 is exposed to the ambient air between the first heater 120 and the second heater 122 for delivering the ambient air to the inner portions 132 of the first heater 120 and the second heater 122.

[0039] In Figure 2 the illustrated embodiment, the peripheral wrapper 104 is applied to the first heater 120 and the second heater 122 respectively, and the peripheral wrapper 104 (see Figure 2A ) can also wrap each of the following: the heater substrate 102 of the first heater 120, the spacer 124, and the heater substrate 102 of the second heater 122. With this structure, a user operating the heater system 100 only needs to open the peripheral wrapper 104 at one location to initiate the exothermic reactions of both the first heater 120 and the second heater 122. Since each of the thermal insulation layer 110, the first heater 120, the second heater 122, and the spacer 124 is elastic, the heater system 100 can be wrapped, folded, or rolled up around the object 114 to be heated.

[0040] To further enhance the heating effect, additional heaters and spacers similar to the first heater 120 and the spacer 124 can be added to the heater system 100 for the peak temperature and / or duration. By alternately combining the layers of the heaters 120, 122 and the breathable spacers 124, all of the heaters 120, 122 can generate heat because oxygen can enter each heater substrate 102 through the breathable cross-section of the spacer 124.

[0041] In this regard, Figure 3Disclosed is a heater system 100, including a plurality of heaters and a plurality of spacers, which are arranged in an alternating manner along the stacking direction. The plurality of heaters include a first heater 120, a second heater 122, and a third heater 140. The second heater 122 is stacked on the third heater 140 in the stacking direction, such that the second heater 122 is located between the first heater 120 and the third heater 140 and separates them. Thus, when the heater system 100 is applied to an object 114, the first heater 120 at least partially covers the second heater 122 and the third heater 140, while the second heater 122 at least partially covers the third heater 140, specifically with respect to the object 114. As Figure 3 shown, the first heater 120, the second heater 122, and the third heater 140 have similar sizes and shapes, such that the first heater 120 substantially covers the second heater 122 and the third heater 140, and the second heater 122 substantially covers the third heater 140, both with respect to the object 114.

[0042] Figure 3 The heater system 100 shown in includes a plurality of spacers, which are arranged in an alternating pattern with the plurality of heaters along the stacking direction. These spacers include a first spacer 142 and a second spacer 144, which have similar characteristics and work in a similar manner, like the spacer 124. The first spacer 142 is located between the first heater 120 and the second heater 122 in the stacking direction. The second spacer 144 is located between the second heater 122 and the third heater 140 in the stacking direction.

[0043] Although in Figure 3 the illustrated embodiment, the plurality of heaters include three heaters, and the plurality of spacers include two spacers stacked in an alternating pattern with the plurality of heaters, the plurality of heaters may further include additional heaters, and the plurality of spacers may also include additional spacers stacked in an alternating pattern with the plurality of heaters, so as to increase the output of the heater system 100 without departing from the scope of the present application. In addition, although Figure 3 depicts three different peripheral packages 104, each of which surrounds a corresponding heater substrate 102, one peripheral package 104 may also be used to wrap all three (or any number of) heater substrates 102.

[0044] The thermal insulation layer 110 is composed of an air-permeable material, which is arranged on the first heater 120 and is located on one side of the first heater 120 and the second heater 122. The thermal insulation layer 110, the first heater 120, the first spacer 142, the second heater 122, the second spacer 144, and the third heater 140 are configured for application to an object 114 to heat the object 114 such that the first heater 120 at least partially covers the second heater 122 and the third heater 140 with respect to the object 114.

[0045] The heater substrate 102 includes a metal (e.g., iron or zinc), carbon, and a specific concentration of an electrolyte solution. Under conditions where the electrolyte may gel or freeze, thereby inhibiting or preventing the heating reaction, the electrolyte composition may be altered to minimize the tendency to gel or freeze. For example, when the electrolyte solution is a sodium bromide solution, agents such as isopropyl alcohol, propylene glycol, ethanol, or ethylene glycol may be added to lower the freezing point of the electrolyte solution. The added freezing point depressant may also result in a decrease in the effective salt concentration. In addition, the added agent may interfere with the effective interaction of oxygen with the carbon or zinc components in the heater substrate 102. On the other hand, an electrolyte solution made of potassium hydroxide (KOH), commonly known as caustic potash, may be used in place of sodium bromide. For example, a 30.8% concentration of potassium hydroxide solution has a freezing point of minus 65 degrees Celsius. Depending on the storage conditions and usage of the heaters 120, 122, 140, one or more heater substrates 102 may contain such altered electrolytes. The purpose of such an altered heater substrate 102 is to "thaw or heat" the other heaters 120, 122, 140 and "initiate" the reaction, which, once initiated, will continue to provide long-term heat.

[0046] Continuing to refer to Figure 3 , the first heater 120 contains a first electrolyte solution, the second heater 122 contains a second electrolyte solution, and the third heater 140 contains a third electrolyte solution. The first electrolyte solution is altered relative to the second electrolyte solution and the third electrolyte solution to inhibit the tendency to gel or freeze in a cold environment. To this end, the first electrolyte solution may contain at least one of isopropyl alcohol, propylene glycol, ethanol, and ethylene glycol in a proportion greater than that of the second electrolyte solution and the third electrolyte solution when each electrolyte solution is sodium bromide. For example, the first electrolyte solution may be composed of potassium hydroxide while the remaining electrolyte solutions are composed of sodium bromide. In addition, although Figure 3 the first heater 120 in

[0047] In this way, the lowest operating temperature of the first electrolyte solution is lower than those of the second and third electrolyte solutions. Thus, when the heater system 100 is started in a cold environment, the first heater 120 is designed to thaw or heat the second heater 122 and the third heater 140 to initiate the exothermic reactions therein, which provide long-term heat compared to the first heater 120.

[0048] In one embodiment, the first heater 120, the second heater 122, and the third heater 140 are each formed of a mixture of activated carbon, zinc, and polytetrafluoroethylene placed on a porous fabric carrier. More specifically, the first heater 120, the second heater 122, and the third heater 140 each comprise a mixture of at least 4% by weight of activated carbon, at least 41% of zinc, and at least 5% of polytetrafluoroethylene. A saturated solution of sodium bromide is added to the mixture of the carbon, zinc, and polytetrafluoroethylene, and the weight of the saturated solution is at least 15% of the mixture of the carbon, zinc, and polytetrafluoroethylene. The mixture of the carbon, zinc, and polytetrafluoroethylene including the saturated solution is added to one side of the porous material layer. In another embodiment, the first electrolyte solution is changed by adding a freezing point depressant such that its lowest operating temperature is lower than -20 °C, while the lowest operating temperatures of the second and third electrolyte solutions are -1 °C.

[0049] The airflow to the first heater 120, the second heater 122, and the third heater 140 can be further adjusted by a breathable membrane or fabric located within the peripheral package 104 to wrap the heater substrate 102, respectively. In this regard, the first heater 120 includes a first breathable membrane or fabric, the second heater 122 includes a second breathable membrane or fabric, and the third heater 140 includes a third breathable membrane or fabric. The air permeability of the first breathable membrane or fabric is greater than those of the second and third breathable membranes or fabrics.

[0050] With this structure, the first heater 120 receives oxygen more easily than the second heater 122 and the third heater 140, thereby increasing the heat generation rate of the exothermic reaction. Since the oxygen intake of the second heater 122 and the third heater 140 is relatively low, the second heater 122 and the third heater 140 are configured to provide a sustained heat generation compared to the first heater 120.

[0051] The heater system 100 can be used to heat a specific object, such as the object 114 described herein, or a local environment. The experiment was conducted as follows.

[0052] A combination including 8% activated carbon, 82% zinc, and 10% polytetrafluoroethylene (by weight) was mixed and placed on a porous fabric carrier to form a similar to Figures 1 to 3The heater substrate of the heater substrate 102 shown. A saturated sodium bromide solution (NaBr) (30% by weight of the total weight of C, Zn, and polytetrafluoroethylene) was added to this mixture. A semi-permeable membrane air flow restrictor made of perforated polypropylene film was placed on the non-coated side of the fabric carrier. The thickness of the polypropylene film layer used in this example was 0.0005 inches.

[0053] The heater substrate is placed within a sealed flexible packaging film made of a single layer or a laminate similar to the Figures 1 to 3 peripheral packaging 104 shown, having minimum oxygen transmission rate characteristics. A metallized polyethylene terephthalate (PET) film was used to make the packaging, which internally sealed the heater substrate and the gas-limiting film. The packaging was constructed such that the label could be removed, allowing air to enter the heater substrate and thereby initiating an exothermic reaction. The increased thickness of the peripheral packaging was very small, approximately 0.01 inches. In some instances, a thermal insulation layer similar to the Figures 1 to 3 thermal insulation layer 110 shown in Figures 1 to 3 was employed, as well as at least one spacer similar to the

[0054] spacer 124 shown in

[0055] Figure 4 A table is depicted that outlines the time it takes for the temperature of the bottle to drop to different temperatures. Referring to Figure 4 , Test No. 4 contains alternating heaters and thermal insulation layers and maintains the temperature for the longest time.

[0056] A second set of four tests was conducted to measure the temperature of the heater or heater system itself under sub-zero conditions, without an object to be heated. The purpose of these tests was to observe the performance of the heater or heater system under sub-zero conditions. In this case, the heater does not need to be tightly wrapped around the object to be heated. For example, the heater can be used to isolate the object from the environment, such as placing the heater and the object in a thermally insulated shipping container.

[0057] The same heaters as described above were stored in a freezer for at least one day before the test. The temperature of the freezer was -20 degrees Celsius. A thermocouple was connected to each heater to measure the temperature of the heater.

[0058] In each test of the second group, the freezer door was opened, the heater (i.e., the peripheral package described above) was started and removed as quickly as possible, and then the freezer door was closed. Subsequently, temperature recording began.

[0059] The four tests conducted in the second group included Test No. 1, Test No. 2, Test No. 3, and Test No. 4. Test No. 1 was set to include a heater without thermal insulation. Test No. 2 was set to include a heater with thermal insulation on both of its sides, such that the thermal insulation sandwiched the heater in the middle. Test No. 3 was set to include two heaters and a spacer sandwiched between two thermal insulations, and the spacer was placed between the heaters. Test No. 4 was set to include four heaters and three spacers stacked alternately and sandwiched between two thermal insulations. In each test, a thermocouple was used to record the temperature of each heater over time.

[0060] Figure 5 The results of Test No. 1 are shown. Figure 6 The results of Test No. 2 are shown. Figure 7 The results of Test No. 3 are shown. Refer to Figure 7 , Heater 2 was stacked on top of Heater 1 such that Heater 2 substantially covered Heater 1. Figure 8 The results of Test No. 4 are shown. Refer to Figure 8 , Heater 4 was stacked on Heater 3, Heater 3 was stacked on Heater 2, and Heater 2 was stacked on Heater 1. According to this structure, Heater 4, Heater 3, Heater 2, and Heater 1 were stacked in the heater system test device in the order from top to bottom.

[0061] The results of the second group of tests showed that when the layers of heaters, spacers, and breathable thermal insulation were stacked together, the heat supply effect was significant. More specifically, the additional layers of alternately stacked heaters and spacers increased the duration for which the heater system maintained the temperature on the object.

[0062] The results of the second group of tests further showed that the thermal insulation performance had an impact on the performance of the heater system. More specifically, the difference in temperature duration between Test No. 1 and Test No. 2 indicated that the heat preservation characteristics of the thermal insulation improved the temperature duration of the heater system. Notably, this improvement occurred despite the fact that the thermal insulation restricted the ambient air flow to the heater and slowed down the exothermic reaction that generated heat.

[0063] Figures 9 to 12Shows the third set of tests conducted to compare the performance between the first heater configuration 150 and the second heater configuration 152. The third set of tests was conducted inside a freezer at a temperature of minus 20 degrees Celsius. A thermocouple 154 was attached to each heater to measure the temperature of each heater in the first heater configuration 150 and the second heater configuration 152. In each test of the third set of tests, the freezer door was opened, the heater was activated (i.e., the above-mentioned peripheral packaging was removed as quickly as possible), and then the freezer door was closed. Then the temperature recording was started. Figure 10 Shows the first heater configuration 150, with the insulation layer 110 open, showing four heaters 112 arranged side by side. As Figure 9 shown, the heaters 112 in the first heater configuration 150 are sandwiched between the insulation layers 110. As Figure 11 shown, the insulation layer 110 of the first heater configuration 150 is made of a continuous material that can be folded to cover the upper and lower sides of the heater 112.

[0064] As Figure 12 shown, the second heater configuration 152 includes four heaters 112 stacked in an alternating pattern and has three spacers 124. The heaters 112 and the spacers 124 are sandwiched between the insulation layers 110. Continuing to refer to Figure 11 , the heaters 112 in both the first heater configuration 150 and the second heater configuration 152 are connected to the thermocouple 154 to record the temperature of the heaters 112 over time.

[0065] Figure 13 and Figure 14 Show the results of the third set of tests based on the temperature readings of the thermocouple 154. Figure 13 Shows a graph that displays the average temperature of the heaters 112 in the first heater configuration 150 and the second heater configuration 152 in each iteration of the third set of tests. Referring to Figure 13 , the data recorded in the graph, Flat-TC1, Flat-TC2, Flat-TC3, and Flat-TC4, represent the readings of the respective thermocouples 154 attached to the corresponding heaters 112 in the first heater configuration 150. The data recorded as Stack-TC1, Stack-TC2, Stack-TC3, and Stack-TC4 represent the readings of the respective thermocouples 154 attached to the corresponding heaters 112 in the second heater configuration 152.

[0066] Figure 13 and Figure 14 Further depict the average values of Flat-TC1, Flat-TC2, Flat-TC3, and Flat-TC4 over time, called Flat Ave. At the same time, Figure 13 andFigure 14 Also depicted are the average values of Stack-TC1, Stack-TC2, Stack-TC3, and Stack-TC4 over time, referred to as Stack Ave.

[0067] As Figure 13 and Figure 14 shown, the heater 112 in the second heater configuration 152 reaches a higher temperature and is able to maintain these higher temperatures for a longer time compared to the heater 112 in the first heater configuration 150. Thus, the third set of tests conducted indicates that arranging the same number of heaters 112 in a stacked configuration with spacers 124 can provide a heater system 100 with higher temperatures and longer durations, as compared to arranging the heaters 112 side by side. Notably, since the heaters 112 in the second heater configuration 152 are separated by spacers 124, each heater 112 is able to react with the ambient air without direct contact with the surrounding environment through the thermal insulation layer 110.

[0068] Figures 15 to 19 Depicts a method of assembling an embodiment of the heater system 100, where the object 114 to be heated is a liquid container. As Figure 15 shown, the thermal insulation layer 110 is made of a breathable fabric, and its shape is formed by the first strip 160 and the second strip 162 intersecting each other perpendicularly. Due to the way the second strip 162 wraps around the object 114 (see Figure 18 and Figure 19 ), the thermal insulation layer 110 also serves as a spacer, similar to the spacer 124 described above. As mentioned above, the thermal insulation layer 110 and the spacer 124 can be made of the same material, and thus can simultaneously perform the functions of providing thermal insulation for the heaters 120, 122, 140 and separating one heater from another.

[0069] The position where the first strip 160 intersects the second strip 162 is closer to the first end 164 of the second strip 162 than to the second end 170 of the second strip 162. The position where the second strip 162 intersects the first strip 160 is closer to the first end 172 of the first strip 160 than to the second end 174 of the first strip 160. With this structure, the first strip 160 includes a first end portion 180 and a second end portion 182 that extend from opposite sides of the second strip 162, and the second strip 162 includes a first end portion 184 and a second end portion 190 that extend from opposite sides of the first strip 160.

[0070] The first strip 160 defines a first opening 192 at a first end portion 180 and a second opening 194 at a second end portion 182. The first opening 192 and the second opening 194 are offset relative to the second strip 162 and are configured to receive an object 114.

[0071] In this method, the object 114 is positioned on the first end portion 180 of the first strip 160, as Figure 16 and Figure 17 shown, the first end portion 180 and the second end portion 182 of the first strip 160 are wrapped around the object 114 such that a portion of the object 114 is inserted into the first opening 192 and the second opening 194.

[0072] Referring to Figure 18 , the heater system 100 includes a fixture 200 which is a flexible cloth strip fixed to the heat insulation layer 110 of the second strip 162. The fixture 200 includes a hook-and-loop fastener device 202 and a main body 204 which is a cloth strip. The hook-and-loop fastener device 202 is designed to detachably fix the fixture 200 to at least one of the main body 204 and the heat insulation layer 110.

[0073] As Figure 19 shown, the fixture 200 is designed to be wrapped around the object 114 and placed on the first strip 160 and the second strip 162 to fix the fixture 200, the first strip 160 and the second strip 162 around the object 114. As shown, the fixture 200 includes the hook-and-loop fastener device 202 for fixing the heat insulation layer 110. The fixture 200 may additionally or alternatively include clips, buttons, nails and similar fixing devices for fixing to the heat insulation layer 110 or itself to fix the heat insulation layer without departing from the present application. In addition, the fixture 200 may not include the main body 204, so that the hook-and-loop fastener device 202 is directly provided on the heat insulation layer 110 and is used to fix the heat insulation layer 110 and the object 114 together without departing from the scope of the present application.

[0074] Continuing to refer to Figure 15 , in one embodiment, the composition of the heater substrate 102 contained in the heater 112 is 8% activated carbon, 82% zinc and 10% polytetrafluoroethylene (by weight). These components are mixed and placed on a porous fabric. A saturated sodium bromide solution (NaBr) (which accounts for 30% of the total weight of C, Zn and polytetrafluoroethylene) is added to the mixture. On the uncoated side of the fabric carrier, a semi-permeable membrane air flow restrictor is placed, which is composed of a perforated polypropylene film. The thickness of the polypropylene film layer used here is 0.0005 inches.

[0075] The heater substrate 102 is placed inside a perimeter package 104, which is a sealed flexible packaging film (single or multi-layer) with minimal oxygen transmission rate characteristics. A metallized polyethylene terephthalate (PET) film is used to create the package, which internally seals the heater substrate 102, a fabric carrier, and a gas barrier film. The perimeter package 104 is constructed such that a label can be removed from it to allow air to enter the heater substrate 102, thereby initiating an exothermic reaction between the heater substrate 102 and ambient air. The perimeter package 104 adds a very small thickness, approximately 0.01 inches.

[0076] Embodiments of the heater system 100 can include a heater layer 112 and a breathable thermal insulation layer 110 combined to increase heating capacity or supplement a heating curve on the thermal output of the heater system 100. The thermal insulation layer 110 can also act as a spacer between heaters. For example, a set of heaters 112 each equipped with its unique heater substrate 102 and perimeter package 104 can be placed on a second strip 162 made of a breathable material. In this case, for example, one of the heaters 112 near the second end portion 190 of the second strip 162 can be a first heater, at least partially superimposed on a second heater, for example, near the first end portion 184 of the second heater, when the second strip 162 is wrapped around the object. Alternatively, a larger heater, with its larger heater substrate 102 and perimeter package 104 can be placed on the second strip 162. In this embodiment, the first heater and the second heater are parts of the larger heater, separated by a spacer in the direction in which the first heater is superimposed on the second heater. Additionally, in either embodiment, only the second strip 162 and the accompanying heaters may be provided, for example, the first strip 160 can be omitted.

[0077] According to Figure 4The provided test results show that a heater system 100 with a heater 112 consisting of a mixture including NaBr, C, Zn, and polytetrafluoroethylene, wrapped around a 250 - milliliter aqueous fluid container without an insulating layer, can heat the fluid such that the temperature of the fluid can reach or exceed 20 °C for 0.5 hours, reach or exceed 15 °C for 1.5 hours, and reach or exceed 10 °C for 3.5 hours when the initial temperature of the fluid is 23 °C and the ambient temperature is maintained at 4 °C. An embodiment of the heater system 100 with an insulating layer 110 wrapped around the heater 112 and the container can keep the temperature of the fluid at or above 20 °C for 3 hours, at or above 15 °C for 6 hours, and at or above 10 °C for more than 6 hours, with the initial temperature of the fluid sample being 23 °C and the ambient temperature maintained at 4 °C. The heater system 100 with two layers of heaters 112 formed from the above - described mixture, and with an insulating layer 110 wrapped around the container between the layers of the heater 112 and on the outside of each layer, can maintain the temperature of the fluid at or above 20 °C for more than 6 hours, with the initial temperature of the fluid sample being 23 °C and the ambient temperature maintained at 4 °C. It is noted that the multiple heaters 112 and insulating layers 110 can be improved to enhance the overall heating performance of the heater system 100.

[0078] A saturated NaBr solution is an example of an electrolyte contained in the heater substrate 102. According to Blagden's law, a saturated NaBr solution will freeze at approximately - 35 °C. To prevent the solution from freezing at very low ambient temperatures, the NaBr electrolyte solution can be mixed with an additive that does not freeze at low temperatures. An example additive for a saturated NaBr solution is propylene glycol at different concentrations (10%, 25%, and 50%, w / w).

[0079] In this way, the electrolyte solution can be adjusted to remain at least partially liquid at temperatures below - 35 °C. Thus, in one embodiment of the heater system 100 with multiple heaters 112, at least one heater 112 can contain an additive such as propylene glycol to remain liquid at lower temperatures, thereby heating the remaining heaters 112 in a relatively cold working environment where the other heaters 112 might freeze and become inoperative.

[0080] In addition, the heater substrate 102 of the perforated polypropylene film with more open areas can accelerate the exothermic reaction between the heater substrate 102 and the ambient air, thereby raising the temperature generated in the reaction relatively earlier. Thus, in one embodiment of the heater system 100 having a plurality of heaters 112, the open area of at least one heater 112 is larger than that of the other heaters 112 to achieve faster initial heating.

[0081] Various heater substrates were tested. These substrates had perforated polypropylene films and included the saturated NaBr solution described above, but with different weight percentages of propylene glycol added to the saturated NaBr solution. One example of the heater substrate 102 with a perforated polypropylene film, containing the saturated NaBr mixture without added propylene glycol described above, was able to heat from an initial temperature of -20 degrees Celsius to 23 degrees Celsius and maintain a temperature of at least 0 degrees Celsius for at least 0.5 hours at an ambient temperature of -20 degrees Celsius. One example of the heater substrate 102 with a perforated polypropylene film, containing a saturated NaBr mixture with 10% propylene glycol (w / w), was able to heat from an initial temperature of -20 degrees Celsius to 21 degrees Celsius and maintain a temperature of at least 5 degrees Celsius for at least 0.5 hours at an ambient temperature of -20 degrees Celsius. One example of the heater substrate 102 with a perforated polypropylene film, containing a saturated NaBr mixture with 25% propylene glycol (w / w), was able to heat from an initial temperature of -20 degrees Celsius to 21 degrees Celsius and maintain a temperature of at least 0 degrees Celsius for at least 0.4 hours at an ambient temperature of -20 degrees Celsius. One example of the heater substrate 102 with a perforated polypropylene film, containing a saturated NaBr mixture with 50% propylene glycol (w / w), was able to heat from an initial temperature of -20 degrees Celsius to 12 degrees Celsius and maintain a temperature of at least 0 degrees Celsius for at least 0.25 hours at an ambient temperature of -20 degrees Celsius. Although the description of the heater substrate containing the above additives (e.g., at least one of isopropanol, propylene glycol, ethanol, or ethylene glycol) is referenced to an ambient temperature as low as -20 degrees Celsius, it is expected that the proposed additives at the above ratios will also work at an initial temperature as low as -40 degrees Celsius. Thus, the saturated NaBr mixture with propylene glycol additive described above can be used for at least one heater substrate in a stack to initiate the exothermic reaction of other heater substrates in the stack that do not need to contain the propylene glycol additive. Similarly, the potassium hydroxide electrolyte solution described above can be used for at least one heater substrate in a stack to initiate the exothermic reaction of other heater substrates in the stack, which may contain a more typical NaBr mixture without any additives.

[0082] In one embodiment, the heater system 100 and the object 114 to be heated are enclosed within a thermally insulated container.

[0083] It should be understood that the various above-described embodiments, as well as other features and functions, or their alternatives or variations, may be desired to be combined into many other different systems or applications. Additionally, various currently unforeseen or unexpected alternatives, modifications, variations, or improvements may subsequently be made by those skilled in the art, and these are also intended to be encompassed in the following claims.

Claims

1. A heater system, characterized in that, The heater system includes: A first heater and a second heater, wherein both the first heater and the second heater include a metal and an electrolyte solution, and the electrolyte solution undergoes a thermal reaction with oxygen to generate heat, and the first heater is stacked on the second heater; At least one airtight package, wherein the at least one airtight package encloses the metal and the electrolyte solution included in the first heater and the second heater, and the airtight package is configured to be opened to allow air to enter the metal and the electrolyte solution; and A breathable spacer, which is deployed between the first heater and the second heater, along the direction in which the second heater is stacked on the first heater, wherein the first heater at least partially covers the second heater.

2. The heater system according to claim 1, wherein The heater system further includes: A plurality of heaters, wherein the plurality of heaters includes the first heater, the second heater, and a third heater, and the second heater is stacked on the third heater such that the second heater is deployed between the first heater and the third heater and separates the first heater and the third heater; A plurality of spacers, all of the plurality of spacers being breathable, the plurality of spacers including the spacer, which is a first spacer, and the plurality of spacers including the first spacer deployed between the first heater and the second heater, and a second spacer deployed between the second heater and the third heater along the direction in which the second heater is stacked on the third heater.

3. The heater system according to claim 1 or 2, characterized in that, The heater system further includes a heat insulation layer made of a breathable material, which is deployed on the first heater, on the side of the first heater opposite to the second heater, wherein the heat insulation layer, the first heater, the spacer, and the second heater are configured to be applied to an object to heat the object such that the first heater at least partially covers the second heater relative to the object.

4. The heater system according to claim 3, wherein The heat insulation layer and the spacer are made of the same material.

5. The heater system according to claim 1, wherein The spacer has a thickness and a porosity and is configured to deliver ambient air to at least one of the first heater and the second heater.

6. The heater system according to claim 1, wherein The spacer is made of a thick non-woven fabric located between the first heater and the second heater.

7. The heater system according to claim 1, wherein, The outer edge of the spacer is exposed to the ambient air between the first heater and the second heater.

8. The heater system according to claim 1, wherein The first heater includes a first breathable membrane or fabric located within the airtight package, and the second heater includes a second breathable membrane or fabric located within the airtight package, wherein the first breathable membrane or fabric has a higher air permeability than the second breathable membrane or fabric.

9. The heater system according to claim 1, characterized in that, The first heater includes a first electrolyte solution, and the second heater includes a second electrolyte solution, and the minimum operating temperature of the first electrolyte solution is lower than that of the second electrolyte solution.

10. The heater system according to claim 9, characterized in that, The first electrolyte solution includes at least one of isopropyl alcohol, propylene glycol, ethanol, ethylene glycol, and potassium hydroxide and the proportion is greater than that of the second electrolyte solution.

11. The heater system according to claim 9, characterized in that, The heater system further includes a third heater, the third heater includes a metal and a third electrolyte solution, and the third electrolyte solution undergoes a thermal reaction with oxygen to generate heat. The second heater is superimposed on the third heater such that the second heater is deployed between the first heater and the third heater and separates the first heater and the third heater. The minimum operating temperature of the first electrolyte solution is lower than that of the third electrolyte solution.

12. The heater system according to claim 11, wherein, Along the direction in which the second heater is superimposed on the first heater, the spacer disposed between the first heater and the second heater is a first spacer. The first spacer includes an outer edge directly exposed to the ambient air between the first heater and the second heater. The first spacer has a thickness and porosity configured to convey ambient air from the outer edge of the first spacer to an inner portion of at least one of the first heater and the second heater. And the heater system further includes: A second spacer, wherein the second spacer is disposed between the second heater and the third heater along the direction in which the second heater is superimposed on the third heater. The second spacer includes an outer edge directly exposed to the ambient air between the second heater and the third heater. The second spacer has a thickness and porosity configured to convey ambient air from the outer edge of the second spacer to an inner portion of at least one of the first heater and the second heater.

13. The heater system according to claim 12, wherein, The heater system further includes a heat insulation layer made of a breathable material, and the heat insulation layer is deployed on the first heater on the side opposite to the second heater. Wherein, the heat insulation layer, the first heater, the first spacer, the second heater, the second spacer, and the third heater are configured to be applied to an object to heat the object, so that the first heater at least partially covers the second heater and the third heater relative to the object.

14. The heater system according to claim 1, wherein Both the first heater and the second heater are formed by a mixture of activated carbon, zinc, and polytetrafluoroethylene placed on a porous fabric carrier.

15. The heater system according to claim 14, characterized in that, At least one airtight package encloses the porous fabric carriers of the first heater and the second heater respectively.

16. The heater system according to claim 14, characterized in that, The at least one airtight package is a first airtight package that encloses the porous fabric carrier of the first heater, and further includes a second airtight package that encloses the porous fabric carrier of the second heater.

17. The heater system according to claim 14, wherein, Both the first heater and the second heater include: A mixture including at least 4% by weight of activated carbon, at least 41% of zinc, and at least 5% of polytetrafluoroethylene; A saturated solution of sodium bromide added to the mixture of carbon, zinc, and polytetrafluoroethylene, wherein the weight of the saturated solution accounts for at least 15% of the mixture of carbon, zinc, and polytetrafluoroethylene; and A porous material layer, wherein the mixture of carbon, zinc, and polytetrafluoroethylene including the saturated solution is added to one side of the porous material layer.

18. The heater system according to claim 1, wherein The spacer operates as a thermal insulation layer, the thermal insulation layer forms a strip-shaped member, the strip-shaped member is configured to wrap around an object to be heated so that when the strip-shaped member wraps around the object, the first heater at least partially covers the second heater relative to the object, and the first heater and the second heater are parts of a larger heater and are separated by the spacer in the direction in which the first heater overlaps the second heater, or the first heater and the second heater are independent and are separated by the spacer in the direction in which the first heater overlaps the second heater.

19. The heater system according to claim 18, wherein, The strip-shaped member includes a first strip-shaped member intersecting a second strip-shaped member, wherein the position where the first strip-shaped member intersects the second strip-shaped member is closer to the first end of the second strip-shaped member than to the second end of the second strip-shaped member, the position where the second strip-shaped member intersects the first strip-shaped member is closer to the first end of the first strip-shaped member than to the second end of the first strip-shaped member, the first strip-shaped member defines an opening offset from the second strip-shaped member, the opening is closer to the first end of the second strip-shaped member than to the second end of the second strip-shaped member, and the heater system further includes: A fixing member, the position where the fixing member is connected to the second strip-shaped member is closer to the first end of the second strip-shaped member than to the first end of the second strip-shaped member, the fixing member is configured to fix the strip-shaped member wrapping around the object, wherein the first heater and the second heater are deployed on the second strip-shaped member.

20. A method for heating an object, characterized in that, The method includes: Providing a first heater and a second heater, wherein both the first heater and the second heater include a metal and an electrolyte solution, the electrolyte solution undergoes a thermal reaction with oxygen to generate heat so that the first heater at least partially covers the second heater using a spacer, the spacer is breathable and is deployed between the first heater and the second heater, along the direction in which the first heater overlaps the second heater; and Opening at least one airtight package to allow air to enter the metal and the electrolyte solution, the at least one airtight package encloses the metal and the electrolyte solution included in the first heater and the second heater.

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