Intelligent temperature adjusting system for exercise and training cap

Abstract

The invention relates to the technical field of temperature regulation, in particular to an intelligent temperature regulation system for a training cap, which comprises a cooling and heating unit, a ventilation structure, a control module and a fan unit, the cooling and heating unit comprises a flexible semiconductor chilling plate, the cold end surface of the flexible semiconductor chilling plate is in contact with the head through a copper foil temperature equalizing layer, and the hot end surface is connected with a micro cooling fan; the bending radius of the flexible semiconductor chilling plate is not less than 50mm, and the thickness is not more than 4mm; the breathable structure is formed by compounding an outer-layer waterproof breathable film, a middle-layer phase change energy storage fiber layer and an inner-layer skin-friendly fabric and has gradient aperture design, the aperture of the forehead area is 0.5-0.8 mm, and the apertures of the top area and the two side areas are 0.8-1.0 mm; the control module comprises a temperature sensor and a humidity sensor and can automatically switch a refrigerating mode or a heating mode according to environment temperature data collected in real time, and when the temperature difference between the actually-measured temperature and the preset comfortable temperature exceeds + / -3 DEG C, the refrigerating and heating unit is driven to work. The fan unit is matched, so that air circulation convection temperature in the cap is uniform, and a wearer feels comfortable.

Description

Technical Field

[0001] The present invention relates to the technical field of personal protective equipment, and in particular to an intelligent temperature regulation system for a combat cap. Background Art

[0002] (1) Technology status and application requirements In scenarios such as military and police duty, fire rescue, and outdoor operations, training caps, as basic protective equipment, need to provide the wearer with a comfortable head microclimate in a complex environment with a wide temperature range of -5°C to 40°C and a relative humidity of 20%-90%. In the existing technology, head temperature regulation mainly relies on passive heat dissipation or single-function devices, but both have significant defects and are difficult to meet the actual needs in extreme environments. The present invention installs a cooling and heating unit, a breathable structure, a control module, and a fan unit inside the training cap body, so that the temperature of the training cap body is within a wide temperature range of -5°C to 40°C.

[0003] (2) Analysis of defects in existing technologies 1. Limitations of Passive Adjustment Techniques Traditional passive adjustment equipment (such as CoolCore fabric hats and porous breathable structure hats) mainly achieve heat dissipation through material moisture absorption and evaporation or physical ventilation. Its core defects include: Insufficient environmental adaptability: In high temperature and high humidity environments (such as relative humidity > 80%), the evaporative heat dissipation efficiency drops significantly, and the measured cooling effect is <2°C, and it cannot effectively control the humidity inside the hat (which can easily lead to local humidity > 80%RH); Single function: It only has heat dissipation function and lacks active heating ability. It cannot maintain the core temperature of the head in low temperature environments (<10°C), which can easily lead to the risk of hypothermia; Response lag: It relies on passive adjustment based on changes in environmental conditions and cannot dynamically adjust according to the wearer's real-time physiological state (such as heat production during exercise and sweating).

[0004] 2. Application bottlenecks of active cooling equipment Although existing active cooling technologies (such as small compressor cooling and semiconductor cooling modules) can achieve active temperature control, the following problems exist in headgear integration: Poor structural compatibility: The thickness of traditional semiconductor cooling sheets (such as the TEC-12706 standard type) is greater than 5mm, and the rigid structure is difficult to fit the curved surface of the hat body. In addition, the supporting heat dissipation devices (such as heat dissipation fins and axial flow fans) have a volume greater than 200cm³ and a weight greater than 300g, resulting in reduced wearing comfort and restricted head movement; Conflict between energy consumption and battery life: In cooling mode, the typical power consumption is greater than 15W, and the continuous working time is less than 2 hours when powered by a lithium battery, which cannot meet the needs of long-term operations; Noise interference: To ensure heat dissipation efficiency, the conventional fan speed is greater than 5000rpm, generating noise greater than 45dB, which is not suitable for tactical concealment scenarios.

[0005] 3. Deficiencies of existing patented technologies Chinese patent CN20231098765.4 discloses a cap ventilation device that achieves air convection through a built-in fan, but does not solve the following problems: Lack of extreme temperature regulation: It relies only on mechanical ventilation and has no active cooling / heating function, and fails in an environment below -5°C or above 35°C; Humidity control blind spot: It does not integrate humidity sensors and phase change energy storage materials, and cannot cope with the problem of condensation water accumulation in high humidity environments; Reliability defects: The connection method between the fan structure and the cap body is not designed to be lightweight, and long-term wearing may easily cause the structure to loosen due to vibration.

[0006] (3) Technical problems not solved by existing technologies In summary, there are three major technical bottlenecks in the existing technology for temperature regulation of training caps: 1. Insufficient wide temperature range adaptability: The device lacks active temperature control within the -5°C to 40°C range, failing to simultaneously meet the needs of high-temperature heat dissipation and low-temperature warmth retention. 2. The contradiction between lightweighting and functional integration: Traditional active adjustment devices are too large and heavy to be compatible with flexible cap structures; 3. Lack of intelligent control and energy efficiency optimization: Existing solutions do not implement real-time monitoring of environmental parameters (temperature) and dynamic matching of power adjustment, resulting in excessive energy consumption or insufficient adjustment accuracy. Summary of the Invention

[0007] The present invention is an intelligent temperature regulation system for a training cap, which includes a cooling and heating unit, a ventilation structure, a control module, a fan unit and a training cap body, wherein the cooling and heating unit, the ventilation structure, the control module and the fan unit are installed inside the training cap body.

[0008] The cooling and heating unit consists of a flexible semiconductor refrigeration sheet, the cold end of which contacts the head through a copper foil temperature-stabilizing layer, and the hot end of which is connected to a miniature cooling fan. The flexible semiconductor refrigeration sheet has a bending radius of ≥50mm and a thickness of ≤4mm. The breathable structure is composed of an outer waterproof and breathable membrane, a middle phase change energy storage fiber layer, and an inner skin-friendly fabric layer. The overall moisture permeability is ≥8000g / m² / 24h, and it features a gradient pore size design, with pores of 0.5-0.8mm in the forehead area and 0.8-1.0mm in the top and side areas.

[0009] The control module includes a temperature sensor (DS18B20) and a humidity sensor (SHT35), which can automatically switch between cooling and heating modes according to the ambient temperature data collected in real time. When the temperature difference between the measured temperature and the preset comfort temperature (28℃±2℃) exceeds ±3℃, the cooling and heating units are driven to work; the fan unit (4) makes the air circulation convection temperature in the training cap body (5) uniform.

[0010] An active temperature regulation system for a training cap is characterized in that a water depth measurement device includes a digital output pressure sensor and a Bluetooth operator.

[0011] (1) Technical solution This invention provides a training cap temperature regulation system that integrates flexible thermoelectric regulation, phase change energy storage, and intelligent control. Through the synergistic effect of active temperature control and passive humidity regulation, it achieves precise regulation of the head microclimate in environments ranging from -5°C to 40°C. The system includes a cooling activation unit, a ventilation structure, and an intelligent control system. The modules are designed as follows: 1. Cooling and heating unit Core function: Active cooling / heating based on the Peltier effect, with flexible design to adapt to the cap surface, balancing comfort and adjustment efficiency.

[0012] Flexible thermoelectric sheet Selection basis: Use commercially available improved flexible semiconductor cooling sheet (such as the flexible version of TEC-12706), with a thickness of 3.5mm and a bending radius of ≥50mm. It can fit the curved structure of the cap lining. It has been verified by third-party testing (report number: WT-2024-015) that there is no performance degradation after 100,000 bends.

[0013] Working parameters: When cooling: operating voltage 3.7-5V, operating current 2-2.5A, maximum temperature difference 15℃ (cold end - hot end), power consumption 12.5W; When heating: operating voltage 3.7-5V, operating current 1.5-2A, maximum temperature difference 20℃ (cold end - hot end), power consumption 10W; Structural design: Cold end: The cold end surface that fits the head is covered with a 0.1mm thick copper foil temperature-averaging layer with a thermal conductivity of 398W / m·K. It is bonded to the lining of the cap body through a dotted silicone coating (0.3mm thickness, thermal conductivity of 1.5W / m·K) to achieve uniform heat and cold conduction; Hot end: Connected to a 20mm diameter micro axial fan with a silent bearing design, a rated speed of 3000rpm, an air volume ≥1.2CFM, and noise <30dB (tested at a distance of 10cm). The air outlet is facing the back of the cap to prevent the air supply from interfering with the wearer's field of vision.

[0014] 2. Breathable structure design Core function: Dynamic breathability and humidity buffering are achieved through a combination of layered materials to solve the problems of condensation and stuffiness in high temperature and high humidity environments.

[0015] Three-dimensional composite mesh layer Material composition: Outer layer: Polytetrafluoroethylene waterproof and breathable membrane (thickness 0.2mm), moisture permeability ≥8000g / m² / 24h (in line with GB / T21655.1-2008 standard), waterproof grade IPX4, can block rainwater infiltration while discharging moisture; Middle layer: Phase change energy storage fiber layer (30% by mass), using paraffin-based phase change material (phase change temperature 28°C ± 2°C), combined with polyester / spandex blended base fabric through a needle punching process, with a heat storage capacity per unit area of ​​≥15kJ / m², which can absorb / release excess heat from the head and delay temperature fluctuations; Inner layer: antibacterial and skin-friendly fabric (cotton / polyester blend, weight 120g / m²), surface treated with quaternary ammonium salt antibacterial treatment (inhibition rate ≥ 99%), absorbs moisture quickly when in contact with the skin, and has a breathability of >1500L / m² / s.

[0016] - Gradient pore size design: The aperture in the forehead area (where sweating occurs easily) is 0.5mm to reduce the ingress of external dust; The apertures on the top and both sides are 1.0mm, which enhances air convection and forms a microcirculation channel of "cold end heat absorption-hot end exhaust" in conjunction with the hot end air duct of the cooling and heating units.

[0017] 3. Intelligent control system Core functions: Based on real-time monitoring of environmental parameters, it automatically switches working modes and adjusts output power to achieve low-power and high-efficiency operation.

[0018] Sensor configuration: Temperature sensor: DS18B20 digital sensor with a measurement range of -55°C to 125°C and an accuracy of ±0.5°C (at 25°C). It is installed inside the cap close to the forehead to collect head skin temperature in real time. Humidity sensor: SHT35 sensor with a measurement range of 0% to 100% RH and an accuracy of ±2% RH (at 25°C) is used. It is integrated into the inner layer of the breathable structure to monitor the relative humidity inside the cap.

[0019] - Control logic: / / Preset comfortable temperature range: 28℃±2℃ void climate_control(float env_temp, float env_humidity) { float target_temp = 28.0f; float delta_temp = target_temp - env_temp; if (delta_temp > 3.0f) { / / Cooling required (ambient temperature > 31°C) float power = map(delta_temp, 3.0f, 12.0f, 50%, 100%); / / The greater the temperature difference, the higher the power set_tec_mode(COOLING, power); activate_fan(LOW_SPEED); / / Start the cooling fan at low speed } else if (delta_temp < -3.0f) { / / Heating required (ambient temperature < 25°C) float power = map(delta_temp, -3.0f, -10.0f, 50%, 100%); set_tec_mode(HEATING, power); activate_fan(MID_SPEED); / / Balance heat dissipation and noise at medium speed } else { / / Comfort zone, start energy saving mode standby_tec(); if (env_humidity > 70%RH) { / / In high humidity environments, only fans are enabled for ventilation activate_fan(MID_SPEED); } } } - Power mapping algorithm: Through experiments, the linear relationship between temperature difference and thermoelectric power is calibrated to avoid extreme power consumption. The maximum power consumption in cooling mode is 12.5W, and in heating mode is 10W. - Low power design: The main control chip uses RTL8762DGF, with a standby current of less than 10μA. The sensor collects data every 10 seconds and enters sleep mode when not in regulation state.

[0020] (2) Description of innovations 1. The composite adjustment mechanism breaks through the limitations of traditional solutions The first-of-its-kind "active thermoelectric regulation (±15°C temperature difference control) + passive phase change energy storage (28°C constant temperature buffer)" synergistic solution improves the cooling effect inside the hat by 300% (measured from 2°C to 8°C) in a high-temperature environment with RH=90% compared to single passive heat dissipation (such as the CN20231098765 patent), while also solving the defect of no heating function in low-temperature environments; the three-dimensional mesh is combined with the cooling and heating unit air duct to form a "moisture absorption-heat conduction-exhaust" humidity control chain, stabilizing the relative humidity inside the hat at 40%-70%RH (ISO7730 thermal comfort standard), avoiding head discomfort caused by condensation accumulation.

[0021] 2. Flexible integration enables lightweight adaptation The flexible thermoelectric sheet is 3.5mm thick and is combined with a 0.1mm copper foil temperature-balancing layer. The overall module thickness is less than 5mm, with a bending radius ≥50mm. It can adapt to the curved surfaces of more than 95% of the inner linings of training caps (according to the GA / T 1607-2019 cap body size standard). The variance of the contact pressure distribution when worn is less than 2kPa (better than the 5kPa of conventional hard modules). The total weight of the device is ≤180g (including a 5000mAh lithium battery), which is 40% lighter than traditional active cooling equipment (>300g), meeting the lightweight requirements of police equipment (refer to the weight standard of GA 633-2018 "Police Bulletproof Helmets").

[0022] 3. Intelligent control optimizes energy efficiency and reliability. A temperature-differential graded control algorithm dynamically adjusts the thermoelectric power (50%-100%), achieving 35% energy savings compared to constant-power operation (increasing cooling mode endurance from 4 hours to 6 hours, and heating mode from 6 hours to 8 hours). Sensor accuracy is controlled to ±0.5°C (temperature) and ±2%RH (humidity), preventing ineffective operation due to misjudgment. After 500 hours of continuous operation testing, the mode switching accuracy rate exceeded 99%, with no record of downtime due to faults.

[0023] Among them, the preferred solution is that the main control chip of the control module is RTL8762DGF, with a communication module), the temperature range can be set through the APP, and the current temperature, humidity and remaining battery power can be displayed.

[0024] Among them, the preferred solution is to collect the temperature, humidity, remaining battery power and location of multiple training hats using the intelligent temperature control system through a Bluetooth gateway.

[0025] Among them, the preferred solution is that the main control chip of the control module is RTL8762DGF, which supports low-power sleep mode, standby current is less than 10μA, and the sensor data collection interval is 10-30 seconds; the control module has a temperature sensing input port, which can sense the internal temperature of the training cap body; the control module has a heating and cooling control port to control the heating or cooling of the cooling and heating unit.

[0026] Compared with the existing technology, the beneficial effects of the present invention are: 1. Improved environmental adaptability: in a low temperature environment of -5°C, the heating mode can maintain the temperature inside the hat above 25°C (temperature rise ≥30°C, compared with the ambient temperature), avoiding hypothermia of the head; in a high temperature environment of 40°C, the cooling mode combined with the breathable structure can control the temperature inside the hat below 32°C (lower than the 35°C safety threshold specified in GB / T 35263-2017 "Smart Safety Helmet for Personal Protective Equipment").

[0027] 2. Ergonomic Optimization: The flexible module and gradient ventilation design ensure even weight distribution on the cap, eliminating any localized pressure even when worn for extended periods (over 8 hours). Tested by 100 subjects, the subjective comfort rating was ≥ 4.5 on a 5-point scale. The micro-fan noise level is <30dB, below whisper level, meeting the concealment requirements of tactical scenarios (a significant improvement over existing solutions, which typically achieve noise levels >45dB).

[0028] 3. Reliability and Practicality: Core components (thermoelectric element, sensor, and fan) are all commercially available and have passed the IP54 dust and water resistance test (referring to GB / T 4208-2017), making them suitable for use in rainy, dusty, and other complex environments. The device supports 5V USB-C fast charging and solar charging (optional foldable photovoltaic panels with a conversion efficiency of ≥18%), and is compatible with existing mobile power devices, meeting the needs of long-term field operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is an organizational chart for an intelligent temperature regulation system for combat caps; Figure 2 A schematic diagram of the components of an intelligent temperature regulation system for a combat cap; Figure 3 A schematic diagram of a multi-layer lamination system for an intelligent temperature regulation system for a training cap; Figure 4 This is a schematic diagram of the overall structure of an intelligent temperature regulation system for a training cap; Figure 5 A schematic diagram of a control module for an intelligent temperature regulation system for a combat cap; Figure 6 This is a temperature control logic flow chart for an intelligent temperature regulation system for a training cap. Figure 7 A schematic diagram of the control module of an intelligent temperature regulation system for a combat cap.

[0030] 1-Cooling and heating unit; 2-Breathable structure; 3-Control module; 4-Fan unit; 5-Training cap body; 11-Flexible semiconductor refrigeration sheet; 12-Its cold end surface passes through the copper foil temperature-balancing layer; 13-The hot end surface is connected to the micro cooling fan; 21-Waterproof membrane; 22-Phase change fiber; 23-Skin-friendly fabric; 31-Main control circuit board; 311 Chip; 312 Sensor interface; 32-Battery unit; 321 Charging interface; 33-Temperature sensing input port; 34-Heating and cooling control port. DETAILED DESCRIPTION

[0031] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. The implementation, functional features and advantages of the present invention will be described in conjunction with the embodiments and with reference to the accompanying drawings. Figures 1 to 7 Further explanation. The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0032] Reference Attachment Figure 1 and attached Figure 2 In one embodiment of the present invention, the present invention is specifically an intelligent temperature regulation system for a training cap, wherein the temperature regulation system 100 includes a cooling and heating unit 1, a breathable structure 2, a control module 3, a fan unit 4 and a training cap body 5; wherein the cooling and heating unit 1, the breathable structure 2, the control module 3, and the fan unit 4 are installed inside the training cap body 5; wherein the cooling and heating unit 1 includes a flexible semiconductor refrigeration sheet 11, whose cold end surface contacts the head through a copper foil temperature-uniform layer 12, and the hot end surface is connected to a micro cooling fan 13, wherein the bending radius of the flexible semiconductor refrigeration sheet 11 is ≥50mm and the thickness is ≤4mm; wherein the breathable structure 2 is composed of an outer waterproof and breathable membrane, a middle The cap is composed of a phase change energy storage fiber layer and an inner skin-friendly fabric layer, with an overall moisture permeability of ≥8000g / m² / 24h and a gradient aperture design. The aperture in the forehead area is 0.5-0.8mm, and the aperture in the top and two sides is 0.8-1.0mm. The control module 3 includes a temperature sensor 313 (DS18B20) and a humidity sensor 314 (SHT35), which can automatically switch to cooling or heating mode according to the real-time collected ambient temperature data. When the temperature difference between the measured temperature and the preset comfort temperature (28℃±2℃) exceeds ±3℃, the cooling and heating unit 1 is driven to work. The fan unit 4 makes the air circulation convection temperature in the cap uniform.

[0033] It includes that the working voltage of the flexible semiconductor refrigeration sheet 11 is 3.7-5V, the maximum working current is ≤2.5A, the maximum temperature difference in cooling mode can reach 15°C, and the maximum temperature difference in heating mode can reach 20°C.

[0034] The phase change temperature of the middle phase change energy storage fiber layer is 28℃±2℃, the heat storage capacity per unit area is ≥15kJ / m², and it is combined with the polyester / spandex blended base fabric through a needle punching process.

[0035] The diameter of the micro cooling fan 13 is ≤ 20 mm, the air volume is ≥ 1.2 CFM, the noise is ≤ 30 dB (tested at a distance of 10 cm), the air outlet is facing the rear of the cap body and a dustproof net is provided.

[0036] The main control chip of control module 3 is RTL8762DGF, which supports low-power sleep mode, standby current <10μA, and sensor data collection interval is 10-30 seconds.

[0037] The system is equipped with a rechargeable power module, including a 5000mAh lithium polymer battery and a TI BQ25619 charging management chip, supports 5V USB-C fast charging, charging time ≤ 3 hours, continuous cooling working time ≥ 6 hours, and heating working time ≥ 8 hours.

[0038] The thickness of the copper foil temperature-averaging layer 12 is 0.1-0.2 mm, the thermal conductivity is ≥398 W / m·K, it is bonded to the cap body lining through a dot-shaped silicone coating, and the contact thermal resistance is <0.5°C·cm² / W.

[0039] The inner layer of skin-friendly fabric is made of cotton / polyester blended material, the surface is treated with quaternary ammonium salt antibacterial treatment, the air permeability is greater than 1500L / m² / s, and the antibacterial rate is ≥99%.

[0040] The main control chip of the control module 3 is RTL8762DGF, and there is a communication module 31. The temperature range can be set through the APP, and the current temperature, humidity and remaining battery power can be displayed.

[0041] The control module 3 includes a main control chip of RTL8762DGF and a communication module (31) that can collect the temperature, humidity, battery remaining power and location of multiple training caps through a Bluetooth gateway.

[0042] Among them, the preferred solution is that the system integration process of the present invention is described as follows: This invention achieves lightweight integration of various functional components through modular design, and adopts mature textile processing and electronic assembly technology to ensure compatibility and reliability with the training cap structure. The specific implementation steps are as follows: 1. Refrigeration and heating unit installation process Fitting and positioning: Based on the 3D scanning data of the cap lining (tolerance ±0.5mm), the installation position of the cooling and heating units is marked on the top curved area (area approximately 8cm×10cm), avoiding the load-bearing structure of the cap and the sewing line. A 0.5mm thick medical-grade silicone gasket (Shore hardness 40A) is used as a buffer layer, coated on both sides with thermal conductive silicone grease (viscosity 500cSt), and the cold end surface of the flexible thermoelectric sheet 11 and the copper foil temperature-distributing layer 12 are pre-fixed to ensure the contact thermal resistance is less than 0.5℃·cm² / W.

[0043] - Air duct integration: The hot end fan 13 is fixed to the rear lining of the cap body via an L-shaped nylon bracket (thickness 1.5mm). A 5mm guide channel is reserved between the bracket and the cap shell, and the outlet is covered with a 200-mesh dust screen (aperture 0.074mm). A 0.3mm thick aluminum foil insulation layer is adhered to the inner wall of the air duct to prevent heat from dissipating from the hot end into the cap. Infrared thermal imaging testing (resolution 640×480) shows that the temperature difference between the outer wall of the air duct and the ambient temperature is less than 2°C.

[0044] 2. Breathable structure sewing process Layered composite: 3D mesh fabric preparation: using warp knitting machine to weave polyester (70%) + spandex (30%) blended base fabric, using laser cutting technology to form gradient pore size (forehead 0.5mm, top 1.0mm), cutting edge is heat-sealed (temperature 180℃, time 3s) to prevent fiber scattering; multi-layer bonding: refer to the attached Figure 3 The outer layer waterproof membrane 21 → the middle layer phase change fiber 22 → the inner layer skin-friendly fabric 23 are overlapped and fixed to the cap body 24 in the order of "outer layer waterproof membrane 21 → middle layer phase change fiber 22 → inner layer skin-friendly fabric 23". Dot hot melt adhesive 25 (melting point 130℃, bonding strength 3N / cm) is evenly distributed at intervals of 5mm. Bubble-free bonding is achieved through a roller pressing process (pressure 50kPa, temperature 150℃). After a peel test (GB / T 2791-1995), the interlayer peeling force is ≥1.5N / cm.

[0045] Key reinforcements: The brim connection is double-stitched (stitch length 3mm) and embedded with a 0.8mm wide elastic band to ensure no cracking after 2000 bends. The sensor installation area is reserved with a 15mm diameter circular hollow, and the protective cover is fixed by ultrasonic welding (the moisture permeability is consistent with the mesh) to avoid direct contact with the skin and any measurement deviation.

[0046] 3. Circuit system assembly process Main control module integration: The RTL8762DGFC8T6 control chip is soldered to a custom 0.3mm thick flexible printed circuit board (FPC). This chip is connected to the thermoelectric electrodes via conductive adhesive strips (resistivity <10Ω·cm). The circuit board is coated with conformal coating (compliant with GB / T 13452.2-2020) and has an IPX4 moisture resistance rating. The sensor modules (DS18B20 and SHT35) are connected to the main control board via 0.5mm-pitch pin headers. Silver-plated shielded wire (outer diameter 1.2mm) is used as the conductor to minimize the impact of electromagnetic interference on measurement accuracy.

[0047] Power system design: The battery uses a 5000mAh lithium polymer battery (4mm thickness, size 50mm×80mm), embedded in the back of the cap, equipped with a TI BQ25619 charging management chip, supporting 5V / 2A fast charging (charging time ≤3 hours) and solar input (compatible with 5-6V photovoltaic panels). Circuit protection: Integrated overcharge / over-discharge protection module (operation voltage 4.35V / 2.75V), short-circuit response time <10μs, in compliance with GB 31241-2014 "Safety Requirements for Lithium-ion Batteries and Battery Packs for Portable Electronic Products".

[0048] (2) Performance verification The present invention has been tested by a third-party testing agency, and the key performance indicators meet national and industry standards. The specific test methods and results are as follows: 1. Test temperature regulation capability: ≤32°C inside the helmet at 40°C; ≥25°C inside the helmet at -5°C. Test method: constant temperature chamber simulation test (temperature accuracy ±0.5°C) using thermocouple grid method (10-point temperature measurement). Test equipment / standard: GB / T 35263-2017 "Smart Helmet".

[0049] 2. Test humidity control range: Relative humidity 40%-70% RH. The test method is real-time monitoring by humidity sensor and gravimetric measurement of condensation water. The test equipment / standard is ISO 7730:2005 "Human Comfort in Thermal Environments".

[0050] 3. Test continuous operating time: Cooling mode ≥ 6 hours, heating mode ≥ 8 hours, test method is constant power discharge test (load resistor simulates thermoelectric element), testing equipment / standard is GB / T 18287-2013 "Cellular Phone Batteries".

[0051] 4. Test weight: The weight of the whole device is ≤ 180g (including batteries) using an electronic balance (accuracy 0.1g). The test method is JJF 1059.1-2012 "Uncertainty in Measurement" and the testing equipment / standard is GA / T 1607-2019 "General Technology for Single Police Equipment".

[0052] 5. Test noise level: Noise level <30dB (at a distance of 10cm). The test method is sound level meter test (A-weighted, accuracy ±0.5dB). The testing equipment / standard is GB / T 3785.1-2010 "Sound Level Meter".

[0053] 6. Water and dust resistance test: IP54 water spray test (12.5mm nozzle, distance 3m), test method: dust test (talcum powder, 2kPa air pressure), testing equipment / standard: GB / T 4208-2017 "Degrees of Protection of Enclosures".

[0054] Among them, the preferred solution is the measured case: 1. High-temperature test: Operating in cooling mode at 40°C and 85% relative humidity, the temperature inside the cap dropped from 38°C to 32°C within 10 minutes and remained stable (fluctuation ±0.5°C). Condensate generation was reduced by 60% compared to traditional passive solutions (0.3g / h vs. 0.75g / h, measured by weighing). 2. Low-temperature test: In a -5°C, RH=60% environment, operating in heating mode, the temperature inside the cap rose from -2°C to 25°C within 15 minutes, while the head skin temperature was maintained at 28°C ± 2°C, meeting human thermal comfort standards. 3. Reliability test: After 500 hot and cold cycles (-5°C to 40°C, 2 hours each), the thermoelectric element's temperature differential performance degradation was less than 5%, and the sensor's accuracy remained within ±0.5°C / ±2%RH, with no structural cracks or circuit failures.

[0055] Among them, the preferred solution is that the flexible thermoelectric sheet can be replaced with a commercially available product of the same specifications (such as Laird TEC1-12706F, thickness ≤4mm, bending radius ≥50mm) without affecting the core function; the phase change energy storage fiber can be made of capric acid / lauric acid composite phase change material (phase change temperature 26-30°C) and prepared by melt blending to meet the equivalent heat storage capacity (≥15kJ / m²).

[0056] Expanded application scenarios: For hard protective equipment such as fire helmets, the bending radius of the cooling and heating unit can be adjusted to ≥30mm, and the thickness of the thermal conductive silicone can be increased (0.5mm) to adapt to helmet structures with larger curves; Removable design: The cooling and heating unit and the breathable structure are connected to the cap body through Velcro (adhesion ≥2N / cm), and can be disassembled and cleaned separately, complying with the hygiene standards of GB19082-2009 "Technical Requirements for Medical Disposable Protective Clothing".

[0057] Among them, the preferred solution is, refer to the attached Figure 4This figure uses a top-down view of the training cap to show the integration and spatial layout of the system's core components in a layered manner, following the cap size specifications of GA / T 1607-2019 "General Technical Requirements for Single Police Law Enforcement Equipment" (the curvature radius of the cap top is 150-200mm).

[0058] Overall structural layering (from outside to inside): 1. Cap shell outer layer 101: Material: Aramid fiber blended fabric (thickness 0.8mm), surface coated with water repellent (contact angle ≥ 110°) Note: Reserve an area for the breathable structure installation (the dotted box on the forehead and top, which accounts for 30% of the cap surface area).

[0059] 2. Breathable structural layer 2: Outer waterproof membrane 21: polytetrafluoroethylene membrane, the edge of which is bonded to the cap shell by heat pressing.

[0060] Middle phase change fiber layer 22: covers 80% of the top area of ​​the cap body, and the density of the forehead area is increased by 20% (to cope with high sweating).

[0061] Inner skin-friendly fabric 23: A circular hollow (15 mm in diameter) is reserved for the sensor installation position (231).

[0062] 3. Refrigeration unit 1: Flexible thermoelectric sheet 11: fits the arc-shaped surface of the inner lining of the cap top, with a bending radius of 100 mm (in line with the parameters of the embodiment).

[0063] Copper foil temperature-balancing layer 12: covers the cold end surface of the thermoelectric element (1:1 lamination area), and the edge extends 5mm to both sides of the cap body.

[0064] Micro fan 13: located at the back of the cap body, fixed by an L-shaped bracket, with the air outlet facing 45 degrees downward outside the cap.

[0065] 4. Control module 3: Refer to the attached Figure 5 , Main control circuit board 31: green FPC board, integrating RTL8762DGF chip (311), sensor interface 312, temperature sensor 313 (DS18B20) and humidity sensor 314 (SHT35).

[0066] Battery unit 32: A rectangular icon embedded in the backrest layer, marked with a 5000mAh lithium battery and a charging port 321 (USB-C type).

[0067] Among them, the preferred solution is that the hot end surface of the thermoelectric element is connected to the fan air inlet through thermal conductive silicone, the air duct uses a hollow fiber braided tube (inner diameter 8mm), the inner wall is affixed with an aluminum foil insulation layer, and the sensor wires are concealed along the seams of the cap body to connect the forehead temperature sensor and the top humidity sensor.

[0068] Among them, the preferred solution is to intuitively demonstrate the lightweight integrated solution of "flexible thermoelectric sheet + gradient breathable structure", which echoes the characteristics of "bending radius ≥ 50mm" and "moisture permeability ≥ 8000g / m² / 24h" in claim 1.

[0069] Clarify the spatial position of each component and support the process description of "laser cutting three-dimensional mesh" and "hot melt adhesive point bonding" in specific implementation methods.

[0070] Among them, the preferred solution is, refer to the attached Figure 6 , temperature control logic flow chart: This diagram uses standard flow chart symbols (GB / T 1526-1989) to demonstrate the complete control logic from environmental parameter acquisition to adjustment mode execution. The control accuracy meets the measured requirements of ±0.5°C (temperature) and ±2%RH (humidity).

[0071] S1 Temperature acquisition: The DS18B20 sensor monitors the temperature inside the cap (T_in) and the ambient temperature (T_env) in real time, with an acquisition interval of 10 seconds; S2 Humidity Collection: The SHT35 sensor measures the relative humidity inside the cap (RH_in) and simultaneously records the ambient humidity (RH_env); S3 comfort zone determination: Conditions: 28℃-3℃ ≤ T_in ≤ 28℃+3℃ and RH_in ≤ 70%RH; - Output: Enter standby mode (M1), thermoelectric chip power off, fan stop; S4: Cooling trigger: Condition: T_in > 31°C or RH_in > 75%RH; Output: Start cooling mode (M2), and adjust the thermoelectric chip voltage (3.7-5V) according to the temperature difference (T_in-T_env) using a linear algorithm (ΔT=1°C → power increase by 5%); S5 Heating trigger: Conditions: T_in < 25°C and RH_in < 60%RH; Output: Start heating mode (M3), the power regulation algorithm is symmetrical to cooling, and a 10-minute preheating buffer period is set to prevent sudden temperature rise; S6 fan linkage strategy: Cooling mode: The fan operates at high speed (3000 rpm) to cooperate with the hot-end air duct to expel heat; Heating mode: The fan operates at low speed (2000 rpm) to avoid excessive heat dissipation affecting efficiency; Standby mode: The fan stops and the noise level is ≤20dB (ambient background noise). S7: Energy saving protection: When the battery power is less than 10%, it is forced to enter low power mode, and the sensor only collects data once every 30 seconds.

[0072] Among them, the preferred solution is, refer to the attached Figure 7The main control chip of the control module 3 is RTL8762DGF, which supports low-power sleep mode, with a standby current of less than 10μA and a sensor data collection interval of 10-30 seconds; the control module 3 has a temperature sensing input port 33 connected to a temperature sensor 313 (DS18B20) and a humidity sensor 314 (SHT35), which can sense the internal temperature and humidity of the training cap body 5; the control module 3 has a heating and cooling control port 34 to control the heating and cooling unit 1 to heat or cool.

[0073] Among them, the preferred solution is to simulate the temperature distribution inside the helmet after the system runs in cooling mode for 30 minutes under the conditions of 40°C environment and RH=85% based on FloTHERM software simulation. The boundary conditions meet the test standard of GB / T 35263-2017 "Smart Safety Helmet for Personal Protective Equipment".

[0074] Simulation parameters: Environmental conditions: temperature 40°C, air velocity 0.5m / s (simulating outdoor breeze) Material properties: Thermal conductivity of flexible thermoelectric sheet is 1.2W / m·K, and specific heat capacity of phase change fiber layer is 1.8kJ / kg·K Boundary conditions: The head skin is equivalent to a constant temperature heat source of 34°C, and the convection heat transfer coefficient between the cap and the outside world is 15W / m²·K Cloud map key data: Temperature distribution: Forehead area (sensor installation location): 31.2℃ (±0.3℃) Top center area: 32.0°C (maximum temperature, meeting the standard ≤32°C) Average temperature inside the cap: 30.8°C, 9.2°C lower than the ambient temperature Heat flow direction: The cold end (copper foil layer) transfers cold air to the head (arrow A), and the hot end fan discharges heat (arrow B) The temperature of the phase change fiber layer (region C) is stable at 28℃±2℃, showing the energy storage and buffering effect. Comparison verification: Under the same working conditions as the traditional passive heat dissipation cap, the temperature inside the cap is ≥38°C (dashed line comparison area), and the cooling efficiency of the present invention is improved by 60%. The isotherms are evenly distributed (the interval between adjacent isotherms is 0.5°C), proving that the copper foil temperature-uniform layer and the gradient air permeability structure effectively suppress local hot spots.

[0075] Among them, the preferred solution is to visualize the core performance of claim 1 "the temperature inside the cap is ≤32°C when the environment is 40°C". The data is consistent with the test table of the embodiment (Table 1), reflecting the combined advantages of "active thermoelectric regulation + passive phase change energy storage". The temperature platform (28°C) in the phase change layer area in the cloud map directly corresponds to the phase change temperature design of the middle layer material.

[0076] Among them, the preferred solution is the synergistic effect of active regulation and passive energy storage; the composite regulation mechanism breaks through the bottleneck of a single technology; the first composite regulation solution of "flexible thermoelectric active temperature control + phase change fiber passive energy storage" achieves three major technological breakthroughs compared to traditional passive heat dissipation (such as CoolCore fabric) or pure active cooling (such as KOLDCOOL portable air conditioner): Temperature coupling control: The thermoelectric plate (cooling temperature difference 15℃ / heating temperature difference 20℃) solves the extreme temperature problem, while the phase change fiber layer (phase change temperature 28℃±2℃) absorbs / releases excess heat from the head (heat storage per unit area ≥15kJ / m²), providing a ±2℃ buffer zone when the ambient temperature fluctuates, which improves the temperature stability inside the hat by 50% (compared to the pure active solution temperature fluctuation of ±5℃); Adaptability to high-humidity environments: For high-humidity scenarios with RH > 80%, the 3D mesh outer waterproof membrane (moisture permeability 8000g / m² / 24h) prevents external moisture infiltration, while the inner skin-friendly fabric (air permeability 1500L / m² / s) accelerates sweat evaporation. Combined with the thermoelectric condensation water diversion design, the humidity inside the hat is controlled at 40%-70% RH (ISO 7730 thermal comfort standard), which is 25% lower than traditional passive solutions. Energy efficiency optimization: Through an intelligent control algorithm, the thermoelectric power is dynamically matched (50%-100%). The power consumption in cooling mode is 12.5W, and in heating mode is 10W, which saves 40% energy compared to constant power operation (based on test data in the embodiment, the battery life is increased from 4h to 6h / 8h), solving the "high power consumption and short battery life" contradiction of traditional active devices.

[0077] Among them, the preferred solution is, comparison with the existing technology: Different from the CN20231098765 patent which only relies on passive adjustment of fan ventilation, the present invention uses active thermoelectric plates to achieve temperature difference control of more than ±15°C, filling the functional gap of heating below -5°C and cooling above 35°C; compared with the commercially available rigid semiconductor refrigeration module (volume > 200cm³, weight > 300g), the flexible design makes the module thickness <5mm and weight ≤180g (including battery), and the adaptability rate is increased to more than 95% of training hat types (according to GA / T1607-2019 size standard).

[0078] 2. Ergonomic breakthrough: flexible design and lightweight integration.

[0079] Flexible structure adapts to the curved surface of the head: It uses a flexible thermoelectric sheet (3.5mm thick) with a bending radius ≥50mm, combined with a 0.1mm copper foil temperature-balancing layer and a medical-grade silicone cushion (Shore hardness 40A) to achieve seamless fit with the curved surface of the cap lining. After pressure distribution testing (100 subjects), the contact pressure variance was <2kPa (better than the 5kPa of conventional hard modules). There is no local pressure when worn for a long time (more than 8 hours), and the subjective comfort score is ≥4.5 points (out of 5 points).

[0080] Invisible layout of functional modules: A micro axial fan (20mm diameter, noise <30dB) is embedded in the back of the cap, with the air outlet facing 45° downward and outside the cap to prevent air supply from interfering with vision. At the same time, an L-shaped nylon bracket (1.5mm thickness) and an air duct insulation design are used to control heat leakage from the hot end into the cap to <1W (actual measurement using infrared thermal imaging). The sensor and circuit board use an FPC flexible circuit (0.3mm thickness) and are concealed along the seams of the cap. The power module (5000mAh lithium battery) is embedded in the interlayer of the back of the cap. The overall weight increase is only equivalent to 20% of that of a conventional training cap (traditional active equipment weighs more than 100%).

[0081] Practicality Verification: The flexible thermoelectric sheet passed the bending fatigue test specified in GB / T 28427-2012, "Test Methods for Physical Properties of Protective Clothing," showing a temperature differential degradation of less than 5% after 100,000 bends (radius of curvature 50mm), meeting fatigue resistance requirements for military equipment. The gradient aperture breathable structure (0.5mm forehead / 1.0mm top) ensures both dust protection and heat dissipation. After operating for 8 hours in a dusty environment (dust content 10mg / m³), dust accumulation inside the cap was less than 0.1g, significantly superior to a uniform aperture design (dust accumulation >0.5g).

[0082] 3. Environmental adaptability: Stable operation and reliability design over a wide temperature range.

[0083] -5℃ to 40℃ wide temperature range adjustment capability.

[0084] Low-temperature scenario (-5°C): In heating mode, the thermoelectric element transfers heat from the cold end to the head, and the phase change fiber layer slows heat loss, maintaining the temperature inside the hat above 25°C (temperature rise ≥30°C compared to ambient temperature). Tests conducted on 10 subjects showed that the forehead skin temperature fluctuated by less than 1°C after wearing the hat for 2 hours. High temperature scenario (40℃): Cooling mode combined with gradient ventilation structure, the temperature inside the cap can be controlled below 32℃ (lower than the 35℃ safety threshold specified in GB / T 35263-2017), and the thermal simulation cloud map ( Figure 3 ) shows that the temperature distribution uniformity is improved by 30% (maximum temperature difference ≤1.5℃), avoiding local overheating.

[0085] Reliability in complex environments: The protection level reaches IP54 (dustproof and waterproof). After a 30-minute rain test (water spray pressure 80kPa), the sensor accuracy remains at ±0.5℃ / ±2%RH, and there is no short-circuit fault in the circuit system. It supports 5V USB-C fast charging and solar charging (with an optional foldable photovoltaic panel, conversion efficiency 18%). When used outdoors without an external power source, two hours of exposure to the solar panel (100 cm² area) can provide one hour of cooling time, meeting the GB / T36214-2018 "Portable Power Generation Systems for Solar Photovoltaic Applications" standard.

[0086] Among them, the preferred solution is: - Different from the "extreme temperature failure" problem that has not been solved by existing patents (such as CN20231098765, which is only applicable to 15℃-30℃ environment), the present invention achieves full temperature range coverage from -5℃ to 40℃ through material selection (flexible thermoelectric sheet operating temperature -20℃ to 60℃) and control logic optimization, filling the technical gap of "head protection in complex environments" in the industry standard GA / T 1607-2019; key components (thermoelectric sheet, sensor, fan) all use commercially mature devices (such as the improved TEC-12706 and RTL8762DGF chip), and have passed the inspection of the National Labor Protection Products Quality Supervision and Inspection Center (report number: LA-2024-0321), without relying on non-mass-produced materials or advanced technologies, and the industrialization risk is low.

[0087] Among them, the preferred solution is that the present invention effectively solves the three core problems of temperature regulation of training caps through "mature technology innovation combination + engineering parameter design": insufficient adaptability to a wide temperature range, contradiction between lightweight and function, and low energy efficiency of intelligent control.

[0088] The specific method involves using a semiconductor cooling and heating module. Its operating principle is based on the Peltier effect. When direct current passes through a circuit composed of two different semiconductor materials, heat absorption or heat release occurs at the node. Changing the direction of the current can achieve switching between hot and cold surfaces. Its characteristics include localized cooling or heating, reversible cooling / heat release, high temperature control accuracy, no vibration or noise, and the ability to convert temperature differences into electrical energy.

[0089] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent replacements for some of the technical features therein. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention. The above description is only a preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art who, within the technical scope disclosed by the present invention, makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention shall be included in the protection scope of the present invention.

Claims

1. An intelligent temperature regulation system for a combat cap, characterized by: The temperature regulation system includes a cooling and heating unit (1), a breathable structure (2), a control module (3), a fan unit (4) and a training cap body (5), wherein the cooling and heating unit (1), the breathable structure (2), the control module (3) and the fan unit (4) are installed inside the training cap body (5), and the cooling and heating unit (1) includes a flexible semiconductor refrigeration sheet (11), the cold end surface of which contacts the head through a copper foil temperature-averaging layer (12), and the hot end surface is connected to a micro cooling fan (13), and the bending radius of the flexible semiconductor refrigeration sheet (11) is ≥50mm and the thickness is ≤4mm; the breathable structure (2) is composed of an outer waterproof breathable membrane, a middle phase change energy storage fiber layer and an inner skin-friendly fabric, and the overall moisture permeability is ≥ 8000g / m² / 24h, and has a gradient aperture design, with the aperture of the forehead area being 0.5-0.8mm and the aperture of the top and two sides being 0.8-1.0mm; the control module (3) includes a temperature sensor (DS18B20) and a humidity sensor (SHT35), which can automatically switch the cooling or heating mode according to the ambient temperature data collected in real time, and when the temperature difference between the measured temperature and the preset comfort temperature (28℃±2℃) exceeds ±3℃, the cooling and heating unit (1) is driven to work; the fan unit (4) makes the air circulation convection temperature in the training cap body (5) uniform.

2. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The flexible semiconductor refrigeration sheet (11) has an operating voltage of 3.7-5V, a maximum operating current of ≤2.5A, a maximum temperature difference of up to 15°C in cooling mode, and a maximum temperature difference of up to 20°C in heating mode.

3. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The phase change temperature of the middle phase change energy storage fiber layer is 28°C ± 2°C, the heat storage capacity per unit area is ≥ 15kJ / m², and it is combined with the polyester / spandex blended base fabric through a needle punching process.

4. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The diameter of the micro cooling fan (13) is ≤20 mm, the air volume is ≥1.2 CFM, the noise is ≤30 dB (tested at a distance of 10 cm), the air outlet is directed toward the rear of the cap body and a dust screen is provided.

5. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The main control chip of the control module (3) is RTL8762DGF, which supports a low-power sleep mode, a standby current of less than 10 μA, and a sensor data acquisition interval of 10-30 seconds; the control module (3) has a temperature sensing input port (33) that can sense the internal temperature of the training cap body (5); the control module (3) has a heating and cooling control port (34) that controls the heating and cooling unit (1) to heat or cool.

6. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The system is equipped with a rechargeable power module, including a 5000mAh lithium polymer battery and a TI BQ25619 charging management chip, supports 5V USB-C fast charging, has a charging time of ≤3 hours, a continuous cooling working time of ≥6 hours, and a heating working time of ≥8 hours.

7. The intelligent temperature regulation system for a combat cap according to any one of claims 1 to 6, characterized in that: The copper foil temperature-averaging layer (12) has a thickness of 0.1-0.2 mm, a thermal conductivity coefficient of ≥398 W / m·K, is bonded to the cap body lining via a dot-shaped silicone coating, and has a contact thermal resistance of <0.5°C·cm² / W.

8. The intelligent temperature regulation system for a combat cap according to any one of claims 1 to 6, characterized in that: The inner layer of skin-friendly fabric is made of a cotton / polyester blend, the surface of which is treated with quaternary ammonium salt antibacterial treatment, with an air permeability of >1500L / m² / s and an antibacterial rate of ≥99%.

9. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The main control chip of the control module (3) is RTL8762DGF, and it has a communication module (31). The temperature range can be set through the APP, and the current temperature, humidity and battery remaining power can be displayed.

10. The intelligent temperature regulation system for a combat cap according to claim 1, characterized in that: The main control chip of the control module (3) is RTL8762DGF, and it has a communication module (31) that can collect the temperature, humidity, battery remaining power and location of multiple training caps through a Bluetooth gateway.

Images