A protective device

Abstract

A protective device 1 for at least partially surrounding a thermally sensitive component 16 comprises a flexible cover 2 surrounding a first 4 and second 6 layer each comprising a plurality of contain

Description

Technical Field of the Invention The present invention relates to a protective device for at least partially surrounding a thermally sensitive component and a method of protecting a thermally sensitive component. Background to the Invention Thermally sensitive components such as dataloggers are typically used in high temperature industrial processes and may be inserted into industrial heating apparatus to measure the conditions within the heating apparatus during use. The thermally sensitive components may be damaged by heat or IR radiation during use. To prevent damage, it is known for the thermally sensitive component to be inserted into a protective device which protects against heat or IR damage whilst allowing the component to work as intended. Known protective devices have several disadvantages - they may be large in size, inflexible and / or fragile, which may prevent their repeated use or the use of the thermally sensitive component in small spaces. Known protective devices may have poor heat dissipation properties under some conditions, such that the thermally sensitive component may become damaged or work inefficiently within high temperature or high IR radiation conditions. Industrial ovens may comprise an oven belt wherein the oven belt may carry an item into the oven for heating or cooking. Thermally sensitive components such as dataloggers, may also be placed on the oven belt and travel into the oven to measure the conditions during heating or cooking. The opening in which the oven belt passes into the oven may be relatively small to maintain heat within the oven and improve the efficiency of the oven. Known protective devices for protecting thermally sensitive components may be large due to the volume of insulating material used in those devices which is required to render them suitable for high temperature applications and therefore may not fit through the opening into some ovens. It would therefore be advantageous to provide a protective device for at least partially surrounding a thermally sensitive component wherein the protective device comprises improved heat dissipation and buffering properties. It would also be advantageous to provide a protective device for at least partially surrounding a thermally sensitive component wherein the protective device is flexible such that thermally sensitive components of different sizes and shapes can be inserted into the protective device, whilst still providing the thermally sensitive components with sufficient physical and thermal protection during use. It would be advantageous to provide a protective device for at least partially surrounding a thermally sensitive component wherein the protective device is relatively small or is relatively thin such that the protective device can be inserted into smaller openings in use, for example oven openings. It would furthermore be advantageous to provide a protective device for at least partially surrounding a thermally sensitive component wherein the protective device is relatively robust such that it can be used repeatedly without the need for replacement. It is an aim of embodiments of the invention to overcome one or more problems of the prior art, whether expressly disclosed herein or not. Summary of the Invention According to a first aspect of the invention there is provided a protective device for at least partially surrounding a thermally sensitive component wherein the protective device comprises a flexible cover surrounding a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use. The protective device of the invention is advantageous because it provides a small, flexible device with superior heat dissipation and buffering properties. The protective device may be a sleeve, a pouch, a shell, a jacket, an envelope, or a container, for example. The maximum thickness of the protective device is the largest thickness of the device including the flexible cover, the first layer and the second layer. In some embodiments the maximum thickness of the protective device is no more than 40 cm. The maximum thickness of the protective device may be no more than 30 cm, 20 cm or 10 cm. In some embodiments the maximum thickness of the protective device is no more than 50 mm. The maximum thickness of the protective device may be no more than 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, or no more than 15 mm. The maximum thickness of the protective device may be at least 100 pm. The maximum thickness of the protective device may be between 10 mm and 50 mm. The maximum thickness of the protective device may be between 10 mm and 40 mm, 10 mm and 35 mm, 10 mm and 30 mm, 10 mm and 25 mm, 10 mm and 20 mm or between 10 mm and 15 mm. This embodiment may be advantageous because it may provide a thin protective device which may enable the protective device containing the thermally sensitive component to be inserted through a small opening in use. The thickness of the protective device may be modified according to the size of the thermally sensitive component and / or the duration of heat exposure. In some embodiments the protective device comprises a thermally sensitive component between the first layer and the second layer. In some embodiments the or each of the first and second layers is completely surrounded by the flexible cover. In some embodiments the flexible cover comprises at least one sleeve or pocket which surrounds the whole of the first and second layers. There may be a separate sleeve or pocket surrounding each of the first and second layers. In other embodiments at least the outer surfaces of the first and second layers not adjacent and / or contacting the thermally sensitive component, in use, are covered by the flexible cover. In some embodiments the first and second layers are located on or within a unitary cover which in some embodiments is folded or foldable to form first and second covers and superpose the first and second layers between the first and second covers. In other embodiments the first and second layers are located on or within separate first and second covers respectively, wherein the first and second covers are joined together to superpose the first and second layers between the first and second covers. Each of the first and second covers may comprise at least one peripheral edge. At least one of the peripheral edges of each of the first and second covers may be sealed together to form a sealed cavity therebetween. In embodiments in which the first and second covers are formed from a unitary body which is folded or foldable to superpose the first and second layers, the sealed cavity may be formed between the folded edge common to the first and second covers and the or each sealed peripheral edge. The flexible cover may be heat sealed at all perimeter edges of the first and second covers. These embodiments may be advantageous because the thermally sensitive component may be covered by the first layer and the second layer and the surrounding flexible cover such that the maximum temperature and maximum amount of IR radiation that reaches the thermally sensitive component is reduced, thereby protecting the thermally sensitive component from heat and IR radiation. In some embodiments the cavity may comprise an opening. The opening may be sized to insert the thermally sensitive component in use. The opening may be formed from free peripheral edges of the first and second covers. In use the opening may be sealed after the thermally sensitive component is inserted into the protective device. The protective device may therefore comprise a thermally sensitive component located between the first layer and second layer and be sealed at all edges of the flexible cover. This embodiment may be advantageous because the thermally sensitive component may be covered by the first layer and the second layer and the surrounding flexible cover such that the maximum temperature and maximum amount of IR radiation that reaches the thermally sensitive component is reduced, thereby protecting the thermally sensitive component from heat and IR radiation. The first layer may comprise at least 2 containers. The first layer may comprise at least 3, 4, 5 or at least 6 containers. The first layer may comprise no more than 20 containers. The first layer may comprise no more than 18, 16, 15, 14, 13, 12 or no more than 11 containers. The first layer may comprise between 2 and 20 containers. The first layer may comprise between 3 and 18, 4 and 16, 5 and 15, 6 and 14, 6 and 12, 6 and 11 or between 6 and 10 containers. The second layer may comprise at least 2 containers. The second layer may comprise at least 3, 4, 5 or at least 6 containers. The second layer may comprise no more than 20 containers. The second layer may comprise no more than 18, 16, 15, 14, 13, 12 or no more than 11 containers. The second layer may comprise between 2 and 20 containers. The second layer may comprise between 3 and 18, 4 and 16, 5 and 15, 6 and 14, 6 and 12, 6 and 11 or between 6 and 10 containers. This embodiment may be advantageous because it may provide optimum thermal protection for the thermally sensitive component. The first layer and the second layer may each comprise at least 2 containers. The first layer and the second layer may each comprise at least 3 containers. The first layer and the second layer may each comprise at least 4 containers. The first layer and the second layer may each comprise at least 5 containers. The first layer and the second layer may each comprise at least 6 containers. The first layer and the second layer may each comprise at least 7 containers. The first layer and the second layer may each comprise at least 8 containers. The first layer and the second layer may each comprise at least 9 containers. The first layer and the second layer may each comprise at least 10 containers. The first and / or second layer may comprise a plurality of directly connected containers. The first and / or second layer may comprise a plurality of indirectly connected containers. The containers may be indirectly connected by a joining portion to form a first and / or second layer. In some embodiments, at least some and preferably all the containers in the first and second layers are unconnected. In some embodiments at least some of the containers in each of the first and second layers are located spaced apart and unconnected. The maximum thickness of the first layer may be no more than 20 cm. The maximum thickness of the first layer may be no more than 10 cm, 5 cm, 4 cm, 3 cm, 2 cm or no more than 1 cm. The maximum thickness of the first layer may be at least 100 pm. The maximum thickness of the first layer may be at least 200 pm, 400 pm, 500 pm, 600 pm, 800 pm or at least 1 mm. The maximum thickness of the first layer may be between 100 pm and 20 cm. The maximum thickness of the first layer may be between 200 pm and 20 cm, 400 pm and 20 cm, 500 pm and 10 cm, 600 pm and 5 cm or between 500 pm and 2 cm. In preferred embodiments the maximum thickness of the first layer is between 500 pm and 5 cm, 600 pm and 4 cm, 800 pm and 3 cm, 1 mm and 2 cm, or between 1 mm and 1 cm. The maximum thickness of the second layer may be no more than 20 cm. The maximum thickness of the first layer may be no more than 10 cm, 5 cm, 4 cm, 3 cm, 2 cm or no more than 1 cm. The maximum thickness of the second layer may be at least 100 pm. The maximum thickness of the second layer may be at least 200 pm, 400 pm, 500 pm, 600 pm, 800 pm or at least 1 mm. The maximum thickness of the second layer may be between 100 pm and 20 cm. The maximum thickness of the second layer may be between 200 pm and 20 cm, 400 pm and 20 cm, 500 pm and 10 cm, 600 pm and 5 cm or between 500 pm and 2 cm. In preferred embodiments the maximum thickness of the second layer is between 500 pm and 5 cm, 600 pm and 4 cm, 800 pm and 3 cm, 1 mm and 2 cm, or between 1 mm and 1 cm. This embodiment may be advantageous because the thickness of the first layer and / or the second layer may correlate to the duration of protection of the thermally sensitive component. This embodiment may also be advantageous because the thickness of the first layer and / or the second layer may be limited to ensure that the protective device can be inserted into an opening with a desired size. In some embodiments the maximum thickness of the first layer is approximately the same maximum thickness as the second layer. The maximum thickness of the first layer may be larger than the maximum thickness of the second layer. The maximum thickness of the first layer may be at least 10 % larger than the maximum thickness of the second layer. The maximum thickness of the first layer may be at least 20 %, 30 %, 40 %, 50 %, 60 %, 70 %, 80 %, 90 %, 100 %, 150 %, or at least 200 % larger than the maximum thickness of the second layer. The maximum thickness of the second layer may be at least 10 % larger than the maximum thickness of the first layer. The maximum thickness of the second layer may be at least 20 %, 30 %, 40 %, 50 %, 60 %, 70 %, 80 %, 90 %, 100 %, 150 %, or at least 200 % larger than the maximum thickness of the first layer. This embodiment may be advantageous because in use, heat and / or IR may be directed more on one side of the protective device than the other thereby requiring a thicker layer on one side to increase the protection of the thermally sensitive component. In embodiments in which each layer is located on or within a first and second cover, each container of the first and second layer may be located spaced apart from adjacent containers, for example each container may be located in its own pocket or sleeve formed from or within the first or second cover, or each container may be connected to the first or second cover spaced apart from adjacent containers. In some embodiments, the containers may be connected to the flexible cover. In some embodiments, the containers may be directly connected to the flexible cover. In some embodiments, the containers may be indirectly connected to the flexible cover. Each container may comprise a housing containing the phase change material. The housing of at least one or each container may comprise a heat reflective material. The housing of at least one or each container may comprise a material capable of reflecting at least 50 % heat radiation. The housing of at least one or each container may comprise a material capable of reflecting at least 60 %, 70 %, 75 %, 80 %, 85 % or at least 90 % heat radiation. The housing of at least one or each container may comprise an infrared (IR) reflective material. The housing of at least one or each container may comprise a material capable of reflecting at least 50 % IR radiation. The housing of at least one or each container may comprise a material capable of reflecting at least 60 %, 70 %, 75 %, 80 %, 85 % or at least 90 % IR radiation. The housing of at least one or each container may comprise a heat and IR reflective material. The housing of at least one or each container may comprise a thermally insulating material. The housing of at least one or each container may comprise a material selected from the group consisting of: fiberglass, carbon fibre, graphite, a metal foil, mineral wool, cellulose, natural fibres such as cotton, silicate, and a polymer and any combination thereof. The polymer may be selected from the group consisting of: polystyrene, polyisocyanurate, polyurethane, polyamide and polyethylene, and any combination thereof. In preferred embodiments, the housing of each container comprises fibreglass. This embodiment may be advantageous because it provides a thin protective device with good heat dissipation properties to protect the thermally sensitive component from heat or IR radiation. At least one or each container may be flexible. This embodiment may be advantageous because it allows the shape of the protective device to be changed to enable a thermally sensitive component to be inserted or to ensure that the protective device fits within the space it is required to fit into. At least one or each container may comprise an elongated shape such that the shape comprises a longitudinal length that is substantially longer than the width of the largest cross section of the container. The cross section may be circular, semi-circular, a quadrilateral or any other shape. At least one or each container may be substantially cylindrical or semi-cylindrical. At least one or each container may be at least 50 % filled with a phase change material. At least one or each container may be at least 60 %, 70 %, 80 %, 90 % or at least 95 % filled with a phase change material. In preferred embodiments, at least one or each container may be approximately 100% filled with a phase change material. This embodiment may be advantageous because no air is trapped inside the container. The phase change material may comprise a solid-liquid, liquid-liquid, or solidsolid phase change material. The phase change material may comprise an organic compound, an inorganic compound or a eutectic compound. The organic compound may comprise paraffin, a fatty acid or a polymer. The phase change material may comprise a polyether. The phase change material may comprise polyethylene glycol. The phase change material may comprise an inorganic compound salt or hydrate. The phase change material may comprise an aerogel. In preferred embodiments the phase change material may comprise a microencapsulated phase change material. A microencapsulated phase change material comprises a phase change material core surrounded by a shell. The phase change material may comprise a density of at least 200 kg / m3. The phase change material may comprise a density of at least 250 kg / m3, 300 kg / m3, 350 kg / m3, or at least 400 kg / m3. The phase change material may comprise a density of no more than 2500 kg / m3. The phase change material may comprise a density of no more than 2000 kg / m3, 1800 kg / m3, 1500 kg / m3, 1000 kg / m3, 750 kg / m3 or no more than 500 kg / m3. The phase change material may comprise a density of between 200 and 2500 kg / m3. The phase change material may comprise a density of between 250 and 2000 kg / m3, 300 and 1800 kg / m3, 300 and 1500 kg / m3, 350 and 1000 kg / m3, 350 and 750 kg / m3 or between 400 and 500 kg / m3. This embodiment may be advantageous because the density of the phase change material may be desirably high without significantly increasing the weight of the protective device. At least part of the flexible cover may comprise a heat reflective material. At least part of the flexible cover may comprise a material capable of reflecting at least 50 % heat radiation. At least part of the flexible cover may comprise a material capable of reflecting at least 60 %, 70 %, 75 %, 80 %, 85 % or at least 90 % heat radiation. At least part of the flexible cover may comprise an IR reflective material. At least part of the flexible cover may comprise a material capable of reflecting at least 50 % IR radiation. At least part of the flexible cover may comprise a material capable of reflecting at least 60 %, 70 %, 75 %, 80 %, 85 % or at least 90 % IR radiation. At least part of the flexible cover may comprise a heat and IR reflective material. The maximum thickness of the flexible cover may be no more than 50 cm. The maximum thickness of the flexible cover may be no more than 40 cm, 30 cm, 20 cm, 10 cm, 5 cm, 1 cm, 8 mm, 6 mm, 5 mm or no more than 4 mm. The maximum thickness of the flexible cover may be at least 100 pm. The maximum thickness of the flexible cover may be at least 200 pm, 400 pm, 500 pm, 600 pm, 800 pm or at least 1 mm. The maximum thickness of the flexible cover may be between 100 pm and 50 cm. The maximum thickness of the flexible cover may be between 200 pm and 40 cm, 400 pm and 30 cm, 500 pm and 20 cm, 600 pm and 5 cm or between 500 pm and 1 cm. in preferred embodiments the maximum thickness of the flexible cover is between 500 pm and 5 mm, 600 pm and 5 mm, 800 pm and 4 mm, 1 mm and 4 mm, or between 1 mm and 3 mm. At least part of the flexible cover may comprise a thermally insulating material. At least part of the flexible cover may comprise a material selected from the group consisting of: fiberglass, carbon fibre, graphite, a metal foil, mineral wool, cellulose, natural fibres such as cotton, silicate, and a polymer and any combination thereof. The polymer may be selected from the group consisting of: polystyrene, polyisocyanurate, polyurethane, polyamide and polyethylene, and any combination thereof. The metal foil may comprise aluminium foil. In preferred embodiments the flexible cover may comprise fibreglass. In preferred embodiments the flexible cover may comprise fibreglass at least partially coated with aluminium foil. This embodiment may be advantageous because it may provide a reflective flexible cover which provides a thin protective device with good heat dissipation properties to protect the thermally sensitive component from heat and / or IR radiation. In preferred embodiments the housing of at least one or each container may comprise fibreglass and at least part of the flexible cover may comprise fibreglass at least partially coated with aluminium foil. This embodiment may be advantageous because it provides a thin protective device with superior dissipation properties to protect the thermally sensitive component from heat and / or IR radiation. The protective device may be for use in a heated environment. The heated environment may comprise an oven. The oven may comprise a food or culinary oven. The oven may comprise a baking oven. The oven may comprise a confectionery oven. The oven may be selected from the group consisting of: a convection oven, a gas oven, a steam oven, a conventional oven and an electric oven and any combination thereof. The heated environment may comprise a kiln. The kiln may comprise a wood firing kiln, a gas firing kiln or an electric kiln. The heated environment may comprise a system for transferring items to be heated into the heated environment such as a conveyor system. The conveyor system may comprise a belt or rollers. Heated environments such as ovens or kilns, may comprise a small opening for inserting the items to be heated and may require the thermally sensitive component, located within the protective device, to be inserted into the small opening such that it can collect data from inside the heated environment. The protective device of the first aspect of the invention may therefore be advantageous because the protective device may be small enough to fit into the opening of the heated environment whilst suitably protecting the thermally sensitive component from thermal and / or IR exposure. According to a second aspect of the invention there is provided a method of protecting a thermally sensitive component comprising locating a thermally sensitive component within a protective device according to the first aspect of the invention. The method may comprise providing first and second layers of the protective device each layer surrounded by a flexible cover, locating a thermally sensitive component in a cavity formed between the first and second layers, and sealing the first and second layers and / or cover to seal the cavity. The method may comprise the steps of: a) providing a first flexible cover on which or in which is located a first layer comprising a plurality of containers; b) providing a second flexible cover on which or in which is located a second layer comprising a plurality of containers; c) positioning a thermally sensitive component on one of the first layer and second layer; and d) covering the thermally sensitive component with the other of the first layer and second layer such that the first and second layers form a cavity within which is located the thermally sensitive component. The first cover, second cover, first layer, second layer, protective device and thermally sensitive component may be as described hereinabove for the first aspect of the invention. The method may further comprise the step of e) sealing the first cover and second cover. Step e) may comprise sealing together any free peripheral edge of the first cover and second cover. In some embodiments the method may comprise providing a unitary cover comprising the first and second layers and folding the unitary cover after step b) or step c). If the unitary cover is folded after step b) then step c) may comprise inserting the thermally sensitive component between the folded first and second covers. If the unitary cover is folded after step c) then step d) may comprise folding the unitary cover to sandwich the thermally sensitive component between the first and second layers. The method may comprise inserting or locating the thermally sensitive component such that a first face of the thermally sensitive component is in contact with the first layer and a second face of the thermally sensitive component is in contact with the second layer. In other embodiments, the method may comprise the steps of: a) providing a first cover on which or in which is located a first layer comprising a plurality of containers; b) providing a second cover on which or in which is located a first layer comprising a plurality of containers; c) partially sealing the first and second layers together to form an opening into a cavity formed between the first and second layers or a cavity which is openable by moving the first and second layers apart; and d) inserting the thermally sensitive component through the opening and into the cavity or through the opening to part the first and second layers and form a cavity in which the thermally sensitive material is located. The first and second covers may be formed from a unitary body or may be separate first and second covers. The method may comprise inserting or locating the thermally sensitive component such that the thermally sensitive component is in contact with both the first layer and the second layer. The method may comprise inserting the thermally sensitive component such that a first face of the thermally sensitive component is in contact with the first layer and a second face of the thermally sensitive component is in contact with the second layer. The method may comprise inserting the thermally sensitive component between adjacent first and second layers and then sealing at least a portion of the flexible cover. The flexible cover may be sealed using a heat-sealing technique. The flexible cover may be sealed using an adhesive. The adhesive may comprise a high temperature resistant adhesive. At least a portion of the first layer may be connected to at least a portion of the second layer by a high temperature resistant additive. At least a portion of the first layer may be connected to at least a portion of the second layer by a high temperature resistant thread or string. The entire thermally sensitive component may be inserted into the protective device. The thermally sensitive component may comprise an electronic device. The thermally sensitive component may comprise a printed circuit board. The thermally sensitive component may comprise a datalogger. According to a third aspect of the invention there is a provided a blank for forming a protective device of the first aspect of the invention, the blank comprising a flexible cover surrounding one or both of a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material. The flexible cover, first layer, second layer, containers and phase change material may be as described and defined in any of the embodiments of the first aspect of the invention. In some embodiments the blank comprises a flexible cover comprising a unitary body surrounding both the first layer and second layer, and which is foldable such that the first layer and second layer may be superposed, in use. According to a fourth aspect of the invention there is provided a kit comprising a first blank of the third aspect of the invention comprising a first layer comprising a plurality of containers, and a second blank of the third aspect of the invention comprising a second layer comprising a plurality of containers. According to a fifth aspect of the invention there is provided use of a protective device according to the first aspect of the invention to protect a thermally sensitive component within a heated environment. The entire thermally sensitive component may be inserted into the protective device. The thermally sensitive component may comprise an electronic device. The thermally sensitive component may comprise a printed circuit board. The thermally sensitive component may comprise a datalogger. The heated environment may comprise an oven. The oven may comprise a food or culinary oven. The oven may comprise a baking oven. The oven may comprise a confectionery oven. The oven may be selected from the group consisting of: a convection oven, a gas oven, a steam oven, a conventional oven and an electric oven and any combination thereof. The heated environment may comprise a kiln. The kiln may comprise a wood firing kiln, a gas firing kiln or an electric kiln. The heated environment may comprise a system for transferring items to be heated into the heated environment such as a conveyor system. The conveyor system may comprise a belt or rollers. Heated environments such as ovens or kilns, may comprise a small opening for inserting the items to be heated and may require the thermally sensitive component, located within the protective device, to be inserted into the small opening such that it can collect data from inside the heated environment. The use of the protective device of the first aspect of the invention may therefore be advantageous because the protective device may be small enough to fit into the opening of the heated environment whilst suitably protecting the thermally sensitive component from thermal and / or IR exposure. Detailed Description of the Invention In order that the invention may be more clearly understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 illustrates a perspective view of a first embodiment of a protective device (1) of the first aspect of the invention. Figure 2 illustrates a cross-sectional view of the first embodiment of a protective device (1) of figure 1. Figure 3 illustrates a top-down view of the first embodiment of a protective device (1) of figure 1 and figure 2. Figure 4 illustrates a top-down view of a first embodiment of a blank (60) of the third aspect of the invention. Figure 5 is a graph showing the temperature of the top of a control printed circuit board (top internal temperature), the temperature of the bottom of the control printed circuit board (bottom internal temperature) and the external temperature at the top of the control protective device (top external temperature) over 7.5 minutes during the conditions of experiment 1. Figure 6 is a graph showing the temperature of the top of the first embodiment of the printed circuit board (top internal temperature), the temperature of the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) over 7.5 minutes during the conditions of experiment 2. Figure 7 is a graph showing the temperature of the top of the first embodiment of the printed circuit board (top internal temperature), the temperature of the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) over 7.5 minutes during the conditions of experiment 3. Figure 8 is a graph showing the temperature of the top of the first embodiment of the printed circuit board (top internal temperature), the temperature of the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) over 7.5 minutes during the conditions of experiment 4. Figure 9 is a graph showing the temperature of the top of the first embodiment of the printed circuit board (top internal temperature), the temperature of the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) over 7.5 minutes during the conditions of experiment 5. A first embodiment of a protective device (1) of the first aspect of the invention is illustrated in figure 1, figure 2 and figure 3. The protective device (1) comprises a flexible cover (2) surrounding a first layer (4) comprising a plurality of containers (6a, 6b, 6c, 6d, 6e, 6f) and a second layer (8) comprising a plurality of containers (10a, 10b, 10c, lOd, lOe, lOf), wherein each container (6a-e and lOa-e) is at least partially filled with a phase change material, and wherein the first layer (4) and the second layer (6) form a cavity (14) therebetween, or are moveable to form a cavity (14) therebetween, into which cavity (14) a thermally sensitive component (16) is inserted or located in use. The first layer (4) comprises 6 containers (6a, 6b, 6c, 6d, 6e, 6f) and the second layer (8) comprises 6 containers (10a, 10b, 10c, lOd, lOe, lOf). It is understood that the number of containers could be between 5 and 20 containers. Each container (6a-e and lOa-e) is substantially semi-cylindrical. Each container comprises a housing (7) containing the phase change material wherein each housing (7) comprises fibreglass. The flexible cover (2) comprises fibreglass coated with an aluminium foil. Each container (6a-e and lOa-e) is at least 90 % filled with an organic microencapsulated phase change material. The first layer (4) comprises an inner surface (20) which forms the top of the cavity (14), and the second layer (8) comprises an inner surface (24) which forms the bottom of the cavity (14). The flexible cover (2) is substantially rectangular and comprises a top portion forming a first cover (28) and a bottom portion forming a second cover (30) as illustrated in figure 2. The first cover (28) surrounds the first layer (4). The second cover (30) surrounds the second layer (8). The flexible cover (2) comprises a periphery edge (3) comprising a first side (35) and an opposing second side (36), a front (37) and an opposing back (38) to form the substantially rectangular shape as illustrated in figure 1 and figure 3. The periphery edge (3) is sealed to form a cavity (14) between the first layer (4) and the second layer (8). A first embodiment of a blank (60) of the third aspect of the invention is provided and illustrated in figure 4. The blank (60) comprises the first cover (28) surrounding the first layer (4) and the second cover (30) surrounding the second layer (8) and a flexible, foldable portion (62) located between the first cover (28) and the second cover (30). In use, a thermally sensitive component (16) is positioned on top of the second cover (30) such that the thermally sensitive component (16) is on top of the second layer (8), and the first cover (28) surrounding the first layer (4) is folded at the foldable portion (62) such that the first layer (20) is located on top of the thermally sensitive component (16). The flexible cover (2) is then sealed around the free peripheral edge of the first cover and the second cover (3) such that the first cover (28) and the second cover (30) are sealed together and the thermally sensitive component (16) is located within the protective device (1) between the first layer (4) and the second layer (8) as illustrated in figure 1 and 2. The maximum thickness (40) of the protective device (1) is approximately 14.5 mm. Heat dissipation properties of the protective device Five experiments were conducted to test the heat dissipation properties of a control protective device (experiment 1) and the first embodiment of the inventive protective device (1) (experiments 2 to 5). In each experiment, the thermally sensitive component (16) was a printed circuit board and the protective device (1) containing the printed circuit board was moved into an industrial oven on an oven belt. The oven comprised a slot jet reattachment (SJR) nozzle. A slot jet reattachment nozzle is a modified slot jet nozzle that enhances heat and mass transfer by creating a larger, more turbulent reattachment zone on the impingement surface compared to the stagnation zone of a traditional slot jet nozzle. The temperatures outside of the control protective device and the inventive protective device (1) and the internal temperatures of the control protective device and the inventive protective device (1) whilst the devices were exposed to heat or IR radiation. Experiment 1: control A control protective device was provided wherein the control protective device comprised a printed circuit board located within a calcium silicate outer enclosure and wherein microencapsulate phase change material was located between the printed circuit board and the calcium silicate outer enclosure. The control protective device did not comprise a first layer and a second layer comprising a plurality of containers. The oven comprised a slot jet reattachment nozzle and the slot jet reattachment nozzle temperature was 100 °C (212 °F). The oven belt speed was 1.3 fpm for 7.5 minutes. There was no infrared emitter (IR). The oven fan speed was 50 % fan speed. The temperature at the top of the printed circuit board (top internal temperature), the temperature at the bottom of the printed circuit board (bottom internal temperature), and the external temperature at the top of the control protective device (top external temperature) were measured during the 7.5-minute experiment. A graph of the temperature change is shown in figure 5. Despite an outside temperature of 100 °C, which is about half the temperature commonly used in industrial ovens (-205 °C), the internal temperature within the control protective device was 73 °C, 27 °C lower than the external temperature after 7.5 min. This shows that the control protective device, which did not comprise the first layer and the second layer comprising a plurality of containers, did not protect the printed circuit board in the high heat environment. Experiment 2: inventive protective device A printed circuit board was inserted into the cavity (14) of the first embodiment of the protective device (1) of the first aspect of the invention according to the first embodiment of a method of protecting the thermally sensitive component. Experiments 2 to 5 were then completed using the protective device (1). The protective device (1) was inserted into an oven on an oven belt. The temperature of the slot jet reattachment nozzle in the oven was 177 °C (350 °F) in 2 zones. The oven belt speed was 2.6 fpm for 7.5 minutes. There was no infrared emitter (IR). The oven fan speed was 50 % fan speed. The temperature at the top of the printed circuit board (top internal temperature), the temperature at the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) were measured during the 7.5 minute experiment. A graph of the temperature change is shown in figure 6. The final printed circuit board top and bottom temperatures were approximately 70.3 °C compared the external temperatures of approximately 110 °C and 130 °C. The temperature difference between the inside and the outside of the protective device (1) was approximately 107 °C. This shows that the inventive protective device, effectively protects the printed circuit board in the high heat environment by providing improved heat dissipation and thereby preventing the printed circuit board from being exposed to high temperatures during the 7.5 minute experiment. Experiment 3: inventive protective device The protective device (1) was inserted into an oven on an oven belt. The temperature of the slot jet reattachment nozzle in the oven was 232 °C (450 °F) in 2 zones. The oven belt speed was 2.6 fpm for 7.5 minutes. There was no infrared emitter (IR). The oven fan speed was 50 % fan speed. The temperature at the top of the printed circuit board (top internal temperature), the temperature at the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) were measured during the 7.5 minute experiment and a graph of the temperature change is shown in figure 7. The final printed circuit board top and bottom temperatures were approximately 86.4 °C. The temperature difference between the inside and the outside of the protective device (1) was approximately 36 °C at the end of the experiment and the temperature of the printed circuit board during the experiment remained significantly lower than the external temperature outside of the protective device (1), especially between 70 seconds and 300 seconds of heat exposure. This shows that the inventive protective device effectively protects the printed circuit board in the high heat environment by providing improved heat dissipation and thereby preventing the printed circuit board from being exposed to high temperatures throughout the 7.5-minute experiment. Due to the limited number of SJR nozzles available, they were only deployed during the first five minutes of the experiment. Meanwhile, the protective device remained inside the rest of the oven, which was filled with hot air during the final 2.5 minutes. Experiment 4: inventive protective device The protective device (1) was inserted into an oven on an oven belt. The temperature of the slot jet reattachment nozzle in the oven was 232 °C (450 °F) in 2 zones. The oven belt speed was 2.6 fpm for 7.5 minutes. Two infrared emitters (IR) were present with a temperature of 1200 °F. The oven fan speed was 50 % fan speed. The temperature at the top of the printed circuit board (top internal temperature), the temperature at the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) were measured during the 7.5 minute experiment and a graph of the temperature change is shown in figure 8. The final printed circuit board top (52) and bottom (54) temperatures were approximately 88.3 °C. The temperature difference between the inside and the outside of the protective device (1) was approximately 32 °C. Due to the limited number of SJR nozzles available, they were only deployed during the first five minutes (300 s) of the experiment. Meanwhile, the protective device remained inside the rest of the oven, which was filled with hot air during the final 2.5 minutes. Then the first infrared emission occurred at 300 second and the second infrared emission occurred at 400 seconds. The temperature within the protective device (1) did not change when the infrared emissions occurred. This shows that the inventive protective device effectively protects the printed circuit board in the high heat and the high infrared environment by providing improved heat dissipation and excellent protection from infrared, thereby preventing the printed circuit board from being exposed to high temperatures or high IR radiation throughout the 7.5-minute experiment. Experiment 5: inventive protective device The protective device (1) was inserted into an oven on an oven belt. The temperature of the slot jet reattachment (SJR) nozzle in the oven was 232 °C (450 °F) in 2 zones. The oven belt speed was 1.3 fpm for 7.5 minutes. No infrared emitters (IR) were present. The oven fan speed was 50 % fan speed. The temperature at the top of the printed circuit board (top internal temperature), the temperature at the bottom of the printed circuit board (bottom internal temperature), the external temperature at the top of the protective device (top external temperature) and the external temperature at the bottom of the protective device (bottom external temperature) were measured during the 7.5 minute experiment and a graph of the temperature change is shown in figure 9. The final printed circuit board top and bottom temperatures were approximately 87.4 °C. The temperature difference between the inside and the outside of the protective device (1) was approximately 94 °C and the internal temperature remained significantly lower than the external temperature throughout the 7.5-minute experiment. This shows that the inventive protective device effectively protects the printed circuit board in the high heat environment by providing improved heat dissipation and thereby preventing the printed circuit board from being exposed to high temperatures for prolonged periods. Conclusion The experiments show that the protective device has excellent heat dissipation properties. Without being bound by theory, it is understood that the presence of the first layer comprising a plurality of containers and the second layer comprising a plurality of containers provides improved heat dissipation properties and improved protection from IR radiation. A second embodiment of a protective device of the first aspect of the invention is provided wherein the protective device comprises a flexible cover surrounding a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use, and wherein each container is substantially cylindrical in shape. The second embodiment of the protective device is essentially the same as the first embodiment of the protective device (1) except for the containers of the second embodiment comprising a circular cross section instead of a semi-circular cross section. A third embodiment of a protective device of the first aspect of the invention is provided wherein the protective device comprises a flexible cover surrounding a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use, and wherein the flexible cover comprises carbon fibre and wherein each container comprises a housing containing the phase change material wherein each housing comprises carbon fibre. The third embodiment of the protective device is essentially the same as the first embodiment of the protective device except for the flexible cover and the container housings comprising carbon fibre instead of fibreglass. A fourth embodiment of a protective device of the first aspect of the invention is provided wherein the protective device comprises a flexible cover surrounding a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use, and wherein the flexible cover comprises graphite and wherein each container comprises a housing containing the phase change material wherein each housing comprises graphite. The fourth embodiment of the protective device is essentially the same as the first embodiment of the protective device except for the flexible cover and the container housings comprising graphite instead of fibreglass. A fifth embodiment of a protective device of the first aspect of the invention is provided wherein the protective device comprises a first flexible cover surrounding a first layer comprising a plurality of containers wherein the first flexible cover is sealed around the first layer, and a second flexible cover surrounding a second layer comprising a plurality of containers wherein the second flexible cover is sealed around the second layer, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use, and wherein the periphery edge of the first layer is sealed to the periphery edge of the second layer. A second embodiment of the method of protecting a thermally sensitive component of the second aspect of the invention is provided wherein the method comprises providing the first flexible cover in which is located the first layer; positioning a thermally sensitive component on the first layer and covering the thermally sensitive component with the second layer such that the first and second layers form a cavity within which is located the thermally sensitive material. The periphery edge around the first flexible cover is subsequently sealed to the periphery edge around the second flexible cover. A third embodiment of the method of protecting a thermally sensitive component of the second aspect of the invention is provided wherein the method comprises providing the first embodiment of the blank of the third aspect of the invention and first sealing the side periphery edges of the first cover and the second cover together to form a pouch with an opening, inserting the thermally sensitive component into the opening, and sealing the opening. The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A protective device for at least partially surrounding a thermally sensitive component wherein the protective device comprises a flexible cover surrounding a first layer comprising a plurality of containers and a second layer comprising a plurality of containers, wherein each container is at least partially filled with a phase change material, and wherein the first layer and the second layer form a cavity therebetween, or are moveable to form a cavity therebetween, into which cavity a thermally sensitive component may be located in use.

2. A protective device according to claim 1 wherein the first layer comprises at least 3 containers and wherein the second layer comprises at least 3 containers.

3. A protective device according to claim 1 or claim 2 wherein each container comprises a housing containing the phase change material wherein the housing of each container comprises a heat and / or IR reflective material.

4. A protective device according to any preceding claim wherein each container comprises a housing containing the phase change material wherein the housing of each container comprises a thermally insulating material, preferably fibreglass, carbon fibre and / or graphite.

5. A protective device according to any preceding claim wherein the flexible cover comprises a heat and / or IR reflective material.

6. A protective device according to any preceding claim wherein the flexible cover comprises a thermally insulating material, preferably fibreglass, carbon fibre and / or graphite.

7. A protective device according to any preceding claim wherein each container comprises fibreglass and the flexible cover comprises fibreglass.

8. A protective device according to any preceding claim wherein each container comprises a thermally insulating material and the flexible cover comprises a heat and / or IR reflective material.

9. A protective device according to any preceding claim wherein each container is flexible.

10. A protective device according to any preceding claim wherein each container is at least 50 % filled with a phase change material, preferably at least 80 % filed with a phase change material.

11. A protective device according to any preceding claim wherein the phase change material comprises a solid-liquid phase change material and / or a microencapsulated phase change material.

12. A protective device according to any preceding claim wherein the maximum thickness of the protective device is between 10 and 50 mm, preferably between 10 and 30 mm.

13. A method of protecting a thermally sensitive component comprising locating a thermally sensitive component within a protective device according to any preceding claim.

14. A method according to claim 13 comprising the steps:a) providing a first flexible cover on which or in which is located a first layer comprising a plurality of containers;b) providing a second flexible cover on which or in which is located a second layer comprising a plurality of containers;c) positioning a thermally sensitive component on one of the first layer and second layer; andd) covering the thermally sensitive component with the other of the first layer and second layer such that the first and second layers form a cavity within which is located the thermally sensitive material.

15. A method according to claim 13 comprising the steps:a) providing a first flexible cover on which or in which is located a first layer comprising a plurality of containers;b) providing a second flexible cover on which or in which is located a first layer comprising a plurality of containers;c) partially sealing the first and second layers together to form an opening into a cavity formed between the first and second layers or a cavity which is openable by moving the first and second layers apart; andd) inserting the thermally sensitive component through the opening and into the cavity or through the opening to part the first and second layers and form a cavity in which the thermally sensitive material is located.

16. A method according to any one of claims 13 to 15 wherein the method further comprises the step of e) sealing any free peripheral edge of the first flexiblecover and second flexible cover.

17. A method according to any one of claims 13 to 16 wherein the thermally sensitive component comprises an electronic device, preferably a printed circuit board.

18. A method according to any one of claims 13 to 17 comprising inserting the 5 thermally sensitive component such that a first face of the thermally sensitivecomponent is in contact with the first layer and a second face of the thermally sensitive component is in contact with the second layer.

19. A blank for forming a protective device of any one of claims 1 to 12, the blank comprising a flexible cover surrounding one or both of a first layer comprising 10 a plurality of containers and a second layer comprising a plurality of containers,wherein each container is at least partially filled with a phase change material.

20. A kit comprising a first blank according to claim 19 comprising a first layer comprising a plurality of containers, and a second blank according to claim 19 comprising a second layer comprising a plurality of containers.IntellectualPropertyOfficeApplication GB2509301.4Search report under Section 17 of the Patents Act 1977Date search completed: 25 September 2025Claims searched: 1-20International classificationSubclass and subgroup Valid from B65D81 / 38 01 / 01 / 2006Field of searchWorldwide search of patent documents classified in the following areas of the IPC:B65DDatabases used in the preparation of this search report:SEARCH-PATENTDocuments considered to be relevantPatent literatureCategory Relevant claims Document of relevance X 1-19 US 2008 / 0164265 A1 (CONFORTI), See Figures 1-4 and 21-22 and Paragraphs [0052], [0057] and [0088].X 1-18 US 6482332 B1 (MALACH), See Figures 3-4 and Column 4 lines 40-57 and Column 5 lines 14-17. X 1-20 US 2009 / 0230138 A1 (WILLIAMS et al.), See Figures 3-6 and 8 and Paragraph [0022].Non-patent literatureCategory Relevant claims Document of relevanceCategoriesLetter or DescriptionsymbolX Document indicating lack of novelty or inventive step.Y Document indicating lack of inventive step, if combined with anotherdocument of the same category.& Member of the same patent family. A Document indicating technological background. P Document published on or after the priority date but before the fling date of the present application. E Earlier application published on or after the filing date of the present application.

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