Cooling material and device

Abstract

A cooling material and device which provide reduction of temperature of a nearby object such as, but not limited to, a machine, a person or an animal, as a multi-layered cooling blanket which captures a fluid, such as, but not limited to, water for absorbing heat from the nearby object and prevents dripping of the fluid or transfer of the fluid to the nearby object. The multi-layered cooling blanket may be used to cool a variety of things, such as machines, computers, vehicles, people and animals.

Description

CLAIM TO PRIORITY OF EARLIER FILED PATENT APPLICATIONS

[0001] This patent application claims priority to the filing date of U.S. Provisional Utility Patent Application 63 / 957,255, filed on Jan. 1, 2026, by Bruce Chinquee, and this patent application claims priority to the filing date as a continuation-in-part (CIP) of U.S. patent application Ser. No. 18 / 981,391, filed on Dec. 13, 2024, by Bruce Chinquee.INCORPORATION BY REFERENCE

[0002] U.S. Provisional Utility Patent Application 63 / 957,255, filed on Jan. 1, 2026, by Bruce Chinquee, and U.S. patent application Ser. No. 18 / 981,391, filed on Dec. 13, 2024, by Bruce Chinquee, are hereby incorporated by reference in their entireties, including drawings.FIELD OF THE INVENTION

[0003] The present invention relates to a material and device which can cool a nearby object.BACKGROUND OF THE INVENTION

[0004] There are many things which generate heat, such as vehicles, batteries, machines, computers, people, animals, etc. For example, the temperature of electronic devices is increased due to electrical resistance in the components. Other mechanical devices generate heat through friction. All of these devices must be continuously cooled to insure the operate properly. Further, there is need to cool people and animals to prevent hyperthermia or to reduce inflammation to promote healing, such as after surgery or after an injury. For the purposes of the present disclosure, we will refer to a nearby object as anything that needs to be cooled.

[0005] Traditional devices for such cooling a nearby object includes frozen materials (e.g., ice blocks, frozen gels, etc.) which are placed in contact with the object, which can cause condensation and wetting of the object. Fans may be place near the object to promote transfer of heat from the object to the immediate atmosphere around the object, but may not be suitable for certain uses such as cooling of open wounds. More technically advanced and complex cooling devices include machines that use refrigerants and compressors to transfer heat, which also require nearby power, and can be bulking, noisy and expensive. Fans and refrigerant-based cooling systems are also prone to breakdowns and failures, leaving the objects they serve at risk for damage, spoilage and potential injury or death.SUMMARY OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

[0006] The present invention pertains to cooling material and device reduce the temperature of a nearby object such as, but not limited to, a machine, a person or an animal, as a multi-layered cooling blanket which captures a fluid, such as, but not limited to, water for absorbing heat from the nearby object and prevents dripping of the fluid or transfer of the fluid to the nearby object. The multi-layered cooling blanket may be used to cool a variety of things, such as machines, computers, vehicles, people and animals.BRIEF DESCRIPTION OF DRAWINGS

[0007] The features of the several embodiments of the present invention will be best understood by reference to the following detailed description in conjunction with the accompanying drawings.

[0008] FIG. 1 illustrates the major components of the cooling system of the present invention.

[0009] FIG. 2 shows the cooling tower used in the present invention for first stage cooling.

[0010] FIG. 3 is a detail view of the vapor loop in the cooling tower.

[0011] FIG. 4 is the cooling enclosure used in the present invention for second stage cooling.

[0012] FIG. 5 shows the input and output ports to the enclosure.

[0013] FIG. 6 illustrates the cooling tower with the top and side walls removed showing the upper cooling reservoir.

[0014] FIG. 7a is a side view of the interior of the enclosure illustrating the elements of the invention inside.

[0015] FIG. 7b is a close-up view of the upper and lower cooling trays in the enclosure, showing the upper tray being substantially wrapped in a cooling blanket material.

[0016] FIG. 8 shows the sump pump used for recirculating the cooling fluid used in the enclosure.

[0017] FIG. 9 shows a cross-sectional view of the cooling blanket used in the present invention.

[0018] FIG. 10 shows a cross-sectional depiction of an example embodiment cooling blanket material according to the present invention.

[0019] FIG. 11 provides a thermal conduction flow diagram and a cross-sectional view of micro-climate cavities of at least one example embodiment.

[0020] FIG. 12 illustrates two example embodiments which utilize the cooling material of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0021] The present inventor has recognized that there is an unmet need remaining in the marketplace to provide a cooling material and device which can cool machines.

[0022] There are multiple industries that this will be able to influence and / or disrupt. For example: automobiles, server farms, air conditioning, and swamp coolers may benefit well from one or more of the embodiments of the present invention. The cooling unit can be replaced or be added to target equipment to make it more efficient. Autos will be able to cool brakes, oil, engine, and cabin more efficiently. Server farms will run cooler and the rooms they are in will be cooler reducing operating temperatures and A / C electrical costs. A / C units for houses and server rooms will be less taxed, especially in very high temp settings like the desert where “box” works more efficiently due to very low humidity. Swamp coolers efficiency significantly increases when water colder than ambient temperature is run in / on its radiators from “box”. This unit (“box”) is unique by using 2 types of cooling. The 2 cooling loops work more efficiently and greater combined than if they were separate systems. The unit (“box”) allows for cooling 15-20 degrees lower than ambient temp causes less strain on equipment being used (higher temps will see greater deltas as high as 80 degrees difference). Heat that is removed from target equipment is cooler than if it was run on a dry radiator. Dry radiators will expel heat temps that are the same as the coolant. Service life of target equipment will be notably lengthened. In conclusion the “box” does not emit heat to cool. The heat that is drawn and expelled from the target is significantly cooler and ambient temps rise far slower. The amount of electrical energy used to dissipate heat is a fraction of the cost of anything being used on the market. Water is the most abundant substance on the planet and almost free so supply chain stability is safe.

[0023] In the following description of the preferred embodiment, reference is made to the accompanying drawings that form a part hereof, and in which is shown-by way of illustration-a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and changes may be made without departing from the scope of the present invention. In the following description, disclosure of the invention is made with primary reference to the use of an evaporative cooling system for a recirculating fluid. It will be apparent to those of skill in the art, however, that the system of the present invention can also be used with other configurations. The reference to a particular construction and arrangement for the cooling system is for explanatory purposes of a specific example or embodiment of the preset invention and is not intended to be limiting in any manner.

[0024] Related Invention. The present invention is related to the invention disclosed and illustrated in the aforementioned pending patent application, U.S. patent application Ser. No. 18 / 981,391, filed on Dec. 13, 2024 by the present inventor, which is incorporated by reference herein. For the purposes of the present disclosure, the related invention details will be repeated in the following paragraphs, whereas they are useful for understanding the principles upon which the present invention builds and extends.

[0025] Referring first to FIG. 1, a block diagram of the major components of cooling system 10 of the related invention are illustrated. An apparatus which is to be cooled is shown in dashed lines. It is to be understood the apparatus does not constitute a part of the system of the present invention. Rather the cooling system of the related invention can be used with a wide variety of different devices or machines which need to be cooled during their operation.

[0026] The primary components of the cooling system of the related invention shown in FIG. 1 are the cooling enclosure 12, the coolant loop 14 and the cooling tower 16. The coolant loop is made of at least three different segments. These segments are labeled 14a, 14b and 14c in FIG. 1. Segment 14a is connected is connected to the input of the apparatus, segment 14b is connected between the cooling tower and the cooling enclosure and segment 14c is connected to the output of the cooling enclosure.

[0027] The coolant loop is a pipe or tubing of suitable diameter to transport a coolant from the apparatus to be cooled and through the various components of the cooling system of the invention. The tubing for the coolant loop may be insulated through the use of a removable insulation jacket. A removable insulation jacket is a cover made from layers of thermal insulation materials that is fastened onto a mechanical component to maximize its efficiency and regulate its temperature. Using such jackets ensures that the covered component is easily accessible and serviceable, unlike traditional stay-in-place insulation. Removable insulation jackets are also known as removable insulation pads and removable insulation covers. Since pipework can operate at temperatures far removed from the ambient temperature, and the rate of heat flow from a pipe is related to the temperature differential between the pipe and the surrounding ambient air, heat flow from pipework can be considerable. In many situations, this heat flow is undesirable. The application of thermal pipe insulation introduces thermal resistance and reduces the heat flow. Thicknesses of thermal pipe insulation used for saving energy vary, but as a general rule, pipes operating at more-extreme temperatures exhibit a greater heat flow and larger thicknesses are applied due to the greater potential savings.

[0028] One section of the coolant loop 14a connects the apparatus to the cooling tower 16. The cooling tower performs first-stage temperature reduction of the coolant. When the coolant exits the apparatus, it has picked up excess heat and is at a high temperature. The coolant then passes through section 14a and enters the cooling tower 16. The cooling tower has a pump 17 connected to it. In FIG. 1, the pump is shown as being integrated with the tower 16 at the bottom portion thereof. It will be apparent to those of skill in the art that the pump can be separated from the cooling tower and still be effective in some embodiments. The pump creates a negative pressure and pulls the coolant downward through the tower. The coolant exits the tower and passes through segment 14b of the coolant loop, where it enters the cooling enclosure.

[0029] The interior of the cooling tower of the related invention is under negative pressure. With negative pressure, the small amount of interior liquid instantly evaporates and condenses in the unit. Heated coolant pumped into the tower transfers heat to vapor chamber loops 22 which are illustrated in FIG. 3. This heat creates vapor in the vapor chamber loop 22w and heated gases rise to the top of the loop. The vapor then passes through the cooling section of the loop and is condensed. That liquid flows downward on the outside of the tower chamber and is returned back to the heated section of the loop which is on the interior of the cooling tower. The sections of vapor chamber loop that are on the exterior of the cooling tower are covered in wet cooling blankets.

[0030] After the coolant exits the cooling tower it passes through segment 14b of the coolant loop and enters the evaporative cooling enclosure, which is used for second stage cooling of the coolant. The coolant then exits the evaporative cooling enclosure and returns to the apparatus through coolant loop 14c. The major components of the two-stage cooling system will now separately be described in more details.

[0031] FIG. 2 shows a more detailed view of the cooling tower of the related invention. As noted above, the cooling tower is connected to the portion of the cooling loop 14a which exits from the apparatus to be cooled. The coolant enters the cooling tower 16 through the entry port 51. The entry port is chosen from tubing which will permit the coolant to enter to cooling tower with a minimum of restriction.

[0032] Located beneath the entry port is the upper chamber 53. The upper chamber contains within it a copper mesh. Copper is chosen because it thermal properties allow for rapid and efficient cooling. Other materials which can be used include cellulose, poly, graphene, carbon, and graphite. Beneath the upper chamber is the vacuum chamber 54. The vacuum chamber 54 is generally larger than the upper chamber. Additionally, cooling blanket material may be disposed within the vacuum chamber. An example embodiment of a cooling blanket material is described in more detail below in connection with FIG. 9.

[0033] A pump 51 is integrated into the base of the cooling tower. In the preferred embodiment, the pump is of the centrifugal type. It will be understood by those of skill in the art that the pump can be of a different style or construction. In other instances, the pump will not be integrated into the base of the cooling tower but can be a separate element. At the base of the cooling tower is the exit port 55. The exit port is connected to the cooing loop 14b.

[0034] In operation, the vacuum chamber is at least partially filled with coolant. The pump 52 is activated and used to reduce pressure in the vacuum chamber. As a result, and in combination with the force of gravity the coolant is sucked into upper chamber of the cooling tower. The heated coolant passes though is sprayed and passes through the mesh. The mesh agitates the coolant and is a medium for evaporation. This negative pressure allows coolant to boil and evaporate in the vacuum chamber due to lower boiling and evaporate point. The vapor loop is semi-submerged once system is running. The vacuum makes heated coolant expand and air space will be created in the vacuum 54 chamber The cooling tower is comparable to a dehumidifier and acts in a similar fashion.

[0035] The cooling tower of this example embodiment includes a vapor chamber. A vapor chamber is a type of heat-spreader technology that uses evaporation and condensation of liquid. Unlike traditional heat sinks, which rely on solid metal, vapor chambers use a sealed chamber filled with a small amount of liquid (usually deionized water) that evaporates when heated. The vapor chamber is bonded to the base of the heat sink, allowing for efficient heat transfer. Vapor-chamber-based heat sinks are most efficient when the heat source is small and the heat sink is fairly large. A vapor chamber heatsink (VCH) is a heat spreader that uses a sealed chamber and a small amount of fluid to quickly move heat away from a source. VCHs are often used in high-powered devices and are considered one of the best heat spreading options for the base of a heatsink. VCHs can be made from substantially sealed copper plates and have an internal support structure to prevent the walls from buckling. When heat is generated, the liquid in the chamber evaporates and turns into vapor. The vapor then moves to the cooler end of the chamber, where it condenses back into liquid and releases heat. VCHs are commonly used in laptops, mobile devices, graphics cards, LEDs, servers, and hard drives. They are also used in automotive applications to cool the engine and transmission. VCHs can reduce conduction loss by 50% or more, resulting in lower thermal resistance. They can also expel heat faster with less fan noise.

[0036] As shown in FIG. 1, the coolant leaves the cooling tower 22 and passes through coolant loop 14c to the enclosure 20. The outside view of the enclosure of the related invention is shown in FIG. 4 The coolant enters the enclosure through an entry port. Referring next to FIG. 5, input port 61 and exit port 62 for the coolant are shown. The input port 61 receives the coolant from section 14b of the coolant loop. The fluid is hot when it enters the enclosure. After the refrigerant is cooled by the use of the present invention, it leave the enclosure through the exit port 22. Although the input and exit ports are shown in the specific location in the related invention as illustrated in FIG. 2, it will be appreciated by those of skill in the art that they can be positioned in alternative locations as may be desired.

[0037] The enclosure 20 of the related invention is shown in FIG. 5, which is a perspective view. As shown the enclosure is substantially rectangular in shape and is of sufficient size to include all of the elements of the present invention. The sides of the enclosure are constructed in a manner which permits one or more of them to be easily removed to allow access to the various components of the invention which are located within. The specific manner of how the sides can be removed is not a limiting factor of the invention. In the preferred embodiment, the sides are connected by screws. Alternatively, they can be connected by hinges, or can be secured together by latches which permit their removal completely. The sides of the enclosure include opening or access ports to permit a power connection to the elements inside. The enclosure can include handles, so it can be easily lifted and carried.

[0038] Referring next to FIG. 6, a perspective view of the example embodiment of the related invention showing the top surface and one of the side surfaces of the enclosure 10 removed. A cooling reservoir 32 is shown. It is in the upper portion of the enclosure and is above the other elements of the cooling system.

[0039] Referring next to FIG. 7a top view of the enclosure is shown of the example embodiment of the related invention. Here the reservoir 32 has been removed. Located underneath the reservoir two radiator assemblies 40 are shown. It will be understood that a different number of radiators can be employed in the present invention. For example, only a single radiator may be employed where the cooling load is not large. In other instances three or more radiators can be placed in the enclosure when a larger cooling capacity is needed. The radiators have the shape of a rectangular prism. Other shapes can also be used. For example, the radiator may be constructed as a cylinder or cone.

[0040] One or more trays are located underneath the radiators. The bottom-most tray acts as a sump. A second pump 48 is located inside the enclosure. It circulates any fluid in the recovery tray back to the top of the enclosure and into the reservoir. This is illustrated in FIG. 8 for the example embodiment of the related invention.

[0041] The radiators 40 have a rigid skeleton, and the skeleton supports a layer of cooling blanket material. Tubing 44 is provided inside of the enclosure and is disposed to pass along a central axis of each of the radiators 40.

[0042] Referring now to FIG. 9, a cross-section an example embodiment of a cooling blanket which is used in the related invention is shown. This particular example of a cooling layer is made from a number of layers which work together to facilitate the transfer of heat and provide an efficient cooling mechanism. The order of material determines which direction the liquid flows and thus controls temperature and which side is cooler. The layers are shown in FIG. 9 and include SSAM, poly foam (polyacrylate), cellulose, plastic pillars, mesh, carbon, graphite, graphene, and neoprene. Layers are stacked in various combinations to make CB Panel (CBP).

[0043] The combination of materials has multiple purposes. Some material combinations hold water in place more efficiently to prevent dripping or transfer of water to the object to be cooled, while other material layers are more effective at transporting heated water via drip siphon effect and some have a more efficient evaporation rate. Each material has its own unique speed in the transportation of water. When poly is used, the flow is significantly slowed and held in suspension. The volume held in suspension is larger due to material super absorbency. With larger volume of water thermal equalization occurs faster due to increased volume. The heat has more immediate space to move into. It has super absorption and slower release, allowing water to absorb heat into larger volume held by that specific medium. This layer is in direct contact of a faster flowing material, acting as a siphon pulling the heated water, like a dry sponge, away from that layer allowing fresh cooler water to be pulled into poly on opposing side of layer.

[0044] Other listed material significantly impacts the rate of evaporation and speed of water exchange, and thus its ability to achieve lower temps faster. The surface area for each material varies and makes maximum cooling efficiency dependent on which material is used. Material also determines the speed at which water is exchanged in the thermal blanket.

[0045] All material works cooperatively with drip siphon effect eliminating laminar flow. Materials are layered in a specific order to choose the water's direction of pull into circulatory system of drip siphon effect. Heated water is removed from source (radiator) via the blanket while being cooled and enters the tray or next step of continued cooling (reservoir at top is covered in the blanket). This description is meant to cover any parts that have the thermal blanket attached.

[0046] A series of fans 48 are included in the enclosure. FIG. 7 illustrates the placement of the fans and their relationship to the radiators and the sides of the enclosure in the example embodiment of the related invention. A series of three fans 48 are placed above the radiators and beneath the upper reservoir 32. Additional fans 48 are on the side of the enclosure. The fans force air from the outside of the enclosure to pass over the radiators and absorb heat from the cooling layers. It will be apparent to those of skill in the art that a different arrangement of fans could be used with equal effectiveness. In addition, the size and shape of the fans can be different from what is shown in FIG. 7.

[0047] FIG. 7 is a side view of the enclosure with one if its side walls removed. Coolant fluid is located in the upper reservoir 42. The coolant passes over cooling blankets attached to radiators; the heated coolant drips onto an upper tray 43; which is also covered in cooling blankets. The upper tray is initially cools the fluid once it leaves heat source. As coolant is being pulled via siphon drip effect it is being cooled by cooling blanket on sides on the upper tray. Holes are located in the bottom of the upper tray 41. Coolant drips through the holes into a lower tray 45. The lower tray acts as a sump as described above. A sump pump recirculates the coolant to the reservoir 42. Once recirculated to top “reservoir tray”from “tray 2”, (reservoir tray is also covered in cooling blanket on all 6 sides) and performs final additional cooling before being dripped over radiators with cooling blanket coverings. By the time the coolant is circulated completely, the coolant (water) is cooled to wet bulb temp meaning it cannot be cooled any further without changing humidity or air pressure.

[0048] A close-up view of the upper tray 43A material for providing thermal cooling with reduced dripping, wicking, pooling and condensation onto a nearby object to be cooled, comprising:

[0049] The material as set forth in Claim 1 wherein the superabsorbent polymer comprises a poly foam.

[0050] The material as set forth in Claim 1 wherein the superabsorbent polymer comprises a polyacrylate.

[0051] The material as set forth in Claim 1 wherein the second layer comprises a solid-state additive manufacturing (SSAM) layer.

[0052] The material as set forth in Claim 1 further comprising at least a third layer comprising one or more materials selected from the group consisting of cellulose, plastic pillars, mesh, carbon, graphite, graphene, and neoprene.

[0053] The material as set forth in Claim 1 wherein the second layer is fabricated using an additive manufacturing process.

[0054] The material as set forth in Claim 6 wherein the additive manufacturing process comprises a 3-dimensional printing process.

[0055] The material as set forth in Claim 1 further comprising at least a third layer disposed between the first and second layers, and wherein the at least third layer comprises copper.

[0056] The material as set forth in Claim 1 further comprising a physical agitation device which, when operated, provides agitation to at least the second layer to promote additional release of the liquid from the superabsorbent polymer.

[0057] The material as set forth in Claim 9 wherein the physical agitation device comprises one or more devices selected from the group comprising a motor, a vibrator, a speaker, a buzzer, and an annunciator. and lower tray 44 are shown in FIG. 7b. In this version of the invention, two trays are used to cool the coolant. It will be apparent to those of skill in the art that additional trays can also be used, according to the thermal needs of the coolant and apparatus being cooled.

[0058] Referring again to the Figures, the operation of the enclosure of the related invention will now be described. The coolant enters the enclosure through the entry port, as described above. A second quantity of coolant is placed in the reservoir tray. The holes in the bottom of the reservoir allow the coolant to drip onto the radiators and the thermal blanket. The air from the fans causes heat to be transferred away. The coolant from the reservoir collects in the sump and is recirculated as discussed above.

[0059] The coolant then exits the enclosure and passes back to the apparatus as shown in FIG. 1.

[0060] Advanced Cooling Material and Device. With the foregoing description of the related invention in mind, those having ordinary skill in the relevant arts will appreciate the weight reduction, portability, cost reduction and utility of the embodiments of the present invention which extend upon, modify and improve the cooling blanket of the related invention. For the purposes of the present disclosure of the example embodiments of the present invention, we will refer to this as a multi-layer cooling blanket due to its material properties of being a flexible, conformable device which provides dry, dripless and condensation free cooling of an object on one side of it, while shedding heat to the opposite side of it, even when the immediate atmosphere on the heat-shedding side is warmer than the object being cooled.

[0061] Embodiments of the present invention combine two or more operational principles of dry evaporative cooling, microclimate management, and advantageous applications of superabsorbent polymer (SAP) materials to achieve “dry” (aka dripless), powerless (passive) cooling.

[0062] Cooling using Superabsorbent Polymer (SAP) Materials. SAPs such as sodium polyacrylate are used in many everyday products. SAPs can “absorb” hundreds of times their own weight in aqueous fluids, usually transforming into a gel (if not already a gel), and keeping the absorbed water from escaping even when in physical contact with a material that is highly absorbent or exhibits a great deal of wicking characteristics at a normal (specified) temperature. In their unbonded states (no aqueous absorption), they an be fibrous or granular.

[0063] When exposed to an aqueous fluid, such as water, the SAP molecules uncoil their polymer chains and trap the liquid through hydrogen bonding, and thus they absorb aqueous fluids due to the hydrogen in the fluids. Ionic concentration of the trapped fluid effects how much fluid the SAP will absorb, so, for example, pure water will be trapped or absorbed in greater quantities w / w than a 0.9% saline aqueous solution will be.

[0064] Many present day products use SAPs only for their absorption function, such as diapers, sanitary pads and incontinence products, and then the products are discarded without ever attempting to release or recover the absorbed fluids.

[0065] Some products, however, utilize the ability to release the captured fluids by SAPs, such as agricultural products which may use SAPs to absorb liquids such as fertilizers and then provide a sustained release of those liquids over time and various environmental conditions.

[0066] When the SAP which has trapped an aqueous fluid is raised to a certain temperature, depending on which SAP is used and which fluid is trapped, the SAP molecules will uncoil and release the fluid molecules. If the temperature is sufficient for evaporation of the released fluid, then energy (heat) is absorbed by the fluid molecules as they transition from liquid to gas, which causes a cooling effect to the nearby object from which the evaporative energy is drawn. For example, LG products of South Korea makes an SAP-infused patch for a patient's forehead which helps with cooling the patient from a fever. Below the release temperature, however, the SAP continues to trap the liquid and does not allow it to easily transfer to another material nearby, such as by wicking or dripping.

[0067] Embodiments of the present invention utilize one or more of the known SAP materials for at least one element to generate a cooling action for the nearby object.

[0068] Microclimate Management. Another design aspect of some embodiments of the present invention is the creation of an management of a microclimate. Microclimate generally refers to a climate of a small area or volume where the conditions may differ from the climate conditions of the larger surrounding area or volume. While the microclimate may be in thermal, atmospheric pressure, light, and / or humidity communication with the larger surrounding climate, there can also be differences between the microclimate and the larger, macroclimate.

[0069] Certain embodiments according to the present invention create and manage a plurality of microclimates in, near or around the device which promote, enhance and improve the cooling functions of the material or device, as will be discussed in more details in the following paragraphs.

[0070] Dry Evaporative Cooling. Evaporative cooling is very common in nature and man-made machines. However, many evaporative cooling devices and systems can reach various operational conditions in which moisture transfers to (e.g., drips, wicks, etc.) or gathers on (e.g., condenses, pools, etc.) nearby articles.

[0071] A First Example Embodiment. Referring again to FIG. 9, a multi-layer thermal cooling blanket example embodiment is shown. As previously stated, the order of material layers determines which direction the liquid flows and thus controls heat movement to determine which side of the blanket is cooler or warmer. The layers are shown in FIG. 9 and include one or more solid-state additive manufacturing (SSAM) layers, poly foam (polyacrylate), cellulose, plastic pillars, mesh, carbon, graphite, graphene, and neoprene. In this configuration, heat energy is absorbed from the bottom-most layer, and transferred to the top-most layer for radiating into the nearby atmosphere.

[0072] Referring now to FIG. 10, a perspective view of a small swatch of such a material is shown in which the three-dimensional contours of the top-most layer of SSAM is observable. This example, minimized stack-up of layers has at top micro-climate surface layer 1001, such as an embossed honeycomb-like hexagonal pattern of indentations in which a microclimate exists. And, it has a SAP layer 1002 which provides the aqueous fluid absorption and cooling release function, as well as one or more structural and / or function enhancing layers 1003 and 1004 disposed there-between, under, and over the micro-climate surface layer and the SAP layer. In this manner, as the SAP releases its captured aqueous fluid, heat energy is absorbed from the bottom layer and transferred 1005 to the micro-climates of the top layer, thereby causing a positive temperature differential ΔT (delta T) as measured from the bottom layer to the top layer (e.g., the bottom layer is cooled).

[0073] The additional layers maybe used to enhance heat energy conduction from the bottom of the device (e.g., from the nearby object being cooled), to provide a liquid seal between the outside climate and the bottom layer, to strengthen the device and provide flexible yet resilient properties, to enhance thermal transmission and to enhance transfer of aqueous fluids to the unbonded SAP material.

[0074] Referring now to FIG. 11, the section 1011 of the example layer stack-up of FIG. 10 is shown in more detail and from a straight-on edge or side view. In this view, it can be seen that the micro-climate outer layer 1001 has a plurality of raised or embossed walls 1015 between which are formed cavities 1010 which operate as open-top microclimate containers. Heat energy from the nearby object (below the bottom layer 1003) is transferred 1005 to the top layer 1001 and dissipated into the microclimate areas or volumes, and the walls 1015 may also perform similarly to heat sink fins to increase the heat radiating surface.

[0075] Enhanced Cooling Using Physical Agitation. Still referring to FIG. 11, an optional element to an example embodiment according to the present invention is a mechanical agitator 1101 which improves or accelerates the release of the trapped liquid from the SAP layer 1002 by imparting physical movement 1102, such as a vibration signal, a sound signal or impulses, to the SAP layer. This may be especially useful for usage environments which do not provide natural physical agitation, such as fixed-location equipment (e.g., computers, medical equipment, factory machines, etc.). Moving equipment, such as vehicles, and clothing items, such as vests, and personal care items, such as fever cooling patches, may provide some physical agitation naturally from the usage environment, but may also benefit from enhanced cooling of synthetic agitation by a motor, vibrator, speaker, buzzer, annunciator, and the like.

[0076] Additional Orientations of the Cooling Material. While it is generally accepted that heat naturally travels upward as shown in FIGS. 10 and 11, the cooling operation of the material is not dependent on this orientation because the thermal energy will seek the path of least thermal resistance. Therefore, any intervening layers between the SAP layer and the outer radiating layer must provide less thermal resistance (e.g., more thermal conductance) than the thermal resistance of any intervening layers between the SAP layer and the nearby object to be cooled.

[0077] In fact, the cooling blanket material can be oriented vertically, such as by hanging, draping or affixing, with the object to be cooled on one side and the ambient climate to receive the released heat on the other side, with the thermal transfer 1005 occurring essentially horizontally. And, in some embodiments, the thermal transfer could be conducted from top to bottom in contravention of the common knowledge that heat generally travels upward.

[0078] Additional Micro-climate Patterns. Although the foregoing example embodiment shows a hexagonal honeycomb-like pattern of walls and cavities, other patterns may work as well, such as circular, oval, octagonal, square (waffle-like), etc., so long as the shape pattern creates micro-climates and / or heat sink fin type operation.

[0079] Additional Layer Stack-ups. While the foregoing stack-up order of layers of materials was found by the present invention to provide excellent dry, passive cooling for certain applications and uses, the present inventor has discovered multiple variations of stack-ups using different orders and different materials, some of which may provide even more cooling capacity but may be more expensive or heavier, and some of which are lighter in weight or less expensive while still providing some cooling capability.

[0080] For example, in one variation embodiment, the outermost layer is produced using “3D printing” methods to create a microfiber layer with the micro-climate cavities formed across it. In another variations, a copper layer between the outermost layer and the SAP layer was found to enhance and improve the cooling capacity, as was a charcoal layer. As such, other embodiments according to the present invention may use various combinations, sub-combinations and re-ordered layer stack-ups to achieve optimal weight, flexibility, cost and cooling capacity for specific uses and applications.

[0081] Additional Embodiments. The foregoing flexible, dry cooling material and device may be employed in a variety of embodiments. Cooling blankets and materials for vehicles, computers, computer peripherals, medical equipment, machines, clothing, medical products, personal care items, patches, bandages, casts, chemical reaction vessels, are among a few of embodiments of the present invention available to those suitably skilled in the relevant arts.

[0082] Conclusion. While the specification describes particular embodiments of a cooling material and device, those of ordinary skill can devise variations of the present invention without departing from the overall inventive concept. The foregoing description is therefore to be understood as illustrative in nature and an example of embodiments of the invention. The full scope of the present invention is limited only by the following claims.

[0083] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof, unless specifically stated otherwise.

[0084] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. A material for providing thermal cooling with reduced dripping, wicking, pooling and condensation onto a nearby object to be cooled, comprising:at least a first layer comprising a superabsorbent polymer (SAP), the first layer having an inner surface and an outer surface, wherein the inner surface is configured to be positioned nearby an object to be cooled; andat least a second layer having an surface layer in thermal and liquid communication with the outer surface of the first layer, and the second layer having an outer surface comprising a plurality micro-climate structures;thereby providing a material which absorbs liquid by the first layer in a charging phase, and which conducts thermal energy from the first layer inner surface through the second layer into the plurality of micro-climate structures in a cooling phase during which the liquid is released from the superabsorbent polymer, thereby providing cooling of a nearby object with reduced dripping, wicking, pooling and condensation onto the nearby object.

2. The material as set forth in claim 1 wherein the superabsorbent polymer comprises a poly foam.

3. The material as set forth in claim 1 wherein the superabsorbent polymer comprises a polyacrylate.

4. The material as set forth in claim 1 wherein the second layer comprises a solid-state additive manufacturing (SSAM) layer.

5. The material as set forth in claim 1 further comprising at least a third layer comprising one or more materials selected from the group consisting of cellulose, plastic pillars, mesh, carbon, graphite, graphene, and neoprene.

6. The material as set forth in claim 1 wherein the second layer is fabricated using an additive manufacturing process.

7. The material as set forth in claim 6 wherein the additive manufacturing process comprises a 3-dimensional printing process.

8. The material as set forth in claim 1 further comprising at least a third layer disposed between the first and second layers, and wherein the at least third layer comprises copper.

9. The material as set forth in claim 1 further comprising a physical agitation device which, when operated, provides agitation to at least the second layer to promote additional release of the liquid from the superabsorbent polymer.

10. The material as set forth in claim 9 wherein the physical agitation device comprises one or more devices selected from the group comprising a motor, a vibrator, a speaker, a buzzer, and an annunciator.

11. A method of manufacture of a material for providing thermal cooling with reduced dripping, wicking, pooling and condensation onto a nearby object to be cooled, the method comprising:affixing at least a first layer to a second layer, wherein the first layer comprises a superabsorbent polymer (SAP), the first layer has an inner surface and an outer surface, wherein the first layer inner surface is configured to be positioned nearby an object to be cooled; wherein the second layer has an inner surface in affixed to the outer surface of the first layer, wherein the second layer inner surface is in thermal and liquid communication with the first layer outer surface; and wherein the second layer has an outer surface comprising a plurality micro-climate structures;thereby producing a material with at least two layers which absorbs liquid via the first layer in a charging phase, wherein the material conducts thermal energy from the first layer inner surface through the second layer into the plurality of micro-climate structures in a cooling phase during which the liquid is released from the SAP, thereby providing cooling of a nearby object with reduced dripping, wicking, pooling and condensation onto the nearby object.

12. The method of manufacture as set forth in claim 11 wherein superabsorbent polymer comprises a poly foam.

13. The method of manufacture as set forth in claim 11 wherein the superabsorbent polymer comprises a polyacrylate.

14. The method of manufacture as set forth in claim 11 wherein the affixing of the first layer to the second layer comprises producing the second layer using an additive manufacturing process.

15. The method of manufacture as set forth in claim 11 wherein the affixing comprises affixing at least a third layer between the first layer and the second layer, wherein the third layer comprises one or more materials selected from the group consisting of cellulose, plastic pillars, mesh, carbon, graphite, graphene, neoprene and copper.

16. The method of manufacture as set forth in claim 11 wherein the second layer is fabricated using an additive manufacturing process.

17. The method of manufacture as set forth in claim 16 wherein the additive manufacturing process comprises a 3-dimensional printing process.

18. The method of manufacture as set forth in claim 11 further comprising coupling to the material a physical agitation device which, when operated, provides agitation to at least the second layer to promote additional release of the liquid from the superabsorbent polymer.

19. The method of manufacture as set forth in claim 18 wherein the physical agitation device comprises one or more devices selected from the group comprising a motor, a vibrator, a speaker, a buzzer, and an annunciator.

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