Induction GEL cooling and heating system

Abstract

The present disclosure relates to an induction gel cooling and heating apparatus and system where a flexible thermoelectric device directly contacts a gel for providing thermal management of the gel. The apparatus and system have applications in both industrial and therapeutic medical fields. The apparatus comprises a flexible thermoelectric device having first and second surfaces, wherein at least the first surface is electrically insulated and a flexible waterproof cover extends over the first surface defining an enclosed space. A gel fills the enclosed space and contacts the first surface. The gel is cooled or heated by the flexible thermoelectric device to a desired temperature and maintained at a thermal equilibrium. The apparatus also comprises a temperature sensor immersed in the gel, a flexible heat sink coupled to the second surface, and a flexible crown for attaching the cover to the flexible thermoelectric device.

Description

INDUCTION GEL COOLING AND HEATING SYSTEMTECHNICAL FIELD

[0001] The present disclosure relates to an induction gel cooling and heating apparatus and system where a flexible thermoelectric device directly contacts a gel for providing thermal management of the gel. The apparatus and system have applications in both industrial and therapeutic medical fields.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to help provide the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it is understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Gel bags have been used for thermal management across both therapeutic and industrial applications. These bags are characterized by a sealed container filled with a gel substance and are capable of adjusting and retaining the gel temperature, whether for heating or cooling purposes.

[0004] Conventional methods of cooling or heating gel pads or bags involve placing the gel pad in a freezer or heating it in hot water or a microwave. These methods are time-consuming and do not allow for precise temperature control of the gel pad.

[0005] When gel bags are used in thermotherapy applications in both the human and / or animal medical field for providing both heat and cold treatments it is notable that the absence of an integrated temperature control mechanism can lead to a significant limitation in its efficacy and comfort. Without the capability to regulate or modulate its temperature, the gel pad may reach temperatures that are either excessively hot or uncomfortably cold, posing a risk of thermal discomfort or even skin damage to the person or animal.Furthermore, this lack of temperature stabilization means the pad is unable to maintain a consistent or controlled temperature throughout the duration of the therapy session, potentially diminishing the therapeutic benefits. The inability to sustain an optimal temperature for the requisite period undermines the gel bags utility in delivering effective heat or cold therapy, which is typically predicated on the precise application of thermal conditions to achieve therapeutic outcomes. While these gel bags may find limited use in temporary emergency situations, they cannot be used in applications where precise temperature control is required.

[0006] In an industrial context, where gel pads can be deployed for thermal management applications such as in equipment cooling, heating processes, or maintaining optimal operating temperatures for sensitive components, the absence of an integrated temperature control system presents significant operational challenges. The inability of these gel pads to regulate or adjust their temperature autonomously can result in ineffective thermal management, leading to potential overheating or excessive cooling of machinery or components. This limitation not only risks compromising the integrity and performance of the equipment but also reduces the efficiency of the thermal management solution. Moreover, the inability to maintain a stable and controlled temperature over time is particularly detrimental in industrial applications where consistent thermal conditions are crucial for process reliability and product quality. The lack of precise temperature control undermines the utility of the gel pads in applications that demand stringent thermal regulation, impacting overall process stability and efficiency.

[0007] The present disclosure seeks to overcome these limitations.BRIEF DESCRIPTION

[0008] Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments.Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0009] The present disclosure relates to an induction gel cooling and heating apparatus and system where a flexible thermoelectric device directly contacts a gel for providing thermal management of the gel. The apparatus and system have applications in both industrial and therapeutic medical fields.

[0010] In an aspect, there is provided a flexible thermoelectric gel cooling and heating apparatus comprising a flexible thermoelectric device having first and second surfaces positioned on opposing sides of the flexible thermoelectric device, wherein at least the first surface is electrically insulated. A flexible waterproof cover extends over the flexible thermoelectric device to cover the first electrically insulated surface and define an enclosed space between the flexible waterproof cover and the first electrically insulated surface. The apparatus further comprises a gel filling the enclosed space between the waterproof flexible cover and the flexible thermoelectric device wherein the gel is displaced across the first electrically insulated surface of the flexible thermoelectric device in direct contacting heat exchange relation therewith and with the flexible waterproof cover.

[0011] In an embodiment, the thermoelectric gel cooling and heating apparatus may comprise a temperature sensor immersed within the gel in the enclosed space between the waterproof flexible cover and the first electrically insulated flexible surface.

[0012] In an embodiment, the gel may be housed within the enclosed space at a pressure that normally expands the flexible waterproof cover in a direction away from the first electrically insulated flexible surface when the flexible thermoelectric device is unflexed.

[0013] In an embodiment the flexible thermoelectric gel cooling and heating apparatus may further comprise a flexible crown mounted with the flexible thermoelectric device wherein the flexible crown has an outer seating surfacethat is spaced away from the first surface, and the flexible waterproof cover being secured with the outer seating surface to provide the enclosed space between the first electrically insulated surface, the flexible waterproof cover and the flexible crown.

[0014] In an embodiment, the flexible thermoelectric device has perimeter edges, and wherein the flexible crown surrounds the perimeter edges of the flexible thermoelectric device and has a rabbet with an overlapping ledge that extends inwardly to overlay and receive a surrounding surface portion of the first surface of the flexible thermoelectric device.

[0015] In an embodiment, the overlapping ledge of the flexible crown covers about 15% of area of the first electrically insulated flexible surface leaving a majority of the first electrically insulated flexible surface uncovered for direct heat transference with the gel.

[0016] In an embodiment the flexible crown may be formed from a thermoplastic polyurethane material.

[0017] In an embodiment, the flexible cover is secured against the outer seating surface of the flexible crown by a heat weld.

[0018] In an embodiment the first surface of the flexible thermoelectric device may be electrically insulated by a graphite adhesive covering the first surface and promoting heat transfer and electrical insulation.

[0019] In an embodiment, the flexible thermoelectric gel cooling and heating further comprises a flexible heat sink thermally coupled to, and electrically insulated from the second surface of the flexible thermoelectric device and wherein the flexible heat sink has a peripheral flange portion against which the flexible crown is seated.

[0020] In an embodiment, the temperature sensor is inserted through a first opening in the flexible crown into the enclosed space and electrical cables pass through a second opening in the flexible crown.

[0021] In an embodiment, the gel may be composed of propylene glycol, methylene blue, hydroxyethyl cellulose, and water.

[0022] In accordance with another aspect, there is provided a method of making a flexible thermoelectric device for cooling and heating a gel, comprising the steps of: providing a flexible thermoelectric device having a first surface and a second surface wherein the first surface has applied thereto a graphite adhesive and wherein an aluminum heat sink is electrically insulated from and thermally attached to the second surface of the flexible thermoelectric device; attaching a flexible crown to the flexible thermoelectric device with the flexible crown having an outer sealing surface spaced from the first surface of the flexible thermoelectric device; inserting a temperature sensor through a first opening in the flexible crown with the temperature sensor projecting away from the flexible crown over the first surface of the flexible thermoelectric device; placing a flexible cover over the first surface of the flexible thermoelectric device and securing the flexible cover with the outer sealing surface of the flexible crown to create an enclosed space between the first surface of the flexible thermoelectric device, the flexible crown, and the flexible cover; injecting a gel through a gel injection opening in the flexible crown into a space between the cover and the flexible thermoelectric device, at a pressure and an amount sufficient to displace the gel across the first surface of the flexible thermoelectric device in direct contact therewith, to encapsulate the temperature sensor in the gel and to expand the flexible cover; and sealing the gel injection opening in the flexible crown.

[0023] In yet another aspect to the method, wherein the flexible crown is seated against the flexible heat sink.

[0024] In another aspect, there is provided a thermal management system comprising a flexible thermoelectric gel cooling and heating apparatus and a thermal management controller. The flexible thermoelectric gel cooling and heating apparatus comprises: a flexible thermoelectric device having first andsecond surfaces positioned on opposing sides of the flexible thermoelectric device, wherein at least the first surface is electrically insulated; a flexible waterproof cover extending over the flexible thermoelectric device to cover the first electrically insulated surface and define an enclosed space between the flexible waterproof cover and the first electrically insulated surface; a gel filling the enclosed space between the waterproof flexible cover and the flexible thermoelectric device wherein the gel is displaced across the first electrically insulated surface of the flexible thermoelectric device in direct contacting heat exchange relation therewith and with the flexible waterproof cover; and, a temperature sensor immersed within the gel in the enclosed space between the waterproof flexible cover and the first electrically insulated flexible surface. The thermal management controller is connected to the flexible thermoelectric gel cooling and heating apparatus. The thermal management controller comprises a user input for setting a desired gel temperature; a power supply device for providing electrical power to the flexible thermoelectric gel cooling and heating apparatus; and, a control module for regulating the electrical power supplied to the flexible thermoelectric device based on the user input and a feedback signal from the temperature sensor, thereby regulating the heating and cooling effect of the flexible thermoelectric device.

[0025] In an embodiment of the system the user input further sets a desired time period for duration of thermal management of the system.

[0026] In an embodiment the system further comprises one or more displays for displaying the desired gel temperature and for displaying remaining time of thermal management operation of the system.

[0027] In an embodiment, the flexible thermoelectric gel cooling and heating apparatus is housed within a thermoelectric wrap that surrounds a body part and has a heat sink exposed externally of the wrap. In this embodiment, the wrap carries cooling fans coupled with the power supply and managed by the thermal management controller to direct air flow over the heat sink.

[0028] In an embodiment the system finds application in medical or industrial fields.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0029] The figures described below depict various aspects of the apparatus, method, and system disclosed therein. It should be under-stood that each figure depicts one embodiment of a particu-lar aspect of the disclosed apparatus, method and system, and that each of the figures is intended to accord with a possible embodi-ment thereof.

[0030] FIG. 1 illustrates an exploded view of an aspect of the subject matter in accordance with one embodiment.

[0031] FIG. 2 illustrates a partially assembled aspect of the subject matter in accordance with one embodiment.

[0032] FIG. 3 illustrates a cross-sectional view aspect of the subject matter in accordance with one embodiment.

[0033] FIG. 4 illustrates a partial exploded view aspect of the subject matter in accordance with the embodiment.

[0034] FIG. 5 illustrates bottom and top views of a crown aspect of the subject matter in accordance with the embodiment wherein the bottom is located to the left of the top view.

[0035] FIG. 6 illustrates a partial enlarged view aspect of the subject matter in accordance with the embodiment.

[0036] FIG. 7 illustrates a top view of an aspect of the subject matter in accordance with the embodiment.

[0037] FIG. 8 illustrates a method for manufacturing and / or assembly of the subject matter in accordance with one embodiment.

[0038] FIG. 9 illustrates a thermal management aspect of the subject matter in accordance with one embodiment.

[0039] FIG. 10 illustrates an apparatus aspect of the subject matter in accordance with the one embodiment.

[0040] FIG. 11 illustrates an application aspect of the subject matter in accordance with one embodiment.DETAILED DESCRIPTION

[0041] The aspects described herein relate to an induction gel cooling and heating apparatus where a flexible thermoelectric device directly contacts a gel to control the thermal management of the gel and hence the apparatus. The apparatus finds application in both industrial and medical fields. The aspects described herein further relate to a thermal management system for a flexible thermoelectric gel cooling and heating apparatus.

[0042] Thermoelectric devices are used in thermal management applications to convert waste heat into useful electricity, or to provide cooling or heating by applying an electric current. Thermoelectric devices typically comprise two ceramic plates that sandwich between them an array of p-type and n-type semiconductor elements connected electrically in series and thermally in parallel. The ceramic plates are thermally conductive and electrically non- conductive. In heating and cooling applications, the thermoelectric device is coupled to a power source, such as for example, a battery to deliver electrical power. Thermoelectric devices act to convert electrical energy into hot and cold surfaces of the thermoelectric device through the phenomenon known as the Peltier effect. The Peltier effect is the basis for many practical applications of thermoelectric devices, such as cooling in electronic components and portable coolers. In the present disclosure a flexible thermoelectric device is employed for transferring heat from one side to the other side of the device in a direction across the device that corresponds to the direction of electrical current flow into and through the device.

[0043] "Flexible thermoelectric device" or (FTED) refers to an energy conversion apparatus designed to generate electrical power from thermal gradients or vice versa, using thermoelectric effects. Key attributes include flexibility, allowing it to conform to various shapes and surfaces, enhancing its application scope. It incorporates materials and structures that ensure efficient thermal heat transfer and electrical insulation, safeguarding against electrical hazards while maximizing thermal energy conversion. The design emphasizes minimizing thermal resistance, optimizing electrical connectivity, and ensuring durability and flexibility for diverse implementations.

[0044] FTED's suitable for use in the aspects described herein are FTED's sold by Tegway Co., Ltd., of Korea (Domain Name tegway.co.kr). The Tegway FTED differs from traditional thermoelectric devices as it omits the use of a ceramic substrate. Consequently, the Tegway FTED has exposed electrodes on both sides of the thermoelectric device. The Tegway FTED compensates for the non-use of ceramic substrates by employing other forms of electrical support for semiconductor insulation on both sides of the thermoelectric device. This may involve anodizing the aluminum surface of heat sinks contacting the thermoelectric device or the use of double-sided adhesive and / or graphite films for electrical insulation and heat diffusion. While several models of FTED's are available from Tegway, the FTED of the embodiment described with respect the embodiment of Figs. 1 to 7 described below uses the Tegway model No. S169A068085.

[0045] In a broad aspect, the present disclosure relates to a system and / or apparatus that cools or heats a quantity of gel by conduction quickly and maintains the desired gel temperature stable. This is achieved through a flexible thermoelectric device having a quantity of gel in direct contact displaced across a flexible surface of the flexible thermoelectric device. This direct proximity of the gel against and displaced across the flexible surface of the thermoelectric device allows the system and apparatus of the present disclosure to precisely manage gel temperature, and in-turn target surface temperature of a target that is in thermal conductive relation with the system and apparatus. There is neitherneed to pre-heat the gel in hot water or by microwave radiation nor to refrigerate the gel to temperatures at or close to freezing. The system and apparatus of the present disclosure is not subject to the time delays and inaccuracy of reaching a gel temperature associated with this form of preheating or refrigeration. Furthermore, the system and apparatus of the present application is able to maintain the gel at a stable temperature which is not possible with the types of gel bags described in the background.

[0046] In an aspect, a flexible thermoelectric gel cooling and heating apparatus comprises a flexible thermoelectric device having first and second surfaces positioned on opposing sides of the flexible thermoelectric device, wherein at least the first surface is electrically insulated. A flexible waterproof cover extends over the flexible thermoelectric device to cover the first electrically insulated surface and define an enclosed space between the flexible waterproof cover and the first electrically insulated surface. The apparatus further comprises a gel filling the enclosed space between the waterproof flexible cover and the flexible thermoelectric device wherein the gel is displaced across the first electrically insulated surface of the flexible thermoelectric device in direct contacting heat exchange relation therewith and with the flexible waterproof cover.

[0047] The flexible thermoelectric device of the present disclosure converts electrical energy into thermal energy by exploiting the Peltier effect. The flexible thermoelectric device can bend and conform to the shape of the object or body part that is being cooled or heated by the gel.

[0048] The flexible waterproof cover of the apparatus that encloses and contains the gel and allows it to contact the first surface of the flexible thermoelectric device. The flexible waterproof cover can have different shapes and sizes depending on the shape and configuration of the flexible thermoelectric device, as long as it can perform its enclosing and containing functions. The flexible waterproof cover is impermeable to the gel and flexible enough to bend and conform to the shape of the target object or body part that is being cooled or heated by the gel.

[0049] “Gel” refers to a thermal conductive gel that can conduct heat or cold from a thermoelectric device to a target surface, which target surface is a surface of a target in thermal coupling relation with the waterproof flexible cover. The gel is a substance that can fill a gap or an enclosed space between the thermoelectric device and the target surface. It can transfer the heat or cold generated by the thermoelectric device efficiently and uniformly. The gel of the present disclosure is also a substance that can adapt to the shape and contour of the thermoelectric device and the target surface. The gel provides direct contact with a surface of the thermoelectric device as well as comfortable and stable contact with the target surface.

[0050] The preferred composition of the thermoelectric conductive gel used in an embodiment is a mixture of propylene glycol, methylene blue, hydroxyethyl cellulose, and water. However, it should be understood that the present disclosure is not limited to any specific type of gel, as long as the gel used provides the desired cooling and heating effects in accordance with the gel properties disclosed herein.

[0051] An advantage of the flexible thermoelectric gel cooling and heating apparatus according to the present disclosure is that the gel can be heated or cooled quickly to a desired temperature, and the gel maintains a thermal equilibrium with the flexible thermoelectric device, ensuring a consistent performance and reducing the risk of overheating or overcooling. The gel has a low viscosity and a high thermal conductivity, which allows it to spread evenly and rapidly over the first surface of the flexible thermoelectric device and to achieve a uniform temperature distribution. The flexible thermoelectric gel cooling and heating apparatus according to the present disclosure can therefore operate under various environmental conditions and meet the demands of different applications that require fast and stable heating or cooling effects.

[0052] The flexible thermoelectric gel cooling and heating apparatus utilizes the gel differently from the gel used in past gel pads in several ways. First, the gel does not need to be frozen or heated before use, as the thermoelectricmodule can quickly cool or heat the gel by conduction. Second, the gel does not lose its temperature rapidly, as the thermoelectric module can maintain a stable and desired temperature for as long as needed. Third, the gel does not require a separate pad or container, as it directly contacts the thermoelectric module and the cover, forming a flexible and integrated apparatus.

[0053] In an embodiment, the flexible thermoelectric gel cooling and heating apparatus includes a flexible crown that serves to attach the flexible waterproof cover spaced apart from the flexible thermoelectric device providing the enclosed space containing the gel. The flexible crown can have different shapes and sizes depending on the shape and configuration of the flexible thermoelectric device, as long as it can perform its attaching function.

[0054] In an embodiment, a temperature sensor passes through the crown into the gel for measuring the gel temperature and providing a feedback signal to a thermal management system.

[0055] Referring to Figs. 1 to 7 there is illustrated an embodiment of the flexible thermoelectric gel cooling and heating apparatus 100. In the exploded view of FIG. 1 the flexible thermoelectric gel cooling and heating apparatus 100 is shown to have a flexible waterproof cover 102, a flexible crown 106, a flexible thermoelectric device 104 and a flexible heat sink 108.

[0056] The flexible thermoelectric device 104 has a first electrically insulated surface 118 and a second surface 120 which surfaces are on opposite sides of the flexible thermoelectric device 104. The first surface 118 is coated with a graphite adhesive 122 that facilitates heat transfer and electrical insulation.

[0057] The flexible thermoelectric device 104 as used in the embodiment of Figs. 1 to 7 is flexible thermoelectric device (FTED) model No. S169A068085 sold by Tegway Co., Ltd., of Korea. This FTED comprises a thermoelectric element, a polymer layer, and an electrode. The length of the FTED can vary depending on the application and the required power output. Since this FTED does not use a ceramic substrate and has exposed electrodes on both sides ofthe device, it is attached to an insulating surface or an insulating film. When attaching this FTED to a heat sink or target, the target or heat sink may have an electrically insulating film or layer on its surface. For example, an aluminum heat sink may be anodized to form a stable and passive insulating film on its surface attached to this FTED. Alternatively, an insulation film may be attached to, or formed on, the surfaces of the FTED. This film should have high thermal conductivity and high electrical insulation resistance to ensure efficient heat transfer and electrical safety. Two types of insulating films that may be used are double-sided insulating film (tape) and graphite film.

[0058] The flexible thermoelectric device 104 may be connected to a power supply (not shown in Figs. 1 to 7) that provides an electric current to the flexible thermoelectric device 104, causing one side of the flexible thermoelectric device 104 to become cold and the other side to become hot, depending on the direction of electrical current flowing through the flexible thermoelectric device 104 in accordance with the Peltier effect. The direction of flow of current through the flexible thermoelectric device 104 can be reversed changing the first side surface 118, between hot and cold surfaces.

[0059] The flexible heat sink 108 is thermally coupled to the second surface 120 of the flexible thermoelectric device 104. The flexible heat sink 108 comprises a flexible metal plate 110 with multiple heat transferfins that increase the surface area for heat dissipation. The flexible heat sink 108 has peripheral flange 112 that extends laterally outwardly of the perimeter edges 128 of the flexible heat sink 108. The flexible heat sink 108 may comprise a soft aluminum materially that is electrically insulated from the flexible thermoelectric device 104 either by an insulating film sandwiched between flexible thermoelectric device 104 and flexible heat sink 108, or an aluminum flexible metal plate 110 of the heat sink 108 being anodized to form a stable and passive insulating film .

[0060] The flexible waterproof cover 102 extends over the flexible thermoelectric device 104 to cover the first electrically insulated surface 118 and define an enclosed space 114 between the flexible waterproof cover 102 and the first electrically insulated surface 118. The flexible waterproof cover 102may be made of a flexible and elastic material, such as for example silicone rubber or a thermoplastic polyurethane (TPU), that can slightly expand and contract with the pressure of the gel 124 (described below) and the flexing of the flexible thermoelectric device 104 and remain impermeable to the gel. The flexible waterproof cover 102 provides a pliable surface for thermally transferring heat to, or away from, a target to be heated and / or cooled by the apparatus 100. It should be understood that the flexible waterproof cover 102 may not be in direct contact with the target and may be housed within a cloth or other material wrap through which the heat transfer occurs.

[0061] The flexible crown 106 attaches the flexible waterproof cover 102 to the flexible thermoelectric device 104. The flexible crown 106 surrounds the perimeter edges 128 of the flexible thermoelectric device 104 and has a rabbet 130 located in the flexible crown 106 extending inwardly from the perimeter edges 128 of the flexible thermoelectric device 104. The rabbet 130 provides an overlapping ledge 132 in sealing contact with a surrounding surface portion 142 of the first electrically insulated surface 118 adjacent to the perimeter edges 128. As best seen in FIG. 5, the flexible crown has an internal edge 148 that abuts against the perimeter edges 128 of the flexible thermoelectric device 104.

[0062] In the present disclosure, the "Rabbet" refers to a longitudinal channel, groove, or recess cut out of an edge or face of the flexible crown that receives in overlapping relation the surrounding surface portion 142 of the first surface of the flexible thermoelectric device. It is intended to receive the peripheral edges of the flexible thermoelectric device and to cover the joint formed therebetween. It is also known as a “rebate”.

[0063] In the embodiment of Figs. 1 to 7, the overlapping ledge 132, surrounding surface portion 142, covers about 15% of the area of the first electrically insulated surface 118 which leaves a majority of the first electrically insulated surface 118 uncovered for direct heat transference with the gel 124. The flexible crown 106 also provides an outer seating surface 144 that is stepped away from, or spaced away from, the first surface 118. The flexible cover 102 may be secured against the outer seating surface 144 to create theenclosed space 126 between the first electrically insulated surface 118, the flexible waterproof cover 102 and the flexible crown 106. The flexible waterproof cover 102 is secured against the outer seating surface 144 by a heat weld providing a water-tight seal. Alternatively, a suitable adhesive may be employed. The flexible crown 106 is formed from a thermal polymer, such as, for example, a thermoplastic polyurethane (TPU) material that has high elasticity, abrasion resistance, and tear strength. In this embodiment, the direct proximity of the gel against and displaced across the flexible surface of the thermoelectric device allows the system and apparatus of the present disclosure to precisely manage gel temperature, and in-turn target surface temperature of a target that is in thermal conductive relation with the system and apparatus. There is neither need to pre-heat the gel in hot water or by microwave radiation nor to pre- refrige rate the gel to temperatures at or close to freezing. The system and apparatus of the present disclosure is not subject to the time delays and inaccuracy of the reaching a gel temperature associated with this form of preheating or refrigeration. Furthermore, the system and apparatus of the present application is able to maintain the gel at a stable temperature which is not possible with gel bags discussed in the background.

[0064] To attach the crown 106 to the heat sink 108, a thin transparent adhesive film 146 may be used. This film may comprise a low-density acrylic film with the help of an adhesion activation. The adhesive film 146 is applied on a peripheral flange 112 of the flexible heat sink 108 and to a heat sink seating surface portion 150 of the crown 106. The flexible crown 106 is then pressed firmly against the heat sink seating surface portion 150 such that flange 112 is secured with surface portion 150. The adhesive film 146 creates a strong bond between the two components.

[0065] The flexible crown 106, the flexible cover 102, and the first electrically insulated surface 118 of the flexible thermoelectric device 104 form a picture frame-like structure that surrounds and encloses a gel 124 and a temperature sensor 134.

[0066] The gel 124 is injected under pressure through temporary gel opening 140 in the flexible crown 106 after flexible waterproof cover 102 has been assembled with the flexible crown 106 to provide the enclosed space 126. After injection, the gel opening 140 is sealed and the gel 124 fills the enclosed space 126. The gel 124 is displaced across the first electrically insulated surface 118 of the thermoelectric device 104 in direct contacting heat exchange relation therewith and in direct contacting heat exchange relation with the flexible waterproof cover 102. The gel 124 is injected into the enclosed space 126 at a pressure and amount that normally expands the flexible waterproof cover 102 in a direction away from the first electrically insulated surface 118 when the flexible thermoelectric device 104 is unflexed. It should be understood that the amount and pressure of the gel 124 injected into space 126, depends on the dimensions of the thermoelectric device 104 and swelling of the flexible waterproof cover 102 during gel filling. During filling of the gel 124 into the enclosed space 126, the cover 102 expands to form a “pad-like” effect, both in substance and visually. This pad-like effect ensures that the gel 124 is positioned in direct contact across the entire first electrically insulated surface 118 of the flexible thermoelectric device 104 located within the boundary of the flexible crown 106. By maintaining a slight pressure on the gel, the apparatus 100 can achieve improved temperature control by uneven distribution of the gel thereby reducing or preventing air gaps. The pad-like effect, or desired firmness of the pad, also makes the apparatus 100 more comfortable and ergonomic for the user, as it adapts to the shape of the body part that may be treated. The gel used in this embodiment is a gel composition comprising propylene glycol, methylene blue, hydroxyethyl cellulose, and water.

[0067] The gel 124 may be cooled or heated by the flexible thermoelectric device 104 to a desired temperature, as measured by a temperature sensor 134. The temperature sensor 134 is inserted through a temperature sensor opening 136 passing through the flexible crown 106. The temperature sensor 134 is immersed within the gel in the enclosed space 126 between the flexible waterproof cover 102 and the first electrically insulated surface 118. The temperature sensor 134 may comprise a flat negative temperature coefficient(NTC) thermistor that provides a signal to a temperature control device that regulates a power supply to the flexible thermoelectric device 104. The temperature control device can also control the speed of fans that may be attached to, or in close proximity to, the flexible heat sink 108. The fans help to dissipate excess heat from the second surface 120 of the flexible thermoelectric device 104 when the target side of the device 104 is being cooled.

[0068] The flexible crown 106 further includes an electrical wiring opening 138 through which electrical cables or wires 116 pass to the flexible thermoelectric device 104. This wiring is connectable with a power supply to supply current to the flexible thermoelectric device 104.

[0069] While the flexible thermoelectric gel cooling and heating apparatus 100 is shown in Figs. 1 to 7 in an unflexed position, it should be understood that the flexible crown 106, the flexible waterproof cover 102, and the flexible thermoelectric device 104 are all bendable and conformable to the shape of a part, or a body part, to be warmed or cooled, and / or treated by the apparatus 100.

[0070] The flexible thermoelectric gel cooling and heating apparatus 100 according to the present disclosure has several advantages in addition to those previously mentioned. For example, the flexible crown provides a durable and resilient support for the flexible thermoelectric device, absorbing thermal expansion and contraction and preventing cracks or delamination. The flexible crown also provides a tight seal for the cover and the gel, preventing moisture, dust, corrosion, or oxidation from entering the space between the cover and the flexible thermoelectric device. The gel 124 provides a good thermal contact for the thermoelectric module, enhancing its efficiency and reliability. The gel 124 also conforms to the shape of the flexible thermoelectric device, and the shape of the flexible waterproof cover 102. The flexible thermoelectric gel cooling and heating apparatus 100 according to the present disclosure is also simple, cost- effective, and easy to manufacture and install in a thermal management system used for industrial applications and / or thermotherapy medical treatments for humans and animals. The flexible thermoelectric gel cooling and heatingapparatus 100 is adaptable to the shape and configuration of a target object or body part and provides precise temperature control for various applications, such as, for example medical treatment, personal comfort, or electronics cooling.

[0071] Referring to FIG. 8 there is shown a flow chart of the method steps for manufacturing a flexible thermoelectric gel cooling and heating apparatus 100 in accordance with an embodiment.

[0072] In step 802, the method 800 provides a flexible thermoelectric device having a first surface and a second surface wherein the first surface has applied thereto a graphite adhesive and wherein an aluminum heat sink is electrically insulated from and thermally attached to a second surface of the flexible thermoelectric device.

[0073] In step 804, the method 800 attaches a flexible crown to the flexible thermoelectric device with the flexible crown having an outer sealing surface spaced from the first surface of the flexible thermoelectric device.

[0074] In step 806, the method 800 inserts a temperature sensor through a first opening in the flexible crown with the temperature sensor projecting away from the flexible crown over the first surface of the flexible thermoelectric device.

[0075] In step 808, the method 800 places a flexible cover overthe first surface of the flexible thermoelectric device and secures the flexible cover with the outer sealing surface of the flexible crown to create an enclosed space between the first surface of the flexible thermoelectric device, the flexible crown, and the flexible cover.

[0076] In step 810, the method 800 injects a gel through a gel injection opening in the flexible crown into a space between the cover and the flexible thermoelectric device, at a pressure and an amount sufficient to displace the gel across the first surface of the flexible thermoelectric device in direct contacttherewith, to encapsulate the temperature sensor in the gel and to expand the flexible cover.

[0077] In step 812, the method 800 seals the gel injection opening in the flexible crown.

[0078] Referring to FIG. 9, there is shown a schematic diagram of a thermal management system 902 according to one embodiment of the present disclosure as it would relate for use in thermotherapy. The thermal management system 902 comprises a controller device 904 and a thermoelectric wrap 906. The controller device 904 has a controller module 908, a temperature display 910, a time display 912, an audio and / or visual alarm 914, and a power supply 916. The thermoelectric wrap 906 houses the flexible thermoelectric gel cooling and heating apparatus 918, similar to the apparatus 100 described above with reference to FIGS. 1-7. The flexible thermoelectric gel cooling and heating apparatus 918 is shown schematically in FIG. 9 to include a temperature sensor 920 and a flexible heat sink 922. The wrap 906 also has two fans 924 for directing air flow over the heat exchanger or flexible heat sink 922. The controller device 904 and the wrap 906 are connected by a power and communication link or cable 928. The power and communication link or cable 928 permits for the controller device to be located remotely from the wrap 906, supplies power from the controller device 904 to the thermoelectric wrap 906 and permits a gel temperature feedback signal to be communicated from the temperature sensor 920 to the controller module 908.

[0079] The controller module 908 controls the operation of the thermal management system 902 based on user input at input 926 and the feedback signal from the temperature sensor 920. A user can set the desired temperature for the gel and desired time period for treatment duration on the temperature display 910 and the time display 912, respectively. The controller module 908 then regulates the electrical current or power supplied to the flexible thermoelectric gel cooling and heating apparatus 918 via power and communication link or cable 928, thereby adjusting and / or maintaining the heating and cooling effect of the flexible thermoelectric gel cooling and heatingapparatus 918. The controller module may be configured to control the temperature of the wrap as applied to a target area. The controller may have appropriate firmware permitting the controller to cycle between heating and cooling temperatures for selected periods of time. The temperature sensor 920 measures the temperature of the gel adjacent to the target area to be treated and relays the information to the controller module 908 via the power and communication link or cable 928. The controller module 908 compares the measured temperature with the desired temperature and adjusts the electrical current or power supplied to the flexible thermoelectric gel cooling and heating apparatus 100 accordingly. The temperature display 910 shows the current temperature of the gel, and the time display 912 shows the remaining time of the treatment or thermal management operation. Depending on the temperature setting of temperature display 910, which may in some embodiments be compared with ambient temperature, the controller module 908 will switch between cooling and heating modes by switching the direction of electrical current supplied to the flexible thermoelectric gel cooling and heating apparatus 918 from the power supply 916. The audio and / or visual alarm 914 alerts the user when the treatment is completed or when there is a malfunction in the system 902. The power supply 916 provides the necessary power for the system 800 and may be a battery, a wall outlet, or any other suitable source of electricity. In an embodiment, the power supply 916 is a rechargeable lithium battery, with a voltage of 24v / 5A-129.5. In an embodiment, the batter may be charged with the use of a wall socket charger, with continuous charging values, V29.5 / 2.5A

[0080] A person, or animal such as for example a horse, may wear the thermoelectric wrap 906 around the body part that needs treatment, such as a knee, an elbow, a shoulder, or a wrist, and secure it with strapping (not shown). The flexible thermoelectric gel cooling and heating apparatus 918 with the thermoelectric wrap 906 conforms to the shape of the body part and provides uniform heating and cooling to the target area. The fans 924 cool the flexible heat sink 922, which dissipates the excess heat generated by the flexible thermoelectric device 104 of apparatus 918, thereby improving the efficiencyand performance of the thermal management system 902. The thermoelectric wrap 906 can have various sizes, shapes, colors, and patterns to suit different body parts and user preferences. The thermal management system 902 can provide effective and convenient thermal cooling and heating therapy for various muscle, tendon, or joint conditions, such as inflammation, pain, swelling, stiffness, or injury.

[0081] It should be understood that the thermal management system for the flexible thermoelectric gel heating and cooling apparatus has various applications and benefits in both the medical and industrial fields.

[0082] One application would be in the field of medical thermotherapy. The thermal management system may be used to provide cold or heat therapy to body parts that suffer from pain, inflammation, injury, or chronic conditions. The system may cool or heat the gel to a desired temperature, and apply it to the target body part, providing a fast and stable thermal treatment. The system may also adjust the temperature and duration of the treatment based on medical advice and monitor the temperature of the gel adjacent to the body part. The system may also conform to the shape of the body part, ensuring a close and comfortable contact. The system may therefore improve the therapeutic outcomes and the user experience.

[0083] Another application may be for electronic cooling. The thermal management system may be used to cool electronic components or devices that generate heat during operation, such as CPUs, GPUs, or batteries. The system may cool the gel to a desired temperature and apply it to the target electronic component or device, providing a fast and efficient cooling effect. The system may also adjust the temperature and duration of the cooling based on the performance and specifications of the electronic component or device and monitor the temperature of the gel and the electronic component or device. The system may also conform to the shape of the electronic component or device, ensuring good thermal contact. The system may therefore improve the performance and reliability of the electronic component or device.

[0084] Another application may be for industrial processes. The thermal management system may be used to cool or heat industrial products or materials that require specific temperature conditions during transport or processing, such as, for example, vaccines, food, human transplant organs, or chemicals. The system may cool or heat the gel to a desired temperature, and apply it to the target product or material, providing fast and stable thermal management. The system may also adjust the temperature and duration of the thermal management based on the requirements and specifications of the product or material, and monitor the temperature of the gel adjacent to the product or material. The system may also conform to the shape of the product or material, ensuring a uniform temperature distribution. The system may therefore improve the quality and safety of the product or material.

[0085] FIG. 10 illustrates a thermal management system 1000 according to an embodiment of the present disclosure. The thermal management system 1000 includes a controller device 1002, a cable 1004, and a thermoelectric wrap 1006. The thermoelectric wrap 1006 houses the flexible thermoelectric gel cooling and heating apparatus 100 of the present disclosure in a pocket (not shown). The thermoelectric wrap 1006 may be used to treat muscles, tendons, or joints of humans or animals by applying heat or cold to the affected area.

[0086] The controller device 1002 controls the temperature and duration of the treatment provided by the thermal management system 1000. The controller device 1002 has a power source (not shown), a digital display 1008 and a user interface 1010. The power source may be a battery, a plug, or any other suitable device that can provide electrical power to the controller device 1002 and the flexible thermoelectric gel cooling and heating apparatus 100. The digital display 1008 is a screen that shows the temperature setting for the wrap and the remaining time of the treatment. The user interface 1010 is a set of buttons, knobs, switches, or any other suitable devices that allow the user to adjust the temperature and duration of the treatment as well as adjust the mode of operation between hot and cold. The controller device 1002 may also have anaudible or visual alarm that signals the end of the treatment or alerts the user of any malfunction.

[0087] The cable 1004 connects the controller module 910 with the flexible thermoelectric gel cooling and heating apparatus 100, providing electrical power and temperature feedback. The cable 1004 may be a flexible, insulated, and durable wire that can withstand the movement and stress of the user. The cable 1004 has a first end that connects to the controller device 1002, and a second end that connects to the flexible thermoelectric gel cooling and heating apparatus 100 and temperature sensor 134 housed in the thermoelectric wrap 1006.

[0088] The thermoelectric wrap 1006 houses two flexible thermoelectric gel cooling and heating apparatus 100 spaced apart from each other for application to different target areas. The thermoelectric wrap 1006 has two fans 1012 for cooling the heat sinks 1014 with their heat sink fins located on the outer surface of the thermoelectric wrap 1006 and exposed externally of the thermoelectric wrap 1006. The fans 1012 direct air flow over the heat sinks 1014 for a cooling effect. The thermoelectric wrap 1006 may be made of a biocompatible, elastic fabric that conforms to the shape of the user's body part, ensuring close contact with the affected area. The thermoelectric wrap 1006 may be secured with adjustable strapping (not shown) that allows the user to adjust the tightness and position of thermoelectric wrap 1006. The strapping may be a hook-and-loop fastener, a buckle, a snap, or any other suitable device that can secure the thermoelectric wrap 1006. The thermoelectric wrap 1006 can have various sizes and shapes depending on the targeted body part that is being treated, such as, for example a knee, an elbow, a shoulder, or a wrist. The thermoelectric wrap 1006 can also have different colors and patterns to suit the user's preference.

[0089] As previously described, the thermoelectric gel cooling and heating apparatus 100 has a temperature probe sensor 134 that measures the temperature of the gel adjacent to the target body part to which heating and cooling is applied. Temperature information from temperature sensor 134 isrelayed to the controller device 1002. The controller device 1002 maintains a stable temperature to the targeted body part, or alternatively varies the temperature in a controlled manner to a different desired temperature to be applied to the targeted body part. The controller adjusts or maintains the desired temperature by controlling the electrical current flowing through the flexible thermoelectric device 104 responsive to a temperature feedback signal from the temperature sensor 134.

[0090] To operate the thermal management system 1000, the user wears the thermoelectric wrap 1006 so that the flexible thermoelectric gel cooling and heating apparatus 100 is positioned adjacent to the muscle, tendon, or joint to be treated and secures the thermoelectric wrap 1006 with suitable strapping, activates the controller device 1002, sets the desired temperature on the digital display 1008 and adjusts the treatment duration based on medical advice. The user may then monitorthe temperature and remaining time on the digital display 1008, and remove the thermoelectric wrap 1006 after the treatment completion. The thermoelectric wrap 1006 may typically heat or cool a treatment area between about 5°C and 44°C and have a typical treatment duration, for example, of between 15 and 30 minutes. While the above temperature range is chosen for treatment of animals, it should be understood that temperature ranges lying outside this range may be used for other applications including industrial applications.

[0091] FIG. 11 illustrates an embodiment of a horse 1102 wearing a thermoelectric wrap 1104, demonstrating its application and mode switching. The horse 1002 has tendons on its lower leg 1106 that may need temperature modulation before and after a work-out. The thermoelectric wrap 1104 is positioned around lower leg 1106, covering the tendons. A controller device 1108 is located above the leg 1104 at behind the horse's shoulder 1112 by a suitable harness, and a cable 1110 extends between the controller device 1108 and thermoelectric wrap 1104. The thermoelectric wrap 1104 conforms to the shape of the lower leg 1106 and comprises 2 wraps 1104. A flexible thermoelectric gel cooling and heating apparatus (not shown) is housed in eachof the two thermoelectric wraps 1104 and provides heating or cooling to the tendons, depending on the settings on the controller device 1108. In this embodiment, the controller device 1108 has a mode switch (not shown) that allows the user to select between heating mode and cooling mode. In heating mode, the thermoelectric wrap 1104 warms up the tendons before a work-out, enhancing their elasticity and flexibility, which in turn improves performance and reduces the risk of injury to the horse 1102. In cooling mode, the thermoelectric wrap 1104 cools down the tendons after the work-out, alleviating inflammation and facilitating recovery for the horse 1102. The thermoelectric wrap 1104 provides a convenient and effective method for achieving these temperature modulation goals, allowing for precise control over the tendons' temperature and duration of treatment. This practice not only supports the horse's physical health and longevity in competitive and recreational riding but also contributes to maintaining peak performance levels by ensuring the tendons are in optimal condition for both exertion and recovery phases.

[0092] While the embodiments set forth in the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. The disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

Claims

CLAIMSWhat is claimed is:

1. A flexible thermoelectric gel cooling and heating apparatus comprising: a flexible thermoelectric device having first and second surfaces positioned on opposing sides of the flexible thermoelectric device, wherein at least the first surface is electrically insulated; a flexible waterproof cover extending over the flexible thermoelectric device to cover the first electrically insulated surface and define an enclosed space between the flexible waterproof cover and the first electrically insulated surface; and, a gel filling the enclosed space between the waterproof flexible cover and the flexible thermoelectric device wherein the gel is displaced across the first electrically insulated surface of the flexible thermoelectric device in direct contacting heat exchange relation therewith and with the flexible waterproof cover.

2. The flexible thermoelectric gel cooling and heating apparatus of claim 1 further comprising a temperature sensor immersed within the gel in the enclosed space between the waterproof flexible cover and the first electrically insulated flexible surface.

3. The flexible thermoelectric gel cooling and heating apparatus of claim 1 wherein the gel is at a pressure within the enclosed space that normally expands the flexible waterproof cover in a direction away from the first electrically insulated flexible surface when the flexible thermoelectric device is unflexed.

4. The flexible thermoelectric gel cooling and heating apparatus of claim 1 further comprising a flexible crown mounted with the flexible thermoelectric device wherein the flexible crown has an outer seating surface that is spaced away from the first surface, and the flexible waterproof coverbeing secured with the outer seating surface to provide the enclosed space between the first electrically insulated surface, the flexible waterproof cover and the flexible crown.

5. The flexible thermoelectric gel cooling and heating apparatus of claim 4 wherein the flexible thermoelectric device has perimeter edges, and wherein the flexible crown surrounds the perimeter edges of the flexible thermoelectric device and has a rabbet with an overlapping ledge that extends inwardly to overlay and receive a surrounding surface portion of the first surface of the flexible thermoelectric device.

6. The flexible thermoelectric gel cooling and heating apparatus of claim 4 wherein the overlapping ledge of the flexible crown covers about 15% of area of the first electrically insulated flexible surface leaving a majority of the first electrically insulated flexible surface uncovered for direct heat transference with the gel.

7. The flexible thermoelectric gel cooling and heating apparatus of claim 5 wherein the flexible crown is formed from a thermoplastic polyurethane material.

8. The flexible thermoelectric gel cooling and heating apparatus of claim 4 wherein the flexible cover is secured against the outer seating surface of the flexible crown by a heat weld.

9. The flexible thermoelectric gel cooling and heating apparatus of claim 1 wherein the first surface of the flexible thermoelectric device is electrically insulated by a graphite adhesive covering the first surface and promoting heat transfer and electrical insulation.

10. The flexible thermoelectric gel cooling and heating apparatus of claim 4 further comprising a flexible heat sink thermally coupled to, and electrically insulated from the second surface of the flexible thermoelectric device and wherein the flexible heat sink has a peripheral flange portion against which the flexible crown is seated.

11. The flexible thermoelectric gel cooling and heating apparatus of claim 4 wherein a temperature sensor is inserted through a first opening in the flexible crown into the enclosed space and electrical cables pass through a second opening in the flexible crown.

12. The flexible thermoelectric gel cooling and heating apparatus of claim 1 wherein the gel is composed of propylene glycol, methylene blue, hydroxyethyl cellulose, and water.

13. A method of making a flexible thermoelectric device for cooling and heating a gel, comprising the steps of: providing a flexible thermoelectric device having a first surface and a second surface wherein the first surface has applied thereto a graphite adhesive and wherein an aluminum heat sink is electrically insulated from and thermally attached to the second surface of the flexible thermoelectric device; attaching a flexible crown to the flexible thermoelectric device with the flexible crown having an outer sealing surface spaced from the first surface of the flexible thermoelectric device; inserting a temperature sensor through a first opening in the flexible crown with the temperature sensor projecting away from the flexible crown over the first surface of the flexible thermoelectric device; placing a flexible cover over the first surface of the flexible thermoelectric device and securing the flexible cover with the outer sealing surface of the flexible crown to create an enclosed space between the first surface of the flexible thermoelectric device, the flexible crown, and the flexible cover; injecting a gel through a gel injection opening in the flexible crown into a space between the cover and the flexible thermoelectric device, at a pressure and an amount sufficient to displace the gel across the first surface of the flexible thermoelectric device in direct contact therewith, to encapsulate the temperature sensor in the gel and to expand the flexible cover; and sealing the gel injection opening in the flexible crown.

14. The method of claim 13 wherein the flexible crown is seated against the flexible heat sink.

15. A thermal management system comprising: a flexible thermoelectric gel cooling and heating apparatus comprising: a flexible thermoelectric device having first and second surfaces positioned on opposing sides of the flexible thermoelectric device, wherein at least the first surface is electrically insulated; a flexible waterproof cover extending over the flexible thermoelectric device to cover the first electrically insulated surface and define an enclosed space between the flexible waterproof cover and the first electrically insulated surface; a gel filling the enclosed space between the waterproof flexible cover and the flexible thermoelectric device wherein the gel is displaced across the first electrically insulated surface of the flexible thermoelectric device in direct contacting heat exchange relation therewith and with the flexible waterproof cover; and, a temperature sensor immersed within the gel in the enclosed space between the waterproof flexible cover and the first electrically insulated flexible surface; and a thermal management controller connected to the flexible thermoelectric gel cooling and heating apparatus, the thermal management controller comprising: a user input for setting a desired gel temperature; a power supply device for providing electrical power to the flexible thermoelectric gel cooling and heating apparatus; and, a control module for regulating the electrical power supplied to the flexible thermoelectric device based on the user input and a feedback signal from the temperature sensor, thereby regulating the heating and cooling effect of the flexible thermoelectric device.

16. The system of claim 15 wherein the user input further sets a desired time period for duration of thermal management of the system.

17. The system of claim 16 further comprising one or more displays for displaying the desired gel temperature and for displaying remaining time of thermal management operation of the system.

18. The system of claim 15, wherein the flexible thermoelectric gel cooling and heating apparatus is housed within a thermoelectric wrap that surrounds a body part and has a heat sink exposed externally of the wrap, and the wrap carrying cooling fans coupled with the power supply and managed by the thermal management controller to direct air flow over the heat sink.

19. The system of claim 15 further comprising a flexible crown mounted with the flexible thermoelectric device wherein the flexible crown has an outer seating surface spaced away from the first surface, and the flexible waterproof cover is secured with the outer seating surface to provide the enclosed space between the first electrically insulated surface, the flexible waterproof cover and the flexible crown.

20. The system of claim 15, wherein the system is used in medical or industrial fields.

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