Composite Down Insulated Thermal Assembly
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Solution Overview
Problem
Existing thermal energy conductive materials with portable power sources suffer from short-lived thermal energy supply, inefficient energy utilization, and lack of flexibility, leading to significant energy loss and limited usage time.
Innovation Solution
A composite lightweight, flexible thermal source transfer assembly using down feather sheets to encapsulate thermal energy sources, such as thin film electrical heaters or gel packs, with a thermally insulating structure to minimize energy loss and enhance energy transfer efficiency, incorporating temperature sensors for controlled energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional conductive heating layers or thin film heaters are used, then heating efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies composite materials by combining down feathers with conductive elements to create a hybrid heating structure. The down feathers serve as both insulation and structural support, while embedded conductive threads or particles provide heating functionality. This composite approach achieves effective heating without requiring complex thin film heater assemblies, thereby reducing device complexity while maintaining heating efficiency.
Solution Approach 2:
The down feather material performs multiple functions simultaneously: it provides thermal insulation, structural support, and when integrated with conductive elements, it becomes the heating element itself. This multi-functionality eliminates the need for separate heating components, reducing overall device complexity while maintaining effective heating performance.
2Use of energy by moving object
If batteries are used to power heating circuits, then portable thermal energy supply is achieved, but duration of action is limited due to short DC supply span
Solution Approach 1:
The patent employs phase change materials that continuously release thermal energy as they transition from solid to liquid state over an extended period. This continuous phase change process provides sustained heating action that extends beyond the limited capacity of standard batteries, maintaining useful thermal output for longer durations without requiring recharging.
Solution Approach 2:
The invention utilizes phase change materials that undergo solid-liquid transitions to store and release thermal energy. These materials absorb heat during melting and release it during freezing, providing extended duration thermal supply that overcomes the limitations of battery-based systems. The phase change process naturally regulates temperature and extends operational duration.
3Duration of action of moving object
If more batteries are used to extend heating time, then duration of action increases, but weight and loss of substance increase
Solution Approach 1:
The patent uses phase change materials that provide extended heating duration through their solid-liquid transition process. These materials offer high energy density and sustained thermal release without requiring additional battery mass. The phase change mechanism naturally extends heating time while maintaining lightweight construction, avoiding the weight penalty of multiple batteries.
Solution Approach 2:
The continuous thermal energy release from phase change materials provides extended heating duration without intermittent operation. This continuous action maximizes the utilization of the thermal energy stored in the phase change material, extending effective heating time without proportionally increasing system weight, unlike battery-based solutions where each additional battery adds significant mass.
4Ease of manufacture
If conductive ink is used to form heating circuits, then ease of manufacture is improved, but manufacturing precision deteriorates due to non-uniform thickness
Solution Approach 1:
The patent incorporates conductive elements at specific localized positions within the down feather structure rather than attempting to create uniform conductive layers. Conductive threads are strategically placed in high-heat-requirement zones, and conductive particles are concentrated where heating is most needed. This localized approach achieves effective heating with simpler manufacturing processes, avoiding the precision requirements of uniform thin film deposition.
Solution Approach 2:
By combining down feathers with discrete conductive elements (threads, particles, or embedded heaters) rather than relying on uniform conductive ink layers, the patent achieves both ease of manufacture and acceptable heating uniformity. The composite structure allows for flexible integration of conductive components without requiring precise coating thickness control, thereby maintaining manufacturing simplicity while achieving functional uniformity.
5Ease of operation
If thermal energy is transferred without insulation, then ease of operation is improved, but loss of energy increases due to thermal loss to environment
Solution Approach 1:
The patent uses down feathers as a natural insulating material that is integrated into the heating structure. The down feathers trap air pockets that provide thermal insulation, reducing heat loss to the environment while maintaining a simple and lightweight design. This composite insulation approach minimizes energy loss without adding complex insulation layers or structures.
Solution Approach 2:
The down feather structure acts as a flexible insulating layer that conforms to the heating element and surrounding surfaces. This flexible insulation structure effectively reduces thermal loss while maintaining ease of operation and adaptability to different shapes and sizes, without requiring rigid or complex insulation systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution extends the usage time of thermal energy sources by minimizing energy loss and ensuring uniform energy distribution, reducing battery drain and preventing overheating, while maintaining flexibility and adaptability to various applications.
Implementation Method 1
a first thermally insulating flexible down material sheet (14) is secured to the top surface (15) of the thermal energy generating membrane (11)... to thermally insulate the thermal energy generating membrane (11) from an ambient temperature side
Implementation Method 2
a second thermally insulating flexible down material sheet (16) is secured to the bottom surface (17) of the thermal energy generating membrane (11)... which absorbs and distributes thermal energy transferred thereto by the thermal energy generating membrane (11)
Data Source
AI summary
A composite light weight, flexible and energy efficient, thermal source energy transfer assembly for the transfer of thermal energy in articles of warmth or cold and its method of construction is described. The assembly comprises a thermal energy generating membrane having opposed top and bottom surfaces. A first thermally insulating flexible down material sheet is secured to the top surface. A second thermally insulating flexible down material sheet is secured to the bottom surface and wherein the first thermally insulating flexible down material sheet has a thermal insulating value superior to the second thermally insulating flexible down sheet to thermally insulate the thermal energy generating membrane from an ambient temperature side of the thermal source energy transfer assembly when retained adjacent a surface area of a user person to be heated or cooled by heat or cold released by the thermal energy generating membrane. The second thermally insulating flexible down material sheet absorbs and distributes thermal energy transferred thereto by the thermal energy generating membrane. Several assembly examples and applications are described.