Disposable Thermal Device with Segmented Activation
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Solution Overview
Problem
Existing thermal devices face issues such as premature activation due to air leakage, limited surface area coverage, inactivation by moisture, low maximum temperatures, and safety risks from caustic or corrosive chemicals, making them unsuitable for disinfection, sanitization, or insecticidal applications.
Innovation Solution
A disposable autonomous thermal device comprising a mixture of an acid and a base, activated by contact with a liquid, which generates controlled exothermal reactions, allowing for adjustable heat generation and distribution across larger areas, with safety features to prevent accidental activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oxidation reactions using metal powder and air are used for heat generation, then thermal therapy applications are achieved, but premature activation occurs due to air leakage and humidity penetration
Solution Approach 1:
The device divides the reactive components into separate compartments: an inner water-filled balloon and an outer container holding metal powder and oxidizing agents. This segmentation prevents premature contact between reactants while enabling controlled reaction when the balloon is punctured, solving the premature activation problem while maintaining heat generation capability.
Solution Approach 2:
The water-filled balloon acts as an intermediary mechanism that, when punctured, releases water to trigger the exothermic reaction between metal powder and oxidizing agents. This intermediary approach provides reliable controlled activation without premature reaction, as the balloon remains intact during storage and transport.
2Area of stationary object
If small heating pads are used for thermal therapy, then localized body areas can be treated, but larger surfaces or volumes cannot be heated
Solution Approach 1:
Multiple heating devices can be joined together using Velcro® strips or other fastening mechanisms on their outer surfaces. This merging capability allows small individual units to be combined into larger heating configurations, expanding the effective heating surface area while maintaining the temperature generation capability of each unit.
3Productivity
If permeable fabrics are used to allow air entry for oxidation, then heat generation is enabled, but the device becomes inactive when damp or wet
Solution Approach 1:
The device uses a flexible water-filled balloon with punctureable surface as the activation mechanism. The balloon material provides moisture resistance during storage and transport, preventing premature activation. When activated, the balloon is punctured to release water, initiating the exothermic reaction. This approach maintains reliability in moist environments while enabling heat generation through controlled activation.
4Temperature
If chemical combinations such as calcium oxide and phosphoric acid are used, then high temperatures are generated, but explosion risk and ecosystem eutrophication occur
Solution Approach 1:
The device changes the chemical parameters by using iron powder with controlled particle size (0.06mm to 1mm) and specific ratios of oxidizing agents (sodium chlorate, calcium peroxide, potassium permanganate) to achieve safe yet effective temperature generation. This parameter optimization prevents explosion risks while maintaining sufficient heat for disinfection and sanitization applications.
Solution Approach 2:
The device employs a composite formulation combining iron powder with multiple oxidizing agents (sodium chlorate, calcium peroxide, potassium permanganate) in specific proportions. This composite material approach distributes the chemical reaction across multiple components, reducing the risk of explosive reactions while achieving the desired temperature range and preventing harmful environmental effects.
5Ease of operation
If adhesive is applied to activate the device when seal is removed, then thermal therapy is enabled, but the adhesive may cause skin irritation or premature activation
Solution Approach 1:
The device removes the adhesive component entirely from the activation mechanism. Instead, activation is achieved by mechanically puncturing the water-filled balloon, which releases water to trigger the exothermic reaction. This extraction of adhesive eliminates skin irritation risks while maintaining simple operation through the puncture-activate mechanism.
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 device provides controlled heat for various applications, including thermal therapy, disinfection, and insecticidal uses, with adjustable temperature and duration, while ensuring safety and effectiveness across different surfaces and volumes.
Implementation Method 1
a composition that, in contact with a liquid, generates a controlled exothermal reaction, said composition consisting of a mixture of two chemical substances, wherein at least one of said substances is an acid and the other a base
Implementation Method 2
Oxidation reactions due to oxygen in the air and in the presence of humidity of certain metals in powder form such as iron for example
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3C
AI summary
The invention relates to a disposable autonomous thermal device that includes a body in the form of a container (1) comprising one or more sheets (5), and an exothermal composition (4) incorporated into the body of the container (1) and which comprises: one or more inorganic or organic acids, an acid of any acidic salt or a mixture of same; one or more inorganic bases selected from one or more hydroxides, a base of any basic salt or a mixture of same; and one or more moisture-absorbing materials, the device further comprising an aqueous liquid (6) separated from the exothermal composition (4), inside or outside the container (1), wherein, when the exothermal composition (4) of the container (1) is combined with the aqueous liquid (6), manually or by means of an auxiliary activating element (50), an exothermal neutralising reaction is produced.