Multilayer cooling assemblies for thermal management

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Solution Overview

Problem

Current thermal management solutions for protective garments and athletic wear, such as phase change materials and airflow-promoting textiles, fail to provide sustained thermal comfort due to limited heat absorption and short-lived cooling effects.

Innovation Solution

Multilayer cooling assemblies incorporating a conductive film or foil heat-dissipating layer, optionally combined with phase change materials in compressible textile or foam layers, to actively dissipate body heat without compromising flexibility or comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If phase change material is used to improve thermal management, then heat absorption capacity is improved, but cooling duration is limited and weight increases

Engineering Contradiction:

Improveheat absorption capacityVSAvoidcooling duration

Core Design Contradiction:

Quantity of substanceVSDuration of action of moving object

Solution Approach 1:

The cooling assembly is divided into multiple functional layers: a compressible layer containing phase change material capsules, a heat-dissipating layer with conductive film, and an optional airflow-promoting layer. This segmentation allows each layer to perform its specific function optimally, with the phase change material providing sustained cooling over time rather than being depleted quickly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly combines multiple materials with complementary thermal properties: phase change material for latent heat storage, conductive film for heat transfer, and airflow-promoting structures for convective cooling. This composite structure addresses the limitation of single-material solutions by integrating the advantages of different thermal management mechanisms.

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If more phase change material is added to increase heat absorption, then thermal management performance is improved, but garment weight and bulk increase

Engineering Contradiction:

Improvephase change material massVSAvoidgarment weight

Core Design Contradiction:

Quantity of substanceVSWeight of moving object

Solution Approach 1:

The phase change material is encapsulated in flexible capsules that can be distributed throughout a thin compressible layer. The conductive heat-dissipating layer uses thin film structures to maximize thermal conductivity while minimizing weight. This approach provides effective thermal management without adding excessive weight or bulk to the garment.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The cooling assembly is designed to provide thermal management where it is most needed, with the compressible layer containing phase change material strategically positioned between the wearer and the external environment. The optional airflow-promoting layer with openings is positioned to maximize convective cooling efficiency at key locations.

Inventive Principle:

Principle #3Local quality

3Loss of energy

If airflow-promoting textiles are used to dissipate heat, then heat dissipation is improved, but cooling effect is marginal and short-lived

Engineering Contradiction:

Improveheat dissipation rateVSAvoidcooling duration

Core Design Contradiction:

Loss of energyVSDuration of action of moving object

Solution Approach 1:

The assembly merges three thermal management mechanisms: phase change material for latent heat storage, conductive film for heat transfer, and airflow promotion for convective cooling. This combination creates a synergistic effect where each mechanism supports the others, providing sustained cooling that lasts throughout the day rather than depleting quickly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The phase change material continuously absorbs heat as it melts, providing sustained cooling over an extended period. The conductive film continuously transfers heat from the wearer to the external environment, and the airflow-promoting layer continuously facilitates convective cooling. This continuous action ensures prolonged thermal comfort without interruption.

Inventive Principle:

Principle #20Continuity of useful action

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 multilayer cooling assemblies enhance thermal comfort by maintaining a cool feeling for an extended period, increasing heat flux and reducing thermal discomfort, while maintaining the mechanical and comfort properties of the garments.

Implementation Method 1

the conductive film/foil transports heat from a wearer's body to an external environment

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a textile layer that includes a phase change material. PCMs have a high heat of fusion and are capable of storing and releasing energy at known, consistent temperatures

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20240399704A1Multilayer cooling assemblies for thermal management

Publication Date: 2024.12.05 ALEXIUM INC

AI summary

Described herein are multilayer cooling assemblies that include at least two compressible layers and a heat-dissipating layer, which imparts beneficial thermal management properties without a significant adverse effect on flexibility and/or cushioning properties, so the assemblies remain suitable for use in protective garments, athletic equipment, performance apparel, and other clothing where they will contact a wearer and where wearer comfort is important.