Segmented Thermal Transfer Apparatus for Conformable Cooling
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Solution Overview
Problem
Designing an ice pack that can effectively alleviate swelling and pain across various body parts and for different patients is challenging due to the varying sizes and shapes of body regions.
Innovation Solution
A thermal transfer apparatus is manufactured using plastic sheets with protrusions and cavities filled with superabsorbent polymers and solutions, where the first thermal transfer media has a lower freezing point than the second, allowing for flexible conformability and efficient heat absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single uniform thermal transfer media is used throughout the ice pack, then the manufacturing process is simple, but the ice pack cannot effectively conform to various body parts of different sizes and shapes
Solution Approach 1:
The thermal transfer apparatus is divided into multiple compartments, each containing thermal transfer media with different freezing points. This segmentation allows each compartment to be optimized for specific body parts, enabling the ice pack to conform to various shapes and sizes while maintaining manageable manufacturing complexity through modular construction
Solution Approach 2:
Different regions of the ice pack contain thermal transfer media with locally optimized properties - specifically, different freezing points tailored to the thermal requirements of different body parts. This local quality differentiation enhances adaptability to various body parts while the overall structure remains relatively simple
2Temperature
If the thermal transfer media freezes completely at low temperatures, then heat absorption capacity is maximized, but the ice pack loses flexibility and conformability
Solution Approach 1:
The ice pack utilizes thermal transfer media with different freezing points in different compartments. When placed in a freezer, the media with higher freezing points freezes first, while media with lower freezing points remains liquid or semi-liquid, maintaining flexibility. This parameter differentiation allows the ice pack to achieve both maximum heat absorption (through frozen portions) and maintained conformability (through liquid portions)
Solution Approach 2:
The thermal transfer apparatus employs composite media consisting of multiple substances with different freezing points. This composite structure enables simultaneous phase states within the same apparatus - some portions frozen for maximum heat absorption, others liquid for flexibility - thereby resolving the contradiction between heat absorption capacity and conformability
3Adaptability or versatility
If multiple thermal transfer media with different freezing points are used in different compartments, then adaptability to different body parts is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process is simplified through segmentation by creating separate compartments for different thermal media. Each compartment can be independently filled with media of specific freezing points, allowing for standardized manufacturing procedures that are replicated across different body part configurations, thus managing complexity through modularity
Solution Approach 2:
The segmented compartment structure serves multiple functions: it enables different freezing point media to be contained separately, allows independent optimization for different body parts, and provides a scalable manufacturing approach. This multi-functionality of the compartment design addresses adaptability requirements while maintaining ease of manufacture through a universal structural template
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 apparatus efficiently absorbs heat and maintains temperature, providing effective cooling conformable to different body parts, with the first thermal transfer media remaining pliable while the second is solid, enhancing patient comfort and cooling duration.
Implementation Method 1
The first thermal transfer media comprises a first superabsorbent polymer and a first solution at least partially absorbed by the first superabsorbent polymer
Implementation Method 2
a first solution at least partially absorbed by the first superabsorbent polymer
Implementation Method 3
absorbing heat from the portion of the body
Implementation Method 4
cooling the thermal transfer apparatus to a temperature of less than or equal to the second freezing point, thereby forming a cooled thermal transfer apparatus
Data Source
AI summary
Methods of manufacturing and using a thermal transfer apparatus are provided. A method of manufacturing can comprise forming a first plastic sheet to define a first open cavity, at least partially filling the first open cavity with a first thermal transfer media comprising a first superabsorbent polymer and a first solution, forming a second plastic sheet to define protrusions and a second open cavity within each protrusion, and filling each second open cavity with a second thermal transfer media comprising a second superabsorbent polymer and a second solution. The method further comprises connecting a third plastic sheet to at least a portion of the second plastic sheet to enclose each second open cavity, positioning the connected second and third plastic sheets such that the protrusions extend into the first open cavity, and connecting the first plastic sheet and the third plastic sheet to enclose the first open cavity.