A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
See Application Data Sheet for list of cross-references, which are hereby incorporated herein by reference.
The present invention relates generally a composite material and more specifically to a composite material having a plurality of layers providing for thermal management.
Airplanes are heavily sealed and pressurized, thus when you're on the ground and the doors are closed you're basically the equivalent of the car sitting there in the parking lot with all the windows closed. The maximum temperature considered comfortable for passengers, preboarding, is generally as high as 90 degrees fahrenheit.
Certain airlines have procedures for crew members and agents to close window shades and open-air vents on the cabin any time the temperature climbs above 80 degrees. In an effort to maintain a comfortable temperature within the aircraft while an aircraft is parked at the gate, a PCA system is utilized. Preconditioned Air Units, or simply PCA units, are giant air conditioners that provide a comfortable environment inside an aircraft when the aircraft's own air conditioning system is not switched on. PCA units supply fresh conditioned air having comfortable temperature and humidity to the aircraft cabin when the aircraft is parked on the aircraft stand (or ramp).
Such a PCA system comprises ambient air that is treated (filtered, compressed, cooled, or heated) in a compressor system (basically an oversized air conditioner). The air is then fed directly into the interior of the aircraft cabin via an insulated hose. However, unlike domestic air conditioners that recirculate a lot of air, PCA units generally don't recirculate any air. They supply only fresh air to the aircraft after dropping its temperature, if it is summer season or, raising its temperature, if it is winter season.
In most cases the PCA system (unit and the insulated hose) are directly exposed to the outside environment. The extreme heat of the summer or the cold of the winter can cause major life cycle issues for a PCA system (unit and the insulated hose), such as, by way of example, negatively affecting an ability to transport the cold airconditioned air to the aircraft during the extreme heat of the summer or heated airconditioned air during the extreme cold of the winter.
There is a need for improved thermal management of the PCA unit and the insulated hose, especially given the weather extremes brought about by global warming.
The present invention provides varying embodiments of thermal management composite material overcome prior art problems noted above.
A first, second, and third embodiment includes thermal management composite material including three primary layers. These layers can include: a) a metalized material attached to a woven or non-woven material; b) an ultra-low thermally conductive material layer; and c) a metalized material attached to a woven or non-woven material. In aspects, the outer layer includes apertures or openings with zones between the apertures (also described herein as perforations) providing functionality to the outer layer and overall composite material.
A fourth embodiment includes a thermal management cover, wherein the cover is comprised of four layers: a) an outer woven or non-woven material layer, either of which comprises a plurality of perforations; b) a metalized material layer; c) an ultra-low thermally conductive material layer; and d) an inner woven or non-woven material.
A fifth embodiment includes a thermal management cover. The cover is comprised of one or more panels, wherein a panel is comprised of three primary layers: a) a fiber reinforced plastic board comprised of one or more of: carbon, fiberglass, and/or polyethylene terephthalate glycol, known as PETG or PET-G; b) one or more of polystyrene or another low conductive material; and c) fiber reinforced plastic board comprised of one or more of: carbon, fiberglass, and/or PETG.
A better understanding of the disclosed technology will be obtained from the following detailed description of the preferred embodiments taken in conjunction with the drawings and the attached claims.
In aspects, the metalized material 100 and/or 104 can be aluminum. In aspects, the metalized material 100 and/or 104 can have a radiation reflectivity of 80% or greater. The woven or non-woven material 100 and/or 104 can be by way of example only, para-aramid material such as a Kevlar®. The ultra-low thermally conductive material can be by way of example only a carbon felt.
In one embodiment, the composite material's innermost layer can comprise a metalized material. In one embodiment, the composite material's outermost layer can comprise a metalized material.
In one embodiment, an outer layer can be woven or non-woven material. For example, woven may include a canvas, nylon or polyester, ripstop among others. Non-woven can be polymer materials that are additively manufactured, injection molded, among other techniques, and/or other polymeric materials.
A sheet of the composite material can be laid flat, so that on each side of the material the outermost layer is metalized. The composite material can have all or a portion of each of the layers affixed and/or bonded to one another. For example, bonding of layers herein can include any known techniques including compression, adhesive, among others.
The composite material can be longer than it is wide.
In aspects, the outer layer or other layers can comprise small openings or apertures/perforations having a functionality and the zones between the opening in cases have functionality. In aspects, the aperture size can range from 0.01 mm to 10 mm depending on the application. Apertures can be applied in a uniform pattern (symmetrically) or be varied across the outer layer to alter the thermal signature/pattern when viewing the material through infrared lenses, cameras, etc. Apertures can also allow for the reflectivity of the second layer to reflect radiant heat away from inner layers. Apertures can be round or any other shape, an may be varied in shape across the outer layer to alter the thermal signature/pattern when viewing the material through infrared lenses, cameras, etc. The outermost layer can be a woven or non-woven material. By way of example, the woven can be a canvas, nylon or polyester riptstop, non-woven. It can be a polymer material that is additively manufactured, injection molded, etc. or other polymeric materials. In applications and aspects of the material, such openings can be critical to functionality, such as in the sense that colors or patterns can be added versus just the reflectivity of the second layer. They can also be critical in changing the thermal signature of anything being covered by the material, and it can change the thermal properties of the layers, layers, or overall composite material.
In one embodiment, the composite material can have a plurality of distance separated standoff spacer strips affixed to the outside layer of the composite material. The standoff spacer strips can comprise of a high temperature thermal resistant plastic or rubber. The standoff spacer strips can be flexible. The standoff spacer strips can be distance separated from one another and positioned widthwise across the composite material. By way of example,
In one embodiment, the composite material can be capable of being rolled. The composite material can be capable of being rolled widthwise making a long vertical tubelike formation. For example, in one embodiment the composite material can comprise a fastener that upon being attached maintains the vertical tubelike formation.
In varying embodiments, the fastener can be one or more of: a mechanical fastener, a magnetic fastener, a loop and hook fastener, a wire fastener, a snap fastener, a zipper fastener, an interlocking mushroom head fastener, and/or a male-female fastener, or any other suitable fastener as recognized by a skilled artisan.
The fastener can, once fastened, form a thermally resistant seal that reduces thermal air exchange between the outside air temperature and the inside air temperature within the tube-like or sleeve-like formation.
Two or more layers of the composite material can be attached and/or bonded to one another by one or more of: glue, lamination, stitching, staples, heat bonding, heat, and pressure bonding. In aspects, the composite material is rigid or substantially rigid. In other aspects, the composite material can be flexible, non-rigid, malleable, and/or deformable.
In aspects, the thermal protecting composite material is in the form of one of: a square, a rectangle, a triangle, or a cylinder, such as noted in
In aspects, the metalized material can be aluminum. In aspects, the metalized material can have a radiation reflectivity of 80% or greater. In aspects, the woven or non-woven material can be an aramid or para-aramid type fiber for example material available under the brand name Kevlar® or a similar material as recognized by a skilled artisan, such as Mylar®.
In aspects, the ultra-low thermally conductive material can be by way of example only a carbon felt.
In aspects, the composite material's innermost layer can be comprised of a metalized material. In aspects, the composite material's outermost layer can be comprised of a metalized material. In aspects, a sheet of the composite material can be laid flat, so that on each side of the material the outermost layer is metalized.
In aspects, the metalized material can be aluminum. In aspects, the metalized material can have a radiation reflectivity of 80% or greater. In aspects, the woven or non-woven material can be by way of example only, Kevlar®.
The cover can comprise four layers that can be attached or bonded to one another. In aspects, the ultra-low thermally conductive material layer can comprise ceramic or other ultra-low conductive material. In aspects, the metalized material layer can comprise aluminum. In aspects, the metalized material can have a radiation reflectivity of 80% or greater. In aspects, perforations in the outermost layer can alter the thermal signature of the cover and provide further functionality as described herein.
The cover can be in any shape, by way of example only, one of: a square, a rectangle, a triangle, an oval, and a circle. In aspects, the metalized material can be aluminum. In aspects, the metalized material can have a radiation reflectivity of 80% or greater. The woven or non-woven material can be by way of example only Kevlar. The ultra-low thermally conductive material can be by way of example only carbon felt. The composite material's innermost layer can be comprised of a woven or non-woven material.
The composite material's outermost layer, innermost layer, or both, can comprise woven or non-woven material, which can include a plurality of perforations. In aspects, a sheet of the composite material can be laid flat such that on each side of the material the outermost layer is perforated. The composite material can have all or a portion of each of the layers affixed or bonded to one another. The composite material can be longer than it is wide. The composite material can have a plurality of distance separated standoff spacer strips affixed to the outside layer of the composite material.
The standoff spacer strips can be comprised of a high temperature thermal resistant plastic or rubber. The standoff spacer strips can be flexible. The standoff spacer strips can be distance separated from one another and positioned widthwise across the composite material. The composite material can be capable of being rolled. The composite material can be capable of being rolled widthwise making a long vertical tubelike formation.
The composite material can comprise a fastener that upon being attached maintains the material in a vertical tubelike formation. The fastener can be one or more of: a mechanical fastener, a magnetic fastener, a loop and hook fastener, a wire fastener, a snap fastener, a zipper fastener, an interlocking mushroom head fastener, and/or a male-female fastener. In aspects, the fastener upon being fastened can form a thermally resistant seal that reduces thermal air exchange between the outside air temperature and the inside air temperature within the tubelike formation.
Two or more layers can be attached or bonded to one another by one or more of: a glue, a lamination, stitching, staples, heat bonding, heat, and/or pressure bonding.
In aspects, the outermost side of the cover can be white.
In aspects, the cover can comprise two or more layers that can be attached or bonded to one another. The cover can be of any shape by way of example one of: a square, a rectangle, a triangle, an oval, or a circle, such as illustrated in
In aspects, the cover can be affixed, bonded, connected, and/or attached to a PCA or air conditioning unit by way of example only: magnets, straps, and/or mechanical or cloth fasteners. In aspects, the thermal management cover can be laid over or otherwise cover a PCA or air conditioning unit without being affixed, bonded, connected, and/or attached to the PCA or air conditioning unit. In aspects, the cover can be releasably affixed, bonded, connected, and/or attached to a PCA or air conditioning unit. In aspects, the thermal management cover can be rigid or substantially rigid. In other aspects, the thermal management cover can be flexible, non-rigid, malleable, and/or deformable. The materials described herein can be used in conjunction with any electronic device or any material that is preferably insulated against heat and/or cold.
The composite material and cover can provide for a significant improvement in the thermal management of air flow that flows into and out of an aircraft or other vehicle. In one embodiment a cover can include perforations or other apertures. These perforations allow for both airflow, as well as reflection of radiant heat off of a second layer.
The apertures can range in sizes, including in various embodiments having sizing between 0.01 mm to 10 mm, depending in part on the underlying temperature management application. Moreover, the apertures can be in a unified pattern or shape or further embodiments can include variations in patterns allowing for altering a thermal signature or pattern when viewed through an infrared lens or camera. Similarly, the apertures can vary in shape, ranging from circular to oval, further providing for adjustment of heat signature and reflection of radiant heat.
For example, in one embodiment, the composite material overcomes the prior art limitations associated with thermal management, including management of a PCA unit and insulated hose, as well as other electronics.
The invention herein includes several Aspects.
The foregoing description of the specific embodiments so fully reveals the general nature of the invention that others can, by applying knowledge within the skill of the relevant art(s) (including the contents of the documents cited and incorporated by reference herein), readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Such adaptations and modifications are therefore intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein.
As used herein, the term “about” refers to plus or minus 5 units (e.g., percentage) of the stated value.
Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the inventions.
As used herein, the term “substantial” and “substantially” refers to what is easily recognizable to one of ordinary skill in the art.
It is to be understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only.
It is to be understood that while certain of the illustrations and figure may be close to the right scale, most of the illustrations and figures are not intended to be of the correct scale.
It is to be understood that the details set forth herein do not construe a limitation to an application of the invention.
Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description above.
Number | Date | Country | |
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63537086 | Sep 2023 | US | |
62424579 | Nov 2016 | US | |
62460946 | Feb 2017 | US | |
62460943 | Feb 2017 | US | |
62492382 | May 2017 | US | |
62492386 | May 2017 | US |
Number | Date | Country | |
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Parent | 18233630 | Aug 2023 | US |
Child | 18829010 | US | |
Parent | 17346235 | Jun 2021 | US |
Child | 18233630 | US | |
Parent | 17226684 | Apr 2021 | US |
Child | 17346235 | US | |
Parent | 16844990 | Apr 2020 | US |
Child | 17226684 | US |
Number | Date | Country | |
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Parent | 15820289 | Nov 2017 | US |
Child | 16844990 | US |