A THERMAL STORAGE AND TRANSFER DEVICE

Abstract: An article of manufacture having a heat sink provided with an endothermic agent which is non-reversible and absorbs large quantities of heat.

Description: TITLE: A THERMAL STORAGE AND TRANSFER DEVICE The present invention relates to composite endothermic materials and the method for constructing the same and, more particularly, it relates to the provision of certain acids and their salts, certain bases and their salts, and certain organic compounds as endothermic reaction agents for use in such composite endothermic materials for the control of temperature and heat in cooling systems for electronic components, structures, surfaces and the like, which are sensitive to changes in temperature . Often, active cooling of such electronic components, particularly delicate TR modules, Impatt diodes, data recorders and the like, is not feasible and even when it is feasible, it reguires continuous high energy cooling which taxes other attached engineering systems such as those typical to missiles, aircraft and related combat systems . Generally, endothermic devices employ phase change material compositions (PCM's). The conventional PCM materials are largely solid or fluidic in nature, for example, being liquids, quasi-liquids, or solids such as a waxes or other meltable compositions. Over time, the conventional PCM's have proven to suffer from many technical problems as well as problems in their use and application. These problems include relatively low latent heat of fusion, the inability to control the shape and form of such fluid PCM materials as well as the evenness of heating and cooling. Other problems are the need to provide a containment housing and the stress placed on the housing, resulting in frequent rupture and spillage of the PCM; the hazard to life and property due to PCM's high heat content and fla mability; and lastly, the uneven heating or cooling hysteresis. For these critical reasons and others, PCM's as thermal storage mediums have a long history of failure and nonuse in commercial and military applications. In Applicant's patent, U.S. Patent No. 4,446,916, Applicant has disclosed what he calls a composite fabric endothermic material (CFEM) , providing devices especially suitable as heat sinks for aerospace and military use. The patented CFEM provides an improved heat sink that absorbs heat at the melting temperatures of a compound embedded within a fibrous mesh or matrix. The CFEM preferably comprises a phase change material which is held by capillary action and chemical adhesions to the fibers of the matrix. As a result a greatly increased surface area for heat transfer is obtained. The normal PCM's can spill hot fluids onto a human's skin, resulting in serious third degree burns due to the sticky contact nature of many hot wax and plastic phase change material and the high heat and sticky adherence to skin. Ruptured non-CFEM or liquified wax PCM disks spill their content and cause flash fires, which spread as the PCM pours out during heating in ovens. Wax-filled disks are prone to fires, which can spread and flow out of stoves; however, CFEM fabric absorbs and contains liquid PCM, making it difficult to ignite. The Applicant has now discovered that while the patented CFEM is suitable for use in food and in military applications. The scope of its suitability for other commercial and civilian applications is limited and is particularly not suitable for high temperature application, flight recorders and oven sensors. In Applicant's pending U.S. Patent Application Serial No. 08/183,199, the disclosure and contents of which are incorporated herein as if more fully set forth, addresses the need for an improved CFEM for use in many commercial and civilian applications, particularly for food, home and commercial packaging operations. In this application, improved CFEMs capable of being employed in a variety of commercial applications such as in the food industry where a need has arisen for heat retaining or heat insulating containers, packages and thermal storage devices. The endothermic agents, i.e. heat absorbing agents suggested in Applicant's pending U.S. Patent Application Serial No. 08/183,199, have accomplished some protection from high temperatures through the physical phenomenon of the absorption of the latent heat of fusion, wherein the appropriate crystaline substance absorbs a quantity of heat to melt without a temperature rise to its surroundings. The phenomenon of the absorption of the latent heat of fusion is reversible and will provide protection when heat generation occurs more than once in the application. However, the Applicant has now discovered that there are many problems inherent in the use of such heat absorbing agents as described above. By virtue of the fact that the phenomena of the earlier application need to be reversible so that heat absorption occurs more than once, they operate in relatively low temperature ranges. In other words they are capable of absorbing not more than 200 cal/g . Thus, they can remove heat for only a short period of time and only at temperatures not exceeding 326°F. Consequently, they are not effective for applications requiring cooling at very high temperatures and for long periods of time as would be needed, for example, in airplane crashes, missile electronics, spacecraft devices, power supplies, data recorders employed as aircraft components, and combat devices and in commercial uses as oven sensors, fire walls and automobile exhaust systems. Latent heat of fusion agents (PCM's) tend to burn at relatively high temperatures raising the overall heat content of the system. In addition, the reversibility of the phenomena virtually guarantees that these agents will also transfer heat into the environment once the environ- ment is at a lower temperature than the respective temperatures of the agents. Consequently, not only do these agents operate as heat absorbing agents, but they can also act as heat transfer agents to cause the very damage to the electronic components that these agents were intended to prevent in the first place. It is, therefore, the object of the present invention to overcome the disadvantages and, in particular, to provide for nonreversible heat absorbing applications. It is a further object of the present invention to provide improved coolant media capable of being employed in a variety of applications such as in airplane crashes, missile electronics, spacecraft devices, power supplies, data recorders employed as aircraft components, and combat devices, as well as in commercial uses such as oven sensors and the like. It is a particular object of the present invention to provide heat absorbing agents capable of absorbing heat at temperatures above 300°F. It is another object of the present invention to provide endothermic mechanisms utilizing the chemical reaction of latent heat of formation or decomposition. These objects as well as others will be found in detail in the following disclosure. The present invention utilizes nonrecyclable, nonreversible endothermic chemical reactions, which make use of the latent heat of decomposition and dehydration reactions to provide new, improved and, particularly, efficacious endothermic cooling systems. What makes these nonrecyclable, nonreversible endothermic chemical reactions particularly appropriate is that they have temperatures of reaction suitable in the temperature range used in the design of flight data recorders, electronics and related devices, i.e. the heat sink structure must be capable of maintaining an interior temperature of between 100°C and 300°C while operating in an external temperature range of 600 to 1100°C and act only as a heat sink and not as a heat generator. The compounds developed in the present invention provide endothermic chemical reactions, which are extremely stable in diverse environments, have long shelf life and high latent heats of reaction. Preferably, the compounds contemplated by the present invention include: boric acid and some borate salts, salts of acetic acid and formic acid, hydroxides of lithium, calcium, aluminum and sodium, carbonate salts of magnesium, lithium and silicon, paraldehyde and paraformaldehyde as well as trioxane, and hydrated salts. Specifically, the present invention makes a broad claim to endothermic agents which thermally decompose into any of the following: 1. Hydrated salts which endothermically decompose into water and salt. 2. Paraldehyde, trioxane and paraformaldehyde which endothermically decompose into formaldehyde. 3. Low molecular weight acids which endothermically decompose into water and oxides. 4. Carbonate salts which decompose into carbon dioxide and an oxide. EXAMPLES I. The following illustrates the endothermic reaction and heat absorption of the aforementioned hydroxides when subject to a temperature of reaction below 1100°C. Lithium hydroxide (LiOH) : LiOH melts at 450 °C 2LiOH decomposes to —► Li 2 0 + 2H 2 0 at 1000°C having absorbed 686 cal/gm Sodium Hydroxide (NaOH) : 2NaOH decomposes to —► to Na 2 0 + 2 H 2 0 at 1000 °C absorbing 324 cal/gm during the decomposition. Aluminum Hydroxide (A1(0H) 3 ): 2A1 (OH) 3 decomposes to -→ A1 2 0 3 + 3 H 2 0 at 1000 °C absorbing 342 cal/gm; and It will be seen from the foregoing that the specified hydroxides decompose at their specified temperatures of reaction to form metal oxides while absorbing large quantities of latent heat of reaction. In some reactions a higher amount of latent heat is absorbed by the melting of the starting hydroxides and the melting of the produced oxides. II. The following illustrates the endothermic reaction and heat absorption of the aforementioned salts when subject to a temperature reaction below 1100°C. Calcium Carbonate (CaC0 3 ) : CaC0 3 decomposes to —► CaO + C0 2 at 840 °C having absorbed 425.6 cal/gm Silicon Carbonate (SiC0 3 ) : SiC0 3 decomposes to -→ SiO + C0 3 at 1100 °C absorbing 380 cal/gm Magnesium Carbonate (MgC0 3 ) : NOTE: The starting endothermic material is composed of Magnesium Carbonate (MgC0 3 ) , Mg(OH) 2 , and H 2 0, i.e.: n MgC0 3 : n Mg(OH) : n H 2 0) n MgC0 3 : n Mg(0H) 2 : n H 2 0 decomposes to —► n MgO + C0 2 and n H 2 0 at 300 °C absorbing 285 cal/gm. Lithium Carbonate (Li 2 C0 3 ) Li 2 C0 3 decomposes to —► Li 2 0 + C0 2 at 1310°C having absorbed 400 cal/gm. III. This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of sodium bicarbonate absorbing in excess of 350 cal/gm between 120°C and 310°C. NaHC0 3 > NaOH + C0 2 T ~ 270°C ΔH° ~ 363 cal/g IV. This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of sodium carbonate absorbing in excess of 320 cal/gm between 200°C and 375°C. MW = 84.0 NaHC0 3 > NaOH + C0 2 Δ H ° = 30 . 45 Kcal/mol ΔH f ° : -226 . 5 -102 -94 . 05 ΔH° = (30,450 cal/mol)/(84 g/mol) = 363 cal/g IV. In particular, it has been found that boric acid absorbs large amounts of heat when decomposing, because boric acid decomposes in stages over a range of temperature to produce boron oxide and water while absorbing nearly 400 cal/gm. Borate salts act similarly for effective heat absorption results. The following illustrates the reactions of Boric acid while absorbing the appropriate latent heats of reaction: This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of boric acid absorbing in excess of 400 cal/gm between 120°C and 350°C. MW = 62 169°C 300°C 2H 3 B0 3 > (2HB0 2 + 2H 2 0) > B 2 0 3 + 3H 2 0 ΛH f : -260 mp = 236°C -302 -57.8 Kcal/mol ΔH° = 53.6 Kcal/2 mol H 3 B0 3 ΔH = (53,600 Kcal/2 mol) (2(62) g/2 mol > 432 cal/g VI. The following illustrates the endothermic reaction and heat absorption of hydrated salts when subject to a temperature reaction below 1100°C. The following hydrate salts provide effective endothermic cooling from 60 - 200°C: LiCl • 3H 2 0 > LiCl + 3H 2 0 (-313 . 5 ) (-97 ) ( -173 ) ΔH, = 42 . 4 Kcal/mole MW = 96 . 39 ( ( 42 . 4 Kcal/mole) / 96 . 39 MgCl 2 • 6H 2 0 > MgCl 2 + 6H 2 0 (-454) (-266) (346.8) ΔH Γ is negative. MgS0 4 • 7H 2 0 > MgS0 4 + 7H 2 0 (-808.7) (-305.5) (-404.6) MW = 246.37 (98.6 Kcal/mole) /246.37 = 400.2 cal/gm (Na) 2 S0 4 • 10H 2 0 > (Na) 2 S0 4 + 10H 2 0 (-1033.48) (-330.9) (-578) ΔH r is 124.58 Kcal/mole MW = 354.12 (124.58 Kcal/mole) /354.12 = 351.8 cal/gm A1 2 0 3 • 3H 2 0 > A1 2 0 3 + 3H 2 0 (-613.7) (-384.84) (-173.4) ΔH Γ = 55.46 Kcal/mole MW = 155.96 (55.46 Kcal/mole) /155.96 = 355.6 cal/gm A1 2 (S0 4 ) 3 • 18H 2 0 > A1 2 (S0 4 ) 2 + 18H 2 0 (-2118.5) (-820.98) (1040.4) ΔH r = 257.12 Kcal/mole MW = 666.14 (257.12 Kcal/mole) /666.14 = 385.98 cal/gm A1F 3 • 3H 2 0 > A1F 3 + 3H 2 0 (-349.1) (-311) (173.4) ΔH. = 64.7 Kcal/mole MW = 137.98 (64.7 Kcal/mole) /137.98 = 468.9 cal/gm A1N0 3 • 9H 2 0 > A1N0 3 + 9H 2 0 (-897.34) (-273.65) (-520.2) ΔH r = 103.49 Kcal/mole MW = 375.01 (103.49 Kcal/mole) /375.01 = 275.98 cal/gm This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of lithium chloride trihydrate absorbing in excess of 440 cal/gm between 90°C and 150°C. MW = 96.4 98°C LiCl 3H 2 0 > LiCl + 3H 2 0 ΔH f °: -313.5 -97.7 -57.8Kcal/mol ΔH° = 42.4 Kcal/mol ΔH° = 440 cal/g This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of lithium nitrate trihydrate absorbing in excess of 320 cal/gm between 50°C and 120°C. MW 123 at 61 ° C LiN0 3 • 3H 2 0 > LiN0 3 + 3H 2 0 ΔH f °: -328.6 -115.3 -57.8 ΔH° = 39.9 Kcal/mol ΔH° = 324 cal/g This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of sodium carbonate decahydrate absorbing in excess of 320 cal/gm between 20°C and 80°C. MW = 266 loses H 2 0 at 34 ° C Na 2 C0 3 • 10H 2 0 > Na 2 C0 3 ( S ) + 10 H 2 0 ΔH f ° : -975 . 6 -270 -57 . 8 Na 2 C0 3 stable ΔH° = 127.6 Kcal/mol ΔH° = 480 cal/g This reaction will provide Endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of Sodium Borate Decahydrate yielding in excess of 350 cal/per gm between 200°C and 375°C. MW = 382 320°C Na 2 B 4 0 7 • 10H 2 O > Na 2 B 4 0 7 + 10H 2 O ΔH f °: -1497 -777.7 -57.8 ΔH° = 141.3 Kcal/mol ΔH° = 370 cal/g This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of epsom salt hydrated absorbing in excess of 350 cal/gm between 120°C and 250°C. MW = 246.5 Epsom Salt -6H 2 0 150°C -7H 2 0 200°C MgS0 4 • 7H 2 0 > MgS0 4 + 7H 2 0 -808.7 -305.5 -58.7 ΔH° = 92.3 Kcal/mol ΔH° = 374 cal/g The following reactions will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of beryllium sulfate hydrate absorbing in excess of 300 cal/gm between 90°C and 450°C. MW = 177.1 100°C BeS0 4 • 4H 2 0 > BeS0 4 • 2H 2 0 + 2H 2 0 -576 . 3 -433 . 2 -57 . 8 BeSo 4 • 2H 2 0 > BeS0 4 + 2H 2 0 ΔH ° = 31 . 6 -433 . 2 -286 . 0 -57 . 8ΔH ° = 31. 6 ΔH° = 334 cal/g (total) This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of hydrated sodium phosphate absorbing in excess of 300 cal/gm between 80°C and 150°C. MW = 377 Na 3 P0 4 • 12H 2 0 > Na 3 P0 4 + 12H 2 0 ΔH f °: -1309 -460 -57.8 ΔH° = (156.4 Kcal/mol) / (377 g/mol) = 412 cal/g This reaction will provide endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of calcium chloride hexahydrate absorbing in excess of 300 cal/gm between 220°C and 350°C. MW = 219 200°C CaCl 2 • 6H 2 0 > CaCl 2 + 6H 2 0 ΔH f : -623.2 -190 -57.8 Kcal/mol ΔH° = 86.4 Kcal/mol ΔH° = 395 cal/g This reaction will provide Endothermic cooling of electronic devices and other surfaces and structures by the thermal decomposition of zinc sulfate heptahydrate absorbing in excess of 300 cal/gm between 220°C and 350°C. MW = 288 280°C ZnS0 4 • 7H 2 0 > ZnS0 4 + 7H 2 0 ΔH,°: -735.1 -233.8 -57.8 Kcal/mol ΔH° = 96.7 Kcal/mol ΔH° = 336 cal/g Other reactions are the decomposition of paraldehyde and paraformaldehyde which, likewise, result in relatively large scale endothermies. Several of the reaction products of the combination of the aforementioned material such as the lithium acetate and formates may also be used. The graphs 4 and 5 show the natural delay in temperature rise for lithium formate and lithium acetate thermal decomposition reactions. It has also been found that the salts of acetic acid and formic acid result in large scale endothermic reactions and absorptions of large quantities of heat. The compounds of the present invention may be employed in composite fabric carriers or matrices of the type discussed in Applicant's aforementioned application or in the prior noted patent. In testing these compounds, flight data recorders were provided in a container forming a heat sink structure. Waferlike cakes formed of boric acid were located in metal enclosures fit within the heat sink structure. The boric acid wafers were formed by compression into rectangular wafers and cakes which fit neatly into the metal enclosures of the heat sink structure. The heat sink structure was then connected with the circuit board of a memory control system. The accompany- ing Graphs 1 and 2 show the natural rise in temperature of a conventional heat sink military flight recorder as compared to the same flight recorder's thermal performance with a boric acid endothermic heat sink formed in accordance with the present invention. Graph 3 shows the use of a hydrated salt (MgS0 4 • 7H 2 0) resulting in a strong cooling effect as applied to the flight recorder of Graph 1. Aluminum hydroxide (A1(0H) 3 ) devices work best as a high temperature endothermic temperature control agent. When Al(OH) 3 decomposes, it leaves behind a strong thermal insulation layer of A1 2 0 which further abates temperature rise through decomposition product to the heat sink device. Other applications of the present invention presented for example and not as limitation include: temperature control coatings, wraps and liners as well as thermal protection for metal and plastic structures; cooling for electronics, oven sensors, missile skins, exhaust pipes, thermal protection in race cars, fire walls and related equipment. Unlike salt hydrates discussed above, hydroxides or carbonates may be stored almost indefinitely provided they are not exposed to temperatures at or above the temperature of reaction. When exposed to reduced pressure and some heat, hydrates tend to lose H 2 0, making them less likely to be fully effective as cooling agents in some aircraft applications, unless properly hermetically sealed, with allowance to permit venting of water vapor at the temperature of reaction. The compounds are commercially available and inexpensive. They may be easily incorporated in and integrated with CFEMs, metal mesh matrices, silicon or carbon fiber or microencapsulated and macroencapsulated in porous silica or porous carbon bodies. The agents may be shaped in the form of enclosures, chips or cakes which can be incorporated in shaped bodies and thus, can be formed in shape and dimension as required. In some applications the agents may be formed into gels and pastes. The special compounds of the present invention provide unforeseen, critical benefits in that the massive quantities of heat are readily absorbed, in a unidirectional reaction. And that once so absorbed, do not reverse and, therefore, cannot act as a heat generator. Thus, protection for sensitive devices is absolute. Above all, all of these compounds produce environmentally harmless vapor products during decomposition and even at elevated temperatures. Various modifications and changes have been disclosed herein, and others will be apparent to those skilled in this art. Therefore, it is to be understood that the present disclosure is by way of illustrating and not limiting of the present invention.

Claims: CLAIMS 1. An article of manufacture for the control of temperature and heat from a heat generating device comprising a heat sink having an endothermic agent, said endothermic agent being selected from the group of hydroxides consisting of aluminum hydroxide, calcium hydroxide, sodium hydroxide, potassium hydroxide and lithium hydroxide and their mixture. 2. An article of manufacture for the control of temperature and heat from a heat generator comprising a heat sink having an endothermic agent comprising boric acid. 3. An article of manufacture for the control of temperature and heat from a heat generating device comprising a heat sink having and endothermic agent, said endothermic agent being selected from the group of organic compounds consisting of paraldehyde, paraformaldehyde and trioxane and their mixture. 4. An article of manufacture for the control of temperature and heat from a heat generating device comprising a heat sink having an endothermic agent, said endothermic agent being selected from the group of salts consisting of lithium formate, lithium acetate, lithium carbonate, calcium carbonate, silicon carbonate, magnesium carbonate, sodium bicarbonate, salts of acetic acid, salts of formic acid, salts of boric acid and their mixtures. 5. An article of manufacture for the control of temperature and heat from a heat generating device comprising a heat sink having an endothermic agent, said endothermic agent being selected from the group of hydrate salts consisting of lithium chloride trihydrate, lithium nitrate trihydrate, sodium carbonate decahydrate, sodium borate decahydrate, hydrated epsom salts, magnesium nitrate hexahydrate, beryllium sulfate tetrahydrate, sodium phosphate, dodecahyrdate, calcium chloride hexahydrate, and zinc sulfate heptahydrate, magnesium chloride hexahydrate, sodium sulfate decahydrate, aluminum oxide trihydrate, aluminum sulfate decaoctahydrate, aluminum flouride trihydrate, aluminum nitrate nonahydrate and their mixtures. 6. The article of manufacture according to Claim 1, wherein the heat sink comprises a retaining matrix, packaging, enclosure or structure to form a heat sink or temperature control surface, device or structure. 7. The article of manufacture according to Claim 2, wherein the heat sink comprises a retaining matrix, packaging, encapsulation, enclosure or structure to form a heat sink or temperature control surface, device or structure. 8. The article of manufacture according to Claim 3 wherein the heat sink comprises a retaining matrix, packaging, encapsulation, enclosure or structure to form a heat sink or temperature control surface, device or structure. 9. The article of manufacture according to Claim 4, wherein the heat sink comprises a retaining matrix, packaging, encapsulation, enclosure or structure to form a heat sink or temperature control surface, device or structure. 10. The article of manufacture according to Claim 5, wherein the heat sink comprises a retaining matrix, packaging, encapsulation, enclosure or structure to form a heat sink or temperature control surface, device or structure.

Applicants: HAYES CLAUDE Q C, HAYES, CLAUDE, Q., C.
Application year: 1997
Main classification: B32B17
IPC codes: B32B17, C01D1, C01D7, C01D15, C09K5, F24J1, F28D20, H01L23