Patent Publication Number: US-9402427-B2

Title: Self-contained thermal distribution and regulation device for cold weather apparel

Description:
BACKGROUND 
     The present invention relates generally to clothing for thermal regulation of the human body, and more particularly, to a self-contained thermal distribution and regulation device for cold weather apparel. 
     The need to maintain body temperature exists where human activities are conducted in extreme temperature environments. Very cold environments are often encountered by individuals who pursue outdoor winter activities such as snowmobilers, motorcycle riders, hunters, snow skiers, and workers, such as construction and highway workers, who work outside during the winter. Also, individuals who work in more pedestrian cold environments, such as refrigerated containers are exposed to extreme cold temperatures. 
     The most prevalent method today for individuals who are exposed to extreme cold temperatures or pursue outdoor winter activities to maintain their body temperature is to wear several layers of clothing, commonly referred to as “layered clothing” or “layering”. Wearing several layers of clothing on top of each other, lowers heat losses to match the body&#39;s internal heat production and protect from environmental elements. Some of the layers have different, largely non-overlapping, functions. Using more or fewer layers, or replacing one layer but not others, allows for flexible clothing to match the needs of each situation. For example, two thin layers can be warmer yet lighter than one thick layer, because the air trapped between layers serves as “thermal insulation”. 
     Layering typically consists of about three layers of clothing that are identified as the inner or base layer, the mid or insulating layer, and the shell or outer layer. The base layer is typically against the wearer&#39;s skin to manage moisture and keep the wearer&#39;s skin dry. The outer layer protects the wearer from environmental conditions such as wind, rain, and snow and also serves as protection over the base and insulating layers. The insulating layer provides warmth to the wearer and may be considered the most important layer worn. 
     The insulating layer is what keeps the wearer warm while they participate in activities in the cold. Materials used for the insulating layer vary widely; from materials used for over a century, such as wool and down, to cutting edge fleece and polypropylene and polyester materials. Additionally, the insulating layer is thick as compared to the other layers, to reduce conductive heat loss. However, heat flow is an inevitable consequence of contact between objects of differing temperature, and thus over time the wearer&#39;s clothing may not sufficiently match their body&#39;s internal heat production and they may get cold. 
     An effort to improve the insulating layer&#39;s ability to lower heat losses to match the body&#39;s internal heat production is realized in so-called “heated clothing” or “heated thermal clothing”. In one example, an item of heated clothing such as a vest or jacket, may comprise two layers of a synthetic material, such as a synthetic fleece, with a heating layer sandwiched between the two fleece layers. Alternatively, an item of heated clothing may comprise a soft inner or base layer, with an outer layer for protection from environmental elements, with the heating layer sandwich between the two layers. 
     In heated clothing, the heating layer typically comprises a heat element system connected to a heat source. There are several heating technologies employed for the heat element system including copper wire, nichrome wire, metal “mesh”, carbon-embedded fabric, and carbon fibers. 
     An electrical heat source is connected to the heat element system, for powering system. For example in heated clothing designed for use on vehicles such as motorcycles and snowmobiles, a 12 volt electrical connector for connecting the heated garment to the vehicle&#39;s battery is used. Some heated garments are provided with a well-known cigarette lighter plug, so that the garment can be plugged into the vehicle&#39;s cigarette lighter receptacle. A disadvantage of this type of heated clothing is that the wearer must be in close proximity to an external electrical power source. 
     For electrically powered heated clothing designed for use where no external power source is available, batteries, including rechargeable batteries, are used to power the heat source. A disadvantage of batteries, both rechargeable and non-rechargeable, is they have a very limited life span, typically only hours before the batteries must be either replaced with new batteries or recharged. A disadvantage of rechargeable batteries, such as nickel metal hydride or lithium batteries, is that their “battery memory” diminishes over time and reduces the battery&#39;s capability to recharge further reducing the useful hours of the battery. Also, there are health concerns about the electrical currents of electrically powered heated traveling in close proximity to the wearer&#39;s body and what effects those electrical currents may have on the wearer&#39;s body. 
     BRIEF SUMMARY 
     In one embodiment, a thermal distribution and regulation device for a garment that includes a self-contained heat source and a heat manifold contacting a surface of the heat source. The heat manifold is mechanically adjusted relative to the heat source to control the contact surface area between the heat source and heat manifold for regulating heat conducted from the heat source. The device also includes a heat conductor in thermal communication with the heat manifold. The heat conductor conducts heat from the heat manifold along the garment. 
     In another embodiment a thermal distribution and regulation system for a garment that includes a self-contained heat source and a heat manifold extending about a surface of the heat source and engaging the surface. The heat manifold is mechanically adjusted relative to the heat source to control the contact surface area between the heat source and heat manifold for regulating heat conducted from the heat source. The system also includes more than one heat conductor in thermo-mechanical communication with the heat manifold and extending along the garment for warming the garment. 
     In another embodiment, a thermal distribution and regulation system for a garment that comprises a self-contained heat source comprising one of a chemical, liquid, and catalytic heat source. A heat manifold extends about a surface of the heat source. The heat manifold is mechanically adjusted relative to the surface of the heat source to control the contact surface area between the heat source and heat manifold to regulate heat conducted from the heat source. The heat manifold configured to engage the surface of the heat source at more than one predetermined location to prevent inadvertent movement between the heat source and heat manifold to control heat conducted from the heat source to the heat manifold. The system also includes a plurality of heat conductors coupled to the heat manifold and affixed to the garment. An end of each of the plurality of heat conductors is coupled to the heat manifold for conducting heat from the heat manifold to the garment, to warm the garment. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a simplified diagram showing an exemplary embodiment, partially in phantom, of a thermal distribution and regulation system for a garment; 
         FIG. 2  is a fragmentary cross-sectional view taken along lines  2 - 2  of  FIG. 1  showing a heat conductor of the exemplary embodiment of the thermal distribution and regulation system for a garment secured to a garment; 
         FIG. 3  is a simplified fragmentary, partially cut-away diagram showing an exemplary embodiment of a heat manifold contacting a surface of a heat source of a thermal distribution and regulation system for a garment; 
         FIG. 4  is a simplified fragmentary, diagram showing an exemplary embodiment of a heat manifold contacting a surface of a heat source of a thermal distribution and regulation system for a garment; and 
         FIG. 5  is a cross-sectional view taken along lines  5 - 5  of  FIG. 4  showing an exemplary embodiment of a heat conductor coupled to a heat manifold in contact with a surface of a heat source. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is made for the purpose of illustrating the general principles of the invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. 
     In one embodiment, a thermal distribution and regulation device for a garment that includes a self-contained heat source and a heat manifold contacting a surface of the heat source. The heat manifold is mechanically adjusted relative to the heat source to control the contact surface area between the heat source and heat manifold for regulating heat conducted from the heat source. The device also includes a heat conductor in thermal communication with the heat manifold. The heat conductor conducts heat from the heat manifold along the garment. 
     In another embodiment a thermal distribution and regulation system for a garment that includes a self-contained heat source and a heat manifold extending about a surface of the heat source and engaging the surface. The heat manifold is mechanically adjusted relative to the heat source to control the contact surface area between the heat source and heat manifold for regulating heat conducted from the heat source. The system also includes more than one heat conductor in thermo-mechanical communication with the heat manifold and extending along the garment for warming the garment. 
     In another embodiment, a thermal distribution and regulation system for a garment that comprises a self-contained heat source comprising one of a chemical, liquid, and catalytic heat source. A heat manifold extends about a surface of the heat source. The heat manifold is mechanically adjusted relative to the surface of the heat source to control the contact surface area between the heat source and heat manifold to regulate heat conducted from the heat source. The heat manifold configured to engage the surface of the heat source at more than one predetermined location to prevent inadvertent movement between the heat source and heat manifold to control heat conducted from the heat source to the heat manifold. The system also includes a plurality of heat conductors coupled to the heat manifold and affixed to the garment. An end of each of the plurality of heat conductors is coupled to the heat manifold for conducting heat from the heat manifold to the garment, to warm the garment. 
     Referring now to  FIG. 1  there is shown, generally at  100 , an exemplary embodiment of a thermal distribution and regulation system for a garment. In the embodiment, shown, the thermal distribution and regulation system comprises a heat manifold  102  coupled to a heat source  104 . A plurality of heat conductors  106  are coupled to the heat manifold  102  and affixed to a garment  108 . 
     As shown in  FIG. 1  and  FIG. 2 , the garment  108  comprises a vest. However it is to be understood that the garment  108  may be any desired or suitable article of clothing. For example, the garment  108  may comprise a jacket, shirt, or insulated shirt. Typically, but not necessarily, the garment  108  comprises an article of clothing that is worn over the torso and that may be used as an insulating layer, such as a vest or jacket. Alternatively, the garment  108  may comprise an article of clothing that is worn over the hands such as gloves or mittens. 
     Referring to  FIGS. 3-5 , in the exemplary embodiment shown, the heat source  104  of the system  100  may optionally comprise any one of a chemical, liquid, and catalytic heat source known in the art. In the exemplary embodiment, the heat source  104  comprises a commercially available catalytic heat source, or heater, that is designed to fit in a pocket of a user&#39;s clothing or to be held in their hand. As shown in  FIG. 1 , the garment  108  includes a pocket  110  dimensioned to retain the heat source  104  and at least a portion of the heat manifold  102 , while allowing a user to access the manifold  102  and heat source  104 . The heat source  104  uses a commercially available replenishable fuel  112  to facilitate the catalytic burning process that generates heat. The fuel  112 , may comprise naphtha, butane, or any suitable fuel. 
     In one embodiment, the heat manifold  102  is configured to extend about an outer surface  114  of the heat source  104 . In one exemplary embodiment, the heat manifold  102  includes a top end  116  and a bottom edge  118  that forms an aperture  120  configured to receive the heat source  104 . In an embodiment of the invention, the heat manifold  102  is formed complementary to the outer surface  114  of the heat source  104  for efficient heat transfer from the heat source  104  to the manifold  102 . 
     As shown in  FIG. 5 , in one embodiment, the heat source  104  has an annular cross-sectional configuration. Accordingly, the head manifold  102  is formed with an annular cross-sectional configuration, so that an inner surface  122  of the manifold  102  extends about the outer surface  114  of the heat source  104  an in close proximity thereto. In one embodiment, the heat manifold  102  is dimensioned with a length L M  that is approximately equal to or less than a length L S  of the heat source  104 . Configuring the heat manifold  102  with a length L M  that is approximately equal to or less than the length L S  of the heat source  104  allows the heat manifold  102  to substantially enclose the heat source  104  when the manifold&#39;s bottom edge  118  is aligned with or proximate to a bottom  124  of the heat source  104 . When the heat manifold&#39;s bottom edge  118  is aligned with or proximate to the bottom  124  of the heat source  104 , heat transfer from the heat source  104  to the heat manifold  102  is maximized. 
     Continuing with  FIGS. 3-5 , the heat manifold  102  is mechanically adjusted relative to the outer surface  114  of the heat source  104  to control the contact surface area between the heat source  104  and heat manifold  102  to regulate heat conducted from the heat source  104  to the manifold  102 . Thus, adjusting the heat manifold  102  along the heat source&#39;s length L S  functions as a mechanical thermostat for regulating the heat conducted from the heat source  104  to the manifold  102  and on to the garment  108 . 
     To provide a user with a substantially precise means of controlling the heat conducted from the heat source  104  to the garment  108 , in one embodiment the outer surface  114  of the heat source  104  is configured with protuberances  126  configured to engage detents  128  in the heat manifold  102 . In one preferred embodiment, the protuberances  126  are spatially positioned about the heat source&#39;s outer surface  114 , while detents  128  are spatially positioned about the heat manifold&#39;s inner surface  122  and along its length L M . A user inserts the heat source  104  into the heat manifold  102  at different depths to control the contact surface area between the heat source  104  and heat manifold  102  for regulating the heat conducted from the heat source  104  to the manifold  102 , along the heat conductors  106  and on to the garment  108 . 
     As shown in  FIG. 3  and  FIG. 4 , the heat source  104  is inserted into the heat manifold  102  until its protuberances  126  reside in a second row of the heat manifold&#39;s detents  128 . In this position, approximately half of the heat source  104  resides within the heat manifold  102  and approximately half of the heat output from the heat source  104  is conducted to the heat manifold  102 . With the heat source&#39;s protuberances  126  residing in the heat manifold&#39;s detents  128 , the heat source  104  is coupled to the manifold  102 . The protuberances  126  engage the detents  128  to prevent inadvertent movement between the heat source  104  and heat manifold  102  and to provide the user with a substantially precise means of controlling the heat conducted from the heat source  104  to the manifold  102 . 
     Referring to the drawing Figures, in one embodiment of the invention, the system  100  includes heat conductors  106  that are coupled to the heat manifold  102  and affixed to the garment  108 . While four heat conductors  106  are shown in  FIG. 1 , this is for ease of discussion only. It is to be understood that there may be any suitable number of heat conductors  106  as needed to provide heat to the garment  108  from the heat source  104 . There may be as few as a single heat conductor  106  to as many heat conductors  106  as desired. 
     In the exemplary embodiment shown, the heat conductors  106  are shown traveling generally vertically, from the heat source  104  towards a neck  132  and shoulder area  134  of the garment  108 . It is to be understood that the heat source  104  may be positioned on and/or secured to the garment  108  at any suitable location. Thus, if the heat source  104  is positioned near the neck  132  and shoulder area  134  of the garment  108 , the heat conductors  106  may travel generally vertically down from the heat source  104  towards a waist  136  of the garment  108 . Alternatively the heat conductors  106  may travel generally transversely across the garment  108 , between the shoulder area  134  and waist  136 . Additionally, while the heat conductors  106  are shown traveling generally vertically across the garment  108 , it is to be understood that they may be secured to the garment  108  in any suitable pattern and/or any pattern which may provide heat transfer from the heat conductors  106  to the garment  108 . 
     In the embodiments, the heat conductors  106  comprises a pliant, thermally conductive material. For example the heat conductors  106  may comprise a copper alloy, steel alloy, copper wire, nichrome wire, carbon fibers, ore any suitable pliant, thermally conductive material known in the art. In one exemplary embodiment, the heat conductors  106  comprise known heat pipes. 
     Referring again to  FIGS. 3-5 , an end portion  140  of each of the plurality of heat conductors  106  is coupled to the heat manifold  102  for conducting heat from the heat manifold  102  to the garment  108 , to warm the garment  108 . In one embodiment, the end portion  140  of each conductor  106  extends about an outer surface  142  of the heat manifold  102  and is affixed thereto using known methods. The conductor&#39;s end portion  140  may be affixed the heat manifold&#39;s outer surface  142  using know methods such as soldering or welding, for example. The conductor&#39;s end portion  140  may be affixed the heat manifold&#39;s outer surface  142  using any know method that provides a secure connection between the manifold  102  and heat conductors  106 , and that does not inhibit heat conduction from the manifold  102  to the heat conductors  106 . 
     As shown in  FIG. 4 , the end portion  140  of a heat conductor  106  extends about the outer surface  142  of the heat manifold  102  in a generally spiral pattern. In a preferred embodiment, the end portions  140  of the heat conductors  106  are configured to extend about the outer surface  142  of the heat manifold  102 , such as in the generally spiral pattern, to maximize contact surface area between the heat conductors&#39; end portions  140  and the heat manifold&#39;s outer surface  142 , to provide maximum heat transfer from the heat source  104  to the heat conductors  106 , and thus to the garment  108 . 
     Referring to  FIG. 1  and  FIG. 2 , the heat conductors  106  are affixed to the garment  108  using known methods. For example, the heat conductors  106  are affixed to the garment  108  using known sewing techniques, known fabric glues, or using any devices and methods known in the art. The heat conductors  106  may also be interleaved between adjacent layers of the fabric comprising the garment  108 . In one embodiment, the heat conductors  106  are affixed an inner layer  144  of the garment  108 , with an outer layer  146  extending over the heat conductors  106 . The heat conductors  106  may be sewn to the inner layer  144  or outer layer  146  using thread  148 . 
     As explained above, embodiments of the invention comprise a thermal distribution and regulation system for a garment. The system includes a self-contained heat source, such as a catalytic heat source. A heat manifold extends about the heat source and is mechanically adjusted relative to the heat source to control the contact surface area between the heat source. Controlling the contact surface area between the heat source and manifold regulates heat conducted from the heat source, through the manifold, and to the heat conductors. The heat manifold is configured with detents that engage protuberances of the heat source at more than one location to prevent inadvertent movement between the heat source and manifold. Adjusting the heat manifold along the heat source functions as a mechanical thermostat for regulating the heat conducted from the heat source to the manifold. The system also includes a plurality of heat conductors coupled to the heat manifold and affixed to the garment. An end of each of the plurality of heat conductors is coupled to the heat manifold for conducting heat from the heat manifold to the garment, to warm the garment. 
     Those skilled in the art will appreciate that various adaptations and modifications can be configured without departing from the scope and spirit of the embodiments described herein. Therefore, it is to be understood that, within the scope of the appended claims, the embodiments of the invention may be practiced other than as specifically described herein.