Air cooling device

Abstract

An air cooling device includes a thermal core, constructed from a series of interconnected hollow disks containing super-absorbent polymer gel in a frozen state, and a thermal insulating sleeve adapted to operatively enclose the frozen core. The enclosure affords a substantially narrow interior sleeve spacing for air flow. The device also includes a fan blower operatively coupled to the sleeve and adapted to draw ambient air within the interior sleeve spacing and over the outer surface of the enclosed frozen core against gravity for cooling. A plurality of substantially narrow surface air flow channels are formed between the interconnected disks. The narrow surface air flow channels and interior sleeve spacing restrict the ambient air flow over the outer surface of the frozen core to prolong the air cooling period.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of pending utility patent application Ser. No. 11/009,922, filed Dec. 10, 2004, which was published on Jun. 15, 2006 under Pub. No. US 2006/0123832 A1 and is incorporated herein in its entirety by reference.

BACKGROUND

Human beings normally function over a fairly narrow ambient temperature range. Adjustment of the amount and type of clothing may afford some relief from rising or falling ambient air temperature. However, as ambient air temperature steadily rises, conditioning the same by some form of heat extraction is a preferred solution to maintaining comfortable body temperature. Typically, such heat extraction is performed by air conditioners.

Air conditioners operate on the principle of heat absorption whereby a refrigerant substance may gradually change phase from solid to liquid or from liquid to gas. Unfortunately, most of the known air conditioners are fairly bulky and costly to maintain. Various types of portable or semi-portable air cooling devices have been developed over the years. Most such air cooling devices are designed to cool an enclosed space, for example, rooms of a building, the interior of a motor vehicle, and the like. These air cooling devices must, therefore, be capable of efficiently cooling a relatively large volume of air. Unfortunately, known devices of this type require relatively costly and/or bulky power sources.

Some known air cooling devices utilize indirect conduction of heat between water and air with the cooling effect of air being relatively low. This increases the size and weight of the air cooling device and requires a bigger space for storage and/or installation. Other air cooling devices use a multi-tube type heat exchanger which requires a large quantity of cooling water to flow in a single pass or in a constantly circulating manner. Additionally, the maintenance of the heat exchanger is somewhat troublesome because of the necessity of cleaning the complicated cooling water tubes. Portable air conditioners or swamp cooler systems are designed for spot cooling, not area cooling, and are thus relatively ineffective.

SUMMARY

Some embodiments disclosed herein are generally directed to an air cooling device.

In accordance with one aspect of the invention, the air cooling device comprises at least one thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency. The interconnected hollow disks are filled with super-absorbent refrigerant. The device also includes at least one thermal insulating sleeve adapted to operatively enclose the thermal core, means for forcing ambient air to flow within the thermal insulating sleeve and over the outer surface of said enclosed refrigerant-filled disks against gravity for cooling, and means for restricting ambient air flow over the outer surface of the refrigerant-filled disks to prolong the air cooling period.

In accordance with another aspect of the invention, the air cooling device comprises a thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency. The interconnected hollow disks are filled with super-absorbent refrigerant. The device also includes a thermal insulating sleeve adapted to operatively enclose the refrigerant-filled disks. The enclosure affords substantially narrow interior sleeve spacing for air flow.

The device further includes a fan blower operatively coupled to the thermal insulating sleeve and adapted to draw ambient air within the interior sleeve spacing and over the outer surface of the enclosed refrigerant-filled disks against gravity for cooling. A plurality of substantially narrow surface air flow channels are formed between the interconnected disks. The narrow surface air flow channels and interior sleeve spacing restrict the ambient air flow over the outer surface of the refrigerant-filled disks to prolong the air cooling period.

In accordance with yet another aspect of the invention, the air cooling device comprises a plurality of interconnected hollow disks being stacked and supported on top of each other via structural ribs. The stacked and interconnected hollow disks are filled with super-absorbent refrigerant. The stacked refrigerant-filled disks provide an optimized thermal mass surface area. The device also comprises a thermal insulating sleeve adapted to enclose the stacked refrigerant-filled disks while affording a substantially narrow interior sleeve spacing for air flow, a first collar configured to receive the bottom portion of the thermal insulating sleeve, a second collar configured to receive the top portion of the thermal insulating sleeve, and a front apron adapted to hold the first and second collars together over a lateral portion of the thermal insulating sleeve.

The device further comprises a cap portion removably coupled to the second collar, and a fan blower operatively housed in the cap portion over the top portion of the thermal insulating sleeve. The fan blower is adapted to draw ambient air within the interior sleeve spacing and over the outer surface of the enclosed refrigerant-filled disks against gravity for cooling. A plurality of substantially narrow surface air flow channels are formed between the stacked disks. The narrow surface air flow channels and interior sleeve spacing restrict the ambient air flow over the outer surface of the stacked refrigerant-filled disks to prolong the air cooling period.

In accordance with still another aspect of the invention, the air cooling device comprises a thermal core including hollow disks being stacked and supported on top of each other via integral rib structures. Each of the integral rib structures has a fluid conduit connecting a respective pair of hollow disks. The stacked and interconnected hollow disks are filled with refrigerant containing at least one super-absorbent polymer (SAP) substance. The device also comprises a sleeve made of blended plastic material containing at least one additive enhancing its thermally insulation properties. The sleeve is configured to enclose the stacked and interconnected SAP refrigerant-filled disks while affording substantially narrow interior sleeve spacing for air flow.

The device further comprises a first collar configured to receive the bottom portion of the sleeve, at least one air filter which is operatively disposed under the bottom portion of the sleeve within the first collar, a second collar configured to receive the top portion of the sleeve, and a front apron adapted to hold the first and second collars together over a lateral portion of the sleeve. Also included are a cap portion removably coupled to the second collar, and a fan blower operatively housed in the cap portion over the top portion of the sleeve. The fan blower is adapted to draw ambient air through the air filter within the interior sleeve spacing and over the outer surface of the enclosed refrigerant-filled disks against gravity for cooling. A multi-directional air vent subassembly is operatively housed in the cap portion proximate to the fan blower.

A plurality of substantially narrow surface air flow channels are formed between the stacked disks. The narrow surface air flow channels and interior sleeve spacing restrict the filtered air flow over the outer surface of the stacked refrigerant-filled disks to prolong the air cooling period. The cooled air is discharged to the environment via the multi-directional air vent subassembly.

In accordance with a still further aspect of the invention, the air cooling device comprises a thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency. The interconnected hollow disks contain super-absorbent polymer (SAP) gel in a frozen state. The device also comprises a thermal insulating sleeve adapted to operatively enclose the frozen core with the enclosure affording a substantially narrow interior sleeve spacing for air flow.

Also included is a fan blower which is operatively coupled to the thermal insulating sleeve and adapted to draw ambient air within the interior sleeve spacing and over the outer surface of the enclosed frozen core against gravity for cooling. A plurality of substantially narrow surface air flow channels are formed between the interconnected disks. The narrow surface air flow channels and interior sleeve spacing restrict the ambient air flow over the outer surface of the frozen core to prolong the air cooling period.

In accordance with a different aspect of the invention, the air cooling device comprises a plurality of interconnected hollow disks being stacked and supported on top of each other via structural ribs. The stacked and interconnected hollow disks contain super-absorbent polymer (SAP) gel in a frozen state. The device further comprises a thermal insulating sleeve adapted to enclose the frozen disks while affording substantially narrow interior sleeve spacing for air flow, a first collar configured to receive the bottom portion of the thermal insulating sleeve, a second collar configured to receive the top portion of the thermal insulating sleeve, and a front apron adapted to hold the first and second collars together over a lateral portion of the thermal insulating sleeve.

Also included are a cap portion rotatably coupled to the second collar, and a fan blower operatively housed in the cap portion over the top portion of the thermal insulating sleeve. The fan blower is adapted to draw ambient air within the interior sleeve spacing and over the outer surface of the enclosed frozen disks against gravity for cooling.

A plurality of substantially narrow surface air flow channels are formed between the stacked disks. The narrow surface air flow channels and interior sleeve spacing restrict the ambient air flow over the outer surface of the stacked frozen disks to prolong the air cooling period.

These and other aspects of the invention will become apparent from a review of the accompanying drawings and the following detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is generally shown by way of reference to the accompanying drawings in which:

FIG. 1 is a front perspective view of an air cooling device in accordance with one embodiment of the present invention;

FIG. 2 is a schematic view showing exemplary air flow in the air cooling device of FIG. 1;

FIG. 3 is a partial perspective view of the exemplary embodiment of FIG. 2;

FIG. 4 is a perspective view of components being used in the air cooling device of FIG. 1;

FIG. 5 is a perspective view of components of the air cooling device of FIG. 1 being in a partially assembled state;

FIG. 6 is a perspective view of the components of FIG. 5 being in fully assembled state;

FIG. 7 is a cross-sectional operational view along section line 7-7 of FIG. 2;

FIG. 8 is a rear perspective view of the air cooling device of FIG. 1;

FIG. 9 is a front elevation view of an air cooling device in accordance with an alternative embodiment of the present invention;

FIG. 10 is a side elevation view of the air cooling device of FIG. 9;

FIG. 11 is an exploded perspective view of a plurality of components of the air cooling device of FIGS. 9-10;

FIG. 12 is an exploded perspective view of one of the components shown in FIG. 11;

FIG. 13 is an exploded perspective view of another component shown in FIG. 11;

FIG. 14 is an exploded perspective view of an air vent assembly which is part of the component shown in FIG. 13;

FIG. 15 is an exploded perspective view of yet another component shown in FIG. 11;

FIG. 16 is an enlarged perspective view of an uncapped thermal core for use with the air cooling device of FIGS. 9-10;

FIG. 17 is a cross-sectional view of a capped thermal core for use with the air cooling device of FIGS. 9-10; and

FIG. 18 is a schematic operational view showing exemplary air flow within the air cooling device of FIGS. 9-10.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments and is not intended to represent the only forms in which the exemplary embodiments may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the exemplary embodiments in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Some embodiments of the invention will be described in detail with reference to the related drawings of FIGS. 1-18. Additional embodiments, features and/or advantages of the invention will become apparent from the ensuing description or may be learned by practicing the invention. In the figures, the drawings are not to scale with like numerals referring to like features throughout both the drawings and the description.

FIG. 1 is a front perspective view of an air cooling device 10 in accordance with one embodiment of the present invention. Air cooling device 10 includes a generally tubular housing 12 (FIG. 1) adapted to accommodate a thermally insulated container 14 containing encapsulated refrigerant 15, as generally shown in FIG. 2. Encapsulated refrigerant 15 is configured as a plurality of compacted frozen balls/bubbles (FIG. 3). Each ball/bubble is filled with a cooling agent that is capable of freezing and sustaining its frozen state for periods longer than water once exposed to the atmosphere. Cooling agents of this type may include ethylene glycol and its polymers, propylene glycol and its polymers, glycerol and its polymers and/or the like.

The cooling agent may be injected in the balls/bubbles before freezing. Alternatively, the cooling agent may be automatically encapsulated at a manufacturing facility. For example, glycol balls may be trapped between two relatively thin, flexible sheets of plastic. The plastic sheets may be heat-sealed together to securely and compactly trap the glycol balls between the sheets. The trapped glycol balls may be mass-produced in encapsulated sheet form and cut to size, as needed. A household or commercial freezer may be used to freeze the encapsulated glycol balls. One or more frozen glycol sheets may be inserted in thermally insulated container 14, as needed. Unused glycol sheets are easily stored away for later use.

Container 14 may be made from plastic, foam or other suitable thermal insulating material. Container 14 has a partially open top 16 (FIG. 4) and a partially open bottom 18 (FIG. 6) adapted to allow air to flow there through. Partially open top 16 and/or partially open bottom 18 may be removed to allow the insertion of encapsulated refrigerant 15. With encapsulated refrigerant 15 packed inside (FIG. 2), container 14 is introduced into the hollow interior of housing 12, as generally depicted by directional arrow 17 in FIG. 5.

Housing 12 is equipped at one end with a blower 19 and at an opposite end with a mesh-like air intake portion 20, as generally illustrated in FIGS. 1-2, 5-8. Ambient air is pulled inside refrigerant-packed container 14 for cooling by blower 19 (FIG. 7) via air intake portion 20 and partially open bottom 18. Blower 19 has fan blade(s) 21 being driven by an integral motor (not shown), an air inlet section 22 and an air outlet section 24 (FIG. 7). Air inlet section 22 is in communication with cold air coming from the interior of container 14 through partially open top 16. Air inlet section 22 may be equipped with an air filter 26 (FIG. 7). The blower motor is turned on by a switch 25 operatively mounted on the exterior of housing 12 (FIGS. 1, 5-6). Once turned on, blower 19 evacuates cold air from the interior of container 14 via air inlet section 22, and blows the same out of the unit via air outlet section 24 and vent 28, as generally shown in FIGS. 1-2.

With blower 19 being mounted at the top, rather than at the bottom of housing 12, the incoming air is forced to flow inside refrigerant-packed container 14 against gravity G (FIG. 7), i.e. the air flow rate is purposely slowed down to allow for a longer air cooling period. A faster flow rate would contribute to a more rapid deterioration of encapsulated refrigerant 15. A relatively slower flow rate would prolong the “cold life” of each frozen glycol ball/bubble. Air is gradually cooled by flowing over the frozen glycol bubbles which collectively serve as a primary cooling source. Cold air is accumulated in air pockets formed between the compacted frozen glycol bubbles. This accumulated cold air serves as a secondary cooling source.

A person skilled in the art would readily appreciate that if there was no accumulation of frozen glycol bubbles, i.e. if container 14 were to be packed with a single contiguous refrigerant mass, cold air would only be produced from flowing around the exterior surface of the refrigerant mass. There would be no secondary source of cooling the air. Moreover, if ambient air were to be blown against (as opposed to being sucked in) such refrigerant mass, the ambient air would rapidly cause deterioration of the refrigerant surface. In such case, the overall cooling efficiency of the device may be degraded.

The provision of multiple refrigerant surfaces and air pockets there between, as contemplated by compactly packing encapsulated refrigerant 15 into thermally insulated container 14, ensures significantly improved cooling efficiency for air cooling device 10 when compared to known cooling devices. The cooled air flows through the entire refrigerant-packed container 14. The size of each frozen glycol ball, as well as the compactness of the balls may be varied, as needed. Obviously, if the ball size was too small, there would be insufficient cooling surface area. On the other hand, if the ball size was too big, the air pockets would grow in size which would have detrimental effect on the cooling of incoming air, i.e. the air flow rate would increase. In one example, the cross section of a frozen glycol ball is about 3.5 inches. Other suitable ball sizes may be utilized, as needed.

Exposing warm ambient air to cold environment leads to condensation. A condensation pan 30 (FIG. 8) is provided inside housing 12 under partially open bottom 18 of refrigerant packed container 14. Condensation pan 30 is adapted to capture water droplets formed during the air cooling process. Since blower 19 is mounted at the top of housing 12, there is no risk of water droplets falling on any electric/electronic part. Also, with the evacuation effect produced from above by air inlet section 22 of blower 19, dispersion of formed water droplets within container 14 would be significantly inhibited. Condensation pan 30 is introduced into or removed from housing 12 via maintenance door 32, as generally depicted in FIG. 8. Maintenance door 32 may be formed as an integral part of mesh-like air intake portion 20. Maintenance door 32 may be adapted to pivot toward and away from the interior of housing 12. Housing 12 may be mounted at one end to a base 34 (FIG. 8).

The air cooling device of FIGS. 1-8 may be configured as a table top unit, a floor standing unit, or a hand-held unit. Other configurations are possible, provided such other configurations reside within the intended scope of the present invention. For example, housing 12 may be adapted to accommodate a plurality of thermally insulated containers, each packed with encapsulated refrigerant. The thermally insulated containers may be operatively coupled in series and/or in parallel. Moreover, each of the glycol-filled balls may be made with a relatively rough (textured) surface to inhibit fluidity, i.e. to further slow down the cooling period for the incoming air.

FIGS. 9-10 are front and side elevation views, respectively, of an air cooling device 40 in accordance with an alternative embodiment of the present invention. Air cooling device 40 includes a thermal core 42 (FIGS. 11, 16-18) and an insulating sleeve 44 (FIGS. 9-11, 18) of a generally tubular construction adapted to receive and support thermal core 42 while permitting air flow around it. Thermal core 42 is made of a series of interconnected hollow disks (FIGS. 16-18) for optimal thermal efficiency. Particularly, the interconnected hollow disk configuration is intended to optimize thermal mass surface area. In this regard, a person skilled in the art would appreciate that heat transfer efficiency is a function of surface area.

The entire interconnected disk structure may be molded of plastic material(s) with the structure being configured for containment of refrigerant. The plastic material(s) used should have suitable thermal transfer characteristics. For example, one or more thermoplastic resins that are polymers of propylene may be used to mold thermal core 42. The term “polymers” generally refers to large molecules made up of chains of identical units that repeat. Other thermally efficient material(s) may be utilized to construct core 42, as needed. Thermal core 42 has an open top 46 (FIG. 16), which may be fitted with a removable cap 47 (FIG. 11), and a closed bottom 48 (FIGS. 11, 16-17).

The hollow disks are stacked and supported on top of each other via a plurality of integral structural ribs. For example, hollow disk 43 is supported over hollow disk 45 via integral support rib structure 49, as generally depicted in reference to FIG. 16. Each support rib structure (49, 51, and 53) may be symmetrically disposed between neighboring hollow disks, respectively (FIG. 17). Each support rib structure is configured to provide a centrally disposed conduit, such as conduit 55 (FIG. 16) of rib structure 49, which allows refrigerant to pass from one hollow disk to another during filling of thermal core 42 before operation of air cooling device 40.

In one embodiment, thermal core 42 is filled via open top 46 (FIG. 16) with a super-absorbent polymer (SAP) substance, which may be in the form of crystalline powder, and water in appropriate quantities. SAP substances use cross-linked polymers to absorb water many times their weight. Some commercially available SAP substances include, for example, potassium polyacrylate (Chemical Abstracts Services or CAS Registry No. 25608-12-2), sodium polyacrylate (CAS No. 9003-04-7), and polyacrylamide (CAS No. 9003-05-8). The structural formula of potassium polyacrylate is: [—CH2-CH(COOK)—]n. The structural formula of sodium polyacrylate is: [—CH2-CH(COONa)—]n. The structural formula of polyacrylamide is: [—CH2-CH(CONH2)-]n.

When water is added, for example, to crystalline sodium polyacrylate, the polymer crystals readily absorb water many times their size and a polymeric gel forms. In the absorbing process, the gel that forms swells considerably. When sodium polyacrylate is immersed in water, there is higher concentration of water outside the polymer. When water approaches a sodium polyacrylate molecule, it is drawn to the interior of the molecule by osmosis. The ability of the sodium polyacrylate polymer to absorb excessive amounts of water is due to osmosis. The term “osmosis” generally refers to diffusion of fluid through a semi-permeable membrane from a solution with a low solute concentration to a solution with a higher solute concentration until there is an equal concentration of fluid on both sides of the membrane. In this case, the sodium polyacrylate molecule absorbs water until there is equal concentration of water inside and outside the molecule.

Once fully hydrated, the sodium polyacrylate gel may be frozen and used in its frozen state as a refrigerant. When the crystals are fully hydrated, the density of the polymer medium stays generally constant throughout its volume. This constant density plays a key role in regulating heat transfer when the polymer gel is used in cooling applications.

Crystalline sodium polyacrylate has been used, for example, in disposable diapers to absorb baby urine. Sodium polyacrylate has also been used by florists to keep cut flowers fresh for a prolonged period of time, in filtration units to remove water from jet and automobile fuel, and in Gro-Creature™ toys which can be hydrated over and over again. Potassium polyacrylate gel is commonly used to absorb chemical spills. Polyacrylamide gel is used in horticulture to retain moisture around root systems of seedlings.

To prepare thermal core 42 for use in cooling applications in accordance with the general principles of the present invention, the user may fill thermal core 42 via open top 46 with a commercially prepared SAP gel such as potassium polyacrylate gel 50, as generally illustrated in FIG. 17. Potassium polyacrylate gel is available commercially from a number of manufacturers such as, for example, Aldon Corporation of Avon, N.Y. Another commercially available SAP substance which may be suitable for practicing the present invention is Super Ice® cold pack manufactured by SCA Packaging NA of Hayward, Calif. Various other SAP preparations may be utilized as refrigerant as long as there is no departure from the intended purpose of the present invention.

Once filled with SAP gel 50, thermal core 42 is placed in a freezer and kept therein until the polymer gel medium is completely frozen. The frozen core is then taken out of the freezer and inserted in insulating sleeve 44 which is adapted to retain the same while maintaining a relatively small gap 41 (FIG. 18) between its inner wall and the outer surface of inserted thermal core 42. In one exemplary embodiment of the present invention, inner gap 41 (FIG. 18) may be set at about 0.25 inch. Other suitable inner gap dimensions may be utilized, as needed.

Sleeve 44 is open at the bottom to allow for air to be sucked in from the bottom (FIG. 18) and flow around the entire outer surface of thermal core 42 (FIG. 18), which is contained therein during operation. The relatively small size of gap 41 is intended to restrict air flow so as to prolong the cooling time for circulating air. Sleeve 44 is also open at the top (FIG. 11) and configured to thermally insulate core 42 during operation of air cooling device 40. Sleeve 44 may be molded of plastic material(s) having suitable thermal insulation properties. Other material(s) and/or combination of materials may be utilized to construct insulating sleeve 44, as needed.

In one embodiment, insulating sleeve 44 is made from a blended plastic material which contains an additive to enhance its thermal insulation properties. Blended plastic of this type is commercially available from a number of vendors. Sleeve 44 is also made with sufficient wall thickness to adequately insulate thermal core 42 during operation. A person skilled in the art would appreciate that thermal insulating sleeve 44 may be configured in other ways as long as such other configurations reside within the intended scope and spirit of the present invention.

As generally illustrated in reference to FIG. 18, the stacked disk configuration of thermal core 42 defines a plurality of relatively narrow surface air flow channels 52, 54, 56. The narrow channels afford a substantially planar air flow. In one exemplary embodiment of the present invention, the width of each inter-disk air flow channel, such as channel width 57 (FIG. 18), may be set at about 0.25 inch with each disk having an outer diameter of about 5.5 inch. Other suitable inter-disk channel width and/or outer disk diameter dimensions may be utilized, as needed. The relatively narrow inter-disk spacing is intended to restrict air flow so as to prolong the cooling time for circulating air. Air flow may also be restricted to a certain extent by the presence of the inter-disk rib support structures, as generally shown in FIG. 18.

Each hollow disk has a substantially concave outer surface area, as generally depicted at 58, 60, 62 and 64, respectively, in reference to FIG. 17, to prevent retainment of surface condensation during operation of air cooling device 40. A person skilled in the art would recognize that the concave outer surface disk area configuration also promotes cooling of the circulating air during operation by increasing the surface area.

Air cooling device 40 also includes a bottom housing 66 adapted to receive the bottom portion of insulating sleeve 44, a top housing 68 configured to receive the top portion of insulating sleeve 44, and a front apron 70, as generally depicted in FIG. 11. Front apron 70 is operatively coupled to bottom housing 66 and top housing 68 over a portion of insulating sleeve 44, as generally shown in reference to FIGS. 9-10. Each housing (66, 68) as well as front apron 70 may be constructed of plastic and/or other suitable materials, as needed.

Bottom housing 66 is assembled from a number of components. Particularly, bottom housing 66 includes a base 72 (FIG. 15) which is of a generally circular cross-section. Base 72 is provided with a plurality of apertures configured to let incoming ambient air through for cooling, as shown, for example, at 73a, 73b, 73c, 73d in FIG. 15. Base 72 is adapted at its bottom side for coupling to air cooling device feet 74a, 74b, 74c, 74d, 74e (FIG. 15) which are configured to allow adequate flow of incoming ambient air via the base apertures. Base 72 accommodates an air filter pad 75 and associated filter frame 77, as generally shown in reference to FIG. 15. Air filter pad 75 may be implemented, for example, as a HEPA (High Efficiency Particulate Air) filter. Other suitable types of air filter may be utilized, as needed.

Base 72 is adapted at its top side for coupling to a base drain plate 76 (FIG. 15). Plate 76 is configured to drain any condensation collected during operation of air cooling device into a removable drip tray 78 (FIG. 15) which slides in/out of a front collar portion 80 (FIG. 15) of bottom housing 66. Front collar portion 80 and base 72 are recessed at one end, respectively, to accommodate drip tray 78, as generally depicted in reference to FIG. 15. Front collar portion 80 operatively couples to a rear collar portion 82. Each collar portion has a generally semi-circular cross-section. The coupled collar portions form a generally tubular bottom collar for insulating sleeve 44. A base ring 84 (FIG. 15) mounts along the top periphery of the two coupled collar portions.

When properly assembled, front and rear collar portions 80, 82 retain internally base drain plate 76, air filter pad 75, filter frame 77, and base 72. The internal structure includes base drain plate 76 being supported on top of base 72 with air filter pad 75 and filter frame 77 operatively disposed in between. A battery pack subassembly 86 may be removably coupled to rear collar portion 82, as generally depicted in reference to FIG. 15.

Subassembly 86 is configured to accommodate a suitable rechargeable battery (not shown). In one exemplary embodiment, battery pack subassembly 86 is attached to rear collar portion 82 via clips (not shown). Other attachment means may be used, as desired. All of the above-described components of bottom housing 66 (with the exception of air filter pad 75) may be molded from plastic material(s). Other material(s) and/or combination of material(s) may be utilized to construct bottom housing 66, provided there is no departure from the intended purpose of the present invention.

Top housing 68 is assembled from two components with each component having a generally circular cross-section. Particularly, a cap portion 90 is operatively coupled to a top collar 88, as generally shown in reference to FIGS. 9-10. Both components may be molded from plastic material(s). Other material(s) and/or combination of material(s) may be utilized, as needed. In one embodiment, cap portion 90 is adapted to twist on/off of top collar 88 to provide easy access to frozen core 42. With cap portion 90 twisted off, thermal core 42 may be easily removed from insulating sleeve 44 for maintenance after its refrigerant has thawed. Thermal core 42 may then be re-frozen for subsequent use, as needed.

Top collar 88 mounts over the top portion of insulating sleeve 44 (FIGS. 9-10). Top collar 88 includes main body 92 which has a generally bottomless pot configuration, as generally shown in FIG. 12. Main body 92 is coupled at one end to a top collar ring 98 (FIG. 12). Top and bottom collar rings 98, 84 are appropriately recessed in the front, as generally shown at 99 (FIG. 12) and 101 (FIG. 15), respectively, to allow for snap attachment of front apron 70 (FIG. 70) thereon. Once attached, front apron 70 holds the top and bottom collars firmly in place over insulating sleeve 44.

Main body 92 is recessed in the front to receive top collar plate 94 which is recessed in turn to receive a logo plate 96 (FIG. 12). Logo plate 96 and top collar plate 94 may be attached to the recessed portion of main body 92 via screws. Other attachment means may be utilized, as needed. An aroma therapy disk (not shown) may be disposed in the pocket formed by recessed area 95 (FIG. 12) on top collar plate 94 and logo plate 96 when mounted thereon. Logo plate 96 is provided with a top aperture 97 which allows aromatic scent(s) to escape and mix with cold filtered air being vented in the immediate vicinity (FIG. 18). Aroma therapy disks are commercially available from a number of vendors.

As generally depicted in reference to FIG. 13, cap portion 90 includes a first housing member 100, a second housing member 102, and a high-performance fan 104 operatively housed there between. In one exemplary embodiment, fan 104 may be implemented as a Nidec™ Gamma 30 Series fan. A control panel (not shown) is also included. Other high-performance fans may be utilized, as needed. First housing member 100 is recessed in the front at 103 to accommodate an air vent subassembly 106 (FIG. 13). Air vent subassembly 106 includes vent port 120, louvers 122 and louver housing 124 (FIG. 14). Louvers 122 are equipped with rear shafts, such as 121, 123 and 125 (FIG. 14), respectively, which are rotatably coupled to louver housing 124 allowing the louvers to pivot up/down, as needed. A person skilled in the art would appreciate that other omni-directional air vent arrangements may be utilized, as needed.

When mounted and operated in accordance with the present invention, high-performance fan 104 draws ambient air through the bottom of air cooling device 40, i.e. via the apertures and associated HEPA filter of base 72 (FIG. 15), into the relatively narrow space defined by the inner wall of insulating sleeve 44 and the stacked-disk curvature of the outer surface of frozen core 42, forces the filtered air to flow around the outer surface of frozen core 42 against gravity (as generally depicted by directional arrow G in FIG. 18) to ensure a prolonged air-cooling period, and blows the filtered cold air out via air vent subassembly 106, as generally illustrated in reference to FIG. 18. In this regard, FIG. 18 schematically shows incoming ambient air being cooled while flowing within inter-disk channels 52, 54, 56 as well as over the concave outer surface of each frozen core disk as it is being drawn upwards toward cap portion 90 by the fan blower contained therein.

First housing member 100 is recessed partially on the top at 105 (FIG. 13) to accommodate an arch-shaped handle 108 (FIG. 13) which is used to hand-carry air cooling device 40 from one location to another, as needed. First housing member 100 is laterally recessed, such as at 107, and apertured at 109 to operatively receive a device knob 110, a LED (Light Emitting Diode) pipe plate 112, a LED pipe 114, a LED base wheel subassembly 116, a rotary switch 118 and associated nut 120, as generally shown in FIG. 13. A top cap ring 122 is configured to mount in peripheral recess 111 of first housing member 100 (FIG. 13).

When configured and used in accordance with the general principles of the present invention, air cooling device 40 is capable of providing hours of efficient cooling operation for the user. Air cooling device 40 may be implemented as a portable table top unit, a floor standing unit, or a hand-held unit. Other implementations are possible, provided such other implementations reside within the intended scope of the present invention. For example, the air cooling device of the present invention may be modified to operate with multiple frozen thermal cores and appropriate portable power source, if needed. The air cooling device of the present invention provides an attractive and thermally efficient portable cooling solution for the home, office and/or the like.

A person skilled in the art would appreciate that embodiments described hereinabove are merely illustrative of the general principles of the present invention. Other modifications or variations may be employed that are within the scope of the invention. Thus, by way of example, but not of limitation, alternative configurations may be utilized in accordance with the teachings herein. Accordingly, the drawings and description are illustrative and not meant to be a limitation thereof.

Moreover, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Thus, it is intended that the invention cover all embodiments and variations thereof as long as such embodiments and variations come within the scope of the appended claims and their equivalents.

Claims

1. An air cooling device, comprising:

at least one thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency, said interconnected hollow disks filled with super-absorbent refrigerant;

at least one thermal insulating sleeve adapted to operatively enclose said at least one thermal core;

means for forcing ambient air to flow within said at least one thermal insulating sleeve and over the outer surface of said enclosed refrigerant-filled disks against gravity for cooling; and

means for restricting ambient air flow over the outer surface of said refrigerant-filled disks to prolong the air cooling period.

2. An air cooling device, comprising:

a thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency, said interconnected hollow disks filled with super-absorbent refrigerant;

a thermal insulating sleeve adapted to operatively enclose said refrigerant-filled disks, said enclosure affording a substantially narrow interior sleeve spacing for air flow;

a fan blower operatively coupled to said thermal insulating sleeve and adapted to draw ambient air within said interior sleeve spacing and over the outer surface of said enclosed refrigerant-filled disks against gravity for cooling; and

a plurality of substantially narrow surface air flow channels being formed between said interconnected disks, said substantially narrow surface air flow channels and interior sleeve spacing restricting the ambient air flow over the outer surface of said refrigerant-filled disks to prolong the air cooling period.

3. An air cooling device, comprising:

a plurality of interconnected hollow disks being stacked and supported on top of each other via structural ribs, said stacked and interconnected hollow disks being filled with super-absorbent refrigerant, said stacked refrigerant-filled disks providing an optimized thermal mass surface area;

a thermal insulating sleeve adapted to enclose said stacked refrigerant-filled disks while affording substantially narrow interior sleeve spacing for air flow;

a first collar configured to receive the bottom portion of said thermal insulating sleeve;

a second collar configured to receive the top portion of said thermal insulating sleeve;

a front apron adapted to hold said first and second collars together over a lateral portion of said thermal insulating sleeve;

a cap portion removably coupled to said second collar;

a fan blower operatively housed in said cap portion over the top portion of said thermal insulating sleeve, said fan blower adapted to draw ambient air within said interior sleeve spacing and over the outer surface of said enclosed refrigerant-filled disks against gravity for cooling; and

a plurality of substantially narrow surface air flow channels being formed between said stacked disks, said substantially narrow surface air flow channels and interior sleeve spacing restricting the ambient air flow over the outer surface of said stacked refrigerant-filled disks to prolong the air cooling period.

4. An air cooling device, comprising:

a thermal core including hollow disks being stacked and supported on top of each other via integral rib structures, each of said integral rib structures having a fluid conduit connecting a respective pair of hollow disks, said stacked and interconnected hollow disks being filled with refrigerant containing at least one super-absorbent polymer (SAP) substance;

a sleeve made of blended plastic material containing at least one additive enhancing its thermally insulation properties, said sleeve configured to enclose said stacked and interconnected SAP refrigerant-filled disks while affording a substantially narrow interior sleeve spacing for air flow;

a first collar configured to receive the bottom portion of said sleeve;

at least one air filter operatively disposed under the bottom portion of said sleeve within said first collar;

a second collar configured to receive the top portion of said sleeve;

a front apron adapted to hold said first and second collars together over a lateral portion of said sleeve;

a cap portion removably coupled to said second collar;

a fan blower operatively housed in said cap portion over the top portion of said sleeve, said fan blower adapted to draw ambient air through said at least one air filter within said interior sleeve spacing and over the outer surface of said enclosed refrigerant-filled disks against gravity for cooling;

a multi-directional air vent subassembly operatively housed in said cap portion proximate to said fan blower; and

a plurality of substantially narrow surface air flow channels being formed between said stacked disks, said substantially narrow surface air flow channels and interior sleeve spacing restricting the filtered air flow over the outer surface of said stacked refrigerant-filled disks to prolong the air cooling period, said cooled air being discharged to the environment via said multi-directional air vent subassembly.

5. The air cooling device of claim 4, wherein said at least one air filter is a high-efficiency particulate air (HEPA) filter.

6. The air cooling device of claim 4, wherein said SAP refrigerant contains potassium polyacrylate gel.

7. The air cooling device of claim 4, wherein said SAP refrigerant contains sodium polyacrylate gel.

8. The air cooling device of claim 4, wherein said SAP refrigerant contains polyacrylamide gel.

9. The air cooling device of claim 4, wherein said stacked and interconnected hollow disks optimize the thermal mass surface area available for air flow.

10. The air cooling device of claim 4, wherein said substantially narrow channels afford a substantially planar air flow.

11. The air cooling device of claim 4, wherein each hollow disk has a substantially concave outer surface area.

12. The air cooling device of claim 4, wherein said first collar is equipped with a removable drip tray for collecting internal condensation.

13. The air cooling device of claim 12, wherein said drip tray is adapted to slide in/out of said first collar.

14. The air cooling device of claim 12, further comprising a base drain plate operatively disposed within said first collar and configured to drain condensation collected during device operation into said drip tray.

15. The air cooling device of claim 4, further comprising a base coupled within said first collar and configured to let incoming ambient air for cooling.

16. The air cooling device of claim 15, further comprising a filter frame.

17. The air cooling device of claim 16, wherein said filter is accommodated within said base.

18. The air cooling device of claim 4, further comprising a battery pack subassembly removably coupled to one side of said first collar.

19. The air cooling device of claim 18, wherein said subassembly is configured to accommodate a rechargeable battery adapted to power said fan blower during device operation.

20. The air cooling device of claim 4, wherein each of said first and second collars exhibits a substantially circular cross-section.

21. The air cooling device of claim 4, wherein said sleeve has a substantially tubular configuration.

22. An air cooling device, comprising:

a thermal core constructed from a series of interconnected hollow disks to optimize thermal efficiency, said interconnected hollow disks containing super-absorbent polymer (SAP) gel in a frozen state;

a thermal insulating sleeve adapted to operatively enclose said frozen core, said enclosure affording a substantially narrow interior sleeve spacing for air flow;

a fan blower operatively coupled to said thermal insulating sleeve and adapted to draw ambient air within said interior sleeve spacing and over the outer surface of said enclosed frozen core against gravity for cooling; and

a plurality of substantially narrow surface air flow channels being formed between said interconnected disks, said substantially narrow surface air flow channels and interior sleeve spacing restricting the ambient air flow over the outer surface of said frozen core to prolong the air cooling period.

23. The air cooling device of claim 22, wherein said SAP gel contains potassium polyacrylate.

24. The air cooling device of claim 22, wherein said SAP gel contains sodium polyacrylate.

25. The air cooling device of claim 22, wherein said SAP gel contains polyacrylamide.

26. An air cooling device, comprising:

a plurality of interconnected hollow disks being stacked and supported on top of each other via structural ribs, said stacked and interconnected hollow disks containing super-absorbent polymer (SAP) gel in a frozen state;

a thermal insulating sleeve adapted to enclose said frozen disks while affording substantially narrow interior sleeve spacing for air flow;

a first collar configured to receive the bottom portion of said thermal insulating sleeve;

a second collar configured to receive the top portion of said thermal insulating sleeve;

a front apron adapted to hold said first and second collars together over a lateral portion of said thermal insulating sleeve;

a cap portion rotatably coupled to said second collar;

a fan blower operatively housed in said cap portion over the top portion of said thermal insulating sleeve, said fan blower adapted to draw ambient air within said interior sleeve spacing and over the outer surface of said enclosed frozen disks against gravity for cooling; and

a plurality of substantially narrow surface air flow channels being formed between said stacked disks, said substantially narrow surface air flow channels and interior sleeve spacing restricting the ambient air flow over the outer surface of said stacked frozen disks to prolong the air cooling period.

27. The air cooling device of claim 26, further comprising an aroma therapy disk.

28. The air cooling device of claim 27, wherein said aroma therapy disk is operatively coupled to said second collar.

29. The air cooling device of claim 3, further comprising an aroma therapy disk.

30. The air cooling device of claim 29, wherein said aroma therapy disk is operatively coupled to said second collar.