Evaporative Cooling System

Abstract

A device for cooling the surface of an object or the skin of a person or animal comprising a plurality of evaporator fins, each having a substantially planar horizontal portion for making contact with an object to be cooled, one or more vertical portions attached to or continuing from the horizontal portion that extends upward there from, and a fabric layer disposed on a surface of the vertical portion. The device includes a support member comprised of one or more parts that connect the plurality of evaporator fins into a larger structure, and can include means to urge the horizontal portions of the evaporator fin assembly against a surface to be cooled. The device can also be embodied as one or more pieces of fabric with a plurality of convoluted evaporator fins adhered to it.

Description

PRIORITY CLAIM

None

FIELD OF THE INVENTION

The present invention relates generally to cooling devices, and more particularly to evaporative coolers that can be used to cool the surface of an object or the skin of a person or animal.

BACKGROUND OF THE INVENTION

On hot days and in hot environments, people have used many methods to cool themselves, as well as their animals, food, drinks, and possessions. Today, many cooling technologies are available, but most fail to provide adequate cooling for portable applications or in applications requiring little or no power. Because the evaporative cooling effect of water and other fluids is simple and economical to harness, many personal evaporative cooling systems have been developed and refined over the years.

U.S. Pat. No. 2,010,132, issued on Aug. 6, 1935 to C. Bischoff disclosed a reservoir having an attached metallic evaporating plate and a distributor for continuously applying a volatile liquid contained in the reservoir to a cellulose backing on the plate. The limit in any such system is the ratio of cooling surface area to target contact area. This system would only provide a 1:1 ratio, which provides minimal benefit over sweating. The same limitation applies to U.S. Pat. No. 2,875,447 A by Goldmerstein, which describes evaporative cooling gear based on bonding a fabric to a metallic band.

U.S. Pat. No. 5,775,590 by Utter (Jul. 7, 1998) and U.S. Pat. No. 5,671,884 by Restive (Sep. 30, 1997) describe devices consisting of a portable water reservoir that, when pressurized by a user, propels water through a hose and out through a tiny nozzle, spraying the user with a fine water mist. U.S. Pat. No. 6,543,247 by Strauss (Apr. 8,2003) discloses a device that is strapped to the front or rear of a user's body and blows air mixed with a water mist up the front or back of a user's body under his or her shirt or blouse. All such misting approaches have the same limit as above, which is that they don't increase the evaporative surface area and thus offer only marginal cooling beyond that provided by sweating.

U.S. Pat. No. 6,257,011 by Siman-Tov, et al. (Jul. 10, 2001) reveals a portable lightweight cooling garment having a channeled sheet that absorbs sweat and/or evaporative liquid, a layer of highly conductive fibers adjacent to the channeled sheet and a device for moving air through the sheet.

U.S. Pat. No. 6,134,714 by Uglene (Oct. 24, 2000) discloses a personal cooling garment with inner and outer layers defining a confined space for containing liquid that can evaporate to create a cooling effect. The drawback of both approaches is that they do not increase the surface area beyond what is provided by the user's skin, and therefore can only make the evaporative cooling effect somewhat more consistent, but not more cooling than perspiring on a breezy day.

U.S. Pat. No. 3,125,865 issued to Bemelman et al (Mar. 24, 1964) described a garment covered at intervals with capillary fibers radiating from a base fabric and adhered to it with a thermally conductive glue. In practice, such an arrangement of materials is unsightly and ineffective.

U.S. Pat. No. 8,530,720 B2 by Freer et al describes a bandage for cooling burn wounds comprised of a number of thermally conductive elements in contact with a fabric. This invention does not employ the evaporating cooling effect because it does not dispose a fluid-wicking fabric on the surfaces exposed to the air. Because of this, it would only provide minimal cooling of the fabric by dissipating heat radiating from the wound through the fabric, into the elements, and then into the air.

U.S. Pat. No. 5,802,865 by Strauss (Sep. 8, 1998) discloses a cooler that uses a fan to evaporate water from a powder-coated heat sink within the device and delivers the resulting coolness to the neck or forehead of a user. Because this device is not flexible, it must be made to fit specific neck or head sizes and is not appropriate for applications needing flexibility. Also, the powder coated heat sink is not nearly as effective as fabric, and creates severe limits in the production of truly efficient evaporator fins.

U.S. Pat. No. 7,721,349 B1 by Strauss describes a wide range of devices based on a system using a plurality of metallic fins with grooved surfaces to evaporate water. The invention also uses fabric to supply water and provide common support for the evaporative elements. The limitation here is that the grooved fins are expensive to produce and inefficient at evaporating water.

SUMMARY OF THE INVENTION

In the present invention, the first object is achieved by providing a cooling device comprising a plurality of evaporator fins, each having; a substantially planar horizontal portion for making contact with an object to be cooled, a vertical portion attached to or continuing from the horizontal portion that extends upward there from, a fabric layer disposed on a surface of at least one of the horizontal and vertical portions, a support member comprised of one or more parts that connect the plurality of evaporator fins into a larger structure.

A second aspect of the invention is characterized by the above cooling device of wherein the support member extends through a slot formed in a root of the vertical portion of each evaporator fin that is adjacent the horizontal portion thereof.

Another aspect of the invention is characterized by the above cooling device further comprising evaporator fin guards that cover the edges of the vertical portions of the evaporator fins.

Another aspect of the invention is characterized by any of the above cooling device wherein the fabric layer extends over the horizontal and vertical portion of each evaporator fin and is a portion of a continuous common fabric layer disposed on the first and second vertical portions.

Another aspect of the invention is characterized by any of the above cooling device wherein the fabric layer is common to at least portions of a plurality of evaporator fins in the device.

Another aspect of the invention is characterized by any of the above cooling device wherein one or more evaporator fins of the plurality include tabs used to crimp over portions of the evaporator fin guards to hold them in place.

Another aspect of the invention is characterized by any of the above cooling device wherein the support member is curved to form an arc that subtends an angle greater than 180 degrees.

Another aspect of the invention is characterized by any of the above cooling device wherein the evaporator fins are attached to a support member as a one-dimensional array.

Another aspect of the invention is characterized by any of the above cooling device wherein the evaporator fins are attached to a support member as a two-dimensional array.

Another aspect of the invention is characterized by the any of above cooling device wherein each evaporator fin is formed by bending a flat portion of metal having a fabric layer attached to at least one side thereof.

Another aspect of the invention is characterized by any of the above cooling device further comprising a second fabric layer that is in substantial contact with the fabric layers of each evaporator fin to provide a fluid reserve capacity.

Another aspect of the invention is characterized by any of the above cooling device further comprising a reservoir with a wick that communicates fluid to a common wick or to the fabric layer of one or more evaporator fins.

Another aspect of the invention is characterized by any of the above cooling device further comprising at least a second fabric layer disposed on the support member that contacts the fabric layers of each evaporator fin to provide a fluid reserve capacity and wicks fluid between evaporator fins

Another aspect of the invention is characterized by any of the above cooling device further comprising at least a second fabric layer disposed on the support member that contacts the fabric layers of each evaporator fin to provide a fluid reserve capacity and wicks fluid between evaporator fins.

Another aspect of the invention is characterized by any of the above cooling device that additionally includes means to urge the horizontal portions of each evaporator fin against a surface to be cooled.

Another aspect of the invention is characterized by any of the above cooling device wherein one or more evaporator fins in the plurality form a fin strip by including one or more additional vertical portion(s) attached to or continuing from said horizontal portion that are covered with a fabric layer.

Another aspect of the invention is characterized by any of the above cooling device comprised of a plurality of said fin strips.

Another aspect of the invention is characterized by any of the above cooling device comprising a common support member that connects said fin strips into a larger array.

Another aspect of the invention is characterized by any of the above cooling device in which said common support member is made of fabric.

Another aspect of the invention is characterized by any of the above cooling device wherein a skin-facing surface of the evaporator fins have one or more thermally conductive post-like extensions designed to penetrate human hair or animal fur and touch the user's skin.

Another aspect of the invention is characterized by any of the above cooling device that additionally includes means to connect the evaporator fins into an array.

Another aspect of the invention is characterized by any of the above cooling device that further comprises means to urge the evaporator fin bases against a surface to be cooled.

Another aspect of the invention is characterized by a cooling device comprising an array of convoluted evaporator fins and a hydrophilic fabric bonded to one or more portions of said evaporator fins.

Another aspect of the invention is characterized by the above cooling device comprised of one or more pieces of fabric with a plurality of convoluted evaporator fins adhered to it.

Another aspect of the invention is characterized by any of the above cooling devices further including means to urge the evaporator fin bases against a surface to be cooled.

Another aspect of the invention is characterized by a cooling device comprising a plurality of evaporator fins disposed in an at least one dimensional array for urging against a member or surface to be cooled, each evaporator fin having a lower portion and an upper portion opposed from the lower portion, a fabric for supporting the at least one dimensional array of cooling fins at the lower portion thereof and covering at least a portion thereof, a barrier layer spaced apart from the fabric and disposed above the upper portions of the plurality of evaporator fins to provide a channel to receive air forced across the evaporator fins

Another aspect of the invention is characterized by the above cooling device further comprising a fan disposed in fluid communication with the channel to force air from outside the cooling device into the channel.

Another aspect of the invention is characterized by the above cooling device wherein the barrier layer comprises a fabric layer that is operative as a fluid reservoir that is disposed facing the channel and an air impenetrable layer disposed on the opposing side of the fabric layer that faces away from the channel.

The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a schematic perspective view of a single evaporator fin with one vertical portion.

FIG. 2 is a schematic perspective view of a single evaporator fin with two vertical portions.

FIG. 3 is a schematic perspective view of a single evaporator fin with extension tabs.

FIG. 4A is a schematic perspective view showing an operative portions of a neck cooling device, whereas FIG. 4B is a side elevation view thereof.

FIG. 5 is a schematic perspective view of a portion of a cooling device with a two-dimensional array of evaporator fins.

FIG. 6 is a schematic perspective view of an evaporator fin strip with multiple vertical portions.

FIG. 7 is a schematic perspective view of a single evaporator fin for use with cooling fabric.

FIG. 8 is a schematic perspective view of a fabric with multiple evaporator fins bonded to it for cooling smooth surfaces.

FIG. 9 is a schematic perspective view of a single evaporator fin for use with cooling skin covered with hair or fur.

FIG. 10 is a schematic perspective view of a fabric with multiple evaporator fins bonded to it for cooling skin through hair or fur.

FIG. 11 is a schematic cross-sectional elevation illustrating the operative principles of an evaporative cooling device that deploys the fabric and fins of FIG. 8 with a means for forcing air.

FIG. 12 is a schematic perspective view illustrating the operative principles of an evaporative cooling device that deploys the fabric and fins of FIG. 11 with an additional water reservoir shown in a cut away view.

REFERENCE NUMERALS

• 1000: evaporative cooling device
• 50: Forced Air
• 100: Evaporator Fin
• 110: Horizontal Evaporator Fin Portion
• 120: Vertical Evaporator Fin Portion
• 130: Crimp tab
• 200: Fabric
• 210: Support Member
• 220: Evaporator Fin Guard
• 230: Reservoir
• 231: Foam
• 232: Snap Cap
• 240: Evaporator Fin Strip
• 250: Fan
• 260: Target Surface
• 270: Barrier
• 280 Evaporator Fin Extension
• 281 Evaporator Fin Extension Tab

DETAILED DESCRIPTION

Referencing FIG. 1, the various embodiments of the cooling device 1000 are comprised of a plurality of thermally conductive Evaporator Fins 100. Each Evaporator Fin 100 has a substantially planar Horizontal Evaporator Fin Portion 110 for making contact with an object to be cooled, and a Vertical Evaporator Fin Portion 120 that extends or continues upward from said horizontal portion. Each Evaporator Fin 100 additionally has a layer of Fabric 200 disposed on at least a portion of Vertical

Evaporator Fin Portion 120. All embodiments additionally employ a common Support Member 210 to assemble the plurality of Evaporator Fins 100 into a larger structure. FIG. 4 shows a springy metal or plastic material being used as Support Member 210. FIG. 8 shows that Fabric 200 can itself be used as a continuous substrate or support member that Evaporator Fins 100 are adhered to or in continuous contact with.

More specifically, FIG. 1 depicts a single Evaporator Fin 100 with one Horizontal Evaporator Fin Portion 110 and one Vertical Evaporator Fin Portion 120. For maximum evaporative surface, Fabric 200 is bonded to the top surface of Horizontal Evaporator Fin Portion 110 and on both sides of Vertical Evaporator Fin Portion 120. Evaporator Fins 100 are preferably bonded to Fabric 200 using a hot melt adhesive film. Thermally conductive Evaporator Fins 100 are preferably made of aluminum for high thermal conductivity and low cost.

Together, all Evaporator Fin 100 surfaces that are covered with fabric and exposed to air comprise the total effective evaporative surface (EES) of the device. The EES does not include portions where fabric is bonded to fins, but the fabric is covered with an Evaporator Fin Guard 220 or the like, because that would block evaporation. The EES also doesn't include portions where Evaporator Fins 100 are not covered with fabric or the like, because without the moist fabric contacting the fins, the evaporative cooling cannot be conducted to Target Surface 260. The higher the total ESS is relative to the total contact area with Target Surface 260 (EES/TS ratio), the more cooling the device, assuming the evaporative surfaces aren't so close together as to restrict airflow. ESS/TS ratios of 1:1 provide little benefit over sweating except consistent supply of water and a surface optimized for evaporation. The embodiments depicted below all have ESS/TS ratios exceeding 3:1, although ratios closer to 2:1 are expected to work better for clothing.

The only way to achieve ESS/TS ratios exceeding 1:1 in device 1000 is to have one portion (Horizontal Evaporator Fin Portion 110) of Evaporator Fins 100 in contact with Target Surface 260, and another portions (Vertical Evaporator Fin Portion 120) extending preferably perpendicular to the first portion. The taller the vertical portions are, the greater the ESS/TS ratio will be, making the device more effective. While the above description of vertical fin portions extending perpendicular to horizontal fin portions is the most effective approach to increasing the EES/TS ratio, any convoluted shape can be used to achieve aesthetic or functional objectives. Convoluted means having one or more folds, creases, indents, outdents, or extended areas, causing Evaporator Fins 100 to deviate from a planar surface.

It should be appreciated that Horizontal and Vertical are relative terms, with horizontal fin portion generally meaning the fin portion that is configured for contacting and urging against a lateral expanse of the target surface 260 to be cooled. Accordingly the support surface preferably has the same outer shape or can be urged to conform to the same outer shape as the target surface 260 to be cooled.

It should also be understood that for embodiments in which the support member is fabric it is optionally related to the fabric layer portion of the fin as a part of the same fabric expanse that extends between the fins so that most of the fins are connected to this common fabric expanse at the fin horizontal portion.

Alternatively, such a fabric support member can be a distinct fabric body than that disposed on the vertical portion of the fins. In such case the distinct fabric body could have properties appropriate for attachment to or over an object or person, water reservoir properties and/or different wicking or evaporative properties than the fabric that is on the fin vertical portions. It should be understood that most fabrics are inherently hydrophilic as the pore structure and surface tension provides a tendency to wick water. Such water wicking can be enhanced by the fabric also having a tendency to absorb water within the fiber, like cotton, wool and other natural fibers.

Previous systems for evaporative cooling of people, pets, and objects by contact have provided limited power and usefulness, especially in portable applications requiring the use of little or no power. The present invention improves on prior art by disposing a fabric on convoluted evaporator fin surfaces. This approach is far more effective for evaporating water or fluids and therefore for moving heat versus using evaporator fin surfaces formed with capillary grooves. It also reduces, and in some cases, eliminates the need for a separate fluid reservoir, making the device easier to make and use, and more affordable. Fabric can also serve as a common support member and as a medium for wicking fluid between evaporator fins. The invention of disposing fabric on the evaporator fins allows for numerous efficient and cost-effective embodiments of the device, most notably including fabrics that create a powerful cooling effect while using zero energy.

The present invention provides for a whole new class of cooling devices that offer numerous advantages over prior art. Such devices can offer long-term cooling relief, operate on zero power and be . . .

1. Smooth, flexible, and comfortable when worn against a user's body

2. Rigid when used to cool inflexible objects

3. As effective as air conditioning

4. Made and sold inexpensively

5. Lightweight and unobtrusive

6. Made to prevent wetting a user's skin or clothing

7. Embodied as clothing, uniforms, protective garments, accessories, or blankets

8. Made to cool food, beverages, or anything that gets too hot

9. Designed to deliver cooling relief through hair or fur

Forced air embodiments of this innovation can be

1. Embodied as jackets, coats, and other outerwear

2. Worn under a backpack, uniforms, motorcycle leathers, or other heavy garments

3. Adapted to helmets, protective gear, or ordinary clothes

4. Embodied as devices with adjustable cooling

5. Automatically controlled to maintain a relatively constant skin temperature

Further advantages will become apparent from a consideration of the drawings and ensuing description.

FIG. 2 depicts a single Evaporator Fin 100 with two vertical Portions 120. Fabric 200 is preferably bonded to all surfaces except the portions in contact with Target Surface 260.

FIG. 3 illustrates that Evaporator Fins 100 stamped from flat metal sheets can include Evaporator Fin Extension Tabs 281 that extend down through hair or fur to touch skin.

FIG. 4 depicts a portion of a cooling device showing several Evaporator Fins 100, each with Fabric 200 bonded to one side, assembled together on Support Member 210. In this embodiment, Support Member 210 passes through slits near the bases of Evaporator Fins 100. Support Member 210 may provide rigid, flexible, or elastic means for connecting Evaporator Fins 100. In a neck cooler embodiment, Support Member 210 is preferably made of a C-shaped springy stainless steel to urge Horizontal Evaporator Fin Portions 110 against a user's skin. The C-shaped springy, which is elastic, steel or other metal of support member 210 support, is curved to form an arc that subtends an angle greater than 180 degrees. Hence, when it is urged open to place around a users neck, it will spring closed to provide a means to urge the connecting member against the users neck that is intended to be cooled. It should be appreciated that other connecting members, such as elastic fabrics that support evaporator fins, can also provide equivalent means to urge the connecting member and hence the fin horizontal surfaces against an object to be cooled.

Evaporator Fin Guards 220 provide a means for connecting Evaporator Fins 100 together, protecting the user from potentially sharp edges of Evaporator Fins 100, and preventing water in Fabric 200 from wicking onto the user's shirt. Crimp Tabs 130 are crimped over posts that project laterally from the bottom of Fin Guards 220 to hold them in place.

FIG. 5 shows a two dimensional array of Evaporator Fins 100 in. The fins in such an array can be connected by attaching Evaporator Fins 100 to a common Support Member 210, which itself could be a fabric.

Evaporator Fins 100 are preferably made by bonding fabric to aluminum, then stamping into the desired shape. Some embodiments may require stamping the aluminum parts first, then applying fabric; however this approach will likely be more expensive. The currently preferred thickness of

Evaporator Fins 100 is approximately 0.01-0.03″. Fabric 200 thickness can vary, but at 0.04″ thick, it is thick enough to provide water for approximately 1 hour of use, while cooling at approximately 85% of peak potential. When Fabric 200 is thinner, it generally promotes more rapid evaporation, but stores less water.

FIG. 6 depicts a single aluminum strip with Fabric 200 adhered to one side that has been folded to create Evaporator Fin Strip 250 with four Horizontal Evaporator Fin Portions 110 and five Vertical Evaporator Fin Portions 120. A single such Evaporator Fin Strip 240 can be used as a complete cooling device by adding means to attach it to a surface to be cooled. In additional embodiments, which are not intended to be mutually exclusive, Multiple Evaporator Fin Strips 240 can be assembled into larger cooling panels using any means. They can also include Evaporator Fin Extension Tabs 281 that extend down through hair or fur to touch skin.

FIG. 7 depicts a single Evaporator Fin 100 designed for use in a cooling fabric. This part is preferably approximately 0.3″ in diameter, and made of stamped or otherwise convoluted aluminum. FIG. 8 shows an array of such Evaporator Fins 100 bonded to Fabric 200.

For such a cooling fabric to work, all of the following conditions must be met:

1. Sufficient Evaporator Fin 100 surface area is continuously adhered to Fabric 200,

2. Evaporator Fins 100 must have a thermal conductivity rating of at least 35 W/mK,

3. A portion of each Evaporator Fin 100 is open to air contact, and

4. A portion of each Evaporator Fin 100 is in contact with Target Surface 260.

Evaporator Fins 100 can be applied to Fabric 200 by any suitable means, including:

1. By applying a hot melt adhesive to the surface of Fabric 200 or Evaporator Fins 100, then heating Evaporator Fins 100 while pressing them into Fabric 200. By applying a negative die on the reverse side, Fabric 200 is forced to stretch, conform, and adhere to the surfaces of Evaporator Fins 100.

2. By making Fabric 200 of a material that will adhere to Evaporator Fins 100 when the Evaporator Fins are heated and pressed into said fabric. This variation would allow for the fabric to be simultaneously pressed into a thinner profile where it touches Evaporator Fins 100, thereby further increasing evaporative efficiency.

3. By using a plastic or metal snap fitting to mechanically retain the fabric against the surfaces of Evaporator Fin 100. it could be applied from the top, having 4 fingers that press Fabric 200 into the interior corners of Evaporator Fins 100, and a fifth finger that goes through a vertical hole in the center of Evaporator Fins 100. If the snap fitting is plastic, it can then be heat staked in a countersink cavity on the underside of Evaporator Fins 100. If it is metal, it can be smacked in the manner of a rivet so the finger that extends into the countersink cavity will expand, holding it in place.

4. By sewing Evaporator Fins 100 to Fabric 200. In this case, holes will be included in necessary locations around the bases of Evaporator Fins 100 for sewing.

5. By cutting slits in Fabric 200 to accommodate penetration of Vertical Evaporator Fin Portions 120 through said slits. Evaporator Fins 100 would first be covered with Fabric 200, which will not continue past the margins of Horizontal Evaporator Fin Portions 110. Once an Evaporator Fin 100 is pressed through the slits, Fabric 200 on Horizontal Evaporator Fin Portion 110 will be glued to Fabric 200 in which said slits were created. This arrangement allows for thin fabric covering Evaporator Fins 100, which is more efficient for evaporation, and thicker fabric in the lattice between Evaporator Fins 100, which is preferable as a reservoir.

Evaporator Fins 100 may also include one or more downward, skin-facing Evaporator Fin Extensions 280 designed to penetrate human hair or animal fur to deliver cooling relief to the user's skin. FIG. 9 shows a single Evaporator Fin 100 with a single downward-facing Evaporator Fin Extension 280. FIG. 10 shows an array of Evaporator Fins 100, each having an Evaporator Fin Extension 280.

By making Evaporator Fins 100 very small and bonding them with a very thin Fabric 200, a cooling bandage can be made that would effectively draw heat from burn wounds.

Forced air embodiments maximize the evaporative cooling power in low airflow applications, including personal cooling indoors, and cooling users wearing heavy garments such as motorcycle leathers, protective garments, thermal, chemical, and other environmental protection suits, bulletproof vests, and space suits.

FIG. 11 depicts a forced air embodiment with Evaporator Fins 100 of the shape depicted in FIG. 7, but Evaporator Fins 100 of any shape or configuration will work. By moving Forced Air 50 air across wet Fabric 200 covering Evaporator Fins 100, the water or fluid will evaporate more quickly, creating a strong cooling effect on Target Surface 260. A barrier layer 270 is paced apart from the fabric 200 and disposed above the upper portions of the plurality of evaporator fins 100 to provide a channel to receive air forced across the cooling fins 100. The Barrier 270, which may or may not touch or be attached to or detachable from the tops of Evaporator Fins 100, prevents air from passing through the device vertically, directing it horizontally across Evaporator Fins 100 disposed with the channel. The fan 250 can also be disposed at one end of the channel, to force or draw are into the channel so that the air exits at the other end of the channel or holes disposed in the barrier 270 for this purpose.

In the embodiment of FIG. 11, Fan 250 draws air in from vents open to the outside of the device 1000, across Evaporator Fins 100 until it reaches the area below Fan 250, where it exits vertically, returning to the space outside the device. Fan 250 could also be placed among Evaporator Fins 100. Barrier 270 may also be made of fabric to function as an additional fluid reservoir and/or as a common wick or support member. To prevent air from penetrating through fabric in such an embodiment, the fabric should be laminated with an air-impenetrable film, preferably on the top side, allowing water in Barrier 270 to wick onto Fabric 200.

Forced air embodiments preferably additionally provide power to drive Fan 250, and a switch to turn Fan 250 on and off. Said switch can also permit multiple or variable fan speeds. By placing thermostats on one or more Evaporator Fins 100, the device 1000 can control Fan 250 to respond automatically to thermal fluctuations.

Further and additional aspects of the invention may include one or more of the following features that can enhance one of more of the performance, versatility and user comfort in the above cooling devices, such as:

1. Means to urge said horizontal portions into contact with an object to be cooled. Such means can include but are not limited to:

a. cords or straps affixed to the distal ends of a device that wraps around an object or body part, and tie, snap, clip, or Velcro together

b. Elastic

c. Belt-and-buckle fixtures

d. “C”-shaped leaf springs

2. Should cooling power need to be reduced:

a. The device may include means to cover all or portions of the surfaces of Evaporator Fins 100 or the area surrounding them with any material that will reduce airflow to said surfaces. By completely enclosing the area around Evaporator Fins 100 with a tightly knit fabric or any material that does not readily allow air to pass through it, the device will stop cooling altogether once the area trapped around the fins is saturated with moisture.

b. The device may include means to cover all or portions of Evaporator Fin 100 bases, thermally insulating Evaporator Fin 100 bases from Target Surface 260.

3. A common wick may be added that delivers water through contact with Fabric 200 to all or a plurality or Evaporator Fins 100 or to portions of Fabric 200 between Evaporator Fins 100.

4. In embodiments where Fabric 200 is too thin to hold sufficient water, one or more additional water Reservoirs 230 may be desirable. FIG. 12 shows one type of reservoir encapsulated in a watertight housing with a enclosable filing port. In FIG. 12, Reservoir 230 is filled with hydrophilic Foam 231 and the bottom is open, placing Foam 231 in wicking contact with Fabric 200. Snap Cap 232 gives the user easy reclosable access for refilling. In simpler embodiments, Reservoir 230 may be additional fluid-wicking material, such as a piece of hydrophilic foam or fabric, disposed in wicking contact with Fabric 200, and need not include a housing or fluid-impenetrable barrier.

5. Evaporator Fin Guards 200 are not essential to the cooling function, but can provide three important functions:

a. Protect a user from potentially sharp Evaporator Fin 100 edges,

b. Prevent the device from communicating fluid to whatever it may touch, such as the shirt of a user, and

c. Hold Evaporator Fins together into a larger assembly.

6. A water-resistant or fluid impenetrable barrier film can be adhered to the underside of Fabric 200 to prevent liquid on the evaporative surfaces from wetting Target Surface 260.

7. A thin barrier film can be provided to cover the bottom of Horizontal Evaporator Fin Portions 110 that contact Target Surface 260. The barrier film would protect the device from being soiled by the user's skin oils and perspiration and protect the user's skin from contact with Evaporator Fins 100 for those with allergies to whatever material Evaporator Fins 100 are made of. The thinner such a barrier is, the less it will reduce the cooling effect from reaching the user's skin. To minimize the thermally insulating effect of such a barrier, it can be filled with a thermally conductive powder or fibers.

Many variations on the embodiments described above can be employed within the intended scope of the invention, such as those elaborated below.

While Evaporator Fins 100 are currently made preferably of aluminum for high thermal conductivity and cost effectiveness, other materials can be substituted. While aluminum has a thermal conductivity of approximately 200 W/mK, it is theoretically possible to accomplish sufficient heat transfer for this invention using any material with a thermal conductivity rating of at least 35 W/mK. Materials made with diamond, graphite, and other non-metallic thermally conductive substances will likely be substituted as costs decrease. Various materials may also be combined to create Evaporator Fins 100.

Evaporator Fins 100 can be any shape, but shapes that are not flat are preferred because they create more evaporative surface area than the contact area they are cooling. The higher the ratio of evaporative surface to the surface Evaporator Fins 100 are cooling the more effective the device will be. Vertical Evaporator Fin Portions 120 can deviate from 90 degrees relative to Horizontal Evaporator Fin Portion 110. Evaporator Fins 100 can also be arranged in any pattern whatever.

While Evaporator Fin Strips 240 are preferably made by adhering Fabric 200 to a strip of aluminum, then stamping it into a shape with multiple Vertical Evaporator Fin Portions 120, other approaches to creating multiple Vertical Evaporator Fin Portions 120 on the same Evaporator Fin 100 are possible. Evaporator Fin Strips 240 can be made by casting, direct metal laser sintering, and other additive and stamping processes, or by injection molding thermally conductive plastic. Fabric 200 can be adhered to such parts after manufacture, or said parts could be coated with wicking fibers, flocking, or other wicking materials.

Evaporator Fins 100 can be added to existing clothing. For example, an apparel manufacturer can take a plurality of Evaporator Fins 100 and bond them to a shirt. Also, a kit could be created that gives consumers the ability to insert Evaporator Fins 100 into existing clothing.

While using a hot melt adhesive film is the preferable means of bonding Evaporator Fins 100 to Fabric 200, any suitable adhesive or adhesive process can work. In all embodiments, as much of the surfaces of Evaporator Fins 100 as possible should be mated with Fabric 200. Any fabric not bonded to the surface of an evaporator fin will not provide cooling function. In embodiments where Fabric 200 is first bonded to Evaporator Fins 100, all available thermally conductive surfaces will be covered with fabric. However, in cooling fabric embodiments in which Fabric 200 is mechanically adhered to the surfaces of Evaporator Fins 100 such as by sewing or using mechanical snap fittings, care should be taken to insure continuous contact between Fabric 200 and Evaporator Fin 100 surfaces. While Fabric 200 need not be adhered to the surfaces of Evaporator Fins 100, it must have direct and continuous physical contact with said surfaces to be effective.

Fabric 200 bonded to Evaporator Fins 100 can be substituted with any material that readily wicks water, including but not limited to woven fabrics, non-woven fabrics, flocking, hydrophilic plastic foams, wet-laid fibers, sprayed fibers, and hydrophilic plastic or metal foams, including any combinations thereof. Any generally thin flexible, planar, and at least partially porous material, being generally formed of fibers and/or voids that absorb or wick fluids, can be used to fulfill the fabric function. The fabric has been described as hydrophilic, but it can also perform the wicking function with any liquid that will tend to evaporate in whatever atmospheric conditions it is used in.

Support Member 210 can be made of any suitable material or combination of materials. This can include, but is not limited to, metal, plastic, leather, and fabric. Support members made of fabric can also serve as a fluid reservoir and as a common wick when disposed in contact with Fabric 200 on Evaporator Fins 100. Support Member 210 can be flexible, stiff, elastic, or springy as needed and could also be hydrophilic to provide extra water or wicking function to the device.

In forced air embodiments, Fan(s) 250 or other air-moving means can be attached to any portion of the device and can even be made removable, allowing the device to be washed. Barrier 270 can also be made removable, so that it and/or the rest of the device can be washed separately. Barrier 270 can be made of any material and have any thickness. It can also be designed as a housing. Such a housing can protect a user and Evaporator Fins 100 from outside objects and forces. Barrier 270 can be impact resistant, and even bullet-proof. It can be made of a plurality of small pieces that interlock and/or overlap in the manner of fish scales, and/or can include wire mesh for physical protection.

Reservoir 230 may or may not be filled with hydrophilic foam or fabric and may or may not have an external housing or waterproof barrier. It could be replaced with a one or more pieces of hydrophilic foam or fabric that are simply attached to Fabric 200. A Reservoir 230 could also be designed to dispense water to Fabric 200 when pressed or squeezed.

Devices can be made that combine units for cooling several parts, such as head, forehead, and neck, and each section can be made detachable from the others. A jacket can be made with a detachable neck cooler portion, and/or with detachable upper and lower arm coolers. Pants can be made with one or more pairs of detachable lower portions, allowing the user to create cooling shorts of varying lengths as needed. A cooling suit can be made of many parts or pieces to be attachable and removable from each other. For complete thermal protection, a whole-body suit can be made in which each part or section can be removed or not.

Various embodiments can be combined in different areas of the device. Other heating and/or cooling means can be added to the device, such as electric heating elements, thermoelectric devices, heat pumps, etc., to extend the heating or cooling potential of the device. Other devices, such as radios, TVs, computers, audio/video recorders/players, cellular and cordless telephones, GPS systems, etc. can be incorporated into any embodiment.

Devices can vary in size, shape, color, and design, and still fall within the intended scope of the invention.

Claims

1. A cooling device comprising:

a. a plurality of evaporator fins, each having; i. a substantially planar horizontal portion for making contact with an object to be cooled, ii. a vertical portion attached to or continuing from the horizontal portion that extends upward there from, iii. a fabric layer disposed on a surface of at least one of the horizontal and vertical portions,

b. a support member comprised of one or more parts that connect the plurality of evaporator fins into a larger structure.

2. The cooling device of claim 1 wherein the support member extends through a slot formed in a root of the vertical portion of each evaporator fin that is adjacent the horizontal portion thereof.

3. The cooling device of claim 1 further comprising evaporator fin guards that cover the edges of the vertical portions of the evaporator fins.

4. The cooling device of claim 1 wherein the fabric layer extends over the horizontal and vertical portion of each evaporator fin and is a portion of a continuous common fabric layer disposed on the first and second vertical portions.

5. The cooling device of claim 1 wherein the fabric layer is common to at least portions of a plurality of evaporator fins in the device.

6. The cooling device of claim 1 wherein one or more evaporator fins of the plurality include tabs used to crimp over portions of the evaporator fin guards to hold them in place.

7. The cooling device of claim 1 wherein the support member is curved to form an arc that subtends an angle greater than 180 degrees.

8. The cooling device of claim 1 wherein the evaporator fins are attached to a support member as a one-dimensional array.

9. The cooling device of claim 1 wherein the evaporator fins are attached to a support member as a two-dimensional array.

10. The cooling device of claim 1 wherein each evaporator fin is formed by bending a flat portion of metal having a fabric layer attached to at least one side thereof.

11. The cooling device of claim 1 further comprising a second fabric layer that is in substantial contact with the fabric layers of each evaporator fin to provide a fluid reserve capacity.

12. The cooling device of claim 1 further comprising a reservoir with a wick that communicates fluid to a common wick or to the fabric layer of one or more evaporator fins.

13. The cooling device of claim 1 further comprising at least a second fabric layer disposed on the support member that contacts the fabric layers of each evaporator fin to provide a fluid reserve capacity and wicks fluid between evaporator fins.

14. The cooling device of claim 1 that additionally includes means to urge the horizontal portions of each evaporator fin against a surface to be cooled.

15. The cooling device of claim 1 wherein one or more evaporator fins in the plurality form a fin strip by including one or more additional vertical portion(s) attached to or continuing from said horizontal portion that are covered with a fabric layer.

16. The cooling device of claim 15 comprised of a plurality of said fin strips.

17. The cooling device of claim 15 further comprising a common support member that connects said fin strips into a larger array.

18. The cooling device of claim 1 in which said common support member is made of fabric.

19. The cooling device of claim 1 wherein a skin-facing surface of the evaporator fins have one or more thermally conductive post-like extensions designed to penetrate human hair or animal fur and touch the user's skin.

20. The cooling device of claim 1 that additionally includes means to connect the evaporator fins into an array.

21. The cooling device of claim 20 that further comprises means to urge the evaporator fin bases against a surface to be cooled.

22. A cooling device comprising an array of convoluted evaporator fins and a hydrophilic fabric bonded to one or more portions of said evaporator fins.

23. A cooling device comprised of one or more pieces of fabric with a plurality of convoluted evaporator fins adhered to it.

24. The cooling device of claim 23 further including means to urge the evaporator fin bases against a surface to be cooled.

25. A cooling device comprising:

a. a plurality of evaporator fins disposed in an at least one dimensional array for urging against a member or surface to be cooled, each evaporator fin having a lower portion and an upper portion opposed from the lower portion,

b. a fabric for supporting the at least one dimensional array of cooling fins at the lower portion thereof and covering at least a portion thereof,

c. a barrier layer spaced apart from the fabric and disposed above the upper portions of the plurality of evaporator finds to provide a channel to receive air forced across the evaporator fins.

26. The cooling device of claim 25 further comprising a fan disposed in fluid communication with the channel to force air from outside the cooling device into the channel.

27. The cooling device of claim 25 wherein the barrier layer comprises a fabric layer that is operative as a fluid reservoir that is disposed facing the channel and an air impenetrable layer disposed on the opposing side of the fabric layer that faces away from the channel.