QL+ Body Temperature Regulating Vest

Project 43.a.01
QL+ Challenger: Lisa Maddox Faculty Advisor: Dr. Richard Savage
Melissa Goss Brittnee Cubero Dillon Lynch Greg Olsen Julian Jazayeri Team Members mgoss@calpoly.edu bcubero@calpoly.edu delynch@calpoly.edu gmolsen@calpoly.edu jjazayer@calpoly.edu

Table of Contents
Introduction ........................................................................................................................... 3 Background Information .......................................................................................................... 4 Current Devices .............................................................................................................. 4 Studies of Interest .......................................................................................................... 5 Codes & Standards ........................................................................................................ 6 Objectives ............................................................................................................................. 6 Design Development ............................................................................................................. 9 Liquid Filled Cooling ....................................................................................................... 9 Evaporative Cooling ......................................................................................................10 Conductive Material .......................................................................................................10 Decision Matrices ..........................................................................................................11 Top Concept .........................................................................................................................11 System Block Diagram ..................................................................................................11 Meeting Project Requirements ......................................................................................13 Supporting Work ............................................................................................................14 Preliminary Manufacturing Plans .......................................................................................... 14 Preliminary Validation Plans .................................................................................................16 Method of Approach ......................................................................................................17 Budget Allocation ..........................................................................................................18 References ............................................................................................................................ 19 Appendices ............................................................................Error! Bookmark not defined.0 Appendix A ....................................................................................................................20 Appendix B ....................................................................................................................21 Appendix C .................................................................................................................... 22 Appendix D .................................................................................................................... 22 Appendix E .................................................................................................................... 23 Appendix F .................................................................................................................... 26 Appendix G ................................................................................................................... 26

Introduction
Stakeholders/Target Audience
Individuals diagnosed with spinal injuries are oftentimes unable to regulate their body temperature below the site of injury. Unaffected individuals regulate their body temperature through conduction, evaporation and radiation methods. Conduction heat loss occurs when the body comes into contact with a cooler surface (i.e. the ground), but evaporation and radiation heat loss depends on signals from the bodys control center. Individuals with spinal damage are unable to relay messages from their sensory neurons to the hypothalamus [1]. As a result, the hypothalamus is unable to stimulate vasodilation and sweating to induce heat loss. When temperatures exceed 104F, the inability to induce heat loss mechanisms poses threats to affected individuals. Specifically, elevated temperatures cause organ malfunctioning, cardiovascular problems and potentially death [2]. Therefore, the purpose of this project is to produce a vest that is capable of maintaining the core body temperature of individuals with spinal injuries at 98.6F.

Challenger background and needs

The proposer of this project is Lisa Maddox. Maddox is a practicing MD that works with multiple sclerosis patients. She has requested a design for a thermal vest that is capable of cooling and heating to maintain an average body temperature of 98F. Ideally this device should regulate the core body temperature in environments that reach 110F.

Purpose of the project

The purpose of this project is to design a vest capable of maintaining an individuals core temperature at 98F. Current vest models exist that utilize ice packs that are inserted into vest pockets. However, once ice packs melt, the excess water increases the overall weight of the vest. In addition, these vests only cool the body for a limited amount of time. The overall purpose of this project is to create a batteryoperated, light-weight, and functional vest that individuals will be inclined to use on a regular basis in warm environments.

Project & Team Description

This is a two-quarter long project that aims to design a body temperature regulated vest. The first quarter will be spent forming an initial design. The second quarter will be dedicated to building, testing and revising the initial design. The project team is composed of five members from biomedical, mechanical and materials engineering backgrounds. Melissa Goss will serve as the team lead to coordinate all correspondence with QL+, manage the project budget and submit project reports. Greg Olsen will serve as the lead communicator with the project challenger and faculty. Other members will be appointed various positions as the design process develops.

Background
Current Devices
Currently, there are five leading types of thermal vests: Ice-pack, evaporative cooling, phase change, fluid cooling and air cooling. A detailed analysis of each vest type is included below. Further specifications for all devices are included in Appendix A. Ice-Pack Vest Ice-Pack vests involve inserting frozen ice-packs into the pockets of jackets. Ice-Pack vests can last anywhere between two to four hours [3]. Ice-pack vests are low-cost, have a high cooling power and the ice packs are able to be reused. However, after melting ice-pack vests can weigh between five and ten pounds. In addition the ice-packs require time to re-freeze. Another disadvantage is the fact that the vest is always in use, even when the body temperature is already at 98F. One current model is the kold-vest [4]. This device uses ice packs to induce cooling. The vest can operate for up to two hours. This is a light-weight design that uses reusable ice packs. The vest costs around $150.00. Evaporative Cooling Vests Evaporative cooling devices use polymer materials soaked in water [5]. Over time, the water will evaporate from the vest in order to cool the bodys surface. The device must be submerged in water for 13 minutes in order to operate for a period of 5-10 hours. These devices are often lightweight, low in cost, have high performance in dry climates, offer durability, operate without the use of ice packs, demonstrate a long performance time. However, these devices require soaking the garment in water which can be inconvenient for the user, have poor performance in high humidity climates and have the lowest overall cooling energy. One current product is Gemplers Evaporative Cooling Vest [6]. The vest is composed of a polymer embedded fabric that is activated by water. This device must be submerged in water for 1-2 minutes and has an operating time of 5-10 hours. This design costs approximately $36.15. Phase Change Vests Phase change vests use a polymer formula to help aid in cooling. Phase change materials become activated at a certain temperature between 0-30C [7]. In a thermal vest, the phase change material would become activated when the body reaches a certain temperature. At this point, the phase change material would begin to melt in order to cool the body primarily through conduction mechanisms. Common phase change materials include ice packs, dry ice, and the most commonly used: paraffin wax. Typically these vests range in cost between $150 and $300. The phase change material is able to cool an individual between 2-3 hours [7]. This method is a passive process that offers a controlled release of a constant temperature which makes these devices easily customizable. They do not require the use of a freezer, and they offer an effective cooling method in all climates. The disadvantages include high cost replacement parts and heavy weight after melting. However, these devices can only cool for approximately 3 hours, they weigh more than other cooling devices, they can have a higher cost and their total cooling power is less than cold pack systems A current model is the Cooling Vest of TST Sweden AB [8]. This model inserts PCM material into the pockets inside the vest. The PCM material melts at 28C and can cool the body for up to two hours. The vest can be recharged in an air conditioned room, a refrigerator or freezer. Another advantage is that the vest weighs only 2 kilograms.

Fluid Cooling Active cooling vests pump coolant through a series of tubes embedded within the vest. The coolant can be activated by temperature sensors and the temperature of the coolant can be adjusted. This design can cost up to $500. The advantages of this design include high efficiency, long cooling periods, can quickly remove a large amount of heat and no wetting is required. The disadvantages include high cost, high energy requirements, need for a water reservoir and the use of a pump. They are also heavier designs that limit the movement of the user. Current models of this device include the Polar Active cooling vest [9]. This product circulates cool water through the vest. It comes in both fitted and adjustable versions. The vest uses a 15 quart wheeled cooler to provide water to the device. The device and cooler are connected by a retractable cord that can be disengaged when not in use. The product costs $810 per vest. Air Cooling These devices direct compressed air around the body from an air supply system which allows excess sweat to be removed through evaporation. These devices are very comfortable, lightweight, and easily adjustable. However, these devices require more energy and therefore add expenses. Current market products include the Kool-Vest [10]. Fresh air is distributed through small holes in the vest to provide evaporative cooling across the worker's back, chest, and face. The vest operates with only 10 - 20psi to accommodate a vortex cooling tube. Another market product is the Personal Air Conditioner [11]. This device uses vortex tubes to separate compressed air into warm and cool streams. The advantage of this model is that it can heat and cool an individual. The disadvantages include high market price (approximately $500+) and the requirement to be connected to compressed air.

Studies of Interest
Thermoelectric Cooling These devices run electric current through the wires of the thermoelectric coolers which apply a voltage of constant polarity to a junction between two metals. This creates a hot and a cold side, with heat sinks that are responsible for transferring the thermal energy from the hot object, in this case the skin, to an object with a lower temperature, the environment. This method is compact, inexpensive, and allow for the process to be reversed, presenting the option of the vest to not only cool, but to also heat. These systems are also inefficient when compared to alternative cooling methods, and they require a constant supply of power. One study using this method incorporated a thermoelectric cooler into an evaporative cooling design[5]. Evaporative Cooling Another study of interest is the Personal-portable Cooling Garment Based on Adsorption Vacuum Membrane Evaporative Cooling by Yifan Yang [12]. Yang designed a thermal vest that used evaporative 2 cooling methods. Using the AVEC cooling method, a cooling capacity of 179 W/m was obtained over a period of four hours.

Codes and Standards

The vest must not cause harm to the user. Specifically, the fabric and design must not cause skin burns, friction burns or pressure sores. Regarding FDA standards, important codes to consider include 21CFR890.9, 21CFR890.5720, 21CFR890.5940 [11]. Code 890.9 addresses issues regarding premarket notification. Code 890.5720 addresses the issue of using circulating water in a cooling or heating pack. Depending on the final design selection, additional FDA codes and standards may need to be considered.Specific FDA codes are included in Appendix B. In regards to testing considerations, a model that accurately represents the conditions of an individual with a spinal cord injury is required. Other models used a torso replica that was capable of modeling evaporative, or sweating, cooling mechanisms [5]. In individuals with spinal injuries, sweating is often impaired below the site of injury.

Objectives
The overall goals of this project are to design a lightweight, non-bulky jacket that uses thermal sensors to regulate an individuals core temperature.

Customer Requirements
The following list contains the proposed customer requirements. These requirements were chosen to create a user-friendly device that can be used on a regular basis. Durable Lightweight Non-insulating Functional for at least 8 hours Maintain core temperature of 98F Moderated by a thermostat Can be worn under clothing Adjustable for different sizes No system failure User-friendly Reduced number of false alarms Lithium ion battery source Chemical based system

Project Requirements
Based on the proposed customer requirements, the following qualitative performance goals were proposed. These qualitative performance goals were then transformed into quantitative functional goals. Performance Goals Durability Light Weight Non-Insulating Long Lasting Maintain Core Temp Thin and compact design Reliability User Friendly Washable Cost Adjustable Safety Withstand drop from 8 ft. Less than 5 lbs Fabric must be breathable Self contained operation 8 hours Reduce temperature from 110 to 98 and regulate Fit under a T-shirt All components must last 10^6 cycles w/ 95% reliability User fully Functional after 3 attempts, Comfortable Must be water resistant Expenses must be under $5,000 Must be able size from small to large shirt size Must be able to operate without any impending danger to user

Functional Requirements Durability Light Weight Non-Insulating Long Lasting Maintain Core Temp Thin and compact design Reliability User Friendly Washable Cost Adjustable Safety Withstand drop from 8 ft Less than 5 lbs more than 170 gram/(hour meter^2) of water permissibility Self contained operation 8 hours Must expel 1000 BTUs/hour Vest must protrude off the body by no more than 1/4 inch All components must last 10^6 cycles w/ 95% reliability User fully Functional after 3 attempts Must be able to function after being submerged in 5 PSI of water Must cost less than $2000 to build and test 30 inch chest to a 46 inch chest All contact materials to be biocompatible

The functional goals were then compared using a rank order comparison shown in Appendix C. Based on the rank order comparison the top four goals were determined to be maintaining core body temperature, safety, light-weight design and non-insulating materials. Detailed explanations for these goals are included below. Maintaining Core Body Temperature: Must expel 1000 BTUs/hour o The main goal of this project is to regulate an individuals body temperature at 98 degrees. If this standard is not met, then ultimately the design does not achieve its overall purpose. In order to maintain an individuals body temperature, 1000 BTUs/hour must be expelled.

Safety: All contact materials to be biocompatible o This device must not be dangerous to use. In order to be FDA approved, certain standards must be met to ensure user safety. Furthermore, it is important that materials are selected that dont cause skin lesions or burns.

Light-weight: Less than 5 lbs o In order to be used on a daily basis the design must be light-weight. This will ultimately increase the users satisfaction and increase the device usage.

Non-insulating: more than 170 gram/(hour meter^2) of water permissibility o The material must be able to expel excess heat to prevent the user from overheating.

Other goals that ranked relatively high included a thin & compact design, reliability of device and longlasting. Thin & Compact Design: Vest must protrude off the body by no more than 1/4 inch This will allow the vest to lie below an individuals clothing. Reliability: All components must last 10^6 cycles w/ 95% reliability This device is responsible for regulating the body temperature in high temperature environments. It must be 95% reliable to ensure that the individual does not succumb to heat stroke. Durability: Withstand drop from 8 ft Must be durable enough to withstand normal daily conditions. If the device can withstand an 8 foot drop, then it should be able to withstand daily activities. Long Lasting: Self contained operation 8 hours This will allow the user to wear the vest during a standard eight hour work day. The least important goals at this time are adjustability, washable and low-cost. User-Friendly: User fully Functional after 3 attempts Must not be a difficult device for the user to operate. They must be able to use the device with minimal instructions. Adjustability: 30 inch chest to a 46 inch chest These are the dimensions of average female and male chest sizes. Washable: Must be able to function after being submerged in 5 PSI of water If the user is using the device on a daily basis, it must be washable. Cost: Must cost less than $2000 to build and test This is the cost for building and prototyping. Individual units may be more expensive than existing models. The rationale for a higher unit cost is dependent on the fact that this device will be used on a daily basis.

Design Development
Based on the design requirements outlined above and preliminary background research, three top conceptual models were designed: the liquid cooling vest, the evaporative cooling vest and the conductive material and phase change vest. Each model is discussed in detail below.

Liquid Cooling Vest

The liquid cooling vest pumps liquid throughout the vest to produce a cooling effect. Liquid is stored in a fluid reservoir and is cooled by a thermoelectric cooler. Figure 1 shows the configuration of the liquid cooled vest design.

Figure 1. Liquid Cooling Vest Configuration. As the liquid travels through the vest-lined tubing, it absorbs heat from the body. The fluid then enters the fluid reservoir, where the thermoelectric cooler (TEC) works to cool the water and remove the heat from the vest reservoir into the surrounding environment. Benefits of this design include increased efficiency and high thermal conductivity. However, this design may also be bulky and heavy for the user. In addition, the current design must be continuously powered and has the potential to leak.

Evaporative Cooling Vest

The evaporative cooling vest uses an air pump in order to remove heat from the user. The vest material is slightly dampened to facilitate heat transfer reactions between the users skin and the fluid tube. Evaporative and convective forms of heat are emitted from the users skin to the fluid tube. From here, heat enters the inlet and outlet where it is removed from the system through a TEC.

Figure 2. Evaporative Cooling Vest Configuration. The benefits of this design include a passive form of cooling that is lightweight. The disadvantages of this design include the need for water components and a bulky design.

Conductive Material Vest

The conductive vest operates similar to a heating blanket. Heat from the body comes into contact with a conductive material and then a TEC in order to expel heat into the surrounding environment.

Figure 3. Conductive Material and Phase Change Cooling Vest. Benefits of this design include a simple design schematic. However some disadvantages of this design include the need for extensive wiring. This may increase the likelihood of negative side effects to the user (i.e. increased likelihood of burns). Also, this is not an efficient design.

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Decision Matrices
To compare the three models a Pugh Matrix was created. The liquid cooling vest was selected as the datum since the most research has been conducted regarding this design. Based on the Pugh Matrix included in Appendix D, both the evaporative and phase change vests only had one advantage over the liquid cooling vest. In addition, they each had several disadvantages compared to the liquid cooling vest and ranked the same in the remaining categories. Therefore, the liquid cooling vest was selected as the final design.

Top Concept
The liquid cooling vest uses a water reservoir, a thermoelectric cooler, vest tubing and a pump to cool a human body. Fluid is pumped through the vest tubing from a water reservoir. The fluid absorbs heat from the body and carries it back to the reservoir. The reservoir is connected to a thermoelectric cooler which absorbs heat from the water and removes it the surrounding atmosphere. At the same time, the water is chilled and prepared to circulate through the tubing as shown in figure 1. The vest will be configured from two different materials, with tube lining within. The inner material will be a highly conductive material. The outer material will be insulating from the outer environment and permeable for evaporative cooling.

System Block Diagram

Figure 4 shows the system diagram of the proposed design. Specific details of each component are detailed below.

AX: Electrical Energy Transfer BX: Mechanical Energy Transfer CX: Thermal Energy Transfer

Figure 4. Device System Block Diagram.

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A.1 Thermal sensors throughout the vest send a voltage potential to an electrical circuit which will activate the thermal vest system if the voltage potential is great enough. A.2 The electrical circuit allows the battery to power the active cooling components of the vest. The cooling fan, the thermoelectric module, and the pump are activated. A.3 Any operating power the system needs to maintain the off and on temperature sensing regulations is supplied by the battery power source. A.4 The system activates the coolant pump at a fixed speed to circulate the cooling or heating fluid though the vest tubes. A.5 The battery sends power to the thermoelectric module which converts the electrical potential into a temperature difference between two plates. The amount of supplied voltage depends on how much the wearers core temperature deviates. A.6 The battery supplies electrical power to the cooling fan to cool the heat exchanger on the waste side of the thermoelectric module. A.7 The battery power source can be recharged from an external AC power source. B.1 The coolant pump converts the electrical energy into mechanical work to circulate the coolant through the cooling vest. B.2 The cooling fan converts electrical energy into mechanical work to remove the hot air in the microclimate of the hot plate thermoelectric cooler heat exchanger. This fan will operate for as long as the vest is active. C.1 The thermoelectric module cools or heats a heat exchanger/fluid reservoir C.2 Thermoelectric module waste plate thermally exchanges energy with a heat exchanger. C.3 The fluid reservoir intakes coolant to thermally treat to operating temperature before recalculating. C.4 The fluid reservoir expels operating temperature fluid to be circulated through the vest. C.5 Operating fluid thermally transfers energy to the conductive tubing throughout the vest. C.6 The conductive tubing conducts heat with the surface of the body.

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Meeting Project Requirements

Functional Requirements Objective Durability Light Weight Non-Insulating Requirement Withstand drop from 8 ft Less than 5 lbs more than 170 gram/(hour meter^2) of water permissibility Justification All materials can withstand drops from 8 ft. Initial iteration may be more than 5 lbs but no more than 10 lbs. Inner and outer vest materials will be able to conduct heat away from body Batteries will be selected to provide device-operation of 8 hours per single use Per MATLAB code, design should expel 1700 BTUs/hour from the users skin Vest will measure inch from the body. Future iterations can reduce this thickness Only component that may needs to be changed often will be the battery First iteration will use an on/off device, user will be able to use device after first use Design will be able to be hand-washed Will cost $1100 for raw materials Materials can be adjusted. Materials selected will not cause harm to user

Long Lasting Maintain Core Temp Thin and compact design Reliability

Self contained operation 8 hours

Must expel 1000 BTUs/hour Vest must protrude off the body by no more than 1/4 inch All components must last 10^6 cycles w/ 95% reliability

User Friendly Washable Cost Adjustable Safety

User fully Functional after 3 attempts Must be able to function after being submerged in 5 PSI of water Must cost less than $2000 to build and test 30 inch chest to a 46 inch chest All contact materials to be biocompatible

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Supporting Work
In order to determine the validity of the proposed design, MATLAB code was used to model heat transfer throughout the model. First this model makes several assumptions: System is at steady-state The atmospheric temperature is known 2 Surface area of the temperature is 5.4 ft TEM operates at steady-state Copper surface acts as an instantaneous conductive surface

Based on these assumptions and several user inputs, the component operating temperatures, input energy required and the steady state ration can be predicted. Based on initial simulations the proposed model should dissipate 1700 BTUs per hour from an individuals skin. The full MATLAB code is contained in Appendix E.

Preliminary Manufacturing Plans

Material Selection & Comparison
Tubing The first step in finding a suitable material was identifying a flexible, durable material that could be injection molded into tubing for our vest. Other key features required were high thermal conductivity which was also lightweight. Using CES we analyzed thermal conductivity versus density in order to find materials that would suit our thermal conductive needs and then used a limiting stage to show materials that could be injection molded, had adequate durability, and Youngs modulus. From CES we determined that a thermoplastic elastomer would be the most effective material for tubing. Using this information we found a company, Cool Polymers, that creates tubing for thermally conductive processes. CoolPoly D8102 Thermally Conductive Thermoplastic Elastomer (TPE) was selected, which is commercially available and meets all of our needs (See MSDS and Material Data Sheet). Vest Material Since the vest is designed with an inner and outer layer there are two parts to vest material selection Outer Layer The external vest fabric must thermally insulate the cooling tubes of the vest from the environment. The fabric must also be highly permeable, to allow for evaporation and comfort of the user. The fabric used in Under Armor ColdGear was selected because it met the requirements for this design. The fabric has similar properties to the conductive vest fabric selected, but is much more thermally insulating. Inner Layer The inner layer is more important and must have good thermal conductivity, moisture management, and Tactile Properties (Cao).Moisture management and tactile properties are important because they improve comfort for the user and add structure for the vest. Using the information from the Textile research journals Fabric Selection for a LCG we determined that a material of 80% polyester, 20% spandex knit would be the ideal inner material. CES does not

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include fabrics, so fabrics used in sports applications and commercially available materials were examined. A fabric Under Armor HeatGear (84% Catonic Polyester, 16% Elastane) was selected because it met all of the requirements for this design and was the most similar material commercially available to the theoretical material. Heat Exchanger The heat exchanger must have a high thermal conductivity and the ability to be formed from sheet. Due to its portable nature it must be light weight, though must be durable to avoid deformation due to daily wear and tear. Due to the fact it is in constant contact with water it needs to be able to withstand corrosion associated. Aluminum 6060 T6 was chosen because it is commercially available meets all requirements. Copper Alloys were eliminated due to their high cost and tendency to corrode when exposed to water. Copper plate The material for the conductive plate must be highly thermally conductive. The highest possible thermal conductivity is needed, at a reasonable price. A graph was made in CES plotting thermal conductivity against price. Materials priced over $100/lb were eliminated because these materials were only slightly more conductive (~5 Btu.ft/h.ft^2.F) and significantly more expensive (~$250/lb). The resulting materials with highest thermal conductivity were a set of copper alloys (C10100, C15100, C18100, C10200, C10500). All of these materials were approximately the same density, so density did not factor into the selection. C10100 was selected because it is highly durable and commonly used in heat transfer applications, such as radiators. Ceramic plate The insulating plate must have a low thermal conductivity, while being lightweight to minimize the weight of the vest. Thermal conductivity was plotted against density. The maximum temperature that the plate might be exposed to would be 120F, so all materials with a melting temperature below 140F were eliminated. The resulting materials were PE Foam, PP Foam, and PE-LD Foam. Of these materials, PP Foam was the most durable when exposed to water, acids, alkali, and organic solvents. The material selected was PP Foam (Closed cell, 0.030), which is found under the trade name Neopolen P30.

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Preliminary Validation Plans

When developing top design concepts various testing methods were considered. The ability to validate the efficiency of pieces of the design will continue to play a large role in the details of the final model that will be developed. The preliminary validation plans are based on testing methods previously explored which were detailed in the background research gathered. One study developed a cooling pad assembly to simulate the cooling effect of their product. The test used a water bag to simulate the cooling core and desiccant powder, which is a substance that generates a dry vicinity, as the source of absorption from the core. To prevent contact between these two layers, a honeycomb spacer was incorporated into the design. The outer bag in this experiment was a generic vacuum storage bag which provided thermal insulation along with the air tight environment suitable for evaporation. Vinyl tubing was used to connect this cooling pad to the pump supplying power to the system. Once the pump was turned on the leads for the thermocouple were attached to the surfaces of each core with tape and timed weight readings of the system were taken to account for the water loss during the procedure. Easily available materials like these will be used in our initial testing plans to test basic cooling capacity of the system.

Control Test
The initial testing plans include four different simulations. The first one will test the Veskimo liquid cooling vest purchased as a standard to compare our final design to. The test will be comprised of a run on a treadmill with a controlled speed and time span wearing the cooling vest. This data will then be compared to a similar run without wearing the cooling vest. To conduct this test properly and thoroughly we will be monitoring mean skin torso temperature, time span, distance of the run, vest flow rate, and temperature flowing into and out of the reservoir. During the simulation with the cooling vest, the individual will wear a trash bag over the vest to prevent evaporative heat transfer from occurring. To conduct this test 6 thermocouples, data acquisition software, the cooling vest, ice, trash bags, a stopwatch, and a treadmill are needed.

Test #2
The second test will test the performance of the heat exchanger. To test the performance of the exchanger we will heat an aluminum cylinder to a fixed temperature and fill a bucket with cold water at a fixed temperature. We will then pump the cold water from the first bucket through the aluminum heated cylinder and into a final bucket. The temperature of the water in the final bucket will be measured and compared to the initial fixed cold temperature. The difference calculated will allow us to determine the amount of heat that the heat exchanger provided to the water. For this test two buckets, a sized aluminum cylinder, two pumps of equal size, tubing, water tight connections, four thermocouples, and data acquisition software are needed

Test #3
The third test will test the thermoelectric module performance. We will have three different trials: one heating trial, one cooling trial, and one without the copper plate to test the heating of the TEM.

Test #4
The fourth test will measure skin-vest tubing performance. We will have an aluminum cylinder with silicon sheeting around it to represent the skin. A cylinder will be filled with water and a heater will warm the water inside the cylinder. Convective tubes will then be used to cool the water. From her we can determine the performance of the design schematic.

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Management Plan
Method of Approach
This project will be two quarters long. The first quarter will be dedicated to background research, formation of design requirements, determination of top conceptual models and the selection of the final design. The first qarter will also include the creation of CAD models and the selection of final product materials. The second quarter will be dedicated to manufacturing and testing the final design. Revisions th will be made based on the test results. The project should be completed by Monday, March 6 , 2012. The following table details the reports to be submitted to QL+ and project milestones. Date rd Monday October 3 Monday October 10 st Monday October 31
th

Monday November 14 st Monday November 21 Monday December 5

nd th

th

Monday January 2 th Monday January 16 th Monday January 23 th Monday February 6 th Monday March 6

Deliverable or Milestone Team Contract Statement of Work Project Planning (Gantt Chart) Design Review Preliminary Project Report CAD Design Drawings Design Review Bill of Materials Concept Design Report Final Materials Selection Prototype Manufacturing Prototype Initial Testing Interim Design Report Final Testing & Data Analysis Final Project Report Design Notebooks Due Proof-of-Concept Prototype

The following flow chart diagrams the general process that will be utilized to complete this project.
Background Research

Create CAD Designs

Selection of Materials

Submit Final Prototype & Report

Customer & Engineering Requirements

Selection of Final Design Concept

Create Test Plans

Repeat Testing, if needed

Contact QL+ Challenger

Initial Drawings & Solid Models

Construct Prototype(s)

Revise Prototype Design(s)

Revise Engineering Requirements

Selection of Top Concepts, MATLAB verification

Test Prototype(s)

Analyze Test Data

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At this point, the problem has been defined and background research conducted. Based on this research the initial design requirements were formed. After meetings with the QL+ Challenger and Engineer, these requirements were further redefined. The top conceptual models were verified in MATLAB to determine the maximum power input. A Pugh comparison showed that the fluid cooling vest was the best design.. At this point the final material selection will take place. All materials will be ordered over the next three weeks. The first two weeks of January will then be spent assembling the components to be tested. Four tests will be designed to test vest performance, heat exchange, TEC module performance and skin to vest tube heat transfer. Based on these tests further revisions to design and testing plans will be made. A detailed Gantt chart is included in Appendix F to measure project progression. Budget Allocation The budge was broken into two areas: vest and test materials. Based on cost estimates from online vendors and local stores the total cost for the vest and tests totaled $1968.64.
Cost ($) 699 452.34 238 170 409.3 1968.64

Vest Test #1 Test #2 Test #3 Test #4 Total Cost

Table 1. Vest and Test Materials Costs Specific breakdowns for the vest and test materials are included in Appendix G.

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References [1] Schmidt KD, Chan CW. Thermoregulation and fever in normal persons and in those with spinal cord injuries. Mayo Clin Proc. 1992 May;67(5):469-75. Review. PubMed PMID: 1405774. [2] Staff, Mayo Clinic. "Heat Stroke - MayoClinic.com." Mayo Clinic. Mayo Clinic. <http://www.mayoclinic.com/health/heat-stroke/DS01025>. [3] "Cooling Vest." Ms Cooling - Body Cooling Devices and Other Personal Cooling Products. MS Cooling Climate Control Products. <http://www.mscooling.com/faq>. [4] "Pro-Kold - Kold Vest and Ice Wrap Products." Pro-Kold Reusable Ice Wraps. Dura*Kold, 2011. <http://www.pro-kold.com/dkkvest.htm>. [5] DAngelo, Sophia, and William Lauwers. "The Cooling Vest Evaporative Cooling." Diss. WORCESTER POLYTECHNIC INSTITUTE, 2009. Print. [6] "Evaporative Cooling Vest, Cooling Workwear - GEMPLER'S." GEMPLER'S - Outdoor Work Supplies, Spray Equipment, PPE & More. GEMPLER'S. <http://www.gemplers.com/product/165504/Evaporative-Cooling-Vest>. [7] "Gear Guide: Cooling Vests & Apparel." ActiveMSers: Staying Active With Multiple Sclerosis. ActiveMSers: Staying Active With Multiple Sclerosis. <http://www.activemsers.org/tipstricks/choosingacoolingvest.html>. [8] "TST Sweden AB Body Temperature Control Vest "Cooling Vest"" GADELIUS. GADELIUS. <http://www.gadelius.com/products/other_disaster_relief_equipment/05_e.htmlment/05_e.html>. [9] "Circulating Cold Water Cooling Vest System for People with MS,surgeons, Race Car Drivers, Truck Drivers and Many Other Applications." PolarProducts.com Polar Products Body Cooling Vests. Polar Products Inc. Web. 31 Oct. 2011. <http://www.polarsoftice.com/softiceactivevest.html>. [10] "Body Cooling Systems." Welcome to Air Systems International, Inc. On-Line Catalog. Air Systems International, Inc. <http://www.airsystems.cc/product_pages/environmental_control/body_cooling_systems.htm>. [11] "Diffuse Air Vest with Unfolding Lapels: 855." Efficient Compressed Air Techology | ITW Vortec. Vortec. <http://www.shopvortec.com/store/855.html>. [12] Yang, Yifan. "Personal-portable Cooling Garment Based on Adsorption Vacuum Membrane Evaporative Cooling." Diss. University of Ottawa, 2011. Print. [13] "Code of Federal Regulations Title 21." US Food and Drug Administration. Department of Health and Human Services, 1 Apr. 2011. Web. <http://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfcfr/CFRSearch.cfm?CFRPart=890>.

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Appendix A Evaporative Cooling Properties Cooling Time Vest Sizes Material Price 5-10 hours S, M, L, XL, 2XL or 3XL Nylon outer with polymer embedded fabric inner. Black poly-cotton trim. $36.15

Phase Change Cooling Properties Vest Weight: Vest Size: Approximately 2 kilograms Chest Size Circumference S-M 84-100cm L-XL 100-116cm XXL116-132cm XXXL Two types; PCM melting point of 28 and 32 Polyester Mixed salt (interior), Valeron coating aluminum (exterior)

Vest Types: Vest Material: PCM Material:

Fluid Cooling Properties Sizes Design Adjustable S, M/L, L/XL 9 foot of insulated water lines from the cooler, optional 5 ft length instead of 9 ft or additional 4 foot lengths are also available. 15 quart wheeled cooler with retractable handle $810

Cooling system Price

Air Cooling (Kool Vest) Properties Material Add ons Cooling method Layout/Design Double coated PVC on nylon scrim material with Velcro front closures and sewn-in adjustable belt vortex adapter or Air Systems' unique Cool-Box Small holes on interior of vest direct air to complete upper torso, front and rear Specially designed plenum directs air to a neck ring for cool air distribution to the neck and face. A rear Velcro strip controls the air volume to the neck ring

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Air Cooling (Personal Air Conditioner) Properties Item # 22815 22825 22835 220 855 Description Vortex Air Conditioner with Belt 900 BTUH Vortex Air Conditioner with Belt 1500 BTUH Vortex Air Conditioner with Belt 2500 BTUH Hot/Cold Air Conditioner with Belt 1500 BTUH Diffuse Air Vest with unfolding Lapels Cooling Capacity 900 Btu/hr 1500 BTU/hr 2500 Btu/hr 1500 Btu/hr Price ($) 114 114 114 302 199

Thermoelectric Cooling Properties TEC temperature Power Supply Material hot side temp is 27C, 50C, maximum watts range between 20 and 22 ATX 300 Watt power supply mesh lined vest, wicking material was a sheet of Shamwow

Appendix B PART 890 -- PHYSICAL MEDICINE DEVICES Subpart A--General Provisions Sec. 890.9 Limitations of exemptions from section 510(k) of the Federal Food, Drug, and Cosmetic Act (the act).

Sec. 890.5720 Water circulating hot or cold pack. (a)Identification. A water circulating hot or cold pack is a device intended for medical purposes that operates by pumping heated or chilled water through a plastic bag and that provides hot or cold therapy for body surfaces. (b)Classification. Class II (special controls). The device is exempt from the premarket notification procedures in subpart E of part 807 of this chapter subject to 890.9. [48 FR 53047, Nov. 23, 1983, as amended at 63 FR 59231, Nov. 3, 1998]

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Appendix C
Maintain Core Temp Safety LightWeight on-Insulating Thin and compact design N Reliability Durability Long Lasting User Friendly Adjustable Washable Cost Durability 1 1 1 1 1 1 ** 0.5 0.5 0.5 0.5 0 LightWeight 1 1 ** 0.5 0.5 0.5 0 0 0 0 0 0 Non-Insulating 1 1 0.5 ** 0.5 0.5 0 0 0 0 0 0 Long Lasting 1 1 1 1 0.5 0.5 0.5 ** 0.5 0.5 0 0 Maintain Core Temp ** 0.5 0 0 0 0 0 0 0 0 0 0 Thin and compact design 1 1 0.5 0.5 ** 0.5 0 0.5 0 0 0 0 Reliability 1 1 0.5 0.5 0.5 ** 0 0.5 0 0 0 0 User Friendly 1 1 1 1 1 1 0.5 0.5 ** 0.5 0 0.5 Washable 1 1 1 1 1 1 0.5 1 1 0.5 ** 0.5 Cost 1 1 1 1 1 1 1 1 0.5 0.5 0.5 ** Adjustable 1 1 1 1 1 1 0.5 0.5 0.5 ** 0.5 0.5 Safety 0.5 ** 0 0 0 0 0 0 0 0 0 0 Sum 10.5 10.5 7.5 7.5 7 7 3 4.5 3 2.5 1.5 1.5 Percentage 15.91 15.91 11.36 11.36 10.61 10.61 4.55 6.82 4.55 3.79 2.27 2.27

Appendix D Liquid D A T Evaporative S + S S S S S S S S 1 2 9 Conductive S + S S S S S S S 1 3 8

Durability LightWeight Non-Insulating Long Lasting Maintain Core Temp Thin and compact design Reliability User Friendly Washable Cost Adjustable Safety + S

U M

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Appendix E %% This Program Models the Thermal System of the Liquid Filled Active Cooling Thermal Vest %% Inputs: Heating/Cooling, Atmoshperic Temperature, Energy Dissipation, Fluid Flow Rate,TEM Temeprature Difference %% Outputs: Input Parameters, Component Operating Temperatures, Input Energy Required, Steady State Ratio %% Assumptions: % System is at steady state at all heat transfer locations % Human Body needs to expel 1000 BTU/hr to maintain the core body temp % Atmospheric temperature is defined % Surface Area of torso is approximatetly 5.4 ft^2 % TEM is operating at steady state % Copper Surface acts as instaneous conductive surface %% Clear Work Space clc; clear; %% Inputs % Cooling or Heating i=1; % i=1 for cooling, i=anything for heating if i==1 n1=.3; %Nud Coeficient else n1=.4; end % Constant Inputs grav=32.2; %Gravitational Constant (ft/s^2) Egen=1000; %Body heat generation (Btu/hr) Tskin=91; %Temperature of the skin (F) Tatm=100; %Atmospheric Temperature Acds=10.8*.5; % Surface area of Torso (ft^2) % Tube Inputs ID=4/16; %Tube Inner Diameter (in) Acs=(ID/2/12)^2*3.14; %Area inside of tube (ft^2) OD=5/16; %Tube Outer Diameter % TEM Inputs dT=50; % TEM side Temperature difference (K) not heat sink temp (K) Vin=1.15*(dT/60); % DC Voltage Input Iin=9; % Input Current (Amps) Ein=Vin*Iin; % Input Energy (Watt) Len=6; % Lenght of TEM (in) Wid=1; % Width of TEM (in) qss=.932; % Equivalent Conduction Heat transfer shape Factor Area=Len*Wid; % TEM Conductive Surface Area (in^2) Khs=250; % Thermal Conductivity of Heat Sink Material(W/(m*K)) % Fluid Properties vis=1.052*10^-5; %Kinematic Fluid viscosity (ft^2/s) uvis=2.034*10^-5; %Dynamic Fluid Viscosity (lb s/ft^2) den=uvis/vis; %Fluid Density ( % Pump Inputs GPM=.03432*.002228; % Nominal Gallons per minute at max voltage (ft^3/s) mdotpu=GPM*den*grav; % Pump Mass flow rate (lb/s) Vpu=26; % Pump Input Voltage Ipu=.18; % Pump Input Amps Epuin=Vpu*Ipu; % Pump Input max power (watt)

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vel=mdotpu/(den*Acs); % Fluid Velocity (ft/s) % Fluid Flow Properties Re=vel*(ID/12)/vis; %Reynolds Number Pr=7; %Prandtl Number k=355; %Fluid Thermal Conductivity (BTU/(hr*ft*F)) % Resivoir Inputs ResLen=8/12; %Resivoir Lenght (ft) ResWid=.5; %Resivor Width (ft) Resthi=1/12; %Resivor Thickness (ft) FinNumro=3; %Number of conductive fin rows FinNumco=2; %Number of Conductive Fin Columns dfin=1.5; %Diameter of cylindrical fins (in) Afin=(dfin/12)^2/4*3.14;%Fin Area (ft^2) reswath=.5; %Resivoir wall thickness (in) reswath2=1/10; %Resivoir wall thickness longitudinal (in) lenfin=Resthi-2*(reswath2)/12;%Fin Length (ft) AinRes=(ResLen-2*reswath/12)*(Resthi-2*reswath2/12)FinNumco*(lenfin*dfin/12); % Internal area inside Resivoir ft^2 Presin=(((ResLen-reswath/12*2)*(ResWid-reswath*2/12))(FinNumro*FinNumco*(3.14/4*(dfin/12)^2)))*2+((ResWid-2*reswath/12)*(Resthireswath2*2/12))*2+((ResLen-reswath*2/12)*(Resthireswath2*2/12))*2+(FinNumco*FinNumro*lenfin*3.14*dfin/12); Dh=2*(AinRes/Presin); %Effective Diameter of resivoir internal (ft) mdott=den*vel*Acs*grav; % Tube mass flow rate (lb/s) Fabric Inputs Kc1=.25; % Breathable Fabric Conduction Ceoficient (W/m*k) %% TEC Operating at Steady State Thp=(Tatm+80)/2+.5*dT; % TEM Hot plate operating Temperature Tcp=(Tatm+80)/2-.5*dT; % TEM Cold plate operating Temperature %% Conduction 2 2-D Conduction from TEC to Heat Sink Stage 1 if i==1 Ths=Tcp-(-Egen/(qss*Area/12*Khs*(1/1.731)))*ResLen; %Temperature of the Heat Sink for 1000(btu/hr) (F) else Ths=Thp+(-Egen/(qss*Area/12*Khs*(1/1.731)))*ResLen; end %% Convection 2 Internal flow Forced Convection Stage 2 % Internal Model (Inside Thermal Resivoir) velres=mdott/(den*AinRes*grav);% Velocity of Fluid inside resivoir Reres=velres*Dh/vis; % Resivoir Reynolds Number if (Reres>=2500) if (Reres>20000) fres=.316*Reres^(-1/4); % Turbulent friction Factor else fres=.184*Reres^(-1/5); % Turbulent friction Factor end Nudres=.023*Reres^(4/5)*Pr^n1; % Fully Developed Turbulent Flow Nusselt else Devres=.05*Reres*Pr*Dh; % Lenght of Fully Developed Flow (ft) fres=64/Re; % Laminor Fully Developed Flow Friction Factor Nudres=3.66+(.0668*(1/Devres))*Reres*Pr/(1+.04*((1/Devres)*Reres*Pr)^(2/3)); % Laminor Fully Developed Flow Nusselt Number (3.66-4.36) Typicaly end H2=Nudres*k/(Dh);

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if i==1 Tf=Ths+Egen/(H2*AinRes); % Temperature of the Flowing Fluid else Tf=Ths-Egen/(H2*AinRes); end %% Convection 1 Internal Flow Stage 3 % Fully developed flow if (Re>=2500) Dev=10*ID/12; % Lenght of Fully Developed Flow (ft) if (Re>20000) f=.316*Re^(-1/4); % Turbulent friction Factor else f=.184*Re^(-1/5); % Turbulent friction Factor end Nud=.023*Re^(4/5)*Pr^n1; % (f/8)*(Re1000)*Pr/(1+12.7*(f/8)^(1/2)*(Pr^(2/3)-1)); % Fully Developed Turbulent Flow Nusselt else Dev=.05*Re*Pr*ID/12; % Lenght of Fully Developed Flow (ft) f=64/Re; % Laminor Fully Developed Flow Friction Factor Nud=3.66+(.0668*(1/Dev))*Re*Pr/(1+.04*((1/Dev)*Re*Pr)^(2/3)); %Laminor Fully Developed Flow Nusselt Number (3.66-4.36) Typicaly end H1=Nud*k/(ID/12); % Convection Coeficient (BTU/(hr*F*ft^2)) if i==1 Ts=Tf+Egen/(H1*Acs); % Temperature of Conductive Surface else Ts=Tf-Egen/(H1*Acs); end %% Conduction 1 1-D Stage 4 Qcd1=Kc1*(1/1.731)*Acds*(Tskin-Ts)/((OD-ID)/12); % Conduction 1 Heat Transfer (Btu/Hr) %% Total Energy Etotal=Ein+Epuin; % Total Input Energy %% Display Resutlts disp('Atmospheric Temperature');disp(Tatm); disp('Thermoelectric Module Plate Temperature Difference');disp(dT) disp('Operating Temperature of the Thermoelectric Module Contact Plate'); if i==1 disp(Tcp); else disp(Thp); end disp('Operating Temperature of the Heat Sink');disp(Ths); disp('Operating Temperature of the Flowing Fluid');disp(Tf); disp('Fluid Flow Reynolds Number');disp(Re); disp('Fluid Flow Tube Velocity (ft/s)');disp(vel); disp('Operating Temperature of Conductive Surface');disp(Ts); disp('Steady State Ratio');disp(Qcd1/Egen); disp('Pump Input Power to System in Watts');disp(Epuin); disp('TEM Input Power to System in Watts');disp(Ein); disp('Max Input Power to System in Watts');disp(Etotal);

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Appendix F

Appendix G
Vest Bill of Materials Component Water Pump Heat Exchanger 1 Thernoelectic Module Fan Assembly Heat Exchanger 2 Copper Plate Polypropolene Foam Rechargeable Batteries Internal Conductive Vest Fabric External Insulative Vest Fabric D8102 TC TPE (Tubing) Velcro Straps Conductive Gel Charging Circuit Sensing/Operating Circuit

Material/Type Micro Pump Aluminum 6060 T6 Multi Stage Mini Comp Aluminum 6060 T6 Copper Polypropolene Foam Lithium Ion Under Armor Under Armor Warm TPE Elastomer Velcro Thermal Grease Thermocouples/circuit

Vendor/Model Xavitech Custom Thermoelectric Novak Elec tronics IDX NP-L7 NP1 Sports Store Sports Store Cool Polymers Crafts Store Noctua NT-H1 Custom Circuit Boards

Volume/QuantityPrice ($) 1 $100.00 300 $0.00 1 $65.00 1 $18.00 20 $0.00 2 $0.00 10 $0.00 1.00 $344.00 6 Ft^2 $60.00 6 Ft^2 $80.00 300 $0.00 6 $12.00 2 $20.00 1 1 Total Cost $699.00

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Material Aluminum 6060 T6 Copper c10100 Polypropolene Foam D8102 TC TPE (Tubing)

Density 0.965 0.323 0.0011 0.0452

Price/lb 1.1 3.3 0.9 5

Price/Vol 1.0615 1.0659 0.00099 0.226

Test #1 Bill of Materials Component Thermocouples Data Acquisistion software Vest Ice Trash Bags

Material/Type Body Sensing Supplied Sports cooling Vest -

Vendor Veskimo -

Volume/Quantity 6 1 1 4 2 Total Cost

Price $80.00 $363.34 $8.00 $1.00 $452.34

Test #2 Bill of Materials Component Thermocouples Data Acquisistion software Ice Heater Tubing Water Pump Alumium Cylinder Water Tight Connectons Buckets

Material/Type Type K,J Supplied Submersible 150 W Standard Tubing 728310 Sub 6060 T6 Neoprene Standard Paint Bucket

Vendor Visi-Therm Home Depot EcoPlus Home Depot Home Depot

Volume/QuantityPrice 4 $80.00 1 4 $8.00 1 $20.00 5 $30.00 2 $45.00 $40.00 4 $10.00 2 $5.00 Total Cost $238.00

Test #3 Bill of Materials Component Thermocouples Data Acquisistion software Aluminum Block Thernoelectic Module

Material/Type Type K,J Supplied 6060 T6 Standard Single

Vendor Custom Thermoelectric

Volume/QuantityPrice 6 $80.00 1 $60.00 1 $30.00 Total Cost $170.00

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Test #4 Bill of Materials Component Alumium Cylinder Water Pump Water Tight Connectons Tubing Buckets Heater Thermocouples Data Acquisistion software Under Armor Under Armor Ice

Material/Type 6060 T6 Standard 25 W Neoprene TPE Elastomer Standard Paint Bucket Submersible 150 W Type K,J Supplied Cool Armor Warm Armor -

Vendor EcoPlus Home Depot Cool Polymers Home Depot Visi-Therm Sports Store Sports Store -

Volume/Quantity 1 2 300 1 1 6 1 6 ft ^2 6 ft ^2 4 Total Cost

Price $40.00 $26.00 $5.00 $67.80 $2.50 $20.00 $80.00 $80.00 $80.00 $8.00 $409.30

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