TRANSFERRING THERMAL ENERGY

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of, and priority to, United States

Provisional Patent Application Serial No. 61/493,864, filed on June 6, 2011, and entitled "SYSTEMS, METHODS, AND DEVICES FOR EFFICIENTLY

TRANSFERRING THERMAL ENERGY," which is hereby expressly incorporated herein by this reference in its entirety. This application is related to U.S. Application

No. 12/843,523, filed July 26, 2010, entitled FLUID STORAGE AND DISPENSING

SYSTEM HEATING UNIT, which is a continuation-in-part of co-pending U.S. Patent

Application No. 12/433,974, filed May 1, 2009, entitled PALLET WARMER

HEATING UNIT, which is a continuation-in-part of co-pending U.S. Patent

Application No. 12/258,240, filed October 24, 2008, entitled HEATING UNIT FOR

WARMING PALLETS, and U.S. Patent Application No. 12/1 19,434, filed May 12,

2008, entitled HEATING UNIT FOR WARMING PALLETS, each of which is a continuation-in-part of U.S. Application No. 11/835,641, filed August 8, 2007, entitled

GROUNDED MODULAR HEATED COVER, which is a continuation-in-part of U.S.

Patent Application No. 1 1/744,163, filed May 3, 2007, entitled MODULAR HEATED

COVER, which is a continuation-in-part of U.S. Patent Application No. 1 1/218,156, filed September 1, 2005, now U.S. Patent No. 7,230,213, issued June 12, 2007, entitled

MODULAR HEATED COVER. U.S. Application No. 12/843,523 is also a continuation-in-part of co-pending U.S. Patent Application No. 11/422,580, filed June

-Page 1- Docket No. 17460.40a 6, 2006, entitled A RADIANT HEATING APPARATUS, which claims priority to and the benefit of U.S. Provisional Patent Application No. 60/688,146, filed June 6, 2005, entitled LAMINATE HEATING APPARATUS. U.S. Patent Application No. 1 1/422,580 is also a continuation-in-part of U.S. Patent Application No. 1 1/218,156, filed September 1, 2005, now U.S. Patent No. 7,230,213, issued June 12, 2007, entitled MODULAR HEATED COVER, which claims priority to and the benefit of each of: (a) U.S. Provisional Patent Application No. 60/654,702, filed February 17, 2005, entitled A MODULAR ACTIVELY HEATED THERMAL COVER; (b) U.S. Provisional Patent Application No. 60/656,060, filed February 23, 2005, entitled A MODULAR ACTIVELY HEATED THERMAL COVER; and (c) U.S. Provisional Patent Application No. 60/688,146, filed June 6, 2005, entitled LAMINATE HEATING APPARATUS. U.S. Patent Application No. 11/422,580 is also a continuation-in-part of U.S. Patent Application No. 1 1,344,830, filed February 1, 2006, now U.S. Patent No. 7,183,524, issued February 27, 2007, entitled MODULAR HEATED COVER, which claims priority to and the benefit of each of: (a) U.S. Provisional Patent Application No. 60/654,702, filed February 17, 2005, entitled A MODULAR ACTIVELY HEATED THERMAL COVER; (b) U.S. Provisional Patent Application No. 60/656,060, filed February 23, 2005, entitled A MODULAR ACTIVELY HEATED THERMAL COVER; and (c) U.S. Provisional Patent Application No. 60/688,146, filed June 6, 2005, entitled LAMINATE HEATING APPARATUS. U.S. Patent Application Serial No. 1 1,344,830 is also a continuation-in-part of U.S. Patent Application No. 11/218,156, filed September 1, 2005, now U.S. Patent No. 7,230,213, issued on June 12, 2007, entitled MODULAR HEATED COVER. U.S. Application No. 12/843,523 is

-Page 2- Docket No. 17460.40a also a continuation-in-part of co-pending U.S. Patent Application No. 12/436,905, May 7, 2009, entitled UNIT FOR WARMING PALLETS OF MATERIAL, which is a continuation of U.S. Patent Application No.12/433,974, filed May 1, 2009, entitled PALLET WARMER LIEATING UNIT, which is a continuation-in-part of co-pending U.S. Patent Application No. 12/258,240, filed October 24, 2008, entitled HEATING UNIT FOR WARMING PALLETS, and U.S. Patent Application No. 12/1 19,434, filed May 12, 2008, entitled HEATING UNIT FOR WARMING PALLETS. Each of the preceding United States patents and patent applications is incorporated herein in its entirety by this reference.

BACKGROUND

1. Technical Field

[0002] The present invention relates to warming and cooling applications. More specifically, the invention relates to methods, systems, and devices for efficiently transferring thermal energy to or from an object in order to heat or cool the object.

2. The Relevant Technology

[0003] The ability to transfer or distribute thermal energy has provided a number of opportunities for increasing human comfort levels for certain activities and has made other activities not previously feasible able to be accomplished. One field where thermal energy transfer or distribution has found particular use is in industries where individuals work with liquid or gaseous materials. For example, when transporting liquids or gases through a conduit, such as a hose or pipe, it can be desirable to maintain the liquid or gas at a desired temperature or within a desired temperature range. Maintaining the fluid conduit at a desired temperature can provide numerous benefits,

-Page 3- Docket No. 17460.40a including preventing the liquid or gas from changing phases during transportation (e.g., between gas, liquid, and solid phases), freezing and/or breaking of the fluid conduit due to extreme temperatures, as well as delivering the liquid or gas at a particular temperature for an intended use.

[0004] Heating and cooling units of various types have been previously implemented for heating or cooling various types of conduits, containers, and products. For instances, relatively long, narrow heating or cool elements have been used to warm or cool pipes. These heating or cooling elements are typically wrapped around or attached along the length of a pipe to provide thermal energy to or sink thermal energy from the pipe and its contents. These typical pipe heating or cooling elements, however, only cover a portion of the pipe. Pipe heating or cooling elements constructed in this fashion often rely on the conductive nature of a metallic pipe to distribute or sink the thermal energy to or from the contents of the pipe. As a result, these types of pipe heating and cooling units commonly provide uneven heating or cooling of the pipe and its contents. That is, the areas of the pipe in close proximity to the heating or cooling element will be warmed or cooled more effectively than the areas of the pipe that are further away from the heating or cooling element. Additionally, most pipe heaters or coolers typically turn on at a specific activation temperature, such as 32°F, and only remain on while the temperature is above or below the activation temperature. Thus, the portion of the pipe and its contents near the heating or cooling element may be maintained at the activation temperature, while other portions of the pipe and its contents may be insufficiently heated or cooled. If more even temperature (e.g., thermal energy) distribution is desired, multiple pipe heaters or coolers may be required.

-Page 4- Docket No. 17460.40a However, this may require the availability of multiple outlet receptacles and/or the use of additional power.

[0005] In addition to providing uneven heating or cooling, typical pipe heating or cooling units can also be inefficient. As noted, typical pipe heating and cooling elements are wrapped around or attached to the outside of the pipe, which often leaves the heating or cooling elements exposed to the cold or warm environment surrounding the pipe. In the case of a heating element, exposure to the cold surrounding environment results in much of the thermal energy generated by the heating element being lost to the cold environment rather than being effective in warming the pipe and its contents. Similarly, in the case of a cooling element, exposure to the warm surrounding environment results in significant amounts of thermal energy from the surrounding environment sinking to the cooling element rather than the cooling element being an effective sink for the thermal energy of the pipe. One method used to limit the amount of thermal energy exchange between the heating or cooling element and the surrounding environment includes wrapping the pipe and heating or cooling element with an insulative material, such as a fiberglass batting.

[0006] While wrapping the pipe and heating or cooling element with a fiberglass batting reduces the amount of thermal energy being exchanged between the heating or cooling element and the surrounding environment, it does relatively little to improve the evenness of the temperature distribution across the pipe and its contents. Additionally, wrapping and securing the fiberglass batting around the pipe and heating or cooling element can be labor-intensive and time-consuming. For instance, the fiberglass batting must first be wrapped and secured around the entire length of the pipe and heating or

-Page 5- Docket No. 17460.40a cooling element. To prevent weather or environmental related damage to the fiberglass batting, a protective shell, such as a foil shell, is then wrapped and secured around the batting. In the event that access to the heating or cooling element or pipe is needed after the fiberglass batting and protective shell are wrapped around the pipe and heating or cooling element, the shell and batting must be removed. Just like its installation, removing the shell and batting can also be time-consuming and labor-intensive. The removal of the shell and batting can also expose the pipe and heating or cooling element to damage. For instance, the shell and batting are typically cut off of the pipe and heating or cooling element. As the shell and batting are cut off of the pipe and heating or cooling element, the pipe or heating or cooling element may also be cut, damaging the ability of the heating or cooling element to provide or sink thermal energy to or from the pipe or creating a leak in the pipe. Still further, once the shell and batting are removed, they typically are not in condition to be reused. As a result, once access to the heating or cooling element or pipe is no longer needed, new batting and shell must be used to rewrap the heating or cooling element and pipe, thereby increasing the cost to insulate the pipe and heating or cooling element.

[0007] Therefore, what is needed is a simple mechanism for efficiently and more evenly transferring and distributing thermal energy from a heating element or to a cooling element to warm or cool an object, as well as insulating the object and the heating or cooling element to prevent significant amounts of thermal energy loss.

[0008] The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above.

-Page 6- Docket No. 17460.40a Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.

-Page 7- Docket No. 17460.40a BRIEF SUMMARY

[0009] One exemplary embodiment described herein is directed to a thermal energy transfer unit for use in transferring thermal energy between a thermal energy unit and an object to be warmed or cooled. The thermal energy transfer unit includes opposing first and second pliable cover layers. Disposed between the first and second cover layers is a thermal energy spreading element. The thermal energy spreading element includes carbon thermally coupled to the thermal energy unit for transferring the thermal energy therebetween. In some embodiment, the thermal energy spreading element includes graphite. Similarly, in some embodiments the thermal energy spreading element includes a contiguous laminate sheet of carbon that substantially uniformly distributes the thermal energy over the object that is to be heated or cooled. Furthermore, the thermal energy spreading element can be thermally isotropic in one plane.

[0010] In addition to the thermal energy spreading element, a thermal insulation layer is disposed between the first and second cover layers. The thermal insulation layer is positioned between the thermal energy spreading element and the first cover layer. In some embodiments, a first side of the thermal insulation layer is attached to a second side of the thermal energy spreading element. The thermal insulation layer can be adapted to direct the thermal energy toward or away from the object.

[0011] The thermal energy transfer unit also includes one or more fasteners disposed in the first or second pliable cover layers to enable the thermal energy spreading unit to be secured around the object by the one or more fasteners. The one or more fasteners can include grommets, snaps, zippers, clips, or combinations thereof.

-Page 8- Docket No. 17460.40a [0012] According to another exemplary embodiment, a thermal energy spreading and insulating unit is configured for use in connection with a fluid conduit that has a thermal energy unit associated therewith. The thermal energy spreading and insulating unit may be adapted for generally uniformly spreading thermal energy from the thermal energy unit over a surface of the fluid conduit and retaining a substantial portion of the thermal energy close to the fluid conduit.

[0013] The thermal energy spreading and insulating unit includes a first cover layer and a second cover layer associated with one another to form an envelope with an interior portion. A thermal energy spreading element is disposed within the interior portion of the envelope formed by the first and second cover layers. The thermal energy spreading element includes a contiguous laminate sheet of carbon thermally coupled to the thermal energy unit for substantially uniformly distributing the thermal energy from the thermal energy unit over the outer surface of the fluid conduit.

[0014] The thermal energy spreading and insulating unit may include a thermal insulation layer disposed within the envelope formed by the first and second cover layers. A first side of the thermal insulation layer may be disposed adjacent a second side of the thermal energy spreading element and a second side of the thermal insulation layer may be positioned adjacent an interior surface of the first cover layer.

[0015] The thermal energy spreading and insulating unit may further include a sealing flap that extends along a length of the thermal energy spreading and insulating unit and one or more fasteners configured to secure the thermal energy spreading and insulating unit around the fluid conduit and at least a portion of the thermal energy unit.

-Page 9- Dooket No. 17460.40a [0016] According to yet another exemplary embodiment, a method of generally uniformly heating or cooling an object is disclosed. The method includes operatively associating a thermal energy unit with the object. The method further includes transferring thermal energy between the object and the thermal energy unit. Transferring the thermal energy may include wrapping a contiguous laminate sheet of carbon around the object with the contiguous laminate sheet of carbon being thermally coupled to the thermal energy unit and the object. Transferring the thermal energy may further include substantially uniformly spreading the thermal energy over the contiguous laminate sheet of carbon and activating the thermal energy unit to generate thermal energy or sink thermal energy thereto. The method may also include wrapping a thermal insulation layer around the object and the contiguous laminate sheet of carbon. The thermal insulation layer may be adapted to direct the thermal energy toward or away from the object.

[0017] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0018] Additional features and advantages will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the teachings herein. Features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Features of the present invention will become more

-Page 10- Docket No. 17460.40a fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

-Page 1 1- Docket No. 17460.40a BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to describe the manner in which the above-recited and other advantages and features can be obtained, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting in scope, embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0020] Figure 1 illustrates an exemplary embodiment of a thermal energy transfer and insulating unit employed to transfer thermal energy between a heating or cooling unit and a fluid conduit;

[0021] Figure 2 illustrates a side view a fluid conduit with an alternative heating or cooling unit wrapped therearound and a thermal energy transfer and insulating unit wrapped around the fluid conduit and the heating or cooling unit to evenly transfer thermal energy between the heating or cooling unit and the fluid conduit;

[0022] Figure 3 illustrates a partially exploded view of the thermal energy transfer and insulating unit of Figure 1 ;

[0023] Figure 4 illustrates an exploded view of some of the components of the thermal energy transfer and insulating unit of Figure 1 showing the construction of the thermal energy transfer and insulating unit with adhesive layers; and

[0024] Figures 5 A through 5C illustrate one method of applying the thermal energy transfer and insulating unit of Figure 1 to a fluid conduit with an associated active heating or cooling unit.

-Page 12- Docket No. 17460.40a DETAILED DESCRIPTION

[0025] Disclosed herein are embodiments of a thermal energy transfer and insulating unit for use in exchanging thermal energy between a heating or cooling element and an object to be warmed or cooled, evenly distributing the thermal energy, and insulating the object and/or the heating or cooling element to limit the exchange of thermal energy with the surrounding environment. In particular, embodiments may include a thermal energy transfer and insulating unit configured to substantially cover the entire outer surface of an object to be warmed or cooled. For instance, the illustrated embodiment is directed towards a thermal energy transfer and insulating unit that is configured to substantially cover the entire outer surface of a fluid conduit, including substantially the full circumference of the fluid conduit. In addition, the illustrated thermal energy transfer and insulating unit is configured to cover at least a portion of a heating or cooling unit associated with the fluid conduit. As used herein, the term "fluid conduit" may refer to, but is not limited to, hoses, pipes, tubes, channels, and the like.

[0026] Furthermore, although the thermal energy transfer and insulating unit of the present invention is described and illustrated as being used in association with a fluid conduit, it will be appreciated that a thermal energy transfer and insulating unit according to the present invention may also be used in connection with other objects. For example, a thermal energy transfer and insulating unit may be sized, shaped, or otherwise configured for use with other types of objects, including tanks, drums, barrels, buckets, bins, boxes, totes, and the like. More specifically, the disclosed thermal energy transfer and insulating unit may be configured to be wrapped or secured

-Page 13- Docket No. 17460.40a around or otherwise substantially enclose all or a portion of an object that is to be heated or cooled regardless of the size or shape of the object. Thus, the scope of the present invention is not limited by that size or shape of the thermal energy transfer and insulating unit or the object that is to be heated or cooled.

[0027] The thermal energy transfer and insulating unit includes a thermal energy spreading element that facilitates the exchange of thermal energy between a heating or cooling element and an object to be heated or cooled. For instance, when the thermal energy transfer and insulating unit is associated with a heating element and an object to be warmed, the thermal energy spreading element facilitates the transfer of thermal energy from the heating element to the object that is to be warmed. More specifically, the thermal energy spreading element is designed to draw the thermal energy from the heating element and efficiently and substantially uniformly spread the thermal energy over the object that is to be warmed.

[0028] In contrast, when the thermal energy transfer and insulating unit is associated with a cooling element and an object to be cooled, the thermal energy spreading element facilitates the transfer of thermal energy from the object to be cooled to the cooling element. More specifically, the cooling element acts as a thermal energy sink which draws thermal energy from the thermal energy spreading element. As discussed herein, the thermal energy spreading element may be designed to more readily spread the thermal energy within the plain (as opposed to out of the plane) of the thermal energy spreading element. As a result, the thermal energy spreading element may efficiently spread the thermal energy across the thermal energy spreading element and transfer the thermal energy to the cooling element. As thermal energy from the

-Page 14- Docket No. 17460.40a thermal energy spreading element sinks to the cooling element, the thermal energy spreading element draws thermal energy out of the object to be cooled. As is understood, removing thermal energy from the object cools the object.

[0029] The thermal energy transfer and insulating unit may also include an insulation layer. The insulation layer may limit or prevent the exchange of thermal energy between the environment surrounding the object that is to be heated or cooled and the heating or cooling element. For instance, the insulation layer may limit or prevent the loss to the surrounding environment of thermal energy (i.e., heat) from a heating element. Rather, the insulation layer may direct the thermal energy toward the object that is to be heated. In the case of cooling, the insulation layer may limit or prevent the cooling element from sinking thermal energy from the warmer surrounding environment, thereby allowing the cooling element to efficiently sink the thermal energy from the object that is to be cooled.

[0030] In light of the above discussion regarding the exchange of thermal energy in heating and cooling applications, it will be understood that the present invention may be configured for use with heating units and/or cooling units. Accordingly, while the following discussion refers to using a thermal energy transfer and insulating unit in association with a heating unit to warm an object, it will be understood that the heating unit is used merely by way of example. As will be understood in light of the disclosure herein, the disclosed thermal energy transfer and insulating unit may be used in association with any type of thermal energy unit. As used herein, the term "thermal energy unit" may refer to any type of heating unit, cooling unit, or combination heating/cooling unit. For instance, a thermal energy unit may be a heating unit, such as

-Page 15- Docket No. 17460.40a a heating unit that includes an electrical heating unit having a resistive element for generating heat. In contrast, a thermal energy unit may include a cooling unit, such as a fluid circulation system that circulates cooled fluid (e.g., water or glycol). A fluid circulation system may also work as a heating unit by circulating a heated fluid. It will be understood that the foregoing heating and cooling units are merely examples of the different types of thermal energy units that may be used to generate or sink thermal energy in order to heat or cool an object.

[0031] Thus, while the following discussion focuses on transferring thermal energy (e.g., heat) from a heating unit to an object that is to be heated with a thermal energy transfer and insulating unit, the heating unit may be replaced with a cooling unit. In such a case, the thermal energy transfer and insulating unit would facilitate that transfer of thermal energy from the object that is to be cooled to the cooling unit. In other words, the thermal energy transfer and insulating unit facilitates the transfer of thermal energy from one object to another, regardless of whether the thermal energy is being transferred from a heating unit to an object to be heated or from an object to a cooling unit to cool the object.

[0032] Figure 1 illustrates one embodiment of a thermal energy transfer and insulating unit configured as a fluid conduit heat spreader and insulator 100, also referred to herein as wrap 100. Wrap 100 is configured to be wrapped around and cover a length of a fluid conduit 102 and at least a portion of a heating unit 104 associated with fluid conduit 102. For instance, as shown in Figure 1, wrap 100 is sized to wrap around the entire circumference of fluid conduit 102 for a length of fluid conduit 102 with a portion of heating unit 104 positioned between fluid conduit 102 and wrap 100.

-Page 16- Docket No. 17460.40a Wrap 100 can be selectively secured around fluid conduit 102 and heating unit 104 with one or more fasteners 106. As will be described in greater detail below, wrap 100 can spread heat from heating unit 104 over the exterior surface of fluid conduit 102 in a substantially even manner to limit or prevent hot and cold spots from forming along and around fluid conduit 102. In addition, wrap 100 can also retain the heat from heating unit 104 close to fluid conduit 100 so that heating unit 104 can more efficiently warm fluid conduit 102 and its contents.

[0033] Heating unit 104 illustrated in Figure 1 includes a heat source 108 and a heat conveying mechanism 110, such as a pipe or hose. For instance, heat source 108 may be configured to heat a liquid or gas, such water, glycol, or air, and pump it through pipe 110. As the heated liquid or gas passes through pipe 110, heat from the liquid or gas is transferred to pipe 110. The heat is then transferred, via conduction, from pipe 110 to fluid conduit 102. It is intended that the heat transferred from heating unit 104 to fluid conduit 102 will maintain fluid conduit 102 and its contents at a desired temperature or within a desired temperature range.

[0034] As will be understood by one of ordinary skill in the art, heating fluid conduit 102 with a heating unit like heating unit 104 will lead to uneven and inefficient heating of fluid conduit 102. In particular, the area of fluid conduit 102 that is in contact with or adjacent to pipe 1 10 will be much warmer than the areas of fluid conduit 102 that are further away from pipe 110. Thus, simply using heating unit 104 to heat fluid conduit 102 and its contents can lead to the formation of hot and cold spots in fluid conduit 102. Additionally, much of the heat from pipe 1 10 can be lost to the

-Page 17- Docket No. 17460.40a environment surrounding fluid conduit 102, resulting in heating unit 104 being highly inefficient.

[0035] Wrap 100 is designed to both evenly spread the heat from heating unit 104 over the surface of fluid conduit 102 and retain the heat close to fluid conduit 102. Thus, wrap 100 is configured to reduce the number and significance of the hot spots normally resulting from heating unit 104. Wrap 100 is likewise configured to increase the efficiency of heating unit 104.

[0036] Wrap 100 is designed to be used in conjunction -with a variety of different types of heating units. For example, as described above in connection with Figure 1, wrap 100 can be used to spread heat from a heated circulation system over a fluid conduit. Alternatively, as shown in Figure 2, wrap 100 (shown in phantom lines) can be used to spread heat from an electrical heating unit 112. In the illustrated embodiment, electrical heating unit 112 includes a heat tape 114 that can be wrapped around fluid conduit 102. Heat tape 114 includes one or more wires or other conductors that convert electrical energy to heat energy, which can then be transferred to fluid conduit 102 via conduction. Electrical heating unit 1 12 also includes a power cable 1 16 and an incoming electrical connector 118 that can be connected to an electrical power source to supply heat tape 114 with electrical energy.

[0037] As suggested above, heating unit 104 may be replaced with a cooling unit for cooling fluid conduit 102. For instance, heat source 108 may be replaced with a cooling source that cools a liquid and passes it through pipe 1 10. In such a case, thermal energy from pipe 102 and its contents would be transferred to wrap 100, which

-Page 18- Docket No. 174 ₆ 0.40a would facilitate that efficient sinking of the thermal energy to the cooled liquid passing through pipe 110, thereby cooling pipe 102 and its contents.

[0038] Although wrap 100 has been described as being used with an active thermal energy unit, such as an active heating or cooling unit, wrap 100 may also be used without such a thermal energy unit. For instance, wrap 100 may be useful in evenly spreading thermal energy over an object to reduce or eliminate hot or cold spots in the object and maintain a generally uniform temperature across the object. By way of example, an object that has been warmed is most likely to lose heat from and develop cool spots near its edges and corners do to thermal energy leaking to the cooler surrounding environment. Similarly, the edges and corners of a cooled object are most likely to develop hot spots from thermal energy sinking to the object from the warmer surrounding environment.

[0039] Wrapping a warmed or cooled object with wrap 100 may reduce or eliminate these hot or cold spots. For example, insulation layer 122 may reduce or eliminate exchange of thermal energy between the warmed or cooled object and the surrounding environment. Additionally, even if hot or cold spots begin to develop on an object due to such thermal energy exchange, thermal energy spreader 124 evenly and efficiently distributes the thermal energy over the surface of the object. Thus, in the case of a warmed object developing cold spots due to energy leaks, thermal energy spreader 124 will evenly and efficiently spread the remaining thermal energy over the surface of the object. Similarly, in the case of a cooled object developing hot spots due to energy sinking from the surrounding environment, thermal energy spreader 124 will evenly and efficiently spread the thermal energy over the surface of the object. In either case,

-Page 19- Docket No. 17460.40a evenly distributing the thermal energy over the surface of the object will help maintain a generally uniform temperature across the object.

[0040] An example of components implemented in one embodiment of wrap 100 is illustrated in Figures 3 and 4. These Figures illustrate the construction of wrap 100, including materials used to assemble wrap 100. Figure 3 illustrates a partially exploded view illustrating the flexible nature of wrap 100 that includes a first cover layer 120, an insulation layer 122, a thermal energy spreader 124, and a second cover layer 126. While the example illustrated in Figure 3 is illustrated as partially exploded, some finished embodiments may be manufactured such that insulation layer 122 and thermal energy spreader 124 may be sealed between first cover layer 120 and second cover layer 126. Sealing processes and details will be discussed in more detail below.

[0041] Figure 4 illustrates a fully exploded view of wrap 100 so as to more clearly illustrate the individual components of wrap 100. As illustrated in Figure 4, first and second cover layers 120 and 126 are generally planar sheets of material that are disposed on opposing sides of the internal components of wrap 100. During construction of wrap 100, first cover layer 120 is positioned as illustrated in Figure 4. Next, insulation layer 122 is positioned on top of first cover layer 120 and thermal energy spreader 124 is then positioned on top of insulation layer 122. Finally, second cover layer 126 is positioned on top of thermal energy spreader 124. With the various components of wrap 100 so positioned, the peripheral edges of first and second layers 120 and 126 can be joined, sealed, or otherwise closed.

[0042] Wrap 100, constructed as described herein, can be used in numerous applications that require thermal energy to be transferred to or from, or spread over an

-Page 20- Docket o. 17460.40a object or surface. As described herein, the various components of wrap 100 may be flexible, and shaped and sized in any number of ways such that wrap 100 can be wrapped around objects of various shapes and sizes, laid on top, beneath, or hung adjacent objects or surfaces, and rolled or folded up when not in use.

[0043] In some embodiments, it may be desirable to limit or prevent the various components of wrap 100 from moving relative to one another or help them retain their shape. In such embodiments, the various components of wrap 100 can be attached to one another. For example, the various components of wrap 100 can be glued, bonded, taped, clipped, or otherwise secured or held together. Attaching the components of wrap 100 together can help to prevent the components from moving relative to one another within wrap 100.

[0044] For example, attaching thermal energy spreader 124 to insulation layer 122 ensures that thermal energy spreader 124 will stay positioned next to insulation layer 122 and will not sag, bunch, or otherwise move within wrap 100. In particular, because insulation layer 122 is formed of a stiffer material than thermal energy spreader 124, attaching thermal energy spreader 124 to insulation layer 122 provides stiffness to thermal energy spreader 124. While insulation layer 122 is referred to as being formed of a "stiffer" material, it will be appreciated that in some embodiments insulation layer 122 may still be flexible enough such that it can be wrapped around a fluid conduit or a barrel, or folded around a box, for example. Likewise, thermal energy spreader 124 and/or insulation layer 122 can be attached to first and/or second cover layers 120 and 126 to prevent the internal components of wrap 100 from moving within first and second cover layers 120 and 126.

-Page 21- Docket No. 17460.40a [0045] Figure 4 illustrates one exemplary embodiment in which various components of wrap 100 are attached together. In the embodiment illustrated in Figure 4, there are two interfaces between the components of wrap 100 for attachment between the components. As used herein, an attachment interface is a surface where two or more components of wrap 100 may be attached together or where surface of two adjacent components contact one another. The first attachment interface 128 is between the top surface of insulation layer 122 and the bottom surface of thermal energy spreader 124. The second attachment interface 130 is between the top surface of thermal energy spreader 124 and the bottom surface of second cover layer 126. In other embodiments, there is only the first attachment interface 128. Still in other embodiments, there are additional attachment interfaces, such as between the bottom surface of insulation layer 122 and the top surface of first cover layer 120.

[0046] Attachment interfaces 128 and 130 can be created by attaching the above identified components of wrap 100 in any suitable manner so that the components maintain their relative positions one to another. For instance, the components of wrap 100 can be secured or attached to one another with glue, tape, clips, pins, brackets, or any other suitable fastener. In one exemplary embodiment, attachment interfaces 128 and 130 are created using an adhesive between the components of wrap 100. One such adhesive suitable for attaching together the components of wrap 100 is 30-NF FASTBOND™ available from 3M located in St. Paul, Minnesota. FASTBOND™ is a non-flammable, heat resistant, polychloroprene based adhesive.

[0047] In order to properly adhere the components of wrap 100 together with FASTBOND™, the interfacing surfaces should be clean and dry. With the surfaces

-Page 22- Docket No. 17460.40a prepared, a uniform coat of FASTBOND™ is applied to both interfacing surfaces. After applying, the FASTBOND™ is allowed to dry completely, which typically takes about 30 minutes. Once the FASTBOND™ on both surfaces is dry, the two FASTBOND™ coated surfaces are joined together.

[0048] For example, when attaching insulation layer 122 to thermal energy spreader 124, a coat of FASTBOND™ is applied to the top surface of insulation layer 122 and the bottom surface of thermal energy spreader 124. Once the FASTBOND™ on each surface is dry, thermal energy spreader 124 is positioned on top of insulation layer 122 and the two layers of FASTBOND™ adhere to one another. The same process can be followed to attach second cover layer 126 to the top surface of thermal energy spreader 124 or to attach the first cover layer 120 to the bottom surface of insulation layer 122.

[0049] In the illustrated embodiment, second cover layer 126 is attached to thermal energy spreader 124 and thermal energy spreader 124 is attached to insulation layer 122. Notably, however, insulation layer 122 and thermal energy spreader 124 can be left unattached from first and/or second cover layers 120 and 126. Not attaching insulation layer 122 and thermal energy spreader 124 to first and/or second cover layers 120 and 126 provides for flexibility and give in wrap 100 when wrap 100 is folded, rolled, or wrapped around an object. Specifically, wrap 100 is configured to be wrapped around an object such that second cover layer 126 is adjacent the object and first cover layer 120 is positioned away from the object (see Figure 1 in which first cover layer 120 is showing). When first and/or second cover layers 120 and 126 are not attached to insulation layer 122 and/or thermal energy spreader 124, first and/or second cover layers 120 and 126 are able to move relative to insulation layer 122 and thermal

-Page 23- DocketNo. 17460.40a energy spreader 124 and stretch as wrap 100 is wrapped around an object. In other embodiments, however, insulation layer 122 and first cover layer 120 are attached to one another while thermal energy spreader 124 and second cover layer 126 are attached to one another. For example, when wrap 100 is used on flat surfaces, such as the ground or a roof, the need for first and second cover layers 120 and 126 to be able to move relative to insulation layer 122 and thermal energy spreader 124 is not as great.

[0050] With continued reference to Figures 3 and 4, as noted above, wrap 100 includes thermal energy spreader 124. In general terms, thermal energy spreader 124 is a layer of material capable of efficiently transferring thermal energy between objects. For instance, when wrap 100 is used in association with a heating unit, thermal energy spreader 124 is capable of drawing thermal energy from the heating unit associated with fluid conduit 102 and distributing that thermal energy away from the heating unit, thereby more evenly spreading the thermal energy over the object that is to be heated. Conversely, when wrap 100 is used in association with a cooling unit, thermal energy spreader 124 is capable of drawing thermal energy from the object that is to be cooled and distributing that thermal energy to the cooling unit. Thermal energy spreader 124 is also able to evenly distribute the thermal energy drawn from the object across the surface of thermal energy spreader 124, thereby reducing or eliminating hotspots on the surface of the object that is to be cooled.

[0051] Thermal energy spreader 124 may comprise a metallic foil, wire mesh, carbon mesh, graphite, a composite material, or other material. Thermal energy spreader 124 in one embodiment is an electrically-conductive material comprising carbon. Graphite is one example of an electrically-conductive material comprising

-Page 24- Docket No. 17460.40a carbon. However, other suitable materials may include carbon-based powders, carbon fiber structures, or carbon composites. Those of skill in the art will recognize that material comprising carbon may further comprise other elements, whether they represent impurities or additives to provide the material with particular additional features. Materials comprising carbon may be suitable so long as they have sufficient thermal conductivity to act as a thermal energy- spreading element. Thermal energy spreader 124 may further comprise a carbon derivative, or a carbon allotrope.

[0052] One example of a material suitable for use as thermal energy spreader 124 is a graphite-epoxy composite. The in-plane thermal conductivity of a graphite-epoxy composite material is approximately 370 watts per meter per Kelvin, while the out of plane thermal conductivity of the same material is 6.5 watts per meter per Kelvin. The thermal anisotropy of the graphite/epoxy composite material is then 57, meaning that thermal energy is conducted 57 times more readily in the plane of the material than through the thickness of the material. This thermal anisotropy allows the thermal energy to be readily spread out over the surface of the material. In heating applications, this allows for more thermal energy to be drawn out of the heating element associated with fluid conduit 102. In cooling applications, this allows for more thermal energy to be drawn out of the object to be cooled and directed to the cooling unit associated with the fluid conduit.

[0053] Thermal energy spreader 124 may comprise a material that is thermally isotropic in one plane. The thermally isotropic material may distribute the thermal energy more evenly and more efficiently. One such material suitable for forming thermal energy spreader 124 is GRAFOIL® available from Graftech Inc. located in

-Page 25- Docket No. 17460.40a Lakewood, Ohio. In particular, GRAFOIL® is a flexible graphite sheet material made by taking particulate graphite flake and processing it through an intercalculation process using mineral acids. The flake is heated to volatilize the acids and expand the flake to many times its original size. The result is a sheet material that typically exceeds 98% carbon by weight. The sheets are flexible, lightweight, compressibly resilient, chemically inert, fire safe, and stable under load and temperature. The sheet material typically includes one or more laminate sheets that provide structural integrity for the graphite sheet.

[0054] Due to its crystalline structure, GRAFOIL® is significantly more thermally conductive in the plane of the sheet than through the plane of the sheet. This superior thermal conductivity in the plane of the sheet allows temperatures to quickly reach equilibrium across the breadth of the sheet, thereby eliminated hotspots on the object that is being heated or cooled.

[0055] Typically, the GRAFOIL® will have no binder, resulting in a very low density, making the wrap relatively light while maintaining the desired thermal conductivity properties. For example, the standard density of GRAFOIL® is about 1.12 g/ml. It has been shown that three stacked sheets of 0.030" thick GRAFOIL® C have similar thermal coupling performance to a 0.035" sheet of cold rolled steel, while weighing about 60% less than the cold rolled steel sheet.

[0056] Another product produced by GrafTech Inc. that is suitable for use as thermal energy spreader 124 is EGRAF® S PRE ADERS HIELD™. The thermal conductivity of the SPREADERSHIELD™ products ranges from 260 to 500 watts per meter per Kelvin within the plane of the material, and the out of plane (through

-Page 26- Docket No. 17460.40a thickness) thermal conductivity ranges from 6.2 down to 2.7 watts per meter per Kelvin. Thus, the thermal anisotropy of the material ranges from 42 to 163. Consequently, a thermally anisotropic planar thermal energy spreader 124 serves as a conduit for the thermal energy within the plane of thermal energy spreader 124, and quickly distributes the thermal energy more evenly over a greater surface area than a foil. The efficient planar thermal energy spreading ability of the planar thermal energy spreader 124 also provides for a higher efficiency in the thermal energy unit (e.g., heating or cooling unit) associated with fluid conduit 102. The higher efficiency of the thermal energy unit facilitates the use of conventional power supply voltages such as 120 volts on circuits protected by 20 Amp breakers, instead of less accessible higher voltage power supplies. In some embodiments, thermal energy spreader 124 is a planar thermal conductor. In certain embodiments, the graphite may be between 1 thousandth of an inch thick and 40 thousandths of an inch thick. This range may be used because within this thickness range the graphite remains pliable and durable enough to withstand repeated rolling and unrolling as wrap 100 is wrapped around and unwrapped off of fluid conduits or other objects, and rolled up for storage. Thermal energy spreader 124 may comprise a flexible thermal conductor. In certain embodiments, thermal energy spreader 124 is formed in a contiguous layer.

[0057] In some embodiments, thermal energy spreader 124 may include an insulating element formed of a thin plastic layer on both sides of thermal energy spreader 124. The insulating element may additionally provide structure to the thermal energy- spreading material used in thermal energy spreader 124. For example, the insulating element may be polyethylene terephthalate (PET) in the form of a thin plastic

-Page 27- Docket No. 17460.40a layer applied to both sides of thermal energy spreader 124 comprising graphite. Those of skill in the art will appreciate that such a configuration may result in the insulating element lending additional durability to thermal energy spreader 124.

[0058] It will be understood by one of ordinary skill in the art that a wrap or fluid conduit thermal energy spreader and insulator of the present disclosure can be shaped and sized as desired or needed for a particular application. For instance, wraps as described herein can be sized to substantially surround fluid conduits of various lengths and diameters. Additionally, as described elsewhere herein, multiple wraps can be coupled together over fluid conduits of nearly any size. In one exemplary embodiment, the wrap is approximately twelve and one half (12½) feet long and one (1) foot wide. In another exemplary embodiment, the wrap is approximately six (6) feet long and eight (8) inches wide. In still another embodiment, the wrap is approximately twenty-five (25) feet long and two and one half (2½) feet wide. It will be appreciated, however, that the wraps can be sized and configured to substantially surround fluid conduits of any size or shape. Likewise, the wraps can be formed in other shapes and sizes to be wrapped around other objects (e.g., tanks, cylinders, drums, totes, boxes, etc.) as noted herein and as will be readily recognized by one of skill in the art.

[0059] Returning once again to Figures 3 and 4, Figures 3 and 4 illustrate insulation layer 122. Insulation layer 122 may be used to reflect or direct thermal energy. For example, in heating applications, it may be desirable to direct all or most of the thermal energy from an associated heating unit toward a particular surface of wrap 100 or toward the object being heated. In the embodiment illustrated in Figures 1 and 5A-5C, for example, it may be desirable to direct thermal energy towards the wall of fluid

-Page 28- Docket No. 17460.40a conduit 102 while directing thermal energy away from an exterior environment in which fluid conduit 102 is located. In the illustrated example, it may be desirable to have thermal energy directed towards the side of wrap 100 which includes second cover layer 126, while directing thermal energy away from the side that includes first cover layer 120. In contrast, in cooling applications it may be desirable to direct all or most of the thermal energy from a surrounding environment away from the object being cooled or the associated cooling element. In the embodiment illustrated in Figures 1 and 5A- 5C, for example, it may be desirable to direct thermal energy from the surrounding environment away from the wall of fluid conduit 102 and pipe 110. Insulation layer 122 may be used to accomplish this task. Some exemplary embodiments of the wrap have been implemented where about 95% of the thermal energy is directed towards a desired surface of the wrap.

[0060] Insulation layer 122 may include a sheet of polystyrene, cotton batting, GORE-TEX®, fiberglass, foam rubber, etc. In certain embodiments, insulation layer 122 may allow some thermal energy generated by the associated heat unit or from the surrounding environment to pass through wrap 100 if desired. For example, insulation layer 122 may include a plurality of vents to transfer thermal energy from the first side of wrap 100 to the second of wrap 100 or vice versa. In certain embodiments, insulation layer 122 may be integrated with either first cover layer 120 or second cover layer 126. For example, first cover layer 120 may include an insulation fill or batting positioned between two films of nylon.

[0061] In some embodiments, first and second cover layers 120, 126 may comprise a textile fabric. The textile fabric may include natural or synthetic products. For

-Page 29- Docket No. 17460.40a example, first and second cover layers 102, 108 may comprise burlap, canvas, cotton or other materials. In another example, first and second cover layers 102, 108 may comprise nylon, vinyl, or other synthetic textile material. First and second cover layers 102, 108 may comprise a thin sheet of plastic, metal foil, polystyrene, or other materials.

[0062] In manufacturing wrap 100, thermal energy spreader 124 and insulation layer 122 may be sealed between first and second cover layers 120 and 126. As illustrated in Figures 3 and 4, first and second cover layers 120 and 126 extend slightly beyond thermal energy spreader 124 and insulation layer 122. This allows first and second cover layers 120 and 126 to be sealed, such as by using an adhesive, heat welding, or another appropriate method or combination of methods.

[0063] Additionally, wrap 100 may be constructed such that first and second cover layers 120 and 122 may include one or more fasteners 106 for securing or connecting wrap 100 around fluid conduit 102 or other object. In some embodiments, fasteners 106 may be attached or formed into the comers of wrap 100. Additionally, fasteners 106 may be distributed about the perimeter of wrap 100. In some embodiments, fastener 106 is a hook and loop fastener such as VELCRO®. For example, wrap 100 may include a hook fabric on one side and a loop fabric on an opposite side. In other alternative embodiments, fasteners 106 may include grommets, snaps, clips, zippers, adhesives, or other fasteners. Further, additional objects may be used with fasteners 106 to accomplish fastening. For example, when grommets are used, elastic cord, such as fixed or adjustable bungee cord may be used to connect to grommets on opposite

-Page 30- Docket No. 17460.40a sides of wrap 100. This may be used, for example, to secure wrap 100 around an object, such as fluid conduit 102.

[0064] A number of fastener arrangements may be implemented for securing the opposing sides of wrap 100 together. For example, Figure 1 illustrates a first portion of wrap 100 having a plurality of grommets therein. Associated with each of the grommets is an elastic cord that can be wrapped around wrap 100 with both ends of the cord being attached to its associated grommet. Other fasteners that can be employed to secure wrap 100 around fluid conduits or other objects include snap fasteners, zippers, hook and loop type fasteners such as VELCRO®, and the like. Fasteners 106 can be adapted to enable selective coupling and decoupling to allow wrap 100 to be selectively opened and closed. Alternatively, fasteners 106 can be adapted to permanently close wrap 100. For example, grommet fasteners 106 can be secured to opposing portions of wrap 100, where a single grommet may be secured to both opposing portions such that wrap 100 permanently maintains a substantially wrapped shape.

[0065] In some embodiments, first cover layer 120 may be positioned at the top of wrap 100 and second cover layer 126 may be positioned on the bottom of wrap 100. In certain embodiments, first cover layer 120 and second cover layer 126 may comprise the same or similar material. Alternatively, first cover layer 120 and second cover layer 126 may comprise different materials, each material possessing properties beneficial to the specified surface environment.

[0066] For example, first cover layer 120 may comprise a material that is resistant to sun rot such as such as polyester, plastic, and the like. Second cover layer 126 may comprise material that is resistant to mildew, mold, and water rot such as nylon. First

-Page 31- Docket No. 17460.40a and second cover layers 120 and 126 may comprise a highly durable material. The material may be textile or sheet, and natural or synthetic. For example, first and second cover layers 120, 126 may comprise a nylon textile. Additionally, first and second cover layers 120, 126 may be coated with a water resistant or waterproofing coating. For example, a polyurethane coating may be applied to the outer surfaces of first and second cover layers 120, 126. Additionally, first and second cover layers 120, 126 may be colored, or coated with a colored coating such as paint. In some embodiments, the color may be selected based on heat reflective or heat absorptive properties. For example, first cover layer 120 may be colored black for maximum solar heat absorption. Second cover layer 126 may be colored grey for a high heat transfer rate or to maximize heat retention beneath wrap 100.

[0067] First and second cover layers 120, 126 may also be formed to be static dissipative. More specifically, first and second cover layers 120, 126 may be formed or coated with materials that may reduce the buildup or discharge of static electricity. For instance, first and second cover layers 120, 126 may be formed or coated with semi- conductive materials such as silicon or appropriate concentrations of carbon fiber, aluminum powders, copper, or other conductive materials. Forming or coating first and second cover layers 120, 126 with such materials may provide first and second cover layers 120, 126 with a surface resistivity of between about lxlO ⁵ ohms/sq. and about lxl 0 ¹² ohms/sq. and/or a volume resistivity of between about lxl 0 ⁴ ohm-cm and about lxlO ¹¹ ohm -cm. Surface and volume resistivities within these ranges may reduce or eliminate the buildup or discharge of static electricity on or from first and second cover layers 120, 126.

-Page 32- Docket No. 17460.40a [0068] As illustrated in Figures 1, 3, and 5A-5C, wrap 100 can also include a sealing flap 132 that extends along the length of wrap 100 that is adapted to reduce the amount of thermal energy lost when wrap 100 is wrapped around fluid conduit 102. Along one edge of wrap 100 illustrated in Figure 3, first and second cover layers 120, 126 extend beyond thermal energy spreader 124 and insulation layer 122 to form sealing flap 132. While the illustrated embodiment does not include thermal energy spreader 124 or insulation 122 in sealing flap 132 of wrap 100, it will be appreciated that thermal energy spreader 124 and insulation layer 122 can also extend into sealing flap 132 of wrap 100. It will be appreciated that sealing flap 132 can be formed independently of first and second cover layers 120, 126. For example, sealing flap 132 can be formed separately from first and second cover layers 120, 126 and attached to first and/or second cover layers 120, 126.

[0069] Wrap 100 can be wrapped and secured around the outer wall of fluid conduit 102 as illustrated in Figures 5A-5C. Specifically, as illustrated in Figure 5 A, with wrap 100 laid open, wrap 100 can be positioned adjacent fluid conduit 102 such that fluid conduit 102 is positioned generally in the middle of wrap 100. In the illustrated example, the lengths of wrap 100 and fluid conduit 102 are parallel. So positioned, wrap 100 can be folded over or wrapped around fluid conduit 102 as shown in Figure 5B. As noted herein, each of the components of wrap 100 is pliable, thus enabling wrap 100 to be folded over or wrapped around fluid conduit 102. To facilitate the folding or wrapping of wrap 100 over fluid conduit 102, insulation layer 122 can include one or more scores therein that allow for insulation layer 122 and the rest of wrap 100 to generally conform to the shape of fluid conduit 102.

-Page 33- Docket No. 17460.40a [0070] With wrap 100 folded over or wrapped around fluid conduit 102, sealing flap 132 can then be folded over to cover any openings between the opposing sides of wrap 100. Fasteners 106 can then be used to secure wrap 100 around fluid conduit 102. For example, in Figure 5C, fasteners 106 comprise grommets and elastic cords. The grommets and elastic cords are spaced along at least one of the long edges of wrap 100. The elastic cords can be wrapped around wrap 100 and secured to the grommets to maintain wrap 100 on fluid conduit 102.

[0071] Additionally, some embodiments may include one or more additional fasteners 106 that can be used to connect multiple wraps 100 to one another. For instance, when multiple wraps 100 are used to spread heat over and insulate adjacent segments of a fluid conduit, it may be desirable to connect the adjacent wraps 100 together. Thus, wraps 100 can include additional fasteners 106 that can be secured together to prevent wraps 100 from being moved apart and exposing portions of the fluid conduit. Like the fasteners used to secure wrap 100 around fluid conduit 102, the fasteners used to connect multiple wraps 100 together can include, but are not limited to, snap fasteners, zippers, hook and loop type fasteners such as VELCRO®, clips, grommets, hooks, cords, and the like.

[0072] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

-Page 34- Docket No. 17460.40a