Take two heat exchangers, place a Thermo Electric Cooling module between them and produce enough cooling to keep a motorcycle helmet comfortable.
If you wish to attempt your own A/C system, you do not have to use the products that I used in my attempt. Any brand mentioned or show in this paper is not an endorsement of that company.
I wanted to keep the system as small as possible. Going with a bigger container would have made prototyping a bit easier however.
The fan is attached to the radiator. I don't think it will be needed when moving but should help when stopped. The bag work by unzipping it and letting the air flow through the radiator.
For the exchangers I used two Corsair Hydro Series H60 liquid cpu cooling systems. This is a picture of a unit as it comes out of the box.
The first thing is to remove the provided liquid tubing. This instantly voids the warranty.
"To insulate around the TEC I used Aerogel. This material is a good thermal insulators because it almost nullify the three methods of heat transfer (convection, conduction, and radiation). Aerogel is a good conductive insulators because it is composed almost entirely from a gas, and gases are very poor heat conductors. Silica aerogel is especially good because silica is also a poor conductor of heat. It is also a good convective inhibitors because air cannot circulate through the lattice. " ~Wiki
The Aerogel shatters microscopically if compressed so I had to peel off 1mm of the insulation to match the height of the TEC with installed thermal pads.
The TEC1-12709 is a Ceramic Plate Thermoelectric Cooling Module that is a heat exchanger. It operates at 12 volts, 45 watts and 3 amps. Also know as a Peltier chip.
|Originally I was going to use Mylar on either side of the aerogel for added insulation but decided it was overkill.|
|I started by placing the thermal pad on the Hot side of the exchanger|
|Aerogel is placed|
|TEC added. Hot side to hot exchanger.|
|The Cold exchanger ready to bolt on.|
|Assembled exchange unit.|
Installing the exchange unit in the back pack.
I first cut a hole the size of the fan blades in the backpack. I installed the radiator and fan on the outside of the pack.
Next comes the exchanger. I used a piece of Styrofoam to fill and flatten the bottom of the pack and used a zip tie to attach it to the unit. The Hot side goes to to fan. Vinyl tubing was used between the radiator and exchange unit.
I had to make the radiator for the head. I could not afford a Cool Shirt or Hood so I made my own.
|I drew this water flow pattern and place a doubled sheet of vinyl sheet from the sewing center|
|I used a soldering iron to seal the plastic.|
|This is the pad that sits under the helmet.|
The power is supplied through a cord which plugs into an installed outlet connected to the motorcycle battery.
|Completed unit, ready to test!|