Omni-spectral thermal camouflage, signature mitigation and insulation apparatus, composition and system

Abstract

A system, apparatus, composition, and methods for producing a modular, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation and thermal insulation system. The thermal management system may comprise one or more composite layers or combinations of ultra-thin and ultra-lightweight non-woven stealth coated substrates. Each composite layer may be coated with specific components to create different thermal camouflage through a biomimicry application process of absorbance, reflective, protective layering, thermal signature mitigation, and/or thermal insulation system capabilities. Layers can be combined to enable dynamic stealth camouflage tunable performances of reflectivity, transmission, emissivity, or absorption in selective visible, near infrared, and infrared wavelength bands whereby each substrate has a unique EM wave propagation control or thermal signature mitigation characteristics. Embodiments enable thermal camouflage, thermal signature mitigation, and thermal insulation solutions that are adaptable to specific battlefield scenarios or environmental requirements.

What is claimed is: 
     
         1 . A stealth material composition, comprising:
 a first layer comprising a substrate layer;   a second layer disposed on the first layer, the second layer comprising a thermal absorption layer comprising a conductive ink disposed on the substrate layer according to a pattern comprising a plurality of random or ordered apertures,   wherein the plurality of random or ordered apertures are arranged to have a periodic separation distance in the range of 0.5 millimeters to 3.5 millimeters; and   a third layer disposed on the second layer, the third layer comprising an aluminum coating disposed on the thermal absorption layer.   
     
     
         2 . The stealth material composition of  claim 1  further comprising a fourth layer disposed on one or both of the second layer and the third layer, wherein the fourth layer comprises a urethane coating. 
     
     
         3 . The stealth material composition of  claim 1  wherein the substrate layer is constructed from a fabric material having a thickness of less than or equal to 1 millimeter. 
     
     
         4 . The stealth material composition of  claim 1  wherein each aperture in the plurality of random or ordered apertures has a size in the range of 0.149 millimeters to 2.0 millimeters. 
     
     
         5 . The stealth material composition of  claim 1  wherein the aluminum coating comprises a vapor metallization aluminum coating. 
     
     
         6 . The stealth material composition of  claim 3  wherein the fabric material is selected from the group consisting of cotton, polyester, polyimide, polypropylene, polyethylene terephthalate, nylon, biaxially-oriented polyethylene terephthalate, polyvinylidene dichloride, and biaxially-oriented polypropylene. 
     
     
         7 . The stealth material composition of  claim 1  wherein the conductive ink comprises iron oxide or chromium oxide. 
     
     
         8 . The stealth material composition of  claim 5  wherein the vapor metallization coating is disposed on at least 10% of a surface area of the thermal absorption layer. 
     
     
         9 . The stealth material composition of  claim 1  wherein each aperture in the plurality of random or ordered apertures comprises an irregular shape. 
     
     
         10 . A stealth material composition, comprising:
 a first layer comprising a substrate layer;   a second layer disposed on the first layer, the second layer comprising a thermal absorption layer comprising a conductive ink disposed on the substrate layer according to a pattern comprising a plurality of random or ordered apertures,   wherein each aperture in the plurality of random or ordered apertures has a size in the range of 0.149 millimeters to 2.0 millimeters; and   a third layer disposed on the second layer, the third layer comprising an aluminum coating disposed on the thermal absorption layer.   
     
     
         11 . The stealth material composition of  claim 10  wherein the pattern comprises a Faraday cage pattern. 
     
     
         12 . The stealth material composition of  claim 10  wherein the substrate layer comprises a mesh material comprising a mesh sieve designation in the range of Number 10 sieve to Number 100 sieve. 
     
     
         13 . The stealth material composition of  claim 10  wherein the substrate layer comprises a fabric material having a weight in the range of 30 grams per square meter to 40 grams per square meter. 
     
     
         14 . The stealth material composition of  claim 10  wherein the substrate layer comprises a fabric material having a density in the range of 10 Denier to 100 Denier. 
     
     
         15 . The stealth material composition of  claim 10  further comprising a fourth layer disposed on one or both of the second layer and the third layer, wherein the fourth layer comprises a mixture of two or more of components selected from the group consisting of urethane, barium sulphate, boron nitride, a fire-retardant, and water. 
     
     
         16 . A stealth material composition, comprising:
 a first layer comprising a substrate layer;   a second layer disposed on the first layer, the second layer comprising a thermal absorption layer comprising a conductive ink disposed on the substrate layer according to a pattern comprising a plurality of random or ordered apertures,   wherein the plurality of random or ordered apertures are arranged to comprise a Faraday cage pattern; and   a third layer disposed on the second layer, the third layer comprising an aluminum coating disposed on the thermal absorption layer.   
     
     
         17 . The stealth material composition of  claim 16  wherein the plurality of random or ordered apertures are arranged to have a periodic separation distance in the range of 0.5 millimeters to 3.5 millimeters. 
     
     
         18 . The stealth material composition of  claim 16  wherein each aperture in the plurality of random or ordered apertures has a size in the range of 0.149 millimeters to 2.0 millimeters. 
     
     
         19 . The stealth material composition of  claim 16  wherein each aperture in the plurality of random or ordered apertures comprises an irregular shape. 
     
     
         20 . The stealth material composition of  claim 16  wherein the aluminum coating comprises a vapor metallization aluminum coating.