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.

Claims

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.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0027] The above and other objects, features and advantages of the present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0028] FIG. 1 is an illustration of an ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system and composition, in accordance with certain aspects of the present disclosure;

[0029] FIG. 2 is an illustration of a conductive Faraday cage pattern, in accordance with certain aspects of the present disclosure;

[0030] FIG. 3 is an illustration of a nano mesh substrate within a thermal camouflage, thermal signature mitigation, and thermal insulation system and composition, in accordance with certain aspects of the present disclosure;

[0031] FIG. 4 is an illustration of a micro insulator substrate within a thermal camouflage, thermal signature mitigation, and thermal insulation system and composition, in accordance with certain aspects of the present disclosure;

[0032] FIG. 5 is a flow chart of the method of fabricating a thermal insulation system and composition, in accordance with certain aspects of the present disclosure;

[0033] FIG. 6 is an illustration of a stealth shell, in accordance with certain aspects of the present disclosure;

[0034] FIG. 7 is an illustration of a stealth tent, in accordance with certain aspects of the present disclosure;

[0035] FIG. 8 is a graph containing the reflectivity, transmission, and emissivity percent data for Stealth Gray Body Diffusion constructs, in accordance with certain aspects of the present disclosure;

[0036] FIG. 9 is a cross-sectional diagram of a thermal insulative stealth material composition, in accordance with certain aspects of the present disclosure;

[0037] FIG. 10A is a plan view illustration of a thermal insulative stealth material composition, in accordance with certain aspects of the present disclosure;

[0038] FIG. 10B is a cross-sectional diagram of a thermal insulative stealth material composition, in accordance with certain aspects of the present disclosure;

[0039] FIG. 11 is a graph of thermal performance data for a garment comprising the thermal insulative stealth material composition of the present disclosure; and

[0040] FIG. 12 is a graph of thermal performance data for a sleeping bag comprising the thermal insulative stealth material composition of the present disclosure.

DETAILED DESCRIPTION

[0041] It should be appreciated that all combinations of the concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. It also should be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the concepts disclosed herein.

[0042] It should be appreciated that various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the disclosed concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes. The present disclosure should in no way be limited to the exemplary implementation and techniques illustrated in the drawings and described below.

[0043] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed by the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed by the invention, subject to any specifically excluded limit in a stated range. Where a stated range includes one or both endpoint limits, ranges excluding either or both of those included endpoints are also included in the scope of the invention.

[0044] As used herein, the term includes means includes but is not limited to, the term including means including but not limited to. The term based on means based at least in part on.

[0045] As used herein, the term omni-spectral means, but not limited to, the wavelength range of X-ray, UV, visible, near infrared (NIR), infrared (IR), mid-range IR (MWIR), SWIR, LWIR, far IR, millimeter, radar radio waves (i.e., 10.sup.?10 to 10.sup.8 meter).

[0046] As used herein, the term black body radiation means the thermal electromagnetic radiation within or surrounding a body in thermodynamic equilibrium with its environment, emitted by a black body (an idealized opaque, non-reflective body).

[0047] As used herein, the term grey or gray body means an object with an emissivity less than unity (i.e., less than 1) and the same at all wavelengths, by comparison with a black body that has unit emissivity or emissivity equal to 1, at all wavelengths.

[0048] As used herein, the term Gray Body Diffusion means an object possessing a relatively similar emissivity through the thermal IR (TIR) spectra.

[0049] As used herein, the term tunable is loosely defined as first creating a straight-line gray body diffusion through the three thermal IR bandwidths on a low thermal mass non-woven substrate through the select application of stealth coatings (biomimicry).

[0050] As used herein the term stealth coating means, but is not limited to, a combination of one, two, or more layers of stealth polymer ink applications to the surface of a substrate.

[0051] As used herein, the term nonwoven or non-woven is a broad term encompassing almost any fabric or textile which is made without weaving fibers together (i.e., loom).

[0052] As used herein, the term spun lace is the process of producing an entanglement of and/or stealth coated fibers (metallic conductive fibers) or materials by means of heavy water jets at very high pressures through jet orifices with very small diameters.

[0053] As used herein the term stealth means any characteristics, properties and/or performance attributes related to thermal camouflage, thermal signature mitigation, electromagnetic propagation/attenuation, and/or thermal insulation.

[0054] As used herein, the term spun bonding is a process for forming nonwoven fabrics by bonding continuous-filament synthetic fibers and/or stealth coated fibers (above) immediately after extrusion.

[0055] As used herein, the term needle punching is a mechanical bonding achieved by entangling of fibers with barbed needles, set into a board, which penetrate the web and then recede.

[0056] As used herein, the term vapor deposition refers to an atomistic deposition process where the coating material is vaporized and condensed onto a selected substrate in a vacuum, forming a thin film.

[0057] As used herein, the term Faraday cage means a volume surrounded by one or more conductive walls with openings or holes capable of neutralizing an external EM field or shielding against an external EM field, such openings or holes having diameters that are smaller than a specific (i.e., target) wavelength to prevent/restrict EM field coupling therethrough.

[0058] As used herein, the term Faraday cage pattern means any pattern or opening or hole of a Faraday cage and is not limited to a specific geometric pattern or specific geometric characteristics. A Faraday cage pattern may include, for example, a metal screen with holes on the door of a microwave oven. The screen keeps the microwaves contained within the oven while allowing light, with its much shorter wavelength, to pass therethrough. The Faraday cage pattern assists in electrical conduction/TIR absorption of the stealth coating and assists in transmission.

[0059] As used herein, an irregular shape means a shape which has sides and/or angles of different lengths and sizes (i.e., the sides are not all of equal length and/or the interior angles are not all the same size).

[0060] As used herein, exemplary means serving as an example or illustration and does not necessarily denote ideal or best.

[0061] Certain objects and advantages of the present disclosure include a thermal signature apparatus and system that allows the individual warfighter to build modular and scalable stealth compositions, including lightweight, layered, thermal signature mitigating compositions (e.g., a thermal nest above and/or around to hide from space, airborne, land based thermal observation/targeting mechanisms), that are adaptable to varying battle environments.

[0062] Exemplary embodiments of the present disclosure provide one or more system, apparatus, 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 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. The layers on the individual substrates may 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. The system enables thermal camouflage, thermal signature mitigation, and thermal insulation solutions adaptable to specific battlefield scenarios or environmental requirements. The systems expand the options for meeting the demands of today's and future stealth missions.

[0063] Reconnaissance measures such as radar use an emitting element to transmit a radiation beam. When such beams encounter an object, they are reflected by the object and returned to the radar. The radar receiver receives the reflected radiation, which is subjected to time analysis (to determine the distance to the detected object) and amplitude-phase analysis (to determine the type of object detected). This mode of operation of radar devices means that the only effective countermeasure is to minimize reflected radiation, resulting in either a lack of detection or, should detection occur, incorrect identification of the object. It is generally accepted that radars operate in the range of electromagnetic radiation, mostly in the centimeter and millimeter wave spectrum. However, battlefield radar and tracking radars work in different wavelengths, from 1 to 20 GHz, 35 GHz, and 94 GHz.

[0064] Camouflage in the radar range focuses on at least two aspects: reducing the radar cross section (RCS) of objects so that a minimal proportion of the radiation emitted by the radar returns to it as the result of being reflected from the object; deformation/blurring of the radar signature of the object camouflaged to eliminate or change the details of the radar signature which allow recognition/identification of the object. Another approach is to use microwave absorbers.

[0065] The absorption of electromagnetic (EM) wave radiation and propagation is a process by which the energy of an EM wave is turned off and then transformed into other energies by interference, which EM wave cannot reflect or transmit through material. Ideal EM wave absorbing materials should have two basic properties: (1) the intrinsic impedance of the material is equal to the impedance of the free space (impedance matching) and (2) the EM wave in the material is rapidly attenuated. These conditions require strong magnetic and/or dielectric loss exhibition.

[0066] Electromagnetic energy/wave consists of a magnetic (H-field) and electric (E-field) component perpendicular to each other and propagates at right angles to the plane containing the two components. The ratio of E to H is defined as the wave impedance (Z.sub.w, in ohms ?) and depends on the type of source and the distance from the source. Large impedances characterize electric fields and small impedances characterize magnetic fields. Far from the source, the ratio of E to H remains constant and equal to 377?, the intrinsic impedance of free space.

[0067] A radar absorbing material (RAM) reduces the energy reflected back to the radar by means of absorption. The main requirements are an effective EM wave impedance and good attenuation at the surfaces of a RAM that result in a good match for the incoming signal once it penetrates the material. RAMs can be categorized into two types: dielectric and magnetic absorbers, which means that the absorption is primarily due to their dielectric and magnetic characteristics, respectively.

[0068] The amount of attenuation offered by an absorber depends on three mechanisms. The first is usually a reflection of the wave from the shield/absorber. The second is an absorption of the wave into the absorber as it passes through the absorber. The third is due to the re-reflections, i.e., the multiple reflections of the waves at various surfaces or interfaces (e.g., air, material) in the shield/absorber. The reflection loss is a function of the ratio Sr/Mr, whereas the absorption loss is a function of the product Sr times Mr, where Sr is the electrical conductivity of the absorber relative to copper and Mr is the magnetic permeability of the shield/absorber relative to free space. The EMI shielding/absorption efficiency (SE), reported as reduction of transmitted wave power, includes the shielding effects due to absorption, reflection, and multiple reflections. Due to multiple reflections inside of a shielding/absorbing material, there can also be after-effects such as secondary reflection and secondary transmission.

[0069] Polymer fabrics or matrices are generally non-magnetic and do not make any magnetic contribution to EM wave attenuation. The absorption by the dielectric materials depends on dielectric loss mechanisms, such as electronic/atomic polarization, orientation (dipolar) polarization, ionic conductivity, and interfacial or space charge polarization. Magnetic loss mechanisms include hysteresis loop (from irreversible magnetization, which is negligible in a weak applied field), domain wall resonance (which usually occurs in the frequency range 1-100 MHz), Natural Resonance, and Eddy current losses. According to Poynting's theorem, there is a directional energy flux density of an EM wave (Poynting vector) that is defined as the cross product of the magnetic field vector and the electric field vector. This means that attenuation of EM waves requires not only electronic contribution, but magnetic as well. However, both dielectric and magnetic materials have relatively low absorption when they are used independently. Therefore, it is ideal to enhance absorption characteristics when dielectric materials are coated or blended with micro-nanomaterials such as metallic flakes or particles.

[0070] Spectral absorption features observed in the visible to short-wave infrared wavelength region result from several distinct processes. In the spectral range from 0.4 to approximately 1.2 micrometer (?m), absorption features are produced mainly by energy level changes in the valence electrons of transition metals, by paired excitations of metal cations, or by charge transfer between metal cations and their associated ligands. Intervalence charge transfer (IVCT) transitions in the visible and near-IR region are transitions in which an electron, through optical excitation, is transferred from one cation to a neighboring cation. Compounds containing an element in two different oxidation states, mixed valence compounds, often show intense absorption in the visible region which can be attributed to IVCT transitions.

[0071] Molecular vibration processes generate absorption features in the SWIR (1.3-2.5 ?m) and the long infrared (LWIR) wavelength range. Common absorption features in the SWIR wavelength range include 2.18-2.22 ?m bands related to AlOH combination bands in aluminous materials such as aluminum flakes. In the mid- and far-IR, away from inter-band transitions, coupling to collective oscillations of free-carriers, called plasmons, and vibrations of the crystal lattice in polar materials can significantly affect the permittivity of a material. Hafnium dioxide (H.sub.fO.sub.2), the most stable form, is a polar crystal with strong absorption from the IR active optical phonon modes. Boron Nitride (BN) is synthesized as white powders and preferentially grows in the hexagonal structure, similarly to graphite. The transmission spectrum for BN deposited on a germanium multiple internal reflection (MIR) plate have been measured from 2.5 to 50 ?m by spectrophotometry. In addition, absorption studies of BN-on-quartz have also been made in the 0.19 to 3.2 ?m range. Several absorption bands are known in the transmission spectrum for BN-on-Ge. The peak at 6.9 ?m is due to the B-N bending mode. The maximum near 6.5 ?m is associated with N=0. The B-H vibration is observed at 4 ?m. A broad structure in the vicinity of 2.9 ?m results from 0-H. Similarly, spectroscopic measurements of Barium Nitrate show infrared absorption bands at 4.2, 5.6, 7, 7.4, 11.6, and 13.6 ?m. The absorption properties of these micro-nano particles make them ideal for incorporation into high performance thermal camouflage, thermal signature mitigation, and thermal insulation solutions for stealth applications.

[0072] An aspect of the present disclosure is a modular, scalable, ultra-thin, and ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system. Referring now to FIG. 1, an illustration 100 of an ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system is shown, according to various embodiments. So as to not unnecessarily obscure the drawings, not every element may be labeled in the drawings, but their function is equivalent to a correspondingly labeled element. In various embodiments, system 102 comprises ultra-thin and ultra-lightweight non-woven shell 104, an EM wave thermal absorption layer 106, and a protective coating layer 108. In various embodiments, the non-woven shell 104 may comprise a fiber type, including but not limited to, polyester, polyimide (e.g., Nylon-6,6), or polypropylene. In various embodiments, the non-woven shell 104 may comprise one or more trapped spun bond fiber 110 of varying length and diameter. In an exemplary embodiment, non-woven shell 104 is fabricated from polyester, preferably Lutradur (Freudenberg Spunweb Company, Durham, NC) with a weight of 30 to 40 gram per square meter (gsm) for light weight and semi-transparency enabling electromagnetic wave (EM) sub-surface diffusion (SSD). In an exemplary embodiment, non-woven shell 104 is fabricated with a thickness of less than or equal to 1 millimeter to create a transparent ultra-thin and ultralight structure with trapped spun bond fibers resembling plant leaf structure mimicry while providing strength. In various alternative embodiments, non-woven shell 104 is fabricated using conductive fibers coated or extruded with graphite, graphite oxide and/or boron nitride. In various embodiments, thermal absorption layer 106 may comprise one or more screen-printed pattern 112 forming one or more resulting hole 114. In various embodiments, the screen-printed pattern comprises a conductive ink containing a radar absorbing material (RAM) mixture of conductive graphite (95%) and a binder (5%). The binder can be 14-V-3138 (Acrylic Latex, Textile Rubber & Chemical, Indian Trail, NC) which is an acrylic emulsion used in the textile industry as an all-purpose binder mostly for printing and coating. In various embodiments, the ink G-RAM mixture may contain one or more graphite particle 116 and boron nitride or barium nitrate particle to serve as a combination RAM-X-ray-IR stealth coating. The ink mixture may comprise a varying percent of graphite or graphite particles and boron nitride, preferably 85% or less graphite and between 2-15% boron nitride. In various embodiments, the conductive graphite can be made synthetically or natural flakes of varying particle sizes. In various embodiments, the synthetic conductive graphite particles may comprise a minimum crystallite height of 100 nm, surface grain ranging from 20 to 45 cm 2 per gram, and particles having a diameter D10 between 2-4 ?m, D50 between 7.5 to 12 ?m, and/or D90 between 10 to 20 ?m. In various embodiments, the natural conductive graphite flakes may comprise particles with diameter D50 of between 4 to 6 ?m and diameter D90 approximately 10-15 ?m. In various embodiments, the synthetic or natural conductive graphite particle or flakes may be produced in various percent formulations ranging 10 to 60% combined with varying percent of Ash ranging from 0.05% to 5% and varying moisture content ranging from 0.1% to 2%. In an exemplary embodiment, one or more said graphite, boron nitride, or barium nitrate are monodispersed particles having a uniform non-limiting diameter of 10 ?m to 20 ?m to achieve gray body diffusion or emissivity performance. In an alternative embodiment, the ink mixture may comprise reflective aluminum or flakes combined with one or more selective NIR-reflective pigment. In various embodiments, the ink mixture may comprise one or more spherical, non-spherical, non-encapsulated, polymeric encapsulated, metallic, magnetic, ferromagnetic, paramagnetic, superparamagnetic, diamagnetic, barium, boron nitride, barium nitrate, barium sulfate, hafnium, dot, particle, microparticle, or nanoparticle (as described above). The dot, particle, microparticle, or nanoparticle particles may enable EM wave propagation control and retarding human black body radiation emission. In various embodiments, one or more said particle provides EM wave propagation control, including but not limited to, sub-surface EM wave diffusion (SSD), electrical conduction, reflection, absorption, transmission, and multi-reflection. In an exemplary embodiment, screen-printed pattern 112 is one or more Faraday cage pattern printed to provide a conductive circuit network structure within system 102. In various embodiments, the printed patterns create one or more resulting hole 114 to enable EM wave propagation control, airflow, and limit heat retention or conduction. In various alternative embodiments, one or more graphite particle 116 can diffuse into non-woven shell 104 containing said conductive fibers to make electrical conduction between one or more graphite particle and one or more conductive carbon fiber. In various embodiments, protective coating layer 108 may comprise low thermal resistant polymer resin to provide a protective shell, including but not limited to, Polydimethylsiloxane (PDMS). In various embodiments, coating layer 108 may comprise melamine or similar compound having low thermal resistance and fire-retardant (FR) properties. In one embodiment, coating layer 108 may comprise Flamex 1916 (Unichem, Inc, Haw River, NC) which is a high phosphorous containing flame retardant. In various embodiments, coating layer 108 confers water resistance and windproof properties to system 102. The resulting system 102 serves as a first line layer with high transmission and layered sub-surface diffusion capabilities for thermal signature mitigation in the long infrared wavelength region. The system 102 may be combined with another system to construct one or more dynamic layers of varying thermal camouflage, thermal signature mitigation, or thermal insulation performance thus creating solutions for omni-spectral adaptable stealth applications.

[0073] Referring now to FIG. 2, an illustration 200 of a conductive Faraday cage pattern in accordance with various embodiments is shown. As described, system 102 of FIG. 1 comprises a layer, shown here as layer 202, equivalent to thermal absorption layer 106 of FIG. 1. In various embodiments, one or more Faraday cage pattern is screen-printed to create a conductive grid. In one embodiment, the conductive grid comprises a pattern of one or more rows of holes 204 on top of the ultra-thin and ultra-lightweight non-woven shell 104 of FIG. 1, containing one or more trapped spun fibers (shown as dash structures). In various embodiments, the conductive grid is printed having holes of non-limiting diameter between 0.5 mm to 2.0 mm, preferably 1.0 mm in diameter, and a periodic separation non-limiting distance of approximately between 1.0 mm to 3.00 mm. In various alternative embodiments, said conductive grid may contain alternative opening or porous geometries and varying dimensions, including but not limited to oval, elliptical, square, rectangular, or hexagonal arranged in a random or ordered pattern. In various alternative embodiments, the screen-printed pattern may comprise a broken pattern with random open areas; for example, like pine needles. The one or more opening, hole, or porous geometry allows transmission and breathability and limits heat retention or conduction resulting in a plant structure mimicry.

[0074] An aspect of the present disclosure includes a modular, scalable, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system with adjustable performances achieved through combining the functions of one or more dynamic layers. In at least one layer, a semi-transparent nano mesh substrate is fabricated and coated to achieve moderate EM wave transmission control to match the Earth albedo percent reflection. Referring now to FIG. 3, an illustration 300 of a nano mesh substrate is shown, according to various embodiments. In accordance with certain embodiments, nano mesh substrate 302 comprises a semi-transparent nano mesh 304, an EM wave thermal absorption layer 306, and a protective coating layer 308. In an exemplary embodiment, nano mesh 304 comprises a 20-Denier multifilament polyester weighing approximately 0.8-1.05 ounce per square yard and with a thickness of between 0.007-0.011 inch. In yet another exemplary embodiment, nano mesh 304 comprises a 20-Denier multifilament polyester with a course count of approximately 42-48 threads per inch and a Wale count of approximately 26-32 threads per inch. In various embodiments, nano mesh 304 may be spun laced or carded, cross-lapped, and calendered to even out one or more of its dimensions. In various embodiments, nano mesh 304 is fabricated with a first thermal absorption layer 306 whereby the composition, features, characteristics, and dimensions are similar to or equivalent to layer 106 of FIG. 1 to achieve ultra-thin and ultra-lightweight properties. In various embodiments, nano mesh 304 is then fabricated with second protective coating layer 308 whereby the composition, features, characteristics, and dimensions are similar to or equivalent to layer 108 of FIG. 1 to achieve ultra-thin and ultra-lightweight properties. In various embodiments, substrate 302 may be combined with system 102 of FIG. 1 to meet the performance specification of a thermal solution for a stealth application. In alternative embodiments, two or more substrate 302 may be combined to meet the performance specification of a thermal solution for a stealth application. In various embodiments, two or more substrate 302 are combined, layer by layer, to achieve specific 2D textile or 3D knit camouflage or stealth performance specifications that are adaptable, adjustable, or tunable to specific battlefield scenarios, conditions, environments, or missions.

[0075] An aspect of the present disclosure is a modular, scalable, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system with adjustable performances achieved through combining the functions of one or more dynamic layers. In a third layer, a non-transparent thin micro insulator is coated to achieve low EM wave transmission, high absorption, and optimal thermal insulation. Referring now to FIG. 4, an illustration 400 of a thin micro insulator is shown. In accordance with certain embodiments, micro insulator 402 comprises a micro substrate 404, an EM wave thermal absorption layer 406 and a protective coating layer 408. In an exemplary embodiment, micro substrate 404 comprises a biocomponent polyester with a weight basis in the range of 16.0 grams per square yard to 17.0 grams per square yard; and more preferably a weight basis of approximately 16.7 gram per square yard. In an exemplary embodiment, micro substrate 404 comprises a biocomponent polyester with a thickness in the range of 9.0 millimeters to 11.0 millimeters; and more preferably, approximately 10 millimeters. In yet another exemplary embodiment, micro substrate 404 comprises a thermal bonded biocomponent polyester with an MD tensile strength in the range of 1000 grams per inch to 1200 grams per inch; and more preferably, 1100 grams per inch. In various embodiments, micro substrate 404 is fabricated with a first thermal absorption layer 406 whereby the composition, features, characteristics, and dimensions are similar or equivalent to layer 106 of FIG. 1 to achieve ultra-thin and ultra-lightweight properties. In various embodiments, micro substrate 404 may be fabricated with second protective coating layer 408 whereby the composition, features, characteristics, and dimensions are similar or equivalent to layer 108 of FIG. 1 to achieve ultra-thin and ultra-lightweight properties. In various embodiments, micro insulator 402 may be combined with system 102 of FIG. 1 and/or nano mesh substrate 302 of FIG. 3 to meet the performance specification of a thermal solution for one or more stealth applications. In alternative embodiments, two or more micro insulator 402 may be combined to meet the performance specification of a thermal solution for a stealth application. In alternative embodiments, one or more micro insulator 402 may be combined with one or more system 102 of FIG. 1 and/or one or nano mesh substrate 302 of FIG. 3 to meet the performance specification of a thermal solution for a stealth application. The arrangement of the layers can be either layer by layer, side by side and/or fully or partially overlapping and may comprise a combination or a permutation of each system, nano mesh substrate, and/or micro insulator. The combination of one or more said individual thermal substrates can create a plant structure mimicry. The combination enables the tailoring, adjusting, varying, or fine-tuning of the thermal or EM wave control performances of reflectivity, transmission, emissivity, or absorbance as a thermal solution of a stealth application. In various embodiments, said arrangement enables the modular, scalable, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system to achieve specific 2D textile or 3D knit camouflage or stealth performance specifications that are adaptable, adjustable, or tunable to specific battlefield scenario, condition, environment, or mission.

[0076] Certain aspects of the present disclosure provide for methods for constructing a modular, scalable, ultra-thin and ultra-lightweight thermal camouflage, thermal signature mitigation and thermal insulation system. Referring now to FIG. 5, a flow chart 500 of the method of fabricating a thermal insulation system is shown. In accordance with various embodiments, the method comprises a first step 502 of selecting a substrate layer (L1); for example, layer 104 of FIG. 1. In alternative embodiments, L1 may be layer 304 of FIG. 4 and/or layer 404 of FIG. 4. In a second step 504, a conductive Faraday cage pattern layer (L2) (e.g., layer 106 of FIG. 1) is printed on top of L1 using the composition, features, characteristics, and dimensions of layer 106 of FIG. 1. In a third step 506, a protective layer (L3) (e.g., layer 108 of FIG. 1) is printed on top of L2 using the composition, features, characteristics, and dimensions of layer 108 of FIG. 1. In various embodiments, one or more ink mixture for L2 or protective layer resin mixture for L3 is prepared by adding the weighed chemical in, for example, the following order (first to last): water, binder, reflective ink, FR chemistry, pigments, block-out and thickener. An exemplary reflective ink mixture may comprise 41% water, 3% Melamine resin, 10% binder, and 30% pigment to form a water or wind resistant coating layer. The ingredients are mixed, and the viscosity is adjusted to be between 12000-14000 cp. In a final step 508, the resulting thermal solution is incorporated into a stealth application, in accordance with various aspects of the present disclosure. In various embodiments, a stealth application may include, but is not limited to, a thermal camouflage, thermal signature mitigation, thermal veil insulation, or thermal wear (e.g., garment) applications, including a uniform, blanket, emergency blanket, tent, garment, sleeping bag, backpack, textile, fabric, assault pack, rucksack, netting, insulation, articles of clothing, uniform, tent, tent liner, poncho liner, sleep system, tarp, shell, blanket, net, bevy, cocoon, helmet cover, pack cover, throw, laminate, ULCANS, reversible camouflage to cover objects and like apparatuses. As a garment, the fabric containing one or more said substrate or system may be used for any suitable garment including, but not limited to, pants, shirts, outerwear such as jackets, shoes, hats, scarves, and belts. The camouflage and thermal management composite systems may undergo further operations to become a stealth liner, laminate system, or needle punched blended single textile applied to any other textile or solid surface; for example, a vehicle (e.g., a tank), a hangar or building structure or the like.

[0077] Aspects of the present disclosure are methods to create one or more high-performance thermal camouflage, thermal signature mitigation, and/or thermal insulation solutions for stealth applications. The following are examples of thermal solutions in which aspects of the present disclosure may be embodied or otherwise incorporated:

Building a Shell in the Battlefield

[0078] Referring now to FIG. 6, an illustration 600 of a stealth shell is shown. In accordance with certain aspects of the present disclosure, a stealth shell is fabricated starting with one nano layer 602, equivalent to nano mesh substrate 302 of FIG. 3. In a second step, another nano layer 604, equivalent to nano mesh substrate 302 of FIG. 3, is layered on top of nano layer 602. In a third step, one layer of a first line shell 606, equivalent to system 102 of FIG. 1, is laid on top of nano layer 604. In a battlefield scenario, a war fighter 608 can easily deploy the ultra-thin and ultra-lightweight shell for concealment.

Stealth Tent

[0079] Referring now to FIG. 7, an illustration 700 of a stealth tent is shown. In accordance with various aspects of the present disclosure, a stealth tent is fabricated starting with one nano layer 702, equivalent to nano mesh substrate 302 of FIG. 3. In a second step, another nano layer 704, equivalent to nano mesh substrate 302 of FIG. 3, is layered on top of nano layer 702. In a third step, one layer of a first line shell 706, equivalent to system 102 of FIG. 1, is laid on top of nano layer 704. In a final step, the inside of tent 708 is lined with one nano layer 710, equivalent to nano mesh substrate 302 of FIG. 3. In various alternative embodiments, two or more combinations of nano layer 702, 704, and 706 (shown as 712) may be applied on top of tent 708 depending on the environment.

[0080] An aspect of the present disclosure is a modular, scalable, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system with adjustable performances achieved through combining the functions of one or more said dynamic layers to achieve specific levels of reflection, absorption, or emissivity in the near-infrared (NIR) and Infrared (IR) of the EM spectrum. An insulation system construct may be fabricated by layering said system 102 of FIG. 1 and nano mesh 302 of FIGS. 3 and/or 402 of FIG. 4 to exhibit low thermal mass properties with a balance of Spectral Radiance to match earth albedo with a battlesight zero responding in selective emissions within the NIR range and Gray Body Diffusion straight-line readings throughout the SWIR MIR and LIR wavelengths. Reflectance is aided by moderating transmission/absorption of these ultra-thin ultra-lightweight non-woven substrates to maximize a moderate Emissivity and create thermal mitigating/regulating structures in layers as each layer added becomes part of a mitigating strategy in the field. Reflectance and transmission can be increased with addition of boron Nitride (BN) in a G-RAM layer and increasing, for example, TiO.sub.2 coatings in the reflective layer of a stealth coating. The BN is also added to assist in heat sink capabilities with the heat absorption (heat sink) function. In an embodiment, one or more exemplary system construct may be fabricated to have a reflectance of more than 20% and less than 80% in the wavelength range of 700 nanometer to 2400 nanometer, preferably less than 50%, most preferably 25% reflectivity in the wavelength range of 1.100 ?m to 24 ?m to mimic the Earth's albedo. In another embodiment, one or more exemplary system construct may be fabricated to possess a transmission of less than 50%, preferably between 25% to 50% transmission, most preferably between 30 to 40%, to maximize absorbance in the nano layer, in the wavelength range of 700 nanometer to 24 ?m. In yet another embodiment, one or more exemplary system construct may be fabricated to possess an emissivity of less than 50%, preferably between 25% to 50% emissivity, most preferably lower than 50% emissivity, with a mean of 40%, to maximize Gray Body Diffusion, in the wavelength range of 700 nanometer to 24 ?m when measured according to the test method described herein.

[0081] Test Method

[0082] A Stealth Gray Body Diffusion construct comprising a combination of system 102 of FIG. 1, nano mesh 302 of FIG. 3 and 402 of FIG. 4 was fabricated for performance testing. Spectral reflectance (p.sub.?) was directly measured using a Thermo-Fisher Scientific Nicolet iS50 FTIR spectrophotometer with a Pike Technologies mid-IR IntegratIR? integrating sphere. Spectral transmittance (TA) was assessed through comparison of reflection measurements made with and without a reflective backing behind a sample Stealth Gray Body Diffusion construct of the present disclosure. Measurements were made following the approach given by Method C of ASTM E408: Standard Test Methods for Total Normal Emittance of Surfaces Using Inspection-Meter Techniques. Referring now to FIG. 8, a graph containing the reflectivity, transmission, and emissivity percent data for five Stealth Gray Body Diffusion constructs is shown. The average reflectivity, transmission, and emissivity results are plotted demonstrating that these constructs can achieve 25% reflectivity, an average of 30 to 40% transmission, and an emissivity of 40% in the wavelength range of 700 nanometer to 24 ?m. These results demonstrate that the constructs of the present disclosure display gray body diffusion characteristics and can be effective as a high-performance omni-spectral thermal camouflage, thermal signature mitigation, and/or thermal insulation system operating in the NIR, the atmospheric windows in the range of 1-3 ?m, 3-5 ?m or 8-12 ?m, as well as longer wavelengths thus potentially satisfying future military camouflage requirements.

[0083] An aspect of the present disclosure is a modular, scalable, ultra-thin, and ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system (e.g., as shown in FIGS. 1-4 and 9-10B and described herein). In various embodiments, the thermal management system may comprise one or more composite layers of ultra-thin and ultra-lightweight, woven, non-woven, natural, or man-made substrates. In various embodiments, the ultra-thin and ultra-lightweight non-woven substrates may comprise a spun bond, thermal bond nano mesh, or a spun lace substrate. In various embodiments, one or more external surface of the said ultra-thin and ultra-lightweight substrates may be coated or printed with one or more first thermal signature emission control conductive layer, a second metallization layer, preferably vapor coated on top of said first conductive layer, and a third outer layer comprising a urethane skin layer. In various embodiments, said first conductive metal layer may be printed, screen printed, pad applied (dipped), sprayed in a solid or broken pattern, or a broken needle pattern, preferably with one or more Faraday cage patterns. In various embodiments, said pattern may comprise a grid comprising a plurality of random or ordered apertures arranged to have a periodic separation distance. In various embodiments, one or more said first coating layer may comprise a conductive thermal signature emission control layer containing one or more oxidized printed ink pattern comprising one or more spherical, non-spherical, non-encapsulated, polymeric encapsulated, metallic, iron, magnetic, iron oxide, ferromagnetic, paramagnetic, superparamagnetic, diamagnetic, Barium, Boron Nitride, Barium Nitrate, Barium Sulfate, Hafnium, Chromium Oxide (for green), oxide ink, dot, particle, microparticle, or nanoparticle enabling EM wave propagation control through an object's surface and retarding human black body radiation emission. In various embodiments, the said second metallization layer comprises a vapor coated metal, preferably aluminum, to enable the tuning of surface reflectivity. In various embodiments, said third outer skin layer comprises a mixture, including but not limited to, a fire-retardant (FR), urethane, Barium Sulphate, Barium Sulfate, and Boron Nitride, to enable further tuning of surface reflectivity, EM wave propagation, or thermal emission control. In accordance with certain aspects of the present disclosure, a dot comprises a polymeric microsphere comprising at least one metallic micro-nanoparticle encapsulated therein. In various embodiments, a metallic micro-nanoparticle comprises a magnetic, superparamagnetic, or diamagnetic iron oxide micro-nanoparticle. A metallic micro-nanoparticle may comprise one or more of iron, iron oxide, magnetite, oxide ink, hematite, barium, hafnium, combinations thereof, and like elements or compounds. In various embodiments, one or more paramagnetic, micro-nanoparticles in the polymeric microsphere dots contain elements such as iron oxide, aluminum oxide, nickel, and copper to provide electromagnetic wave propagation control and aid in subsurface diffusion, conduction, reflection, absorption, transmission, and multi-reflection. In various embodiments, one or more spherical polymeric dots encapsulating magnetite, barium sulfate, and/or hafnium micro-nanoparticles provide EM wave propagation control, including but not limited to subsurface diffusion, X-ray mitigation (opacity), reflection, absorption, transmission, and multi-reflection. In various embodiments, one or more said particle provides EM wave propagation control of an object's surface area spectral exitance, including but not limited to, sub-surface EM wave diffusion (SSD), electrical conduction, reflection, absorption, transmission, heat movement and multi-reflection. In various embodiments, the individual ultra-thin and ultra-lightweight non-woven substrates may be combined to construct one or more dynamic layers of varying thermal camouflage, thermal signature mitigation, or thermal insulation performance. The high-performance thermal camouflage, thermal signature mitigation, and thermal insulation system comprising one or more stealth ultra-thin ultra-lightweight thermal substrates enables omni-spectral adaptable stealth applications.

[0084] An aspect of the present disclosure is a modular, scalable, ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation system with adjustable performances. In various embodiments, the thermal management system may comprise one or more composite layers of ultra-thin and ultra-lightweight woven or non-woven substrates constructed to achieve tunable performance achieved by selectively adjusting a low thermal mass substrate material (natural or man-made) photonic spectral exitance and by dynamic layering resulting in varying degrees of substrate reflectance, transmittance, emissivity, or absorbance properties. In an exemplary embodiment, a substrate may comprise a low thermal mass spun bond and transparent to semi-transparent first layer coated with an oxide ink, second layer coated with aluminum, and a third skin layer to achieve high transmission and layered sub-surface diffusion capabilities for thermal signature mitigation in the long infrared wavelength region and moderate EM wave transmission control to match the Earth albedo percent reflection. In various embodiments, the thermal camouflage, thermal signature mitigation, and thermal insulation system may have an external surface treated with one or more durable water repellent (DWR) layer to provide one or more functions, including but not limited to, protecting structural integrity, conferring softness, or establishing a desired comfort level, when used in conjunction with a garment shell or garment liner.

[0085] Aspects of the present disclosure provide for a modular, scalable, ultra-thin and ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation apparatus, composition, and/or system, as well as methods for constructing the same. Referring now to FIG. 9, a diagram 900 of an ultra-thin, ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation apparatus, composition, and system 902 is shown. In accordance with certain aspects of the present disclosure, system 902 comprises a first layer 904, a second layer 906, a third layer 908, and, optionally, a fourth layer 910. First layer 904 may comprise an ultra-thin and ultra-lightweight woven or non-woven shell layer. Second layer 906 may comprise a thermal signature emission control conductive layer. Third layer 908 may comprise a vapor coated metallization layer. The vapor coated metallization layer may comprise a vaporized metal (e.g., aluminum) deposited on top of or diffused within, or throughout a portion of, first layer 904 and/or second layer 906. Fourth layer 910 may comprise a urethane skin layer comprising a urethane coating.

[0086] In various embodiments, the woven or non-woven shell of first layer 904 may comprise a fabric material comprising a fiber type including, but not limited to, cotton, polyester, polyimide (e.g., Nylon-6,6), polypropylene, PET, Nylon. BoPET (biaxially-oriented polyethylene terephthalate), polyvinylidene dichloride (PVDC), biaxially oriented polypropylene (BOPP), or blends thereof and the like. In various embodiments, the woven or non-woven shell of first layer 904 may comprise one or more spun bond fiber of varying length and diameter. In an exemplary embodiment, the woven or non-woven shell of first layer 904 is fabricated from polyester, preferably Lutradur (Freudenberg Spunweb Company, Durham, NC) with a weight of 30 to 40 gram per square meter (gsm) for light weight and semi-transparency enabling electromagnetic wave (EM) sub-surface diffusion (SSD). In an exemplary embodiment, the woven or non-woven shell of first layer 904 is fabricated with a thickness of less than or equal to 1 millimeter to create a transparent ultra-thin and ultralight structure with trapped spun bond fibers resembling plant leaf structure mimicry while providing strength. In various embodiments, first layer 904 comprises a woven or non-woven fabric with density in the range preferably 10-100 Denier (D), more preferably 30-50 D, most preferably, 10-20 D. In various embodiments, second layer 906 (i.e., thermal absorption layer) may comprise one or more screen-printed pattern forming one or more resulting apertures on first layer 904. In certain embodiments, first layer 904 comprises a mesh material. In various embodiments, said mesh material may comprise a mesh with non-limiting mesh sieve designation in the range of No. 10 to No. 100. In various embodiments, the screen-printed pattern comprises a conductive oxide ink and may comprise the incorporation of a binder. The binder can be 14-V-3138 (Acrylic Latex, Textile Rubber & Chemical, Indian Trail, NC) which is an acrylic emulsion used in the textile industry as an all-purpose binder mostly for printing and coating. In various embodiments, the oxide ink mixture may contain iron oxide or chromium oxide (e.g., Chroma Olivine Green-4426). The ink mixture may comprise a varying percent of Chroma Olivine Green (4426), preferably 50%, and binder Cryl 65088, preferably also 50%. In an alternative embodiment, the ink mixture may comprise reflective aluminum or aluminum flakes combined with one or more selective NIR-reflective pigment. In various alternative embodiments, the oxide ink mixture may comprise one or more spherical, non-spherical, non-encapsulated, polymeric encapsulated, metallic, magnetic, ferromagnetic, paramagnetic, superparamagnetic, diamagnetic, barium, boron nitride, barium nitrate, barium sulfate, hafnium, dot, particle, microparticle, or nanoparticle. The dot, particle, microparticle, or nanoparticle particles may enable EM wave propagation control and retarding human black body radiation emission. In various embodiments, one or more said particle provides EM wave propagation control, including but not limited to, sub-surface EM wave diffusion (SSD), electrical conduction, reflection, absorption, transmission, and multi-reflection. In various embodiments, fourth layer 910 may comprise a urethane skin layer comprising a mixture containing one or more components including urethane (Permax 4399), barium sulphate (BS) (GTO BarSul), boron nitride (BN) (GTI BN-3), fire-retardant (FR) (Performax 93), and water. In a non-limiting example, the urethane skin layer may comprise 68% urethane, 9.7% FR, 12.3% water, 9% BS, and 1% BN. In various embodiments, a surface of first layer 904 and/or a surface of adjacent second layer 906 may be coated with a durable water repellent (DWR) (for example, 100% Unigard 2276 Repellent) to provide one or more functions, including but not limited to, protecting structural integrity, conferring softness, or establishing a chosen user comfort level, when system 902 is used in conjunction with a garment shell or garment liner.

[0087] Aspects of the present disclosure provide for a modular, scalable, ultra-thin and ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation apparatus, composition and system and methods for constructing the same. In various embodiments, the methods may comprise one or more steps for coating one or more ultra-thin, ultra-lightweight thermal substrates with one or more electric conductive oxide ink layer, vapor coated metallization layer, thermal resistant/thermal conductive layer, or thermal reflective (selective emission) pigment patterns, Faraday cage pattern, broken needle pattern, urethane skin mixture, DWR layer, to create one or more high-performance thermal camouflage, thermal signature mitigation and thermal insulation solutions.

[0088] Referring now to FIGS. 10A-10B, a plan view diagram and a cross-sectional diagram of a modular, scalable, ultra-thin and ultra-lightweight thermal camouflage, thermal signature mitigation, and thermal insulation apparatus, composition and system 1000 are shown. In accordance with certain aspects of the present disclosure, system 1000 may comprise an embodiment of system 900, as shown and described in FIG. 9. System 1000 may further illustrate the vapor deposition process as described in FIG. 9.

[0089] In accordance with certain aspects of the present disclosure, system 1000 may comprise a substrate layer 1002 (e.g., equivalent to first layer 904 in FIG. 9) and a conductive metal layer 1006 (e.g., equivalent to second layer 906 in FIG. 9). Conductive metal layer 1006 may comprise a conductive ink disposed on substrate layer 1002 in a printed pattern. The printed pattern may comprise one or more ordered pattern, random pattern and/or a broken needle pattern. The printed pattern may comprise one or more Faraday cage patterns (e.g., as described in FIG. 2). The conductive ink may comprise one or more iron oxide or chromium oxide ink. In various embodiments, said printed pattern may comprise a grid comprising a plurality of random or ordered apertures 1004 (e.g., equivalent to apertures 204 of FIG. 2) arranged to have a periodic separation distance in the range of 0.5 millimeters to 3.5 millimeters; and more particularly, 1.0 millimeters to 3.0 millimeters. In various embodiments, the printed patterns create one or more resulting apertures 1004 having a size in the range of 0.149 millimeters to 2.0 millimeters to enable EM wave propagation control, airflow, and limit heat retention or conduction. In various embodiments, the printed patterns are printed on one or more mesh comprising a non-limiting mesh sieve designation ranging from No. 10 to No. 100 to enable EM wave propagation control, airflow, and limit heat retention or conduction. In accordance with certain aspects of the present disclosure, system 1000 is constructed using a vapor coated metallization process to apply a vapor coated metallization layer 1010 to conductive metal layer 1006 (and/or substrate layer 1002). Vapor coated metallization layer 1010 may be equivalent to third layer 908 in FIG. 9. Vapor coated metallization is the process of applying exact controlled amounts of vaporized aluminum 1008 (shown as a triplet hash in FIGS. 10A-10B) to the surface of conductive metal layer 1006 to control or tune the thermal camouflage, thermal signature mitigation, and thermal insulation properties of system 1000. In various embodiments, the deposition of vapor coated metallization layer 1010 may be substantially on top of conductive metal layer 1006 such that the deposition process may result in one or more oxide gaps (e.g., materials covered by vaporized aluminum 1008) covering at least 10% of the surface area of conductive metal layer 1006. The pattern of apertures 1004 may result in uneven application of vaporized aluminum 1008 to conductive metal layer 1006. The creation of one or more oxide gaps may alter the EM wave reflectivity or thermal emissivity of system 1000. For a non-limiting example, vaporized aluminum 1008 may confer 68% reflectivity in combination with iron oxide gaps within conductive metal layer 1006 of approximately 25%, resulting in the breakup of EM wave propagation or thermal emission background contrast resembling nature. In various embodiments, the methods of vapor coated metallization may comprise one or more steps for combining one or more individual stealth coatings on thermal substrates by combining a lower conductive absorption layer; for example, substrate layer 1002, conductive metal layer 1006, vapor coated metallization layer 1010, and an outer protective layer or skin layer (e.g., fourth layer 910 as shown in FIG. 9) to create plant structure mimicry in layering of chemistry and substrates.

[0090] In accordance with certain embodiments, construction methods of the present disclosure may comprise one or more steps for constructing one or more thermal substrates with specific individual or combined thermal or EM wave control performances of reflectivity, transmission, emissivity, or absorbance. In various embodiments, construction methods of the present disclosure may comprise one or more steps for constructing one or more thermal substrates with specific individual or combined layers possessing varying degrees of tunable reflectivity, transmission, emissivity, or absorbance. In various embodiments, construction methods of the present disclosure may comprise one or more steps for combining one or more said individual thermal substrates to create one or more dynamic thermal or EM wave control performances. In various embodiments, construction methods of the present disclosure may comprise one or more steps to create one or more high-performance thermal camouflage, thermal signature mitigation, and/or thermal insulation solutions, including but not limited to, a stealth coating, veil, shell, poncho liner, extreme cold weather kit, tent, military uniform, thermal nest, netting, insulation, or the like, using one or more ultra-thin and ultra-lightweight woven or non-woven treated substrates. In various embodiments, construction methods of the present disclosure may comprise one or more steps for creating one or more thermal solutions using at least one spun bond, thermal bond, spun lace, quilting, needling process, chemical or physical vapor deposition process. These methods enable the construction of one or more modular, scalable, adaptable, and lightweight high-performance thermal camouflage, thermal signature mitigation, and/or thermal insulation system.

[0091] Thermal Performance Testing

[0092] An extreme cold weather kit with stealth poncho liner and a stealth sleeping bag were constructed comprising system 902 of FIG. 9 and system 1000 of FIGS. 10A-10B for performance testing. Cold testing results were collected from field testing conducted in Enterprise, UT during December 2022. Referring now to FIG. 11, a graph of the thermal performance of a stealth poncho liner constructed from the stealth material composition of the present disclosure is shown. Body, foot, inside tent, and outside temperature were collected for comparison. While the outside temperature fluctuated between a min. of 10.9 degrees Fahrenheit and a max of 26.5 degrees Fahrenheit, with an average of 22.1 degrees F., the poncho liner user's body temperature fluctuated between a minimum of 35.5 degrees F. to a maximum of 84.1 degrees F., with an average of 77.6 degrees F. The inside tent temperature fluctuated between a min. of 42.9 degrees F. and a max of 62.1 degrees F. Referring now to FIG. 12, a graph of the thermal performance of a stealth sleeping bag constructed from the stealth material composition of the present disclosure is shown. Body, foot, inside tent, and outside temperature were collected for comparison. While the outside temperature fluctuated between a min. of 0.2 degrees Fahrenheit and a max of 14.2 degrees Fahrenheit, with an average of 6.1 degrees F., the sleeping bag user's body temperature fluctuated between a min. of 32.3 degrees F. to a max of 83.9 degrees F. with an average of 75.7 degrees F. The inside tent temperature fluctuated between a min. of 21.3 degrees F. and a max of 57.1 degrees F.

[0093] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0094] The indefinite articles a and an, as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean at least one. As used herein, the terms right, left, top, bottom, upper, lower, inner and outer designate directions in the drawings to which reference is made.

[0095] The phrase and/or, as used herein in the specification and in the claims, should be understood to mean either or both of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with and/or should be construed in the same fashion, i.e., one or more of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the and/or clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to A and/or B, when used in conjunction with open-ended language such as comprising can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0096] As used herein in the specification and in the claims, or should be understood to have the same meaning as and/or as defined above. For example, when separating items in a list, or or and/or shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one of a number or lists of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as only one of or exactly one of, or, when used in the claims, consisting of, will refer to the inclusion of exactly one element of a number or list of elements. In general, the term or as used herein shall only be interpreted as indicating exclusive alternatives (i.e., one or the other but not both) when preceded by terms of exclusivity, such as either, one of, only one of, or exactly one of. Consisting essentially of, when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0097] As used herein in the specification and in the claims, the phrase at least one, in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase at least one refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, at least one of A and B (or, equivalently, at least one of A or B, or, equivalently at least one of A and/or B) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0098] In the claims, as well as in the specification above, all transitional phrases such as comprising, including, carrying, having, containing, involving, holding, composed of, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases consisting of and consisting essentially of shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0099] The present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its exemplary forms with a certain degree of particularity, it is understood that the present disclosure of has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be employed without departing from the spirit and scope of the invention.