Highly Insulative, Double Air Gap HybridSil Thermal Array Wetsuits for Retained Insulation During Cold Water Diving

Through Navy SBIR funding, NanoSonic has created an innovative, commercially scalable wetsuit composite that integrates a heat reflective double air gap that has been empirically tailored to provide R-values as high as 4.0 ft2.oF.hr/Btu and compressive resistance necessary for maintaining > 75% of its insulative performance while under a compressive force simulating 100’ of diving depth. To successfully achieve its Phase I objectives, NanoSonic iteratively designed and optimized a HybridSil polyurethane foam that deforms only 3.5% when compressed at 59 psia for 1-hour and is readily bonded to commercially available neoprene wetsuit foams. Upon completion of the Phase I SBIR program, NanoSonic’s innovative foam and deposition process have been empirically optimized to provide three-dimensionally patterned wetsuit composites that harness a diver’s body heat to provide a previously unavailable combination of passive insulation, flexibility, and environmental durability. Of critical importance for future Phase II prototype wetsuit construction, team partner Wetwear has established manufacturing procedures for integrating HybridSil wetsuit composites into future prototype cold-water wetsuits for Navy diver testing, feedback, and iterative design optimization.   Equipped with initial Navy diver reviews from the Phase I Option, NanoSonic and Wetwear will work to refine and optimize its cold-water wetsuit designs through a Phase II base SBIR program designed to support two iterations of form, fit, and function (FFF) testing. Each testing round will include up to ten wetsuits that are custom tailored to the specific size of each diver. During the onset of the Phase II base program, NanoSonic and Wetwear will adapt the overall design of the cold-water wetsuit based on the NEDU compiled feedback from the Navy divers. Of significant interest will be adjusting the thickness, spacing, and location of the HybridSil thermal array wetsuit composites to achieve optimal combinations of thickness, insulation, buoyancy, and free-swimming maneuverability.