Compact Liquid Cooling Garment with Integrated Vapor Compression Refrigeration for Extreme High-Temperature Environments

Extreme high-temperature environments pose challenges for human thermal comfort and safety. This study introduces a compact portable liquid cooling garment weighing 3.6 kg in total with an integrated 1.99 kg vapor compression refrigeration unit (172 mm × 80 mm × 130 mm). This system innovatively integrates a patented evaporator-pump module and an optimized miniature rotary compressor, achieving a 151 W cooling capacity at 55 °C ambient temperature, surpassing existing portable systems in compactness and performance. Human trials with eight male participants at 35 °C (walking) and 40 °C (sitting) demonstrated that the liquid cooling garment system significantly improved thermal comfort. The mean thermal comfort vote decreased from 2.63 (uncomfortable) to 1.13 (slightly uncomfortable) while walking and from 3.88 (very uncomfortable) to 1.25 (slightly uncomfortable) while sitting. The mean skin temperature in the final stable state was reduced by 0.34 °C in walking trials and 1.09 °C in sitting trials, and heart rate decreased by up to 10.2 bpm in sedentary conditions. Comprehensive human trials under extreme heat further validate this system’s efficacy. This lightweight, efficient system offers a practical solution for personal thermal management in extreme high-temperature environments, with potential applications in industrial safety, military operations, and emergency response.