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Hypothermia can kill in an emergency situation! Prevention through preparation is the best way to deal with hypothermia, but many survival kits don’t have adequate components to deal with this deadly condition. Size is one of the reasons. Most items designed for the prevention of hypothermia are just too large to carry in a small kit. This may have changed.

A new emergency cold weather survival vest called the AeroVest™ was designed by SolaTec® Technologies, Inc. I found this vest interesting and wondered if it worked. Upon contacting the manufacturer, they informed me that it had been reviewed by a couple of individuals, but would like it reviewed during winter months. I indicated we would be willing to review the vest, and if we found it adequate for emergency use, we would add it to our growing line of unique survival products. The manufacturer therefore sent us several of the AeroVest™ to review.

Upon receiving the AeroVest™, and opening it, my first thought was a large, funny shaped, Mylar balloon. However, upon further examination, my next thoughts were "How creative" and "Now this is thinking outside the box." But would it actually work as an emergency device for cold weather?

SolaTec® AeroVest™ in package.

First, let me describe this vest. It consists of a two-layer metalized nylon shell to block out wind and rain. It has 18 air pockets which can be inflated with air for a third layer of insulation, which creates a thermal barrier. The inside, shiny metal layer, reflects back your core body heat. The outside is a yellow/orange color which allows you to be seen in an emergency situation. The vest is a one size fits all (small to extra-large) and weighs only 2 oz. I found it could be folded down to the size of a pack of cigarettes. It is described as a one-time use item, but, in my opinion, it can be re-used, without a problem.

After waiting for a good snow day (which didn’t happen) I headed out with the vest on a day when it was 28˚ and cloudy. I hiked for about one mile in a medium weight Bergelene™ underwear top, wool sweater, a Gore-Tex® Jacket, and gloves on my upper body. Normally in this weather I would have been wearing my Filson Double-Mackinaw Cruiser. I stopped and stood around the woods and it didn’t take long for my upper trunk to get cool. It was time to test the vest.

  I had the vest folded up in the outside chest pocket of my Gore-Tex® jacket. I removed the jacket and put the vest on. It donned easily, and per the instructions, I fastened it closed with the double stick tape (one side is permanently attached to the left side of the vest). The instructions indicate that you should not make it too snug in order to have room for inflation. The vest didn’t feel as weird as I thought it would, and even without being inflated, it seemed to provide some warmth and did block the wind.

AeroVest™ being taken out of a jacket pocket and put on.

The next step was to inflate the vest. The vest is provided with a simple straw for this purpose. It should be noted that upon initially opening the package, I thought the straw might be a little short, as I have a long neck. So I also brought a piece of rubber tubing 1/4" in diameter by 12" long. The straw must be placed into one of the two inflation nozzle holes at the top left and right side of the vest near your neck. Next, the instructions state that you should gently blow air into the vest, but you should be careful not to over inflate it. Only a little air is required for maximum warmth and 2-5 breaths per side is recommended.

Well I tried the straw provided with the vest to inflate the right side. I found it a real neck twister to get the straw in the inflation nozzle, and I also learned that the straw has to go in further than a short distance before you can start to inflate it with your breath. Once the straw is in the right position, inflation is rather simple. For the left side, I tried my rubber hose. Again, at least for me, get the tube into the inflation nozzle was a neck twister, but then I could stand normal during inflation because of the length and flexibility of the hose. The left side inflated easily.

I was actually a little surprised at how warm my truck felt after inflation. My arms and neck were still cold, but my truck was toasty. I hung around in the woods for awhile testing the vest in the sitting position, as well as laying down both on my back and side. Sitting was no problem and the vest was not uncomfortable while sitting. I lay down on my back, and it was a little like lying on an over-inflated air mattress. But my back was insulated from the ground and still warm. I also tried lying on my side but it was not as comfortable and the air tends to move forward and back into the air chambers, leaving little on the side to insulate you from the ground. Although it might take some getting used to, in an emergency situation, I would rather try to sleep with it than without it.

AeroVest™ being worn in the sitting and lying down positions.

I finally decided to don my Gore-Tex® jacket over the vest. The jacket went on over the vest without a problem and I really started to warm up. It now looked like I was wearing a puffy jacket, but I was warm. I next donned my pack over the jacket and I must admit it was comfortable. It was like having an air space between the pack and my back, which was exactly what I had. At this point it was time to hike out. It should be noted that with the pack on while hiking, the weight of the pack did displace air towards the front of the vest which caused compression on my chest, only slightly restricting breathing. Although not hard to breathe, it did take a little more effort. If I was going to wear a pack with the vest I would put less air in it, or leave it either looser or unfastened around the chest.

Putting a jacket, and then a pack, on over the AeroVest™

Upon returning to the office, I was able to take the vest off without destroying it, by carefully pulling the right side off the tape on the left side. I was also able to re-apply the strip of shiny cover material that had originally been on the tape strip. Keep in mind, if you don’t keep the cover material for the tape strip, the tape (which is very sticky) will stick to everything.

I also felt it necessary to see how hard it would be to puncture the vest. I couldn’t puncture it with a fingernail, so I tried a small semi-sharpened stick. I had to push, but I did puncture it. I next sealed the hole with a piece of duct tape and re-inflated the vest. After 2 days, the vest was still inflated, even after pressing hard on the inflated panel. I also wanted to try to deflate the vest and found that you really have to get the straw in the right position before the air will start coming out. But once in the correct position, I found that the vest deflated easily, starting at the top back and working the air forward and up towards the inflation (now deflation) nozzle. I was able to fold the vest up into a small package like the original.

AeroVest™ with a puncture patch made with duct tape.

I do recommend you carry a small piece of rubber tubing for ease of inflation.  I have also recommended to the manufacturer that the tape strip be replaced with Velcro. It would add a slight bit more to the weight and volume, but would allow the vest to be put on and taken off with ease.

Overall, I found the vest a viable emergency use device for the prevention of hypothermia. It can be packaged small enough whereby it can be carried in a small survival kit, or a pocket. Would I rather have a regular insulated vest? Of course I would. But between no vest and this vest, I’ll take it. I now carry one in the rear game pocket of my Filson, as well as in all my small to large survival kits. Now if I can only get one to fit in my mini kit!  You can purchase it from either our Shelter or Protection Products page for $13.95 (MSRP is $14.95).     

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