Methods for encapsulating phase change materials

Abstract

A method for forming an encapsulated shape stabilized phase change composite material includes mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition, mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material, cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules, coating the phase change composite material granules with a sealant, and coating the phase change composite material granules with a barrier filler. The resulting encapsulated phase change materials could be further compressed into composite sheet and fabricated for building product applications.

Description

Cross- Reference to Related Application

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63 / 626,725, filed on January 30, 2024, the disclosure of which is incorporated herein by reference in its entirety. Field of the Disclosure

[0002] The present disclosure relates to methods for encapsulating phase change materials, as well as acoustic building structures comprising encapsulated phase change material. Background

[0003] Building materials, such as acoustics structures, planks, and panels for ceiling and wall systems, are designed to balance interests with respect to aesthetics, material cost, structural integrity, acoustics, temperature control, and environmental impact.

[0004] Accordingly, those skilled in the art continue research and development in the field of acoustic building structures. Summary

[0005] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0006] Applicants have discovered methods for manufacturing materials for acoustic building panels for storing thermal energy.

[0007] A method for forming an encapsulated shape stabilized phase change composite material includes mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition, mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material, cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules, coating the phase change composite material granules with a sealant, and coating the phase change composite material granules with a barrier filler.

[0008] In one example, the composite carrier is a powdered carrier including one or more of perlite, diatomaceous earth, clay, celite, biochar, and expanded graphite.

[0009] In one example, the method includes mixing a strength additive with the liquid phase change material composition and the composite carrier. In one example, the strength additive includes cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane.

[0010] In one example, the method includes mixing a nucleating agent with the phase change material and liquid carrier.

[0011] In one example, the cooling includes freezing the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules. In one example, the mixing includes dry infusing the phase change material into the composite carrier. In one example, the mixing includes vacuum infusing the phase change material into the composite carrier.

[0012] In one example, the phase change material is present at a concentration ranging from about 40 wt. % to about 90 wt. %, based on the total dry weight of the phase change composite material granules. In one example, the phase change material includes an inorganic salt hydrate. In one example, the phase change material includes calcium chloride hexahydrate. In one example, the sealant is oil-based. In one example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica. In one example, the coating includes spraying the phase change composite material granules with the sealant. In one example, the coating includes submerging the phase change composite material granules with the sealant. In one example, the coating includes soaking the phase change composite material granules with the sealant. In one example, wherein the coating is performed in a rotating vessel.

[0013] In one example, the method includes drying the phase change composite material granules. In one example, the drying is performed at room temperature.

[0014] In one example, the method includes freezing the phase change composite material granules prior to coating them with the sealant. In one example, the phase change composite material granules have an average diameter ranging from about 0.05” to about 1”.

[0015] Also disclosed is a method for encapsulating phase change composite material granules.

[0016] In one example, the method includes coating the phase change composite material granules with a sealant, coating the phase change composite material granules with a barrier filler, and drying the phase change composite material granules.

[0017] In one example, the sealant is oil-based. In one example, the sealant water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica. In one example, the coating includes spraying the phase change composite material granules with the sealant. In one example, the coating includes submerging the phase change composite material granules with the sealant. In one example, the coating includes soaking the phase change composite material granules with the sealant. In one example, the coating is performed in a rotating vessel.

[0018] In one example, the drying is performed at room temperature. In one example, the method includes freezing the phase change composite material granules prior to coating them with the sealant. In one example, the freezing includes lowering the phase change composite material granules to a temperature below 60° F. In one example, the phase change composite material granules have an average diameter ranging from about 0.05” to about 1”. In one example, the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the phase change composite material granules.

[0019] Also disclosed is a method for forming an acoustic building panel for storing thermal energy.

[0020] In one example, the method includes providing a substrate having a first major surface opposite a second major surface, applying encapsulated phase change composite material granules to the second major surface of the substrate, and consolidating the encapsulated phase change composite material granules to form a composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface.

[0021] In one example, the substrate includes one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In one example, the substrate has a porosity ranging from about 70% to about 96%. In one example, the substrate has a density ranging from about 5.0 lbs / ft3 to about 30.0 lbs / ft3. In one example, the composite layer further includes cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane. In one example, the composite layer has a thickness ranging from about 1mm to about 25mm, from about 2mm to about 4mm, or from about 2.5mm to about 3.5mm. In one example, the composite layer stores at least 20 kj / SF of thermal energy. In one example, the composite layer is activated at a temperature ranging from about 60 °F to about 80 °F. In one example, the composite layer includes one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0022] In one example, the encapsulated phase change composite material granules comprise an inorganic salt hydrate. In one example, the encapsulated phase change composite material granules comprise calcium chloride hexahydrate. In one example, the encapsulated phase change composite material granules are encapsulated in a single or multiple layers of coating containing sealant binder and barrier fillers.

[0023] In one example, the method includes mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition, mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material, cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules, coating the phase change composite material granules or the composite layer with a sealant, and coating the phase change composite material granules with platy barrier filler to yield the encapsulated phase change composite material granules or the composite layer.

[0024] In one example, the sealant is oil-based. In one example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica.

[0025] In one example, the coating includes spraying the phase change composite material granules with the sealant. In one example, the coating includes submerging the phase change composite material granules with the sealant. In one example, the coating includes soaking or coating with roll coater or curtain coater processes of the phase change composite material granules with the sealant. In one example, the coating is performed in a rotating vessel. In one example, the drying is performed at room temperature.

[0026] In one example, the method includes freezing the phase change composite material granules prior to coating them with the sealant. In one example, the freezing includes lowering the phase change composite material granules to a temperature below 60° F. In one example, the encapsulated phase change composite material granules have an average diameter ranging from about 0.05” to about 1”. In one example, the phase change material is present at a concentration ranging from about 40 wt. % to about 90 wt. %, based on the total dry weight of the encapsulated phase change composite material granules.

[0027] In one example, the method includes applying a film to the second major surface prior to applying the encapsulated phase change composite material granules to the second major surface of the substrate. In one example, the film includes a polymeric material. In one example, the film includes PET. In one example, the film includes a low permeability paint.

[0028] In one example, the method includes applying a sealing layer over the second major composite layer surface. In one example, the sealing layer includes PET. In one example, the sealing layer includes a low permeability paint. In one example, the sealing layer includes foil.

[0029] In one example, the method includes applying a coating over the edge composite layer surface. In one example, the coating includes a low permeability paint. In one example, the acoustic building panel is a ceiling tile. In one example, the acoustic building panel is a wall panel.

[0030] Also disclosed is an acoustic building panel for storing thermal energy.

[0031] In one example, the acoustic building panel includes a substrate having a first major surface opposite a second major surface. The acoustic building panel also includes a composite layer over the second major surface of the substrate, the composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface. The composite layer includes encapsulated phase change composite material granules including a composite carrier and a phase change material infused into the composite carrier.

[0032] In one example, the encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler. In one example, the sealant is oil-based. In one example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica. In one example, the composite layer further includes cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane. In one example, the composite layer has a thickness ranging from about 1mm to about 25mm, from about 2mm to about 4mm, or from about 2.5mm to about 3.5mm. In one example, the composite layer stores at least 20 kJ / SF of thermal energy. In one example, the composite layer is activated at a temperature ranging from about 60 °F to about 80 °F. In one example, the composite carrier includes one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite. In one example, the phase change material includes an inorganic salt hydrate. In one example, the phase change material includes calcium chloride hexahydrate. In one example, phase change material is infused into the composite carrier. In one example, the phase change material is vacuum infused into the composite carrier. In one example, the substrate includes one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In one example, the substrate has a porosity ranging from about 70% to about 96%. In one example, the substrate has a density ranging from about 5.0 lbs / ft3 to about 30.0 lbs / ft3.

[0033] In one example, the acoustic building panel includes a film positioned between the substrate and the composite layer. In one example, the film includes a polymeric material. In one example, the film includes PET. In one example, the film includes a low permeability paint.

[0034] In one example, the acoustic building panel includes an adhesive positioned between the film and the substrate. In one example, the acoustic building panel includes a sealing layer positioned over the composite layer. In one example, the sealing layer includes PET. In one example, the sealing layer includes a low permeability paint. In one example, the sealing layer includes foil.

[0035] In one example, the acoustic building panel includes a coating over the edge composite layer surface. In one example, the coating includes a low permeability paint.

[0036] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred examples of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure. Description of the Drawings

[0037] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.

[0038] Figure 1 is a top perspective view of an acoustic building panel according to an example of the present disclosure;

[0039] Figure 2 is a cross-sectional view of an acoustic building panel of the present disclosure;

[0040] Figure 3 is a cross-sectional view of an acoustic building panel of the present disclosure;

[0041] Figure 4 is a cross-sectional view of an acoustic building panel of the present disclosure;

[0042] Figure 5 is a top perspective view of a surface covering system according to an example of the present disclosure;

[0043] Figure 6 is a cross-sectional view of a surface covering system of the present disclosure;

[0044] Figure 7 is a cross-sectional view of a surface covering system of the present disclosure; and

[0045] Figure 8 is a ceiling system comprising the acoustic building panel of the present disclosure. Detailed Description

[0046] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0047] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0048] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0049] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a “wt. %” refers to the amount of that molecule, or molecules, present in the composition based on the total weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition in a dry state. The “dry state” refers to solvent being present in the composition at an amount less than 5.0 wt. %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present “based on the wet weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition which includes at least 5 wt. % of solvent.

[0050] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / - 5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0051] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein arc incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0052] In the description of examples disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as "lower," "upper," “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0053] As used herein, terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0054] The present disclosure relates to acoustic panels comprising phase change materials. A phase change material is a substance which releases / absorbs energy at phase transition to provide useful heating and / or cooling. Thus, incorporating a phase change material into a building panel (which may be used in a ceiling system, a wall system, a floor system, or the like) may render the building panel capable of assisting in heating or cooling an interior space. In some examples a phase change material may change from a solid to a liquid as it absorbs heat. In some examples, the phase change material may change from a liquid to a gas as it absorbs heat. In other examples, the phase transition may be between two non-classical states of matter, such as conformity of crystals, where the material goes from conforming to one crystalline structure to conforming to another crystalline structure, which may be a higher or lower energy state.

[0055] Phase change materials may be organic phase change materials such as hydrocarbons like paraffins and lipids and sugar alcohols. Phase change materials may be inorganic phase change materials such as salt hydrates. In some embodiments, the phase change material may comprise a salt hydrate material. An example of a phase change material is a salt hydrate phase change material comprising water mixed with calcium chloride and a nucleating agent. Non-limiting examples of appropriate nucleating agents include silica dust, quartz, or combinations thereof. Examples of other phase change materials are paraffin and other salt hydrates. However, other types of phase change material can also be used. Phase change materials may be solid-liquid phase change materials or solid to solid phase change materials. Other phase change materials now known or later discovered may be used.

[0056] Disclosed herein are coating formulations, encapsulating and manufacturing processes for PCM materials, and acoustic panels for acoustical, energy-storing building products. Phase change materials (PCM) have many unique features for energy storage and help maintain a relatively constant temperature by adsorption and release heat when the surrounding temperature increases or decreases, respectively. When used in building materials, they help reduce energy consumption and carbon footprint.

[0057] The present disclosure addresses several developments and advancements in PCM formulation, protective sealing coating, and encapsulating processes. The following factors are considered with respect to the present disclosure: salt hydrate type and ratio, supporting material combinations and ratio, desired material shape and size, coating formula and application rate, coating application method and equipment, material drying and processing, supporting acoustical materials and thickness, laminate adhesive, and surface film type and thickness.

[0058] In one or more examples, disclosed is a method for forming an encapsulated shape stabilized phase change composite material. The encapsulated phase change composite material granules may have an average diameter ranging from about 0.05” to about 1”, including all ranges and sub-ranges between.

[0059] The method includes mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition. In one example, the phase change material includes an inorganic salt hydrate. In another example, the phase change material includes calcium chloride hexahydrate.

[0060] In one or more examples, the method includes mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material. The phase change material may be added in an amount such that it is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the phase change composite material granules. In another example, the phase change material is added based upon the salt hydrate type and ratio needed for the intended application.

[0061] In one example, the mixing includes dry infusing the phase change material into the composite carrier. In another example, the mixing includes vacuum infusing the phase change material into the composite carrier. The composite carrier may be a powdered carrier including one or more of perlite, diatomaceous earth, clay, celite, biochar, and expanded graphite.

[0062] The method further includes cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules. In one example, the cooling includes freezing the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules. Freezing may be at any temperature below at least 60° F, and is variable based on the composition of the shape stabilized phase change composite material.

[0063] In one or more examples, the method includes coating the phase change composite material granules with a sealant. The method may further include freezing the phase change composite material granules prior to coating them with the sealant. In one example, the freezing includes lowering the phase change composite material granules to a temperature below 60° F.

[0064] The sealant provides barrier properties to limit moisture intake within the granules. In one example, the sealant is oil-based. In another example, the sealant water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0065] The coating may include spraying the phase change composite material granules with the sealant, submerging the phase change composite material granules with the sealant, soaking the phase change composite material granules with the sealant, or any other means for covering all surface area of the granules with the sealant. In one example, the coating is performed in a rotating vessel such that the granules are continuously jostled within the rotating vessel while the sealant is applied via the means disclosed above.

[0066] The method further includes coating the phase change composite material granules with a barrier filler. This may occur simultaneously while coating with the sealant or subsequent coating with the sealant. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In another example, the barrier filler includes mica.

[0067] In one or more examples, the method further includes mixing a strength additive with the liquid phase change material composition and the composite carrier. In one example, the strength additive includes cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane. The method may further include mixing a nucleating agent with the phase change material and liquid carrier.

[0068] For example, the method may include mixing a thickener, such as a cellulose type thickener, with the liquid phase change material composition and the composite carrier. In one example, the method includes mixing hydroxy ethylcellulose with the liquid phase change material composition and the composite carrier.

[0069] In one or more examples, the method includes drying the phase change composite material granules. In one example, the drying is performed at room temperature.

[0070] Also disclosed is a method for encapsulating phase change composite material granules.

[0071] In one example, the method includes coating the phase change composite material granules with a sealant, coating the phase change composite material granules with a barrier filler, and drying the phase change composite material granules. In another example, the coated phase change composite material granules or layer could be directly used for further fabrication processes.

[0072] The method may further include freezing the phase change composite material granules prior to coating them with the sealant. In one example, the freezing includes lowering the phase change composite material granules to a temperature below 60° F.

[0073] The sealant provides barrier properties to limit moisture intake within the granules. In one example, the sealant is oil-based. In another example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0074] The coating may include spraying the phase change composite material granules with the sealant, submerging the phase change composite material granules with the sealant, soaking the phase change composite material granules with the sealant, or any other means for covering all surface area of the granules with the sealant. In one example, the coating is performed in a rotating vessel such that the granules are continuously jostled within the rotating vessel while the sealant is applied via the means disclosed above.

[0075] Coating the phase change composite material granules with a barrier filler may occur simultaneously while coating with the sealant or subsequent coating with the sealant. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In another example, the barrier filler includes mica.

[0076] In one example, the drying is performed at room temperature. The encapsulated phase change composite material granules have an average diameter ranging from about 0.05” to about 1”. In one example, the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the encapsulated phase change composite material granules.

[0077] Referring to Fig. 1, disclosed is an acoustic building panel 100 for storing thermal energy. The acoustic building panel 100 may be a ceiling panel or a wall panel. The acoustic building panel 100 includes a porous substrate 110 having a first major surface 112 and a second major surface 114 opposite the first major surface 112.

[0078] Referring to FIG. 8, the present disclosure may further include a ceiling system 1 comprising one or more of the acoustic building panels 100 installed in an interior space, whereby the interior space comprises a plenum space 3 and an active room environment 2. The plenum space 3 provides space for mechanical lines within a building (e.g., HVAC, plumbing, etc.). The active space 2 provides room for the building occupants during normal intended use of the building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.).

[0079] In the installed state, the acoustic building panels 100 may be supported in the interior space by one or more parallel support struts 5. Each of the support struts 5 may comprise an inverted T-bar having a horizontal flange 31 and a vertical web 32. The ceiling system 1 may further comprise a plurality of first struts that are substantially parallel to each other and a plurality of second struts that are substantially perpendicular to the first struts (not pictured). In some embodiments, the plurality of second struts intersects the plurality of first struts to create an intersecting ceiling support grid 6. The plenum space 3 exists above the ceiling support grid 6 and the active room environment 2 exists below the ceiling support grid 6.

[0080] In the installed state, the first major surface 112 of the substrate 110 of the acoustic building panel 100 may face the active room environment 2 and the second major surface 114 of the substrate 110 of the acoustic building panel 100 may face the plenum space 3. The acoustic building panel 100 may be installed such that the horizontal flange 31 contacts the first major surface 112 of the substrate 110 of the building panel 100, thereby vertically supporting the acoustic building panel 100 in the ceiling system 1.

[0081] The substrate 110 of the acoustic building panel 100 may be comprised of any material having requisite material properties. In one example, the substrate 110 of the acoustic panel 100 is a porous matrix includes one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In another example, the acoustic building panel 100 is fire resistant such that it has a FSR rating of ASTM E84 Class A (FSI less than 25, SDI less than 450).

[0082] Referring to Fig. 2, the acoustic building panel 100 further includes a composite layer 130 over the second major surface of the substrate 114, the composite layer 130 having a first major composite layer surface 132 opposite a second major composite layer surface 134 and an edge composite layer surface 136 extending from the first major composite layer surface 132 to the second major composite layer surface 134. The composite layer 130 includes a composite carrier material and a phase change material infused into the composite carrier material.

[0083] Still referring to Fig. 2 and to Fig. 3, in one or more examples, the composite layer 130 comprises encapsulated phase change material composite granules. In one or more examples, the composite layer 130 further comprises one or more of cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane. In another example, the composite carrier comprises one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0084] For example, the composite layer 130 may include a thickener, such as a cellulose type thickener, with the liquid phase change material composition and the composite carrier. In one example, the composite layer 130 includes hydroxyethylcellulose.

[0085] The composite layer 130 may be further characterized by its physical properties and dimensions. In one or more examples, the composite layer 130 has a thickness ranging from about 1mm to about 25 mm, from about 2mm to about 20mm, or from about 4mm to about 15 mm. In another example, the composite layer 130 stores at least 20 kJ / SF of thermal energy. In another example, the composite layer is activated at a temperature ranging from about 60 °F to about 80 °F.

[0086] The phase change material may be selected based upon its thermal properties and compatibility with the composite carrier material. In one or more examples, the phase change material comprises an inorganic salt hydrate. In another example, the phase change material comprises calcium chloride hexahydrate.

[0087] The phase change material may be present within the composite carrier such that it is stabilized from leaking out of the composite carrier. In one or more examples, the phase change material is infused into the composite carrier. In another example, the phase change material is vacuum infused into the composite carrier. In yet another example, the phase change material is impregnated within the composite carrier material.

[0088] The encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler. In one example, the sealant is oil-based. In another example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0089] The barrier filler may be selected to reduce clumping of the granules while helping seal the granules such that minimal to no moisture is absorbed into the granules. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica.

[0090] The substrate may be characterized by its material and physical properties. In one or more examples, the substrate has a porosity ranging from about 70% to about 96%. In one or more examples, the substrate has a density ranging from about 5.0 lbs / ft3 to about 30 lbs / ft3.

[0091] Referring to Fig. 2, the acoustic building panel 100 further includes a film 120 positioned between the substrate 110 and the composite layer 130. In one or more examples, the film comprises a polymeric material. The film 120 is a barrier layer between the composite layer 130 and the substrate 110 such that it does not impact the acoustic properties of the substrate 110. In one or more examples, the film 120 comprises PET. In another example, the film 120 comprises a low permeability paint. The acoustic building panel 100 may further include an adhesive positioned between the film 120 and the substrate 110 to adhere the film 120 to the substrate 110.

[0092] Referring to Fig. 4, the acoustic building panel 100 further includes a sealing layer 150 positioned over the composite layer 130. The sealing layer 150 acts as a barrier to protect the composite layer 130 from separation from the substrate 110. In one or more examples, the sealing layer 150 comprises PET. In in another example, the sealing layer comprises a low permeability paint. In yet another example, the scaling layer comprises foil. The scaling layer 150 may have a thickness ranging from about 1 mil to about 25 mils.

[0093] Still referring to Fig. 4, in one or more examples, the acoustic building panel 100 further includes a coating 140 over the edge composite layer surface 136 of the composite layer 130. In one or more examples, the coating 140 comprises a low permeability paint. The coating 140 is selected to keep the composite layer 130 as applied to the substrate 110. The coating 140 may have a thickness ranging from about 1 mil to about 25 mils.

[0094] Referring to Figures 5, 6, and 7. also disclosed is a surface covering system 200 for storing thermal energy. The surface covering system 200 includes a plurality of acoustic building panels 205 configured to be positioned adjacent to each other to form a plurality of seams 215 between each of the plurality of building panels 205.

[0095] Referring to Fig. 6, in one or more examples, each acoustic building panel 205' includes a substrate 210 having a first major surface 212 opposite a second major surface 214. Each acoustic building panel 205' includes a composite layer 230 over the second major surface 214 of the substrate 210. The composite layer 230 has a first major composite layer surface 232 opposite a second major composite layer surface 234 and an edge composite layer surface 236 extending from the first major composite layer surface 232 to the second major composite layer surface 234. The composite layer 230 includes a composite carrier including a phase change material, such that the phase change material is infused into or impregnated within the composite carrier.

[0096] In one or more examples, the composite layer 230 comprises encapsulated phase change material composite granules. The encapsulated phase change material composite granules may be formed by dry infusion or vacuum infusion of the phase change material into the composite carrier so as to stabilize the phase change material within the composite carrier. The composite carrier includes one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0097] The encapsulated phase change material composite granules may be encapsulated with a sealant and a barrier filler. In one example, the sealant is oil-based. In another example, the sealant includes water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0098] The barrier filler may be selected to reduce clumping of the granules while helping seal the granules such that minimal to no moisture is absorbed into the granules. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In one example, the barrier filler includes mica.

[0099] In one or more examples, the composite layer 230 further comprises cement for binding the materials of the composite layer together. In another example, the composite layer 230 further comprises siloxane.

[0100] The composite layer 230 may be present at any thickness needed for achieving desired thermal storage capacity for the given application. In one or more examples, the composite layer 230 has a thickness ranging from about 1mm to about 25 mm, from about 2mm to about 20mm, or from about 4mm to about 15 mm. the composite layer 230 may be further characterized by its material properties. In one or more examples, the composite layer 230 stores at least 20 kJ / SF of thermal energy. In another example, the composite layer 230 is activated at a temperature ranging from about 60 °F to about 80 °F.

[0101] The phase change material may be selected based upon its thermal properties and compatibility with the composite carrier material. In another example, the phase change material comprises an inorganic salt hydrate. In yet another example, the phase change material comprises calcium chloride hexahydrate.

[0102] The phase change material may be present within the composite carrier such that it is stabilized from leaking out of the composite carrier. In one example, the phase change material is infused into the composite carrier. In another example, the phase change material is vacuum infused into the composite carrier. In yet another example, the phase change material is impregnated within the composite carrier.

[0103] Each substrate 210 may be comprised of any standard acoustic building material. In one or more examples, the substrate 210 comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. The substrate 210 may be further characterized by its physical and material properties. In one or more examples, the substrate 210 has a porosity ranging from about 70% to about 96%. In another example, the substrate 210 has a density ranging from about 5.0 lbs / ft3 to about 30 lbs / ft3.

[0104] Referring to Fig. 6 and 7, in one or more examples, the surface covering system 200 further includes a film 220 positioned between the substrate 210 and the composite layer 230. In one or more examples, the film comprises a polymeric material. In another example, the film 220 comprises PET. In yet another example, the film 230 comprises a low permeability paint. The surface covering system 200 further includes an adhesive positioned between each film 220 and substrate 210 of the plurality of building panel 205.

[0105] Referring to Fig. 7, in one or more examples, the surface covering system 200 further includes a sealing layer 250 positioned over the composite layer 230. In one or more examples, the sealing layer comprises PET. In another example, the sealing layer comprises a low permeability paint. In yet another example, the sealing layer comprises foil.

[0106] Still referring to Fig. 7, in one or more examples, the surface covering system 200 further includes a coating 240 over the edge composite layer surface. In one or more examples, the coating 240 comprises a low permeability paint.

[0107] Also disclosed is a method for forming an acoustic building panel 100 for storing thermal energy, such as a ceiling tile or a wall panel. In one example, the method includes providing a substrate 110 having a first major surface 112 opposite a second major surface 114.

[0108] The method further includes applying an encapsulated phase change composite material to the second major surface 114 of the substrate 110. In one example, the encapsulated phase change composite material includes encapsulated phase change material composite granules which could be further processed as composite sheet or layer.

[0109] The method further includes consolidating the encapsulated phase change composite material granules to form a composite layer 130 having a first major composite layer surface 132 opposite a second major composite layer surface 134 and an edge composite layer surface 136 extending from the first major composite layer surface 132 to the second major composite layer surface 132.

[0110] In one or more examples, the composite layer 130 further comprises cement for binding the shape stabilized phase change material composite granules to form the composite layer 130. In another example, the composite layer 130 further comprises siloxane, or other polymer resin binders including acrylic, polyester, polyvinyl acetate, urethane, alkyd, etc. In yet another example, the composite layer 130 comprises one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0111] In one or more examples, the composite layer has a thickness ranging from about 1mm to about 25 mm, from about 2mm to about 20mm, from about 3mm to about 15 mm, or about 3mm. In another example, the composite layer stores at least 20 kJ / SF of thermal energy. In yet another example, the composite layer 130 is activated at a temperature ranging from about 60 °F to about 80 °F.

[0112] In one or more examples, the composite layer 130 formed by the method comprises an inorganic salt hydrate. In another example, the composite layer 130 includes calcium chloride hexahydrate. In another example, the composite layer 130 includes one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0113] The substrate 130 of the method may be comprised of any standard acoustic building materials. In one or more examples, the substrate comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. The substrate may be further characterized by its physical properties. In one example, the substrate has a porosity ranging from about 70% to about 96%. In another example, the substrate has a density ranging from about 5.0 lbs / ft3 to about 30.0 lbs / ft3.

[0114] In one example, the encapsulated phase change composite material granules comprise an inorganic salt hydrate. In another example, the encapsulated phase change composite material granules comprise calcium chloride hexahydrate. In yet another example, the encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler.

[0115] In one or more examples, the method further includes mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition. In one or more examples, the mixing comprises dry infusing the phase change material into the composite carrier. In another example, the mixing comprises vacuum infusing the phase change material into the composite carrier.

[0116] The method further includes mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material. In one example, the mixing is performed in a pin mixer.

[0117] In one or more examples, the method further includes mixing a binder with the liquid phase change material and composite carrier. In one example, the binder includes carboxylated polyvinyl acetate homopolymer. In another example, the binder includes polyvinyl acetate. In another example, the binder includes crosslinkable polyvinyl acetate.

[0118] The method further includes cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules prior to applying to the substrate. In one example, the cooling includes freezing such that the shape stabilized phase change composite material granules arc frozen.

[0119] The method further includes coating the phase change composite material granules with a sealant and coating the phase change composite material granules with a barrier filler to yield the encapsulated phase change composite material granules.

[0120] In one example, the sealant is oil-based. In another example, the sealant includes waterbased emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In one example, the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40. In another example, the barrier filler includes mica.

[0121] In one example, the coating includes spraying the phase change composite material granules with the sealant. In another example, the coating includes submerging the phase change composite material granules with the sealant. In yet another example, the coating includes soaking the phase change composite material granules with the sealant. The coating may be performed in a rotating vessel, and the drying may be performed at room temperature.

[0122] In one example, the method includes freezing the phase change composite material granules prior to coating them with the sealant. The freezing includes lowering the phase change composite material granules to a temperature below freezing temperature, such as below about 60° F. In one example, the encapsulated phase change composite material granules have an average diameter ranging from about 0.05” to about 1”. In another example, the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the encapsulated phase change composite material granules.

[0123] In one or more examples, the method further includes applying a film 120 to the second major surface 114 prior to applying the shape stabilized phase change composite material to the second major surface 114. In one or more examples, the film 120 comprises a polymeric material. In another example, the film 120 comprises PET. In yet another example, the film 120 comprises a low permeability paint.

[0124] In one or more examples, the method further includes applying a sealing layer 150 over the second major composite layer surface 134 of the composite later 130. In one or more examples, the sealing layer 150 comprises PET. In another example, the sealing layer 150 comprises a low permeability paint. In yet another example, the sealing layer 150 comprises foil.

[0125] In one or more examples, the method further includes applying a coating 140 over the edge composite layer surface 136. In one example, the coating 140 comprises a low permeability paint.

[0126] EXAMPLES

[0127] The following examples TABLE 1 Control 1 Sample 1 Sample 2 Sample 3 Sample 4 PCM (g) 500 500 500 500 500 Defoamer Emulsion (g) 0 5 5 5 5 Nonionic Surfactant (g) 0 5 5 5 5 Thickener (g) 0 5 10 15 25 pH 5.38 5.64 6.02 6.02 6.1 Thickener% 0.00% 1.00% 1.90% 2.90% 4.70%

[0128] Table 1 illustrates the composition of several Samples with different amount of thickener and a Control tested for moisture stability over several weeks. The defoamer used is a solvent-free emulsion of a polyether siloxane copolymer containing fumed silica. The nonionic surfactant used includes secondary alcohol ethoxylates. Increasing the thickener load in the formula accelerates the viscosity rise of the phase change material composite. TABLE 2 Control 1 Sample 1 Sample 2 Sample 3 Sample 4 1 Day 1.1% 1.1% 1.1% -0.1% 1.0% 9 Days 11.3% 10.6% 9.8% 8.5% 9.8% 15 Days 17.3% 16.1% 14.8% 13.8% 14.9% 27 Days 25.2% 23.4% 22.9% 21.3% 22.4%

[0129] Table 2 illustrates moisture stability for each Sample and the Control 1 for 1 Day, 9 Days, 15 Days, and 27 Days. Moisture pickup could be reduced up to 15% after 27 days when the composite materials exposed to ambient conditions at the relative humidity around 50%. Given that water content can significantly impact the phase change performance of the composite material, enhanced moisture stability is a highly desirable and beneficial feature. TABLE 3 Control 3 Sample 8 Sample 6 Sample 7 Water 323.33 201.44 245.15 214.5 Calcium Chloride DiHydrate 666.67 666.67 666.67 666.67 Potassium Nitrate 21 21 21 21 Potassium Bromide 21 21 21 21 Strontium Chloride Hexahydrate 12.67 12.67 12.67 12.67 Binder A 0 251.33 Binder B 206.67 Binder C 237

[0130] Table 3 includes compositional data for several Samples and a Control tested for moisture stability. TABLE 4 Control 3 Sample 8 Sample 6 Sample 7 1 Day 8.7% 7.3% 8.0% 8.3% 5 Days 37.6% 32.7% 33.5% 33.8%

[0131] Table 4 shows the moisture pickup of the resulting composite materials after 1 day and 5 days. Similar to the previously mentioned improvement in moisture stability from the thickener, adding a polymeric binder to the composite clearly enhances moisture stability.

[0132] EXEMPLARY CLAIM SET.

[0133] The disclosure may be further characterized by the following exemplary claim set.

[0134] A method for forming an encapsulated shape stabilized phase change composite material comprising: mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition; mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material; cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules; coating the phase change composite material granules with a sealant; and coating the phase change composite material granules with a barrier filler.

[0135] The method according to exemplary claim 1, wherein the composite carrier is a powdered carrier comprising one or more of perlite, diatomaceous earth, clay, celite, biochar, and expanded graphite.

[0136] The method according to any one of exemplary claims 1 or 2, further comprising mixing a strength additive with the liquid phase change material composition and the composite carrier.

[0137] The method according to exemplary claim 3, wherein the strength additive comprises cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane.

[0138] The method according to any one of exemplary claims 1 to 4, further comprising mixing a nucleating agent with the phase change material and liquid carrier.

[0139] The method according to any one of exemplary claims 1 to 5, wherein the cooling comprises freezing the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules.

[0140] The method according to any one of exemplary claims 1 to 6, wherein the mixing comprises dry infusing the phase change material into the composite carrier.

[0141] The method according to any one of exemplary claims 1 to 6, wherein the mixing comprises vacuum infusing the phase change material into the composite carrier.

[0142] The method according to any one of exemplary claims 1 to 8, wherein the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the phase change composite material granules.

[0143] The method according to any one of exemplary claims 1 to 9, wherein the phase change material comprises an inorganic salt hydrate.

[0144] The method according to any one of exemplary claims 1 to 10, wherein the phase change material comprises calcium chloride hexahydrate.

[0145] The method according to any one of exemplary claims 1 to 11, wherein the sealant is oilbased.

[0146] The method according to any one of exemplary claims 1 to 12, wherein the sealant comprises water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0147] The method according to any one of exemplary claims 1 to 13, wherein the sealant comprises polyurethane.

[0148] The method according to any one of exemplary claims 1 to 14, wherein the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40.

[0149] The method according to any one of exemplary claims 1 to 15, wherein the barrier filler comprises mica.

[0150] The method according to any one of exemplary claims 1 to 16, wherein the coating comprises spraying the phase change composite material granules with the sealant.

[0151] The method according to any one of exemplary claims 1 to 17, wherein the coating comprises submerging the phase change composite material granules with the sealant.

[0152] The method according to any one of exemplary claims 1 to 18, wherein the coating comprises soaking or coating with roll coater or curtain coater processes of the phase change composite material granules with the sealant.

[0153] The method according to any one of exemplary claims 1 to 19, wherein the coating is performed in a rotating vessel.

[0154] The method according to any one of exemplary claims 1 to 20, further comprising drying the phase change composite material granules.

[0155] The method according to exemplary claim 21, wherein the drying is performed at room temperature.

[0156] The method according to any one of exemplary claims 1 to 22, further comprising freezing the phase change composite material granules prior to coating them with the sealant.

[0157] The method according to any one of exemplary claims 1 to 23, wherein the phase change composite material granules have an average diameter ranging from about 0.05” to about 1”.

[0158] A method for encapsulating phase change composite material granules, the method comprising: coating the phase change composite material granules with a sealant; coating the phase change composite material granules with a barrier filler; and drying the phase change composite material granules.

[0159] The method according to exemplary claim 25, wherein the sealant is oil-based.

[0160] The method according to any one of exemplary claims 25 or 26, wherein the sealant comprises water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0161] The method according to any one of exemplary claims 25 to 27, wherein the sealant comprises polyurethane.

[0162] The method according to any one of exemplary claims 25 to 28, wherein the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40.

[0163] The method according to any one of exemplary claims 25 to 29, wherein the barrier filler comprises mica.

[0164] The method according to any one of exemplary claims 25 to 30, wherein the coating comprises spraying the phase change composite material granules with the sealant.

[0165] The method according to any one of exemplary claims 25 to 31, wherein the coating comprises submerging the phase change composite material granules with the sealant.

[0166] The method according to any one of exemplary claims 25 to 32, wherein the coating comprises soaking the phase change composite material granules with the sealant.

[0167] The method according to any one of exemplary claims 25 to 33, wherein the coating is performed in a rotating vessel.

[0168] The method according to any one of exemplary claims 25 to 34, wherein the drying is performed at room temperature.

[0169] The method according to any one of exemplary claims 25 to 35, further comprising freezing the phase change composite material granules prior to coating them with the sealant.

[0170] The method according to exemplary claim 36, wherein the freezing comprises lowering the phase change composite material granules to a temperature below 60° F.

[0171] The method according to any one of exemplary claims 25 to 37, wherein the phase change composite material granules have an average diameter ranging from about 0.05” to about 1”.

[0172] The method according to any one of exemplary claims 25 to 38, wherein the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the phase change composite material granules.

[0173] A method for forming an acoustic building panel for storing thermal energy, the method comprising: providing a substrate having a first major surface opposite a second major surface; applying encapsulated phase change composite material granules to the second major surface of the substrate; and consolidating the encapsulated phase change composite material granules to form a composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface.

[0174] The method according to exemplary claim 30, wherein the substrate comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0175] The method according to any one of exemplary claims 40 or 41, wherein the substrate has a porosity ranging from about 70% to about 96%.

[0176] The method according to any one of exemplary claims 40 to 42, wherein the substrate has a density ranging from about 5.0 lbs / ft3 to about 30.0 lbs / ft3.

[0177] The method according any one of exemplary claims 40 to 43, wherein the composite layer further comprises cement.

[0178] The method according to any one of exemplary claims 40 to 44, wherein the composite layer further comprises fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane.

[0179] The method according to any one of exemplary claims 40 to 45, wherein the composite layer has a thickness ranging from about 1mm to about 25mm, from about 2mm to about 20mm, or from about 5 mm to about 15mm

[0180] The method according to any one of exemplary claims 40 to 46, wherein the composite layer stores at least 20 kJ / sf of thermal energy.

[0181] The method according to any one of exemplary claims 40 to 47, wherein the composite layer is activated at a temperature ranging from about 60 °F to about 80 °F.

[0182] The method according to any one of exemplary claims 40 to 48, wherein the composite layer comprises one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0183] The method according to any one of exemplary claims 40 to 49, wherein the encapsulated phase change composite material granules comprise an inorganic salt hydrate.

[0184] The method according to any one of exemplary claims 40 to 50, wherein the encapsulated phase change composite material granules comprise calcium chloride hexahydrate.

[0185] The method according to any one of exemplary claims 40 to 51, wherein the encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler.

[0186] The method according to any one of exemplary claims 40 to 52, further comprising: mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition; mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material; cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules; coating the phase change composite material granules with a sealant; and coating the phase change composite material granules with a barrier filler to yield the encapsulated phase change composite material granules.

[0187] The method according to exemplary claim 53, wherein the sealant is oil-based.

[0188] The method according to any one of exemplary claims 53 or 54, wherein the sealant comprises water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0189] The method according to any one of exemplary claims 53 to 55, wherein the sealant comprises polyurethane.

[0190] The method according to any one of exemplary claims 53 to 56, wherein the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40.

[0191] The method according to any one of exemplary claims 53 to 57, wherein the barrier filler comprises mica.

[0192] The method according to any one of exemplary claims 53 to 58, wherein the coating comprises spraying the phase change composite material granules with the sealant.

[0193] The method according to any one of exemplary claims 53 to 59, wherein the coating comprises submerging the phase change composite material granules with the sealant.

[0194] The method according to any one of exemplary claims 53 to 60, wherein the coating comprises soaking the phase change composite material granules with the sealant.

[0195] The method according to any one of exemplary claims 53 to 61, wherein the coating is performed in a rotating vessel.

[0196] The method according to any one of exemplary claims 53 to 62, wherein the drying is performed at room temperature.

[0197] The method according to any one of exemplary claims 53 to 63, further comprising freezing the phase change composite material granules prior to coating them with the sealant.

[0198] The method according to exemplary claim 64, wherein the freezing comprises lowering the phase change composite material granules to a temperature below 60° F.

[0199] The method according to any one of exemplary claims 40 to 65, wherein the encapsulated phase change composite material granules have an average diameter ranging from about 0.05” to about 1”.

[0200] The method according to any one of exemplary claims 40 to 66, wherein the phase change material is present at a concentration ranging from about 30 wt. % to about 90 wt. %, based on the total weight of the encapsulated phase change composite material granules.

[0201] The method according to any one of exemplary claims 40 to 67, further comprising applying a film to the second major surface prior to applying the encapsulated phase change composite material granules to the second major surface of the substrate.

[0202] The method according to exemplary claim 68, wherein the film comprises a polymeric material.

[0203] The method according to exemplary claim 68, wherein the film comprises PET.

[0204] The method according to exemplary claim 68, wherein the film comprises a low permeability paint.

[0205] The method according to any one of exemplary claims 40 to 71, further comprising applying a sealing layer over the second major composite layer surface.

[0206] The method according to exemplary claim 72, wherein the sealing layer comprises PET.

[0207] The method according to exemplary claim 72, wherein the sealing layer comprises a low permeability paint.

[0208] The method according to exemplary claim 72, wherein the sealing layer comprises foil.

[0209] The method according to any one of exemplary claims 40 to 75, further comprising applying a coating over the edge composite layer surface.

[0210] The method according to exemplary claim 76, wherein the coating comprises a low permeability paint.

[0211] The method according to any one of exemplary claims 40 to 77, wherein the acoustic building panel is a ceiling tile.

[0212] The method according to any one of exemplary claims 40 to 77, wherein the acoustic building panel is a wall panel.

[0213] An acoustic building panel for storing thermal energy comprising: a substrate having a first major surface opposite a second major surface; and a composite layer over the second major surface of the substrate, the composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface, the composite layer comprising: encapsulated phase change composite material granules comprising: a composite carrier; and a phase change material infused into the composite carrier.

[0214] The acoustic building panel according to exemplary claim 80, wherein the encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler.

[0215] The acoustic building panel according to any one of exemplary claims 80 or 81, wherein the sealant is oil-based.

[0216] The acoustic building panel according to any one of exemplary claims 80 to 82, wherein the sealant comprises water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

[0217] The acoustic building panel according to any one of exemplary claims 80 to 83, wherein the sealant comprises polyurethane.

[0218] The acoustic building panel according to any one of exemplary claims 80 to 84, wherein the barrier filler is a platy material having an aspect ratio of at least about 1:2 to 1:40.

[0219] The acoustic building panel according to any one of exemplary claims 80 to 85, wherein the barrier filler comprises mica.

[0220] The acoustic building panel building panel according to any one of exemplary claims 80 to 86, wherein the composite layer further comprises cement.

[0221] The acoustic building panel according to any one of exemplary claims 80 to 87, wherein the composite layer further comprises fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd. In another example, the strength additive can include siloxane.

[0222] The acoustic building panel according to any one of exemplary claims 80 to 88, wherein the composite layer has a thickness ranging from about 1mm to about 25 mm, from about 2mm to about 20mm, or from about 5 mm to about 15mm.

[0223] The acoustic building panel according to any one of exemplary claims 80 to 89, wherein the composite layer stores at least 20 kJ / SF of thermal energy.

[0224] The acoustic building panel according to any one of exemplary claims 80 to 90, wherein the composite layer is activated at a temperature ranging from about 60 °F to about 80 °F.

[0225] The acoustic building panel according to any one of exemplary claims 80 to 91, wherein the composite carrier comprises one or more of perlite, diatomaceous earth, clay, biochar, and expanded graphite.

[0226] The acoustic building panel according to any one of exemplary claims 80 to 92, wherein the phase change material comprises an inorganic salt hydrate.

[0227] The acoustic building panel according to any one of exemplary claims 80 to 93, wherein the phase change material comprises calcium chloride hexahydrate.

[0228] The acoustic building panel according to any one of exemplary claims 80 to 94, wherein the phase change material is infused into the composite carrier.

[0229] The acoustic building panel according to any one of exemplary claims 80 to 95, wherein the phase change material is vacuum infused into the composite carrier.

[0230] The acoustic building panel according to any one of exemplary claims 80 to 96, wherein the substrate comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0231] The acoustic building panel according to any one of exemplary claims 80 to 97, wherein the substrate has a porosity ranging from about 70% to about 96%.

[0232] The acoustic building panel according to any one of exemplary claims 80 to 98, wherein the substrate has a density ranging from about 5.0 lbs / ft3 to about 30.0 lbs / ft3.

[0233] The acoustic building panel according to any one of exemplary claims 80 to 99, further comprising a film positioned between the substrate and the composite layer.

[0234] The acoustic building panel according to exemplary claim 100, wherein the film comprises a polymeric material.

[0235] The acoustic building panel according to exemplary claim 100, wherein the film comprises PET.

[0236] The acoustic building panel according to exemplary claim 100, wherein the film comprises a low permeability paint.

[0237] The acoustic building panel according to any one of exemplary claims 80 to 103, further comprising an adhesive positioned between the film and the substrate.

[0238] The acoustic building panel according to any one of exemplary claims 80 to 104, further comprising a sealing layer positioned over the composite layer.

[0239] The acoustic building panel according to exemplary claim 105, wherein the sealing layer comprises PET.

[0240] The acoustic building panel according to exemplary claim 105, wherein the sealing layer comprises a low permeability paint.

[0241] The acoustic building panel according to exemplary claim 105, wherein the sealing layer comprises foil.

[0242] The acoustic building panel according to any one of exemplary claims 80 to 108, further comprising a coating over the edge composite layer surface.

[0243] The acoustic building panel according to exemplary claim 109, wherein the coating comprises a low permeability paint.

[0244] A ceiling tile comprising the acoustic building panel according to any one of exemplary claims 80 to 110.

[0245] A wall panel comprising the acoustic building panel according to any one of exemplary claims 80 to 110.

[0246] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.

Claims

1. A method for forming an encapsulated shape stabilized phase change composite material comprising:mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition;mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material;cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules;coating the phase change composite material granules with a sealant; and coating the phase change composite material granules with a barrier filler.

2. The method according to claim 1, wherein the composite carrier is a powdered carrier comprising one or more of perlite, diatomaceous earth, clay, celite, biochar, and expanded graphite.

3. The method according to any one of claims 1 or 2, further comprising mixing a strength additive with the liquid phase change material composition and the composite carrier, wherein the strength additive comprises cement, fiber, silicon, starch, thickener, gelation agent, or other polymeric or copolymeric resins, such as polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

4. The method according to any one of claims 1 to 3, wherein the mixing comprises dry infusing the phase change material into the composite carrier or vacuum infusing the phase change material into the composite carrier.

5. The method according to any one of claims 1 to 4, wherein the phase change material comprises calcium chloride hexahydrate.

6. A method for encapsulating phase change composite material granules, the method comprising:coating the phase change composite material granules with a sealant;coating the phase change composite material granules with a barrier filler; and drying the phase change composite material granules.

7. The method according to claim 6, wherein the sealant comprises water-based emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions, including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

8. The method according to any one of claims 6 or 7, wherein the coating comprises spraying the phase change composite material granules with the sealant, submerging the phase change composite material granules with the sealant, or soaking the phase change composite material granules with the sealant.

9. The method according to any one of 6 to 8, further comprising freezing the phase change composite material granules prior to coating them with the sealant , wherein the freezing comprises lowering the phase change composite material granules to a temperature below 60° F.

10. A method for forming an acoustic building panel for storing thermal energy, the method comprising:providing a substrate having a first major surface opposite a second major surface;applying encapsulated phase change composite material granules to the second major surface of the substrate; andconsolidating the encapsulated phase change composite material granules to form a composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface.

11. The method according to claim 10, wherein the substrate comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

12. The method according to any one of claims 10 or 11, further comprising:mixing a phase change material with a liquid carrier in a heated environment to yield a liquid phase change material composition;mixing the liquid phase change material composition with a composite carrier to yield a shape stabilized phase change composite material;cooling the shape stabilized phase change composite material to yield shape stabilized phase change composite material granules;coating the phase change composite material granules with a sealant; andcoating the phase change composite material granules with a barrier filler to yield the encapsulated phase change composite material granules.

13. An acoustic building panel for storing thermal energy comprising:a substrate having a first major surface opposite a second major surface; anda composite layer over the second major surface of the substrate, the composite layer having a first major composite layer surface opposite a second major composite layer surface and an edge composite layer surface extending from the first major composite layer surface to the second major composite layer surface, the composite layer comprising:encapsulated phase change composite material granules comprising:a composite carrier; anda phase change material infused into the composite carrier.

14. The acoustic building panel according to claim 13, wherein the encapsulated phase change composite material granules are encapsulated in a sealant and a barrier filler.

15. The method according to any one of claims 13 or 14, wherein the sealant comprises waterbased emulsion, such as ammonia-free alkyd emulsion or copolymeric resin emulsions,including but not limited to polyvinyl acetate, acrylic, polystyrene, polyolefin, polyester, polyurethane, alkyd.

16. The acoustic building panel according to any one of claims 13 to 15, wherein the composite layer stores at least 20 kJ / SF of thermal energy.

17. The acoustic building panel according to any one of claims 13 to 16, wherein the composite carrier comprises one or more of perlite, diatomaceous earth, clay, biochai’, and expanded graphite.

18. The acoustic building panel according to any one of claims 13 to 17, wherein the phase change material comprises an inorganic salt hydrate.

19. The acoustic building panel according to any one of claims 13 to 18, wherein the phase change material is vacuum infused into the composite carrier.

20. The acoustic building panel according to any one of claims 13 to 19, wherein the substrate comprises one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

21. The acoustic building panel according to any one of claims 13 to 20, further comprising a film positioned between the substrate and the composite layer, wherein the film comprises a polymeric material, PET, or a low permeability paint.

22. The acoustic building panel according to claim 21, further comprising an adhesive positioned between the film and the substrate.

23. The acoustic building panel according to any one of claims 13 to 22, further comprising a sealing layer positioned over the composite layer, wherein the sealing layer comprises PET, a low permeability paint, or foil.

24. A ceiling tile comprising the acoustic building panel according to any one of claims 13 to23.

25. A wall panel comprising the acoustic building panel according to any one of claims 13 to24.

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