Composite Thermal Member With Protective Layer for High-Temperature Storage
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Solution Overview
Problem
Existing thermal energy storage systems face challenges in containing high-temperature thermal energy storage materials due to significant structural stresses from thermal expansion and chemical reactivity, leading to container failure, safety risks, and compromised heat transfer capabilities.
Innovation Solution
A composite thermal member comprising a refractory material, a binder, a thermal energy storage material, and an outer protective layer, formed through a slurry mixture process that includes silicon carbide, calcium aluminate cement, and a glassy outer layer, allowing operation in oxidizing atmospheres up to 1400°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If refractory materials are used to contain thermal energy storage material at high temperatures, then the container can withstand the thermal energy storage material, but significant structural stresses arise from thermal expansion and contraction during heating and cooling cycles
Solution Approach 1:
The patent applies parameter changes by adjusting the thermal expansion coefficient of the container material to match that of the thermal energy storage material. This parameter matching reduces the differential thermal expansion and contraction during heating and cooling cycles, thereby minimizing structural stresses while maintaining container strength at high temperatures.
Solution Approach 2:
The patent employs composite materials by combining refractory materials with specific thermal expansion properties and binder materials to create a container composite. This composite structure allows the container to withstand high temperatures while accommodating thermal expansion and contraction of the thermal energy storage material, reducing structural stresses.
2Use of energy by moving object
If thermal energy storage material is heated to high temperatures for phase change, then thermal energy can be stored, but the material oxidizes in air degrading performance
Solution Approach 1:
The patent applies inert atmosphere by providing an oxygen-free environment around the thermal energy storage material during high-temperature heating. This inert atmosphere prevents oxidation of the thermal energy storage material, allowing it to undergo phase change and store thermal energy without degrading performance.
Solution Approach 2:
The patent uses an inert gas or vacuum as an intermediary medium between the thermal energy storage material and the external environment. This intermediary prevents direct contact between the material and oxygen, eliminating oxidation while allowing thermal energy storage to proceed at high temperatures.
3Reliability
If thermal energy storage material reacts with refractory material of the container, then containment is achieved, but the container is compromised
Solution Approach 1:
The patent applies parameter changes by carefully selecting and adjusting the chemical composition and reactivity parameters of both the thermal energy storage material and the container material. This parameter optimization ensures that the materials are chemically compatible at high temperatures, achieving reliable containment while preventing reactions that would compromise the container.
4Object-affected harmful factors
If thermal energy storage material is maintained in evacuated or inert gas environment, then oxidation is prevented, but system complexity and expense increase
Solution Approach 1:
The patent applies inert atmosphere by using simple inert gases or vacuum environments to prevent oxidation of the thermal energy storage material. This approach provides effective oxidation protection while avoiding the need for complex containment systems, thereby reducing overall system complexity and expense.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite thermal member provides enhanced structural integrity, reduces oxidation, and enables flexible design, increasing energy storage density and safety while simplifying system maintenance and cost.
Implementation Method 1
High temperature thermal energy storage materials, such as silicon based materials, may be used in thermal energy storage and retrieval applications where a thermal energy storage material is heated in a thermal energy storage mode until it undergoes a phase change to become a liquid
Implementation Method 2
a thermal energy storage material is heated in a thermal energy storage mode until it undergoes a phase change to become a liquid
Implementation Method 3
the phase change material expands upon solidification which can result in the container being subject to even more significant structural stresses
Implementation Method 4
Thermal energy storage materials such as silicon-based materials will oxidise in air degrading their performance
Data Source
AI summary
A composite thermal member for storing thermal energy is disclosed. The composite thermal member comprises a refractory material, a binder material, a thermal energy storage material and a glassy outer protective layer. Also disclosed is a method of forming a composite thermal member for storing thermal energy.