Flexible PCM sheet materials
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Solution Overview
Problem
Existing flexible thermal regulation materials face limitations in flexibility, thermal conductivity, and capacity due to encapsulation of phase change materials (PCMs), which restricts their ability to be cut, rolled, or deformed, and results in high flow resistance and reduced thermal transmission.
Innovation Solution
A flexible PCM sheet material with geometrically defined polymer-bound PCM elements fixed on a carrier structure, allowing for unhindered thermal conduction and dimensional stability, enabling the material to be cut, rolled, and stacked while maintaining high thermal storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phase change materials are encapsulated to prevent bleeding and maintain flexibility, then the material can be handled more easily, but the flexibility is limited and the assembly cannot be cut or deformed arbitrarily
Solution Approach 1:
The invention removes the encapsulation layer entirely and instead uses a polymer-bound phase change material where the PCM is chemically bound to polymer beads. This extraction of the encapsulation concept while retaining the PCM containment function solves the contradiction by allowing direct cutting and deformation without capsule damage.
Solution Approach 2:
The invention changes the physical state and binding mechanism of the PCM from free liquid in capsules to polymer-bound material. This parameter change in the PCM's molecular state allows it to remain contained while enabling arbitrary cutting and deformation of the material assembly.
2Reliability
If encapsulation is used to contain liquid PCM, then bleeding is prevented, but mass and volume are lost reducing overall capacity
Solution Approach 1:
The invention extracts the encapsulation layer that was consuming mass and volume, replacing it with a polymer-bound PCM system. This eliminates the capsule wall mass while maintaining PCM containment through chemical binding, thereby maximizing the quantity of usable PCM for thermal storage.
Solution Approach 2:
The invention creates a composite material system where PCM is bound to polymer beads, forming a new composite that combines the thermal storage properties of PCM with the structural integrity of the polymer matrix, eliminating the need for separate encapsulation layers.
3Quantity of substance
If encapsulation layers are made thin to preserve capacity, then mass loss is reduced, but the system becomes fragile and prone to complete failure
Solution Approach 1:
The invention changes the PCM from a free liquid requiring thin protective walls to a polymer-bound material that is inherently contained within the polymer matrix. This parameter change in the PCM's physical state eliminates the need for thin encapsulation layers while maintaining system integrity through the robust polymer structure.
4Use of energy by moving object
If liquid or gaseous thermal carrier media are used with encapsulated PCM, then thermal transmission can occur, but flow resistance is very high hindering thermal transmission
Solution Approach 1:
The invention utilizes the porous structure of the polymer bead matrix to allow liquid or gaseous thermal carrier media to flow through while maintaining contact with the polymer-bound PCM. The porous structure provides flow paths that reduce resistance while ensuring efficient thermal transmission between the carrier media and the PCM.
5Quantity of substance
If macroencapsulated PCM is adhered on a flexible matrix, then thermal storage is achieved, but the fixed size of elements determines bending and winding radius limiting flexibility
Solution Approach 1:
The invention segments the PCM into polymer-bound beads distributed throughout the flexible matrix, rather than using large macroencapsulated elements. This segmentation allows the material to be bent and wound freely while maintaining thermal storage capacity through the distributed bead structure.
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 solution provides a flexible, dimensionally stable PCM sheet material with optimized thermal conductivity and capacity, allowing for efficient heat storage and transmission, and enabling the material to be easily formed into various shapes and configurations without losing thermal performance.
Implementation Method 1
phase change material elements disposed thereon separately in specific geometry. The phase change material elements themselves comprise geometrically defined structures of polymer-bound phase change material
Implementation Method 2
flexible PCM sheet materials with high latent thermal energy storage density
Implementation Method 3
optimized thermal conductivities, are dimensionally stable even during temperature changes and after phase transitions
Data Source
AI summary
The invention relates to flexible PCM sheet materials having a high latent thermal energy storage density for the purpose of heat management. The flexible PCM sheet material includes a flexible supporting structure and phase-change-material elements arranged thereon separately in a specific geometry. The phase-change-material elements are geometrically defined structures composed of polymer-bound phase-change material. The flexible PCM sheet materials are characterized by a high latent heat storage capacity and optimized thermal conductivity, are dimensionally stable even in the event of temperature changes and after phase transitions, can be rolled, folded, wound, or cut to size without problems, and can be transported, stored, processed, or used in a single layer or in multiple layers.