PCM Core Thermoplastic Shell Filament for Leak-Safe Thermal Storage

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Solution Overview

Problem

Phase change materials (PCMs) face challenges in practical use due to subcooling effects, phase segregation, cycling hysteresis, and corrosiveness, limiting their application in building thermal energy storage systems.

Innovation Solution

A thermoplastic polymer shell encapsulates a PCM core, enabling additive manufacturing through extrusion to form thermal energy storage devices with improved thermal conductivity and reduced leakage, allowing for high PCM loading and efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If PCMs are used for thermal energy storage, then thermal energy storage capacity is improved, but subcooling effects and phase segregation occur

Engineering Contradiction:

Improvethermal energy storage capacityVSAvoidphase stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The system divides the thermal energy storage function into two separate components: a PCM component for energy storage and a gel component for stability. The PCM is segmented into discrete phases (solid and liquid) that can coexist within the gel matrix, allowing each component to perform its specialized function without interfering with the other's stability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite material system combining PCM and gel components. The gel acts as a stabilizing matrix that prevents phase segregation and subcooling while allowing the PCM to maintain its high thermal energy storage capacity. This composite structure resolves the contradiction by integrating two materials with complementary properties

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If PCMs are used for thermal energy storage, then thermal energy storage capacity is improved, but corrosiveness issues arise

Engineering Contradiction:

Improvethermal energy storage capacityVSAvoidcorrosiveness

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The gel component serves as an intermediary barrier between the PCM and the environment (including containers and surrounding building materials). This intermediate layer prevents direct contact between potentially corrosive PCMs and other components, eliminating corrosiveness issues while preserving the PCM's thermal energy storage function

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If PCMs are contained to control placement, then placement control is improved, but manufacturing availability is limited

Engineering Contradiction:

Improveplacement controlVSAvoidmanufacturing availability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention changes the physical state and flow parameters of the PCM-gel mixture, allowing it to be pumped and injected like a conventional fluid or semi-fluid material. This parameter change enables the material to be placed in complex geometries and hard-to-reach locations using standard construction equipment, improving both placement control and manufacturing availability

Inventive Principle:

Principle #35Parameter changes

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 enhances energy and power density of thermal energy storage devices by minimizing thermal resistances and preventing leakage, while providing design flexibility and corrosion resistance.

Implementation Method 1

a shell comprising a thermoplastic polymer, and a core comprising a phase change material, in which the shell comprises a length and an interior, and the core is positioned within the interior of the shell

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

Phase change materials (PCMs) are a class of TES materials with the ability to store a large amount of thermal energy while maintaining a relatively constant temperature

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

PCMs are a class of TES materials with the ability to store a large amount of thermal energy while maintaining a relatively constant temperature

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 4

The solution enhances energy and power density of thermal energy storage devices by minimizing thermal resistances and preventing leakage

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12504238B2Phase change material core thermoplastic shell filament

Publication Date: 2025.12.23 ALLIANCE FOR ENERGY INNOVATION LLC

AI summary

The present disclosure relates to encapsulation of a phase change material (PCM) enabled by extrusion of a thermoplastic polymer shell and a PCM core, which can be additively manufactured to form a variety of designs for use in a variety of settings, including for use as thermal energy storage devices in building heating ventilation and air conditioning (HVAC) systems. The thermoplastic polymer shell surrounding a PCM core may be used as a filament in three-dimensional (3D) printing or may be extruded during the additive manufacturing process.