PCM storage units or panels, methods of using the same, and automated ultrasonic seam welder and method of using the same
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Solution Overview
Problem
Phase change materials (PCMs) used in building thermal energy storage systems face challenges due to poor heat conductivity and flammability, which limits their commercial application in HVAC industries, especially in fire-prone environments, as they fail to meet stringent fire safety ratings and suffer from durability issues.
Innovation Solution
The development of PCM storage units with metal or metal alloy sides, hermetically sealed to enhance thermal efficiency and fire resistance, using ultrasonic welding for a robust and leak-proof perimeter seal, allowing for improved heat transfer and compliance with fire safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional film-based packaging is used for PCM, then the packaging is flexible and easy to manufacture, but the heat conductivity is poor and fire resistance is insufficient
Solution Approach 1:
The patent employs composite material construction by combining metal sides (aluminum or steel) with PCM core and insulating layers. This composite structure achieves both high fire resistance from the metal components and maintained manufacturability through standardized assembly processes, directly resolving the contradiction between ease of manufacture and fire resistance
2Ease of manufacture
If traditional film-based packaging is used for PCM, then the packaging is flexible and easy to manufacture, but the thermal efficiency is poor
Solution Approach 1:
The composite structure incorporates metal sides with high thermal conductivity alongside insulating materials. This dual-function composite design improves thermal efficiency by enabling better heat transfer from the PCM while maintaining ease of manufacture through modular construction approaches
Solution Approach 2:
The patent applies local quality differentiation by using high-conductivity metal materials specifically at the sides where heat transfer is most critical, while using insulating materials in other regions. This targeted material placement optimizes thermal efficiency without compromising manufacturing simplicity
3Ease of manufacture
If traditional heat sealing is used to seal PCM packaging, then the sealing process is simple, but the seal durability and leak-proof performance are insufficient
Solution Approach 1:
The patent replaces the traditional thermal heat sealing process with ultrasonic welding technology. This substitution maintains ease of manufacture through automated processing while dramatically improving seal durability and leak-proof performance, as ultrasonic welding creates stronger molecular-level bonds compared to thermal melting
4Use of energy by moving object
If PCM is used in fire-prone environments, then thermal energy storage is achieved, but the flammability of PCM creates safety hazards
Solution Approach 1:
The patent extracts the PCM from direct exposure to fire-prone environments by enclosing it within a metal container with high fire resistance. This separation allows the PCM to perform thermal energy storage functions while the metal housing protects against flammability hazards, enabling safe deployment in fire-prone environments
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 PCM storage units demonstrate enhanced thermal energy storage and release capabilities, meet stringent fire safety ratings, and are more durable, effectively addressing the limitations of traditional PCM systems by providing improved heat transfer and fire resistance.
Implementation Method 1
an automated ultrasonic seam welder and method of using the same
Implementation Method 2
PCM energy storage systems may be designed to transfer and store thermal energy as latent heat and to reduce the amount of energy used to heat and cool residential, commercial, industrial, and special purpose-built buildings
Implementation Method 3
thermal energy is stored as latent energy and released by the PCM media as the PCM transitions, or changes phase, at pre-determined temperatures
Implementation Method 4
The PCM storage units demonstrate enhanced thermal energy storage and release capabilities, meet stringent fire safety ratings, and are more durable, effectively addressing the limitations of traditional PCM systems by providing improved heat transfer and fire resistance
Data Source
AI summary
According to some embodiments, a PCM storage unit comprises a first side and a second side, each side having a perimeter; a perimeter seal joining the first and second sides together at the perimeters of the first and second side, whereby the first and second sides are at least partly spaced apart from each other to define at least one PCM storage area between the first and second sides; and PCM contained in the least one PCM storage area; wherein the first and second sides are made of metal or metal alloy. The PCM storage unit can comprise the first and second sides that are hermetically sealed by the perimeter seal, or can comprises a PCM that is flammable. The PCM contained in the least one PCM storage area can have a Smoke Developed Index greater than 50 when burned.