Phase Change Gel Particles in Polyurethane Foams
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Solution Overview
Problem
Conventional polyurethane foams have low thermal conductivity and limited thermal storage capacity, which restricts their ability to effectively regulate temperature and provide comfort in applications like mattresses and pillows.
Innovation Solution
Incorporating phase change gel particles made from plasticized copolymer resins containing thermally-conductive materials into polyurethane foam formulations, which are then crosslinked and reduced in size to enhance thermal conductivity and storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polyurethane foam is used, then the foam structure is simple and easy to manufacture, but the thermal conductivity is low and thermal storage capacity is limited
Solution Approach 1:
The patent incorporates phase change gel particles containing thermally-conductive materials into polyurethane foam to create a composite material system. The phase change gel particles serve as thermal management components within the foam matrix, combining the structural benefits of polyurethane foam with the thermal conductivity and storage capacity of phase change materials, thereby resolving the contradiction between simple foam structure and improved thermal performance
2Quantity of substance
If phase change gel particles are incorporated into polyurethane foam, then thermal conductivity and storage capacity improve, but the manufacturing process becomes more complex
Solution Approach 1:
The phase change gel particles are pre-synthesized and prepared before incorporation into the polyurethane foam. This preliminary action allows the complex phase change material to be manufactured and characterized separately, then easily integrated into the foam system, reducing the overall manufacturing complexity while maintaining high thermal storage capacity
3Use of energy by moving object
If phase change gel particles are added to enhance thermal performance, then heat transfer capability improves, but the foam formulation complexity increases
Solution Approach 1:
The phase change gel particles act as intermediary thermal management agents within the polyurethane foam. These particles facilitate heat transfer and storage functions without requiring fundamental changes to the foam formulation itself, allowing thermal performance enhancement while maintaining relatively simple foam base composition
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 integration of phase change gel particles into polyurethane foams significantly improves thermal conductivity and storage capacity, leading to enhanced heat transfer and comfort in bedding and cushioning products.
Implementation Method 1
phase change materials, otherwise known as PCMs
Implementation Method 2
phase change gel particles...enhance thermal conductivity and storage capacity
Implementation Method 3
mixing in one or more phase change materials and optional additives such as thermally-conductive materials
Data Source
AI summary
Combinations of gelatinous elastomer containing one or more phase change materials, known as “phase change gel”, and polyurethane foam may be made by introducing at least partially cured phase change gel particles comprising plasticized triblock copolymer resin and/or diblock copolymer resin and one or more phase change materials, into a mixture of polyurethane foam-forming components including a polyol and an isocyanate. The phase change gel can be crosslinked to form a cured gelatinous gel, which is then reduced in size before introduction. After the foam-forming components polymerize to make polyurethane foam, the phase change gel particles are discrete visible particles dispersed throughout the foam. The polyurethane reaction is exothermic and can generate sufficient temperature to at least partially melt the styrene-portion of the triblock copolymer resin thereby extending the crosslinking. The combination of phase change gel and polyurethane foam increases the heat storage capacity and thermal conductivity of the foam.