Plastic PCM Pellets With Polymer Coating for Seepage and Ignition Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current Phase Change Material (PCM) applications face challenges such as high production costs, limited effectiveness due to heat transfer limitations, and flammability issues, which hinder their widespread deployment for reducing peak cooling load and corresponding CO2 emissions in buildings.
Innovation Solution
Development of plastic PCM compounds comprising organic PCMs and polymers, which can be converted into form-stable pellets, injection molded articles, extruded sheets, and tubes, coated to prevent paraffin seepage and enhance ignition resistance, allowing for efficient latent heat storage and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional PCM applications are used, then thermal storage capacity is achieved, but production costs are high and flammability issues occur
Solution Approach 1:
The patent uses polymer coatings as an intermediary layer between the organic PCM (paraffin) and the external environment. This coating layer acts as a barrier that prevents direct contact and ignition of the flammable paraffin, while still allowing thermal energy storage functionality. The coating serves as a protective mediator that eliminates flammability hazards without compromising thermal storage capacity.
Solution Approach 2:
The patent creates composite material structures by combining organic PCM (paraffin) with polymer materials (coatings, encapsulation matrices). This composite approach integrates the high latent heat storage capability of paraffin with the fire-resistant and structurally stable properties of polymers, resulting in a material system that maintains thermal storage functionality while eliminating flammability risks.
2Quantity of substance
If traditional PCM applications are used, then thermal storage is achieved, but heat transfer limitations reduce effectiveness
Solution Approach 1:
The patent employs porous polymer structures and foam materials as encapsulation matrices for the PCM. These porous structures provide large surface area-to-volume ratios and interconnected pathways that facilitate efficient heat transfer throughout the PCM mass. The porosity allows thermal energy to penetrate and distribute through the paraffin more effectively, overcoming the natural heat transfer limitations of bulk PCM materials.
Solution Approach 2:
The patent applies different polymer materials with varying thermal conductivities to different regions or aspects of the PCM system. High thermal conductivity polymers are used in regions where rapid heat transfer is critical, while other polymer compositions provide structural support or fire resistance. This localized optimization of material properties enhances overall heat transfer efficiency without compromising other essential functions.
3Productivity
If PCM deployment is expanded widely, then peak cooling demand reduction is achieved, but production costs and manufacturing complexity increase
Solution Approach 1:
The patent develops polymer-PCM composite systems that can be manufactured using conventional plastic processing techniques already widely available in the industry. The same polymer matrices and coating processes used for standard plastic products can be adapted for PCM encapsulation, eliminating the need for specialized manufacturing equipment or processes. This universality enables cost-effective large-scale production and easy integration into existing manufacturing supply chains.
Solution Approach 2:
The patent optimizes the physical and chemical parameters of the polymer-PCM composites to match standard processing conditions. By adjusting parameters such as melting temperature, viscosity, and curing characteristics of the polymer materials, the system can be processed using conventional extrusion, injection molding, or coating techniques without requiring modified equipment or processes, thereby simplifying manufacturing and reducing costs.
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 enables cost-effective, wide-scale deployment of PCMs for shifting peak cooling demand to off-peak hours, reducing energy consumption, and lowering CO2 emissions by enhancing thermal storage capacity and safety features.
Implementation Method 1
Phase Change Material (PCM) having a solid-liquid phase transition (i.e., melting and freezing) temperature of 21-26° C. (70-79° F.) and relatively high latent heats of phase transition (>60 J/g)
Implementation Method 2
coated to prevent paraffin seepage
Implementation Method 3
form-stable pellets, injection molded articles, extruded sheets, and tubes
Data Source
AI summary
The present invention generally relates to a method for manufacturing phase change material (PCM) pellets. The method includes providing a melt composition, including paraffin and a polymer. The paraffin has a melt point of between about 10° C. and about 50° C., and more preferably between about 18° C. and about 28° C. In one embodiment, the melt composition includes various additives, such as a flame retardant. The method further includes forming the melt composition into PCM pellets. The method further may include the step of cooling the melt to increase the melt viscosity before pelletizing. Further, PCM compounds are provided having an organic PCM and a polymer. Methods are provided to convert the PCM compounds into various form-stable PCMs. A method of coating the PCMs is included to provide PCMs with substantially no paraffin seepage and with ignition resistance properties.