Plastic PCM Pellets and Coatings for Leak-Resistant Thermal Storage
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Solution Overview
Problem
Current Phase Change Material (PCM) applications face challenges such as high production costs, limited effectiveness due to paraffin flammability, and inefficient heat transfer mechanisms, which hinder their widespread deployment for reducing peak cooling load and corresponding CO2 emissions.
Innovation Solution
Development of plastic PCM compounds comprising organic PCMs and polymers, converted into form-stable pellets, injection molded articles, extruded sheets, and tubes, with coatings 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
1Reliability
If conventional PCM applications are used, then thermal storage function is provided, but production costs are high and deployment is limited
Solution Approach 1:
The patent combines paraffin PCM with polyethylene polymer to create a composite material that integrates thermal storage functionality with structural integrity. This composite approach allows the PCM to be formed into stable pellets and molded articles without requiring expensive encapsulation, thereby reducing production costs while maintaining thermal storage effectiveness
Solution Approach 2:
The patent modifies the physical and chemical parameters of the PCM system by incorporating polymers that raise the melting point slightly above 0°C while maintaining high latent heat. This parameter adjustment enables the material to function effectively in building thermal storage applications without requiring costly containment structures
2Use of energy by moving object
If paraffin-based PCMs are used, then high latent heat is achieved, but flammability safety issues arise
Solution Approach 1:
The patent converts the harmful flammability of paraffin into a beneficial safety feature by formulating the composite so that the polymer matrix acts as a flame retardant. The polyethylene structure provides thermal stability and reduces flammability while preserving the high latent heat storage capacity of the paraffin PCM
Solution Approach 2:
By creating a composite of paraffin and polyethylene, the patent achieves a material that combines the high latent heat of paraffin with the flame-retardant properties of the polymer matrix, effectively resolving the safety issue while maintaining energy storage performance
3Ease of manufacture
If simple PCM formulations are used, then production cost is reduced, but heat transfer efficiency is insufficient
Solution Approach 1:
The composite formulation of paraffin and polyethylene creates a material with optimized thermal properties. The polymer matrix provides structural continuity that facilitates heat distribution throughout the PCM pellets and molded articles, improving heat transfer efficiency without requiring complex formulations or additional heat transfer additives
Solution Approach 2:
The patent optimizes the local composition and structure of the PCM composite to enhance heat transfer at critical interfaces. The polymer distribution within the paraffin matrix is designed to create optimal thermal pathways from the exterior surfaces to the interior bulk of the PCM articles, improving overall heat transfer efficiency
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 CO2 emissions and improving thermal efficiency in buildings by effectively storing and releasing heat, while ensuring safety and efficiency in heat transfer.
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
relatively high latent heats of phase transition (>60 J/g)
Implementation Method 3
coatings to prevent paraffin seepage and enhance ignition resistance
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.