Microcapsules and other containment structures for articles incorporating functional polymeric phase change materials
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Solution Overview
Problem
Existing temperature-regulating textiles using phase change materials (PCMs) face challenges such as high costs, rupture of microcapsules, need for additional binders, poor fabric flexibility, and limited application on natural fibers like cotton, flax, and wool, as well as excessive moisture absorption issues with hydrophilic materials.
Innovation Solution
Development of functional polymeric phase change materials (FP-PCMs) with crystallizable side chains that form covalent or electrovalent interactions with substrates, allowing for integration into natural and synthetic fibers, enhancing thermal regulation and durability while avoiding hydrophilic issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If microcapsules containing phase change materials are used in textiles, then temperature regulating properties are improved, but manufacturing cost increases and microcapsules may rupture
Solution Approach 1:
The invention extracts the phase change material from microcapsule containment and directly incorporates it into the polymer fiber structure during manufacturing. This eliminates the microcapsule shell that is prone to rupture while retaining the thermal regulation function through the PCM-integrated fiber matrix.
Solution Approach 2:
The invention merges the phase change material with the polymer fiber structure by incorporating PCM into the fiber during extrusion or finishing processes. This combines the structural function of the fiber with the thermal regulation function of the PCM, eliminating the need for separate microcapsule containment.
2Temperature
If microcapsules are used to contain phase change materials, then temperature regulation is achieved, but additional resinous binders are required for adhesion
Solution Approach 1:
The invention merges multiple functions into the fiber structure itself: the polymer matrix provides structural support, the incorporated PCM provides thermal regulation, and the fiber surface provides adhesion to the substrate. This eliminates the need for separate microcapsules and resinous binders.
Solution Approach 2:
The polymer fiber structure serves multiple functions simultaneously: structural integrity, thermal regulation through embedded PCM, and adhesion to substrates. This multi-functionality reduces the total number of components needed in the system.
3Temperature
If microcapsules are incorporated into fabrics, then thermal properties are enhanced, but fabric flexibility deteriorates
Solution Approach 1:
The invention removes the rigid microcapsule shell structure that interferes with fabric flexibility. By integrating PCM directly into the flexible polymer fiber matrix, the thermal regulation function is maintained while the fabric retains its natural flexibility and drape.
Solution Approach 2:
The PCM is incorporated locally within the fiber structure at concentrations that provide thermal regulation without compromising the overall fabric flexibility. The distribution and concentration of PCM can be optimized to balance thermal performance with mechanical properties.
4Temperature
If hydrophilic phase change materials are used, then temperature regulation is provided, but excessive moisture absorption occurs
Solution Approach 1:
The invention changes the hydrophilicity parameter of the PCM by selecting hydrophobic phase change materials or by modifying the polymer matrix to be hydrophobic. This reduces moisture absorption while maintaining the thermal regulation function through the PCM's phase change properties.
Solution Approach 2:
The invention uses composite materials where the polymer matrix and PCM are selected to have appropriate hydrophobicity. The composite structure provides thermal regulation through PCM while the hydrophobic character of the materials minimizes excessive moisture absorption.
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
FP-PCMs provide effective temperature regulation, improved fabric flexibility, and durability by forming stable bonds with substrates, reducing costs and moisture absorption problems, and enabling broader fiber and fabric applications.
Implementation Method 1
phase change materials (PCMs)
Implementation Method 2
form a covalent or an electrovalent interaction with another material
Implementation Method 3
form a covalent or an electrovalent interaction with another material
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
An article comprises a substrate, a first functional polymeric phase change material, and a plurality of containment structures that contain the first functional polymeric phase change material. The article may further comprise a second phase change material chemically bound to at least one of the plurality of containment structures or the substrate. In certain embodiments, the article further comprises a second phase change material and a binder that contains at least one of the first polymeric phase change material and the second phase change material. The containment structure may be a microcapsule or a particulate confinement material.