Porous PCM Thermal Storage Module With Molded Heat Exchanger

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Solution Overview

Problem

Phase-change materials used in thermal storage systems suffer from low thermal conductivity and require complex manufacturing processes involving numerous finned tubes, leading to high costs and increased leakage risks.

Innovation Solution

A module for thermal storage using a porous matrix with open pores, integrated directly with heat-exchangers, simplifies manufacturing by eliminating the need for additional plates and inserts, enhancing heat diffusion and reducing the number of tubes through a porous structure with varying porosities and metallic walls.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a large number of finned tubes are used to diffuse heat in the phase-change material, then thermal conduction is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvethermal conductionVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the heat-exchanger tubes with the structural walls of the storage module by integrating them into a single molded component. This eliminates the need for separate assembly of tubes and walls, reducing manufacturing complexity while maintaining thermal conduction efficiency through the integrated heat-exchanger structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The walls of the storage module serve dual functions: they provide structural support and simultaneously act as heat-exchangers. This multi-functionality eliminates the need for separate finned tubes, simplifying manufacturing while achieving effective heat diffusion throughout the phase-change material.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a large number of finned tubes are assembled to collector plates, then thermal conduction is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improvethermal conductionVSAvoidmanufacturing time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The heat-exchanger tubes and collector plates are merged into a single integrated component molded from the same material. This eliminates the time-consuming assembly process of attaching separate tubes to plates, while the integrated structure maintains effective thermal conduction to the phase-change material.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If numerous tubes are used for heat-exchange, then thermal conduction is improved, but leakage risks increase

Engineering Contradiction:

Improvethermal conductionVSAvoidleakage risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The heat-exchanger tubes are integrated into the wall structure as a single continuous component, eliminating multiple connection points and joints. This monolithic structure eliminates leakage risks associated with assembled tube-plate connections while maintaining thermal conduction efficiency.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If the number of tubes is reduced, then manufacturing is simplified, but heat transfer performance deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat transfer

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The walls serve as both structural elements and heat-exchangers, eliminating the need for numerous separate tubes. The integrated design maintains heat transfer performance by incorporating thermal conduction pathways directly into the wall structure that contacts the phase-change material.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent employs porous metallic foam material for the walls, which provides high surface area and enhanced thermal conduction properties. This porous structure enables effective heat transfer with fewer components, maintaining thermal performance while simplifying manufacturing.

Inventive Principle:

Principle #31Porous materials

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

This approach improves thermal conduction, reduces manufacturing complexity and costs, and enhances mechanical strength, allowing for easier assembly and increased energy storage density.

Implementation Method 1

the thermal conduction between the heat-transfer fluid and the phase-change material should be optimised

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the meltdown of the phase-change material... the solidification of the phase-change material

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS12467697B2Module for thermal storage by a phase-change material whose manufacture is simplified

Publication Date: 2025.11.11 GRIMS

AI summary

A module for thermal storage by a phase-change material includes a vat, at least one heat-exchanger having first and second connecting ends configured to be connected to a heat-transfer fluid network, the first and second connecting ends penetrating and opening into the vat, and a structure received in the vat and configured to contain a phase-change material. The structure includes a porous matrix made of a metallic material with communicating cells crossed by the heat-exchanger and in contact with the external surface of the heat-exchanger. The matrix is obtained by moulding around the heat-exchanger. The vat includes at least one wall made of a metallic material formed directly during moulding and integral with the matrix.