Solid Gel Beads via Oil-in-Water Macro-Emulsion for Thermal Management
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Solution Overview
Problem
There is a need for improved gel phase change materials (PCMs) for thermal management applications that are easier to manufacture, particularly in a continuous process, as existing methods often result in low yields and are not suitable for temperatures below 65°C.
Innovation Solution
The development of solid gel beads formed through an oil-in-water macro-emulsion process using a 5 carbon to 60 carbon alkane or alkene phase change material combined with a styrene-based polymer, specifically a styrene-ethylene-butylene-styrene triblock copolymer, where the mixture is processed at a temperature below the melting point of the PCM to create homogenous, irregularly shaped beads without forming a viscoelastic liquid, allowing for a continuous manufacturing method with high yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional heating and mixing methods are used to form gel PCMs above the glass transition temperature of KRATON polymers, then a viscoelastic liquid is formed that can be molded, but the manufacturing process becomes complex and yields are low
Solution Approach 1:
The invention changes the temperature parameter from above glass transition temperature (traditional method) to below glass transition temperature (new method). This parameter change transforms the material state from viscoelastic liquid to solid gel beads, enabling continuous manufacturing with high yields while simplifying the process by eliminating the need for heating and viscous stirring
Solution Approach 2:
Instead of heating the PCM above the glass transition temperature to form a viscoelastic liquid (traditional approach), the invention inverts the approach by processing at temperatures below the glass transition temperature to directly form solid gel beads. This inversion eliminates the need for complex heating and molding steps, achieving continuous manufacturing with high yields
2Reliability
If gel PCMs are manufactured using existing encapsulation or gelling methods, then phase change functionality is achieved, but the processes are not suitable for continuous manufacturing and result in low yields
Solution Approach 1:
The invention enables continuous manufacturing by maintaining the process in a continuous state without interruption for heating, mixing, and molding cycles. The oil-in-water macro-emulsion process allows continuous formation of solid gel beads with high yields, eliminating the batch processing limitations of traditional encapsulation and gelling methods while preserving phase change functionality
3Manufacturing precision
If processing temperature is set based on linear relationship Y=0.6X+45 to the melting point of PCM, then homogenous solid gel beads are formed without viscoelastic liquid, but the process requires precise temperature control
Solution Approach 1:
The invention implements temperature control based on the linear relationship Y=0.6X+45, where the processing temperature is determined by the melting point of the PCM. This feedback mechanism ensures that the temperature is always set appropriately for the specific PCM being used, achieving homogenous solid gel beads while providing a clear guideline for temperature control system design
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 method enables the production of high-yield, homogenous solid gel beads that can be easily molded and packaged, providing effective thermal management with improved processing efficiency and cost-effectiveness compared to traditional PCM technologies.
Implementation Method 1
solid gel beads are formed in an oil-in-water emulsion with turbulent mixing in the water
Implementation Method 2
Many hydrocarbon PCMs operate by melting and freezing to take in and release energy to the surroundings
Implementation Method 3
Many hydrocarbon PCMs operate by melting and freezing to take in and release energy to the surroundings
Implementation Method 4
The solid gel beads are formed in an oil-in-water emulsion with turbulent mixing in the water
Data Source
AI summary
Solid gel beads formed from a gel product of a 5 carbon to 60 carbon alkane phase change material, 5 carbon to 60 carbon alkene phase change material, or a combination thereof and a styrene-based polymer are homogeneous, has an uneven exterior surface, and a major axis length in a range of 1000 μm to 100 mm. Methods for making the solid gel bead include providing water having a preselected temperature based on a linear relationship to the melting point of a phase change material composition, mixing the phase change material composition with the styrene-based polymer at or below the preselected temperature with stirring to form a pulp, and mixing the pulp into the water with turbulent mixing while maintaining the temperature of the mixture at the preselected temperature.