Thermal mangagement foam
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Solution Overview
Problem
The existing methods for producing polyurethane foam with phase change materials (PCMs) face challenges in maintaining the quality of the foam due to heat absorption by PCMs during the foaming process, which can interfere with the foaming process and result in decreased thermal energy storage capacity and handling issues with high PCM content.
Innovation Solution
A method involving preheating the PCM and polyol above the melting point but below the boiling point, mixing them with a low viscosity fluid, and controlling the isocyanate to polyol ratio to form a homogenous second mass with a PCM content of less than 60% by mass, ensuring the reaction heat is retained and viscosity is managed for improved processing and thermal energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If PCM content is increased to enhance thermal energy storage capacity, then thermal energy storage capacity is improved, but foam quality and handling properties deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the PCM during the foaming process. Specifically, the PCM is heated to a temperature above its melting point (typically 40-60°C) before and during the foaming step. This temperature parameter change prevents the PCM from absorbing reaction heat during foaming, thereby maintaining foam quality while enabling higher PCM content (up to 60% by mass) for enhanced thermal energy storage capacity.
2Use of energy by moving object
If PCM content is increased to achieve higher thermal energy storage, then thermal energy storage is improved, but processing difficulty increases
Solution Approach 1:
The patent applies preliminary action by preheating the PCM to a temperature above its melting point before the foaming process begins. This preliminary heating step ensures that the PCM is in a liquid state and will not absorb heat during the exothermic foaming reaction. By performing this preparatory action, the patent enables easier processing of high-PCM-content formulations (up to 60% by mass) while maintaining high thermal energy storage capacity.
3Use of energy by moving object
If reaction heat is absorbed by PCM during foaming, then thermal energy storage is enhanced, but foaming process quality deteriorates
Solution Approach 1:
The patent applies preliminary anti-action by preheating the PCM above its melting point before the foaming process. This preliminary action counteracts the potential harmful effect of heat absorption during foaming. By ensuring the PCM starts at a temperature above its melting point, the patent prevents the PCM from absorbing reaction heat that would otherwise interfere with the foaming process, thereby maintaining manufacturing precision while preserving thermal energy storage enhancement.
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 enhances the quality and consistency of the polyurethane foam by reducing heat absorption during foaming, facilitating easier processing, and achieving higher thermal energy storage without compromising the foam's quality or handling difficulties.
Implementation Method 1
PCMs make use of the heat effect by absorbing thermal energy when the surrounding temperature is higher than the melting point of the PCM, and releasing thermal energy when the surrounding temperature is lower than the melting point of the PCM
Implementation Method 2
PCMs typically have a defined melting point that enables the use of the energy of the latent heat absorbed or released during the phase change (between solid and liquid) for thermal energy storage
Implementation Method 3
Conducting the foaming step of the method at a temperature above the melting point(s) of the PCM(s) allows the reaction heat (of polyol and isocyanate) to be retained in the foaming process
Data Source
Figure 1
Figure 2A~3B
Figure 4~5B
AI summary
A method of producing a plastic material, and a product (30; 40; 50; 60) comprising such a material, the method comprising: forming a homogenous first mass by mixing (200) polyol and at least one phase change material (PCM) in powder or slurry form; and producing a homogenous second mass by admixing (22) isocyanate to the homogenous first mass, while a temperature of the PCM is above the melting point of the PCM and below the boiling point of the PCM. The homogenous second mass has a PCM content of less than 60% by mass.