Processing of phase change materials by fused deposition modeling: Toward efficient thermal energy storage designs

Singh, Paramjot; Odukomaiya, Adewale; Smith, Matthew K.; Aday, Anastasia; Cui, Shuang; Mahvi, Allison

doi:10.1016/j.est.2022.105581

Processing of phase change materials by fused deposition modeling: Toward efficient thermal energy storage designs

Journal Article · Fri Sep 09 00:00:00 EDT 2022 · Journal of Energy Storage

DOI:https://doi.org/10.1016/j.est.2022.105581· OSTI ID:1898002

Singh, Paramjot ^[1]; ^[1]; Smith, Matthew K. ^[2]; Aday, Anastasia ^[1]; ^[3]; ^[1]

National Renewable Energy Laboratory (NREL), Golden, CO (United States)
TCPoly Inc., Atlanta, GA (United States)
National Renewable Energy Laboratory (NREL), Golden, CO (United States); University of Texas at Dallas, Richardson, TX (United States)

We report that recently, several efforts have emerged that employ additive manufacturing techniques to integrate phase change material (PCM) thermal energy storage into geometrically complex designs for advanced thermal management. In this work, we contribute to this emerging research by reporting on the production of a composite nylon-based filament for fused deposition modeling incorporating encapsulated PCMs for 3D printing heat sink geometries. Microencapsulated PCM (MEPCM) with a 6 degrees C transition temperature was selected as the material for thermal energy storage. This transition temperature was selected due to its suitability to provide thermal energy storage to target air-conditioning applications in buildings. In an attempt to improve the thermal conductivity of the composite, fine boron nitride fillers were added, although the effect on improvement was found to be negligible in the overall composite mixture. The nylon-MEPCM ratio in the filaments was optimized, and filaments containing up to 40 wt% MEPCM were successfully synthesized, which were found optimal for 3D printing complex heat sink and other geometries. Thermal and mechanical properties of the filaments were characterized, including latent heat of fusion, thermal conductivity, phase change temperature, tensile strength, and more. Thermal infrared imaging of heat sink geometries printed using the MEPCM filaments undergoing thermal discharging was also conducted. This work presents the most promising result to date in the open literature for a 3D-printed PCM composite in the combination of size, energy density, and geometric complexity of printed parts.

View Accepted Manuscript (DOE)

Research Organization:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Building Technologies Office

Grant/Contract Number:: AC36-08GO28308

OSTI ID:: 1898002

Report Number(s):: NREL/JA-5500-82022; MainId:82795; UUID:f96ed6c4-7722-4bbe-a67f-3344e425a489; MainAdminID:67777

Journal Information:: Journal of Energy Storage, Journal Name: Journal of Energy Storage Journal Issue: Part B Vol. 55; ISSN 2352-152X

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (34)

Extrusion 3D Printing of Polymeric Materials with Advanced Properties Jiang, Zhen; Diggle, Broden; Tan, Ming Li Advanced Science, Vol. 7, Issue 17 https://doi.org/10.1002/advs.202001379	journal	August 2020
Influence of interface interaction on the ultimate tensile properties of polymer composites Pukánszky, B. Composites, Vol. 21, Issue 3 https://doi.org/10.1016/0010-4361(90)90240-W	journal	May 1990
Phase separation and apparent phase dissolution during cure process of thermoset/thermoplastic blend Kim, Bong Sup; Chiba, Tsuneo; Inoue, Takashi Polymer, Vol. 36, Issue 1 https://doi.org/10.1016/0032-3861(95)90676-S	journal	January 1995
A review of phase change materials for vehicle component thermal buffering Jankowski, Nicholas R.; McCluskey, F. Patrick Applied Energy, Vol. 113 https://doi.org/10.1016/j.apenergy.2013.08.026	journal	January 2014
Design and performance evaluation of a dual-circuit thermal energy storage module for air conditioners Goyal, Anurag; Kozubal, Eric; Woods, Jason Applied Energy, Vol. 292 https://doi.org/10.1016/j.apenergy.2021.116843	journal	June 2021
Thermal conductivity enhancement of phase change materials using a graphite matrix Mills, Andrew; Farid, Mohammed; Selman, J. R. Applied Thermal Engineering, Vol. 26, Issue 14-15 https://doi.org/10.1016/j.applthermaleng.2005.11.022	journal	October 2006
Experimental characterization of heat transfer in an additively manufactured polymer heat exchanger Arie, Martinus A.; Shooshtari, Amir H.; Tiwari, Ratnesh Applied Thermal Engineering, Vol. 113 https://doi.org/10.1016/j.applthermaleng.2016.11.030	journal	February 2017
Thermal management of lithium-ion battery cells using 3D printed phase change composites Nofal, Malek; Al-Hallaj, Said; Pan, Yayue Applied Thermal Engineering, Vol. 171 https://doi.org/10.1016/j.applthermaleng.2020.115126	journal	May 2020
Fabrication and properties of novel polymer-metal composites using fused deposition modeling Ryder, Matthew A.; Lados, Diana A.; Iannacchione, Germano S. Composites Science and Technology, Vol. 158 https://doi.org/10.1016/j.compscitech.2018.01.049	journal	April 2018
Phase change materials and products for building applications: A state-of-the-art review and future research opportunities Kalnæs, Simen Edsjø; Jelle, Bjørn Petter Energy and Buildings, Vol. 94 https://doi.org/10.1016/j.enbuild.2015.02.023	journal	May 2015
Design and optimization of a hybrid air conditioning system with thermal energy storage using phase change composite Aljehani, Ahmed; Razack, Siddique Ali K.; Nitsche, Ludwig Energy Conversion and Management, Vol. 169 https://doi.org/10.1016/j.enconman.2018.05.040	journal	August 2018
Development of composite phase change cold storage material and its application in vaccine cold storage equipment Zhao, Yi; Zhang, Xuelai; Xu, Xiaofeng Journal of Energy Storage, Vol. 30 https://doi.org/10.1016/j.est.2020.101455	journal	August 2020
Experimental investigation of phase change materials fabricated using selective laser sintering additive manufacturing Nofal, Malek; Al-Hallaj, Said; Pan, Yayue Journal of Manufacturing Processes, Vol. 44 https://doi.org/10.1016/j.jmapro.2019.05.043	journal	August 2019
Thermal energy regulation with 3D printed polymer-phase change material composites Wei, Peiran; Cipriani, Ciera E.; Pentzer, Emily B. Matter, Vol. 4, Issue 6 https://doi.org/10.1016/j.matt.2021.03.019	journal	June 2021
Time scale matching of dynamically operated devices using composite thermal capacitors E. Green, Craig; G. Fedorov, Andrei; K. Joshi, Yogendra Microelectronics Journal, Vol. 45, Issue 8 https://doi.org/10.1016/j.mejo.2014.05.013	journal	August 2014
Effect of wood content in FDM filament on properties of 3D printed parts Kariz, Mirko; Sernek, Milan; Obućina, Murčo Materials Today Communications, Vol. 14 https://doi.org/10.1016/j.mtcomm.2017.12.016	journal	March 2018
3D printable thermoplastic polyurethane blends with thermal energy storage/release capabilities Rigotti, D.; Dorigato, A.; Pegoretti, A. Materials Today Communications, Vol. 15 https://doi.org/10.1016/j.mtcomm.2018.03.009	journal	June 2018
Thermal conductivity of polymer-based composites: Fundamentals and applications Chen, Hongyu; Ginzburg, Valeriy V.; Yang, Jian Progress in Polymer Science, Vol. 59 https://doi.org/10.1016/j.progpolymsci.2016.03.001	journal	August 2016
Materials used as PCM in thermal energy storage in buildings: A review Cabeza, L. F.; Castell, A.; Barreneche, C. Renewable and Sustainable Energy Reviews, Vol. 15, Issue 3, p. 1675-1695 https://doi.org/10.1016/j.rser.2010.11.018	journal	April 2011
A review of potential materials for thermal energy storage in building applications Tatsidjodoung, Parfait; Le Pierrès, Nolwenn; Luo, Lingai Renewable and Sustainable Energy Reviews, Vol. 18 https://doi.org/10.1016/j.rser.2012.10.025	journal	February 2013
Latent heat storage in building elements: A systematic review on properties and contextual performance factors Mavrigiannaki, A.; Ampatzi, E. Renewable and Sustainable Energy Reviews, Vol. 60 https://doi.org/10.1016/j.rser.2016.01.115	journal	July 2016
A review on phase change material (PCM) for sustainable passive cooling in building envelopes Akeiber, Hussein; Nejat, Payam; Majid, Muhd Zaimi Abd. Renewable and Sustainable Energy Reviews, Vol. 60 https://doi.org/10.1016/j.rser.2016.03.036	journal	July 2016
Advanced/hybrid thermal energy storage technology: material, cycle, system and perspective Ding, Zhixiong; Wu, Wei; Leung, Michael Renewable and Sustainable Energy Reviews, Vol. 145 https://doi.org/10.1016/j.rser.2021.111088	journal	July 2021
Polymer Encapsulation Strategy toward 3D Printable, Sustainable, and Reliable Form-Stable Phase Change Materials for Advanced Thermal Energy Storage Ma, Jiahao; Ma, Tian; Cheng, Jue ACS Applied Materials & Interfaces, Vol. 14, Issue 3 https://doi.org/10.1021/acsami.1c23972	journal	January 2022
Nanoencapsulation of phase change materials for advanced thermal energy storage systems Shchukina, E. M.; Graham, M.; Zheng, Z. Chemical Society Reviews, Vol. 47, Issue 11 https://doi.org/10.1039/C8CS00099A	journal	January 2018
Application and research progress of phase change materials in biomedical field Ma, Kunlin; Zhang, Xuelai; Ji, Jun Biomaterials Science, Vol. 9, Issue 17 https://doi.org/10.1039/D1BM00719J	journal	January 2021
Addressing energy storage needs at lower cost via on-site thermal energy storage in buildings Odukomaiya, Adewale; Woods, Jason; James, Nelson Energy & Environmental Science, Vol. 14, Issue 10 https://doi.org/10.1039/D1EE01992A	journal	January 2021
Phase-Change Materials/HDPE Composite Filament: A First Step Toward Use With 3D Printing for Thermal Management Applications Freeman, Thomas B.; Spitzer, David; Currier, Patrick N. Journal of Thermal Science and Engineering Applications, Vol. 11, Issue 5 https://doi.org/10.1115/1.4042592	journal	March 2019
Tailoring Surface Roughness Using Additive Manufacturing to Improve Internal Cooling Snyder, Jacob C.; Thole, Karen A. Journal of Turbomachinery, Vol. 142, Issue 7 https://doi.org/10.1115/1.4047380	journal	June 2020
Materials research and development needs to enable efficient and electrified buildings Cui, Shuang; Odukomaiya, Adewale; Vidal, Judith MRS Bulletin, Vol. 46, Issue 12 https://doi.org/10.1557/s43577-021-00241-x	journal	December 2021
Improving Performance of Cold-Chain Insulated Container with Phase Change Material: An Experimental Investigation Huang, Li; Piontek, Udo Applied Sciences, Vol. 7, Issue 12 https://doi.org/10.3390/app7121288	journal	December 2017
Inorganic Salt Hydrate for Thermal Energy Storage Xie, Ning; Huang, Zhaowen; Luo, Zigeng Applied Sciences, Vol. 7, Issue 12 https://doi.org/10.3390/app7121317	journal	December 2017
PCMs for Residential Building Applications: A Short Review Focused on Disadvantages and Proposals for Future Development Bland, Ashley; Khzouz, Martin; Statheros, Thomas Buildings, Vol. 7, Issue 3 https://doi.org/10.3390/buildings7030078	journal	August 2017
A 3D Printable Thermal Energy Storage Crystalline Gel Using Mask-Projection Stereolithography Mao, Yuchen; Miyazaki, Takuya; Sakai, Kohei Polymers, Vol. 10, Issue 10 https://doi.org/10.3390/polym10101117	journal	October 2018

Similar Records

Additive Manufacturing of Thermal Energy Storage Composites with Microencapsulated Phase Change Materials Supported in a Multi-Polymer Matrix

Conference · Wed Nov 13 23:00:00 EST 2024 · OSTI ID:2478102

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Journal Article · Tue Aug 19 20:00:00 EDT 2025 · Progress in Additive Manufacturing · OSTI ID:2587295

Fused filament fabrication of novel phase-change material functional composites

Journal Article · Tue Jan 12 19:00:00 EST 2021 · Additive Manufacturing · OSTI ID:1817443

Related Subjects

25 ENERGY STORAGE
composite filament
fused deposition modeling
phase change material
polymer heat exchanger
thermal energy storage

Processing of phase change materials by fused deposition modeling: Toward efficient thermal energy storage designs

Citation Formats

References (34)

Similar Records

Related Subjects