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

Conference · Thu Nov 14 04:00:00 EST 2024

OSTI ID:2478102

Foster, Kyle E. O.; Freeman, Thomas B.; Lizier-Zmudzinski, Irena; Dudt, Susan; Morgan, Karl B.; Boetcher, Sandra K. S.; Odukomaiya, Adewale

Advanced manufacturing techniques, such as additive manufacturing (AM), that can directly integrate phase change materials (PCMs) have garnered interest in recent years due to their potential for development of highly efficient thermal energy storage architectures. Complex, high surface area geometries embedded with PCMs that are only feasible with AM can improve thermal management with reduced material waste. Our work focuses on developing composite filaments with microencapsulated phase change materials (MEPCM) bound within a single or dual polymer matrix that can be processed through standard filament extruders and additively manufactured using off-the-shelf 3D printers. Polymer powders, rather than polymer pellets, were key to homogenously mixed filaments achieving high MEPCM loadings with no deterioration in thermal energy storage (TES) capability during extrusion. Composite filaments contain upwards of 60 wt% MEPCM and were printed without loss in feature resolution, print speed, or layer adhesion. Storage enthalpies of printed composites range from 100 - 130 kJ/kg, which were within 5% of the theoretical enthalpy based on weight fraction of MEPCM and maintained enthalpies within 1% over 500 thermal cycles. We can reliably manufacture low density, high surface area structures like 15% gyroid infill, along with dense, compact pucks at a 100% concentric infill. Prints were also scalable to a 900 cm3 honeycomb infill heat exchanger model that has an estimated energy storage capacity of 9 Wh.

• 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. Building Technologies Office; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing and Materials Technologies Office (AMMTO)
• DOE Contract Number: AC36-08GO28308
• OSTI ID: 2478102
• Report Number(s): NREL/PR-5500-90911; MainId:92689; UUID:3f4b02f4-85f8-45d4-a441-65fe5b91a601; MainAdminId:74287
• Country of Publication: United States
• Language: English

Related Subjects

3D printing
ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION,SOLAR ENERGY
additive manufacturing
advanced manufacturing
composites
phase change materials
thermal energy storage materials
thermal management