Polymeric composites having enhanced reversible thermal properties and methods of forming thereof

Abstract

Polymeric composites and methods of manufacturing polymeric composites are described. In one embodiment, a set of microcapsules containing a phase change material are mixed with a dispersing polymeric material to form a first blend. The dispersing polymeric material has a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C. The first blend is processed to form a polymeric composite. The polymeric composite can be formed in a variety of shapes, such as pellets, fibers, flakes, sheets, films, rods, and so forth. The polymeric composite can be used as is or incorporated in various articles where a thermal regulating property is desired.

1 . A method of manufacturing a polymeric composite, comprising: 
 mixing a plurality of microcapsules containing a phase change material with a dispersing polymeric material to form a first blend, the dispersing polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; and    processing the first blend to form the polymeric composite.    
     
     
         2 . The method of  claim 1 , wherein the phase change material has a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.  
     
     
         3 . The method of  claim 1 , wherein the phase change material includes a paraffinic hydrocarbon having from 16 to 22 carbon atoms.  
     
     
         4 . The method of  claim 1 , wherein the plurality of microcapsules are coated with water to form a wet cake.  
     
     
         5 . The method of  claim 4 , further comprising heating the first blend until the first blend includes less than 1 percent by weight of water.  
     
     
         6 . The method of  claim 1 , wherein the latent heat of the dispersing polymeric material is at least 60 J/g.  
     
     
         7 . The method of  claim 1 , wherein the transition temperature of the dispersing polymeric material is in the range of 22° C. to 40° C.  
     
     
         8 . The method of  claim 1 , wherein the dispersing polymeric material includes a polymer selected from the group consisting of polyethylene, polyethylene glycol, polyethylene oxide, polypropylene, polypropylene glycol, polytetramethylene glycol, polypropylene malonate, polyneopentyl glycol sebacate, polypentane glutarate, polyvinyl myristate, polyvinyl stearate, polyvinyl laurate, polyhexadecyl methacrylate, polyoctadecyl methacrylate, and polyesters.  
     
     
         9 . The method of  claim 1 , wherein the mixing the plurality of microcapsules with the dispersing polymeric material includes: 
 melting the dispersing polymeric material to form a melt; and    dispersing the plurality of microcapsules in the melt to form the first blend.    
     
     
         10 . The method of  claim 9 , wherein the dispersing polymeric material has an affinity for the plurality of microcapsules to facilitate dispersing the plurality of microcapsules in the melt.  
     
     
         11 . The method of  claim 1 , wherein the processing the first blend to form the polymeric composite includes: 
 processing the first blend to form granules;    mixing the granules with a matrix polymeric material to form a second blend; and    processing the second blend to form the polymeric composite.    
     
     
         12 . The method of  claim 11 , wherein the processing the first blend to form the granules includes: 
 cooling the first blend to form a solid; and    granulating the solid to form the granules.    
     
     
         13 . The method of  claim 11 , wherein the matrix polymeric material includes a high molecular weight polymer.  
     
     
         14 . The method of  claim 11 , wherein the mixing the granules with the matrix polymeric material includes: 
 melting the matrix polymeric material to form a melt; and    dispersing the granules in the melt to form the second blend.    
     
     
         15 . The method of  claim 14 , wherein the matrix polymeric material has an affinity for the dispersing polymeric material to facilitate dispersing the granules in the melt.  
     
     
         16 . The method of  claim 11 , wherein the mixing the granules with the matrix polymeric material includes: 
 dry blending the granules with the matrix polymeric material to form a dry blend; heating the dry blend to form the second blend.    
     
     
         17 . The method of  claim 11 , wherein the polymeric composite is formed as pellets, and the processing the second blend includes: 
 cooling the second blend to form a solid; and    granulating the solid to form the pellets.    
     
     
         18 . A method of manufacturing a polymeric composite, comprising: 
 melting a first temperature regulating material to form a first melt;    dispersing a second temperature regulating material in the first melt to form a first blend;    processing the first blend to form granules;    melting a matrix polymeric material to form a second melt;    dispersing the granules in the second melt to form a second blend; and    processing the second blend to form the polymeric composite.    
     
     
         19 . The method of  claim 18 , wherein the first temperature regulating material includes a polymeric phase change material having a latent heat of at least 50 J/g and a transition temperature in the range of 10° C. to 50° C.  
     
     
         20 . The method of  claim 18 , wherein the second temperature regulating material includes a plurality of microcapsules containing a phase change material having a latent heat of at least 50 J/g and a transition temperature in the range of 10° C. to 50° C.  
     
     
         21 . The method of  claim 20 , wherein the first temperature regulating material includes a polymer having an affinity for the plurality of microcapsules.  
     
     
         22 . The method of  claim 18 , wherein the processing the first blend includes: 
 extruding the first blend into a thread; and    granulating the thread to form the granules.    
     
     
         23 . The method of  claim 18 , wherein the matrix polymeric material includes a polymer having an affinity for the first temperature regulating material.  
     
     
         24 . The method of  claim 18 , wherein the matrix polymeric material includes a polymer selected from the group consisting of polyamides, polyamines, polyimides, polyacrylics, polycarbonates, polydienes, polyepoxides, polyesters, polyethers, polyflourocarbons, formaldehyde polymers, natural polymers, polyolefins, polyphenylenes, silicon containing polymers, polyurethanes, polyvinyls, polyacetals, polyarylates, and mixtures thereof.  
     
     
         25 . The method of  claim 18 , wherein the polymeric composite is formed as pellets, and the processing the second blend includes: 
 extruding the second blend into a thread; and granulating the thread to form the pellets.    
     
     
         26 . A method of manufacturing a polymeric composite, comprising: 
 melting a first polymeric material to form a first melt, the first polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.;    dispersing a temperature regulating material in the first melt to form a first blend, the temperature regulating material including a phase change material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.;    mixing the first blend with a second polymeric material to form a second blend; and    processing the second blend to form the polymeric composite.    
     
     
         27 . The method of  claim 26 , wherein the first polymeric material corresponds to a dispersing polymeric material.  
     
     
         28 . The method of  claim 26 , wherein the temperature regulating material further includes a containment structure that contains the phase change material.  
     
     
         29 . The method of  claim 26 , wherein the first polymeric material and the second polymeric material are different.  
     
     
         30 . The method of  claim 26 , wherein the second polymeric material corresponds to a matrix polymeric material.  
     
     
         31 . The method of  claim 26 , wherein the mixing the first blend with the second polymeric material includes: 
 melting the second polymeric material to form a second melt; and    mixing the first blend with the second melt to form the second blend.    
     
     
         32 . The method of  claim 26 , wherein the polymeric composite is formed as pellets, and the processing the second blend includes extruding the second blend to form the pellets.  
     
     
         33 . A polymeric composite, comprising: 
 a polymeric material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.; and    a plurality of microcapsules dispersed in the polymeric material, the plurality of microcapsules containing a phase change material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 50° C.    
     
     
         34 . The polymeric composite of  claim 33 , wherein the latent heat of the polymeric material is at least 60 J/g.  
     
     
         35 . The polymeric composite of  claim 33 , wherein the transition temperature of the polymeric material is in the range of 22° C. to 40° C.  
     
     
         36 . The polymeric composite of  claim 33 , wherein the polymeric material includes a polymer selected from the group consisting of polyethylene glycol, polyethylene oxide, polytetramethylene glycol, and polyesters.  
     
     
         37 . The polymeric composite of  claim 33 , wherein the phase change material includes a paraffinic hydrocarbon having from 16 to 22 carbon atoms.  
     
     
         38 . The polymeric composite of  claim 33 , wherein the polymeric composite includes from 10 percent to 30 percent by weight of the microcapsules containing the phase change material.  
     
     
         39 . The polymeric composite of  claim 33 , wherein the polymeric composite includes from 15 percent to 25 percent by weight of the microcapsules containing the phase change material.  
     
     
         40 . A polymeric composite, comprising: 
 a blend of a polymeric material and a non-encapsulated phase change material, the polymeric material having a partial affinity for the non-encapsulated phase change material, such that the non-encapsulated phase change material forms a plurality of domains dispersed in the polymeric material, the non-encapsulated phase change material having a latent heat of at least 60 J/g and a transition temperature in the range of 10° C. to 50° C.    
     
     
         41 . The polymeric composite of  claim 40 , wherein the polymeric material includes a polymer selected from the group consisting of polyolefins and copolymers of polyolefins.  
     
     
         42 . The polymeric composite of  claim 40 , wherein the non-encapsulated phase change material includes a paraffinic hydrocarbon having from 16 to 22 carbon atoms.