Encapsulation of thermal energy storage media

Abstract

In one embodiment, a phase change material is encapsulated by forming a phase change material pellet, coating the pellet with flexible material, heating the coated pellet to melt the phase change material, wherein the phase change materials expands and air within the pellet diffuses out through the flexible material, and cooling the coated pellet to solidify the phase change material.

1 - 29 . (canceled) 
     
     
         30 . A phase change material pellet comprising:
 a phase change material pellet comprising an internal void;   a flexible, nonreactive, permeable polymer coating the phase change material pellet, the polymer comprising an outer surface;   a first metal layer that has been applied to the polymer outer surface to render it electrically conductive, the first metal layer consisting essentially of metal; and   
       a second metal layer that has been deposited on the first metal layer. 
     
     
         31 . The phase change material pellet of  claim 30 , wherein the first metal layer is selected from the group consisting of nickel, palladium, aluminum, copper, alloys thereof, zinc, zinc-iron, and zinc-nickel alloy. 
     
     
         32 . The phase change material pellet of  claim 30 , wherein the polymer surface comprises a hydrophobic polymer. 
     
     
         33 . The phase change material pellet of  claim 30 , wherein the polymer surface is made of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), polyimide, polyvinylidene fluoride (PVDF), or a mixture thereof. 
     
     
         34 . The phase change material pellet of  claim 30 , wherein the first metal layer comprises a plurality of small metal particles that have been applied to the polymer surface. 
     
     
         35 . The phase change material pellet of  claim 34 , wherein the small metal particles are approximately 20 to 30 microns in diameter. 
     
     
         36 . The phase change material pellet of  claim 34 , wherein the small metal particles are made of a metal selected from the group consisting of nickel, palladium, aluminum, copper, zinc, alloys of any of the foregoing, zinc-iron, and zinc-nickel alloy. 
     
     
         37 . The phase change material pellet of  claim 34 , wherein the small metal particles have been applied to the polymer surface using a powder coating technique. 
     
     
         38 . The phase change material pellet of  claim 37 , wherein the powder coating technique is selected from the group consisting of rubbing, jar milling, or rolling. 
     
     
         39 . The phase change material pellet of  claim 30 , wherein the second metal layer has been deposited using an electroless deposition technique followed by an electroplating technique. 
     
     
         40 . The phase change material pellet of  claim 30 , wherein the second metal layer is made of copper, nickel, tin, palladium, cobalt, silver, zinc or an alloy of any of the foregoing. 
     
     
         41 . The phase change material pellet of  claim 30 , wherein the second metal layer is approximately 1 micron to 2 millimeters thick. 
     
     
         42 . A metal-plated thermal storage object comprising:
 a phase change material core comprising a flexible, nonreactive, permeable polymer surface and an interior void;   a first metal layer directly contacting the polymer surface, the first metal layer being selected from the group consisting of nickel, palladium, aluminum, copper, alloys of the foregoing, zinc, zinc-iron, and zinc-nickel alloy; and   a second metal layer directly contacting the first metal layer.   
     
     
         43 . The metal-plated thermal storage object of  claim 42 , wherein the phase change material core and/or the metal-plated thermal storage object are spherical. 
     
     
         44 . The metal-plated thermal storage object of  claim 42 , wherein the phase change material core is or comprises an organic or inorganic salt, a salt mixture, and/or a salt eutectic. 
     
     
         45 . The metal-plated thermal storage object of  claim 42 , wherein the phase change material core has a diameter of approximately 1 to 2 inches. 
     
     
         46 . The metal-plated thermal storage object of  claim 42 , wherein the first metal layer is composed of nickel, palladium, aluminum, copper, or an alloy thereof. 
     
     
         47 . The metal-plated thermal storage object of  claim 42 , wherein the first metal layer and/or the second metal layer has a thickness of between 1 micron and 2 millimeters. 
     
     
         48 . The metal-plated thermal storage object of  claim 42 , wherein the second metal layer is composed of copper, nickel, tin, palladium, cobalt, silver, zinc or an alloy thereof. 
     
     
         49 . The polymer-coated phase change material pellet of  claim 30 , wherein the pellet has a diameter of approximately 1 to 2 inches.