Flexible phase change material composite for thermal management systems
A thermal management composite, comprising a phase change material within a carbon or graphite matrix. The matrix is coated with a polymer coating to improve flexibility. The matrix can be a molded carbon or graphite material or a carbon or graphite cloth.
1. A thermal management composite, comprising:
a carbon or graphite matrix including a phase change material; and
an elastomeric binder material impregnated throughout the matrix; and
an elastomeric polymer coating on at least one outer surface of the composite.
2. The composite of claim 1 , wherein the matrix comprises woven or nonwoven carbon or graphite fibers.
3. The composite of claim 2 , wherein the matrix comprises phase change material disposed in voids between the fibers or bundles of the fibers, and a polymer coating on at least one surface of the matrix, and wherein the matrix can be wrapped around one or more battery cells.
4. The composite of claim 3 , wherein the matrix comprises a molded composite.
5. The composite of claim 4 , wherein the phase change material comprises a microencapsulated wax.
6. The composite of claim 4 , further comprising a polymer coating on each of a top side and a bottom side of the matrix.
7. The composite of claim 1 , wherein the matrix comprises a molded composite.
8. The composite of claim 7 , wherein the polymer coating comprises graphite dispersed therein.
9. The composite of claim 1 , wherein the phase change material comprises a wax.
10. The composite of claim 1 , further comprising a microencapsulated phase change material.
11. The composite of claim 1 , carbon or graphite matrix comprises a molded carbon or graphite powder.
12. A method of making a thermal management composite, the method comprising:
impregnating a carbon or graphite matrix with a phase change material and an elastomer binder material; and
coating at least one side of the impregnated matrix with an elastomeric polymer coating.
13. The method of claim 12 , wherein the matrix comprises woven or nonwoven carbon or graphite fibers.
14. The method of claim 12 , further comprising:
mixing the phase change material and the elastomer binder material with a carbon or graphite material to obtain a matrix mixture;
molding the matrix mixture into the impregnated matrix of the carbon or graphite matrix impregnated with the phase change material and the elastomer binder material; and
coating the at least one side of the impregnated matrix with the elastomeric polymer coating.
15. The method of claim 12 , further comprising dip coating or spray coating the matrix with the phase change material and/or the polymer coating.
16. The method of claim 12 , wherein the coating comprises a coating polymer material mixed with carbon or graphite powder or fibers.
17. The method of claim 14 , further comprising dip coating or spray coating the matrix with the phase change material and/or the polymer coating.
18. A thermal management composite, comprising:
a matrix of carbon or graphite fibers or bundles of the fibers with a plurality of voids between the fibers or the bundles of the fibers within the matrix, the matrix having an outer surface;
a phase change material dispersed throughout the matrix within the voids;
an elastomeric binder material dispersed throughout the matrix within the voids; and
an elastomeric polymer coating on the outer surface of the composite.