Fabrication and analysis of small-scale thermal energy storage with conductivity enhancement

The operation and useful operating parameters of a small-scale Thermal Energy Storage (TES) device that collects and stores heat in a Phase Change Material (PCM) is explored. The PCM utilized is an icosane wax. A physical device is constructed on the millimeter scale to examine specific effects of low-cost thermal conductivity enhancements that include copper foams and other metallic inserts. Numerical methods are utilized to establish useful operating range of small-scale TES devices in general, and the limits of thermal conductivity enhancement on thermoelectric operation specifically. Specific attention is paid to the manufacturability of the various constructs as well as the resulting thermal conductivity enhancement. A maximum thermal conductivity of 3.8 W/m K is achieved in experimental testing via copper foam enhancement. A simplified copper matrix achieves conductivity of 3.7 W/m K and allows significantly reduced fabrication effort. These results compare favorably to baseline wax conductivity of .5 W/m K. Power absorption is recorded of about 900 W/m2. Modeling reveals diminishing returns beyond 4–6 W/m K for devices on this scale. Results show the system capable of extending thermoelectric operation several minutes through the use of thermal energy storage techniques within the effective conductivity ranges.