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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

A Novel and Scalable Method for Microencapsulating Salt Hydrate Phase Change Materials in Core–Shell Fibers

Phase change materials (PCMs) are in high demand for applications such as thermal energy storage in buildings, electronics cooling, and thermal management of electric vehicle batteries and data centers. Among these materials, salt hydrate PCMs are particularly attractive due to their high thermal energy storage capacity and low cost. However, they suffer from two major issues: leakage in the melted phase and phase segregation during phase transitions. Microencapsulation is the primary process capable of addressing both of these challenges. However, there is no reliable or scalable method available for microencapsulating salt hydrate PCMs. As a result, the full potential of salt hydrates for building and data center applications has yet to be realized. In this work, we present an innovative method for the microencapsulation of salt hydrate PCMs using a co‐axial pushing technique. This process creates core–shell fibers, with the salt hydrate as the core and a polymer as the shell. Our approach demonstrates strong potential for scalable microencapsulation of salt hydrate PCMs. In conclusion, achieving scalability could enable their widespread use in applications such as data center cooling, battery thermal management, and building climate control.

Sharma, Jaswinder [Oak Ridge National Laboratory (↗
NASA NTRS1992

Microencapsulated PCM slurries for heat transfer and energy storage in spacecraft systems

The technical feasibility for providing significantly enhanced heat transport and storage as well as improved thermal control has been investigated during several Small Business Innovative Research (SBIR) programs for NASA, the United States Air Force (USAF), and the Strategic Defense Initiative Organization (SDIO) using microencapsulated phase change materials (PCMs) in both aqueous and nonaqueous two-component slurries. In the program for SDIO, novel two-component coolant fluids were prepared and successfully tested at both low (300 K) and intermediate temperatures (460 to 700 K). The two-component fluid slurries of microencapsulated PCMs included organic particles in aqueous and nonaqueous liquids, as well as microencapsulated metals that potentially could be carried by liquid metals or used as powdered heat sinks. Simulation and experimental studies showed that such active cooling systems could be designed and operated with enhancements of heat capacity that exceeded 10 times or 1000 percent that for the base fluid along with significant enhancement in the fluid's heat capacity. Furthermore, this enhancement provided essentially isothermal conditions throughout the pumped primary coolant fluid loop. The results suggest that together with much higher fluid thermal capacity, greater uniformity of temperature is achievable with such fluids, and that significant reductions in pumping power, system size, and system mass are also possible.

Colvin, David P.↗
NASA NTRS2006

Microencapsulation system and method

A microencapsulation apparatus is provided which is configured to form co-axial multi-lamellar microcapsules from materials discharged from first and second microsphere dispensers of the apparatus. A method of fabricating and processing microcapsules is also provided which includes forming distinct droplets comprising one or more materials and introducing the droplets directly into a solution bath to form a membrane around the droplets such that a plurality of microcapsules are formed. A microencapsulation system is provided which includes a microcapsule production unit, a fluidized passage for washing and harvesting microcapsules dispensed from the microcapsule production unit and a flow sensor for sizing and counting the microcapsules. In some embodiments, the microencapsulation system may further include a controller configured to simultaneously operate the microcapsule production unit, fluidized passage and flow sensor to process the microcapsules in a continuous manner.

Morrison, Dennis R.↗
NASA NTRS2009

Microencapsulation system and method

A microencapsulation apparatus is provided which is configured to form co-axial multi-lamellar microcapsules from materials discharged from first and second microsphere dispensers of the apparatus. A method of fabricating and processing microcapsules is also provided which includes forming distinct droplets comprising one or more materials and introducing the droplets directly into a solution bath to form a membrane around the droplets such that a plurality of microcapsules are formed. A microencapsulation system is provided which includes a microcapsule production unit, a fluidized passage for washing and harvesting microcapsules dispensed from the microcapsule production unit and a flow sensor for sizing and counting the microcapsules. In some embodiments, the microencapsulation system may further include a controller configured to simultaneously operate the microcapsule production unit, fluidized passage and flow sensor to process the microcapsules in a continuous manner.

Morrison, Dennis R.↗
NASA NTRS2005

Low-Shear Microencapsulation and Electrostatic Coating

A report presents additional information on the topic of a microencapsulation electrostatic processing system. Information in the report includes micrographs of some microcapsules, a set of diagrams that schematically depict the steps of an encapsulation process, and brief descriptions of (1) alternative versions of the present encapsulation processes, (2) advantages of the present microencapsulation processes over prior microencapsulation processes, and (3) unique and advantageous features of microcapsules produced by the present processes.

Morrison, Dennis R.↗
NASA NTRS2014

Recent Developments on Microencapsulation for Autonomous Corrosion Protection

This work concerns recent progress in the development of a multifunctional smart coating based on microencapsulation for the autonomous control of corrosion. Microencapsulation allows the incorporation of desired corrosion control functionalities, such as early corrosion detection and inhibition through corrosion controlled release of corrosion indicators and inhibitors, as well as self-healing agent release when mechanical damage occurs.While proof-of-concept results have been reported previously, more recent efforts have been concentrated in technical developments to improve coating compatibility, synthesis procedure scalability, as well as fine tuning the release property of encapsulated active agents.

Corrosion↗
NASA NTRS2015

Microencapsulation Technologies for Corrosion Protective Coating Applications

Microencapsulation technologies for functional smart Coatings for autonomous corrosion control have been a research area of strong emphasis during the last decade. This work concerns the development of pH sensitive micro-containers (microparticles and microcapsules) for autonomous corrosion control. This paper presents an overview of the state-of-the-art in the field of microencapsulation for corrosion control applications, as well as the technical details of the pH sensitive microcontainer approach, such as selection criteria for corrosion indicators and corrosion inhibitors; the development and optimization of encapsulation methods; function evaluation before and after incorporation of the microcontainers into coatings; and further optimization to improve coating compatibility and performance.

Microencapsulation↗
NASA NTRS2006

Pulse-Flow Microencapsulation System

The pulse-flow microencapsulation system (PFMS) is an automated system that continuously produces a stream of liquid-filled microcapsules for delivery of therapeutic agents to target tissues. Prior microencapsulation systems have relied on batch processes that involve transfer of batches between different apparatuses for different stages of production followed by sampling for acquisition of quality-control data, including measurements of size. In contrast, the PFMS is a single, microprocessor-controlled system that performs all processing steps, including acquisition of quality-control data. The quality-control data can be used as real-time feedback to ensure the production of large quantities of uniform microcapsules.

Morrison, Dennis R.↗
NASA NTRS2011

Microencapsulation of Corrosion Indicators for Smart Coatings

A multifunctional smart coating for the autonomous detection, indication, and control of corrosion is been developed based on microencapsulation technology. This paper summarizes the development, optimization, and testing of microcapsules specifically designed for early detection and indication of corrosion when incorporated into a smart coating. Results from experiments designed to test the ability of the microcapsules to detect and indicate corrosion, when blended into several paint systems, show that these experimental coatings generate a color change, indicative of spot specific corrosion events, that can be observed with the naked eye within hours rather than the hundreds of hours or months typical of the standard accelerated corrosion test protocols.. Key words: smart coating, corrosion detection, microencapsulation, microcapsule, pH-sensitive microcapsule, corrosion indicator, corrosion sensing paint

Li, Wenyan↗
DOE OSTI2025

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Here, the present study examines the thermal energy storage (TES) effectiveness and printability of microencapsulated phase-change material (MEPCM) combined with thermoplastic polyurethane (TPU) for fused filament fabrication (FFF). Two formulations were assessed: 24D MEPCM, which changes phase at 24 ° C, compounded with TPU pellets and 43D MEPCM, which changes phase at 43 ° C, integrated with TPU powder. These combinations are designed to evaluate the effectiveness of the form of the TPU (pellets versus powder) in the FFF process. The investigation includes a comprehensive analysis of thermal characteristics, encompassing phase-change temperature, latent heat of fusion, thermal conductivity, and thermal decomposition, which are assessed through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Additionally, mechanical properties, including stress-strain behavior, are examined to evaluate material suitability for TES applications, while microstructural visualization is used to provide deeper insights into material performance, structural integrity, and the quality of printed components. The 24D MEPCM and TPU pellets formulation experienced a significant loss of approximately 39.6% of PCM during filament extrusion and printing, resulting in a reduced effective latent heat. Therefore, further characterization of the pellet formulation was discontinued due to excessive leakage. In contrast, the 43D MEPCM and TPU powder formulation demonstrated minimal PCM loss, with the 60 wt.% composition achieving an effective latent heat of 132 J/g. This value represents the highest effective latent heat currently documented in the literature for PCM-polymer-composite materials produced using an FFF-based additive manufacturing process.

25 ENERGY STORAGE↗
DOE OSTI2025

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

Additive manufacturing (AM) techniques to directly integrate phase change materials (PCMs) are of interest for efficient thermal energy storage (TES) architectures. Complex, high surface-to-volume ratio composites embedded with PCM can improve thermal management with reduced material waste for customizable device fabrication. Reducing feature sizes of TES-integrated heat exchangers using AM can increase heat transfer without thermal conductivity enhancement. Here, composite AM materials containing 60 wt% microencapsulated phase change materials (MEPCM) are fabricated using off-the-shelf printers at common speeds and resolutions. High MEPCM loading in filaments is achieved with powder extrusion using two polymers, thermoplastic-polyurethane (TPU) and polycaprolactone (PCL), that mediate flexibility and rigidity for effective extrusion and printing without filament fracture or buckling. Furthermore, with PCL and TPU at 20 wt% each and 60 wt% MEPCM (P 20 T 20 M 60 ), smooth, form-stable filaments are consistently printed. Powder-based extrusion displays negligible damaging effects on the MEPCM. Printed P 20 T 20 M 60 demonstrates 105 J/g of energy storage with no degradation through 250 thermal cycles, within 5% of the theoretical storage enthalpy. Combining PCL/TPU shows good interfacial adhesion between print layers and produces high surface area objects, like 15% gyroids, and dense, 100% infilled pucks. Prints are also scalable to a 900 cm 3 honeycomb heat exchanger with an estimated 9 Wh energy storage.

25 ENERGY STORAGE↗
DOE OSTI2025

A Novel Approach for Microencapsulating Salt Hydrate-Based Phase Change Materials

Energy storage technologies, particularly those utilizing phase change materials (PCMs), have gained attention for their high energy density and efficient thermal management. PCMs, which store energy through solid-liquid phase transitions, can efficiently capture and release thermal energy, but face the challenge of leakage during the phase change process. Inorganic PCMs, such as salt hydrates, offer high energy storage capacity, but are difficult to encapsulate due to their corrosive nature. Conventional encapsulation techniques for inorganic PCMs are limited, particularly for scalable applications. In this work, we present an innovative method for the encapsulation of salt hydrate-based inorganic PCMs (CaCl 2 ·6H 2 O) using co-axial electrospinning. The process involves the creation of co-axial fibers, with salt hydrate as the core and polymer (e.g., PVP) as the outer shell, effectively preventing leakage and improving the stability of the PCM. This approach demonstrates the potential for scalable microencapsulation of inorganic PCMs, marking the first report of using co-axial electrospinning for this purpose. This novel technique could contribute to enhancing the performance and applicability of PCMs in thermal energy storage systems and other energy efficiency applications.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Enhanced heat transport in environmental systems using microencapsulated phase change materials

A methodology for enhanced heat transport and storage that uses a new two-component fluid mixture consisting of a microencapsulated phase change material (microPCM) for enhanced latent heat transport is outlined. SBIR investigations for NASA, USAF, SDIO, and NSF since 1983 have demonstrated the ability of the two-component microPCM coolants to provide enhancements in heat transport up to 40 times over that of the carrier fluid alone, enhancements of 50 to 100 percent in the heat transfer coefficient, practically isothermal operation when the coolant flow is circulated in an optimal manner, and significant reductions in pump work.

Colvin, D. P.↗
NASA NTRS2001

Microencapsulation and Electrostatic Processing Device

A microencapsulation and electrostatic processing (MEP) device is provided for forming microcapsules. In one embodiment, the device comprises a chamber having a filter which separates a first region in the chamber from a second region in the chamber. An aqueous solution is introduced into the first region through an inlet port, and a hydrocarbon/ polymer solution is introduced into the second region through another inlet port. The filter acts to stabilize the interface and suppress mixing between the two immiscible solutions as they are being introduced into their respective regions. After the solutions have been introduced and have become quiescent, the interface is gently separated from the filter. At this point, spontaneous formation of microcapsules at the interface may begin to occur, or some fluid motion may be provided to induce microcapsule formation. In any case, the fluid shear force at the interface is limited to less than 100 dynes/sq cm. This low-shear approach to microcapsule formation yields microcapsules with good sphericity and desirable size distribution. The MEP device is also capable of downstream processing of microcapsules, including rinsing, re-suspension in tertiary fluids, electrostatic deposition of ancillary coatings, and free-fluid electrophoretic separation of charged microcapsules.

Morrison, Dennis R.↗
NASA NTRS2011

Microencapsulation of Self Healing Agents for Corrosion Control Coatings

Corrosion, the environmentally induced degradation of materials, is a very costly problem that has a major impact on the global economy. Results from a 2-year breakthrough study released in 2002 by the U.S. Federal Highway Administration (FHWA) showed that the total annual estimated direct cost associated with metallic corrosion in nearly every U.S. industry sector was a staggering $276 billion, approximately 3.1% of the nation's Gross Domestic Product (GOP). Corrosion protective coatings are widely used to protect metallic structures from the detrimental effects of corrosion but their effectiveness can be seriously compromised by mechanical damage, such as a scratch, that exposes the metallic substrate. The incorporation of a self healing mechanism into a corrosion control coating would have the potential to significantly increase its effectiveness and useful lifetime. This paper describes work performed to incorporate a number of microcapsule-based self healing systems into corrosion control coatings. The work includes the preparation and evaluation of self-healing systems based on curable epoxy, acrylate, and siloxane resins, as well as, microencapsulated systems based on passive, solvent born, healing agent delivery. The synthesis and optimization of microcapsule-based self healing systems for thin coating (less than 100 micron) will be presented.

Jolley, S. T.↗
NASA NTRS2011

Microencapsulation Technology for Corrosion Mitigation by Smart Coatings

A multifunctional, smart coating for the autonomous control of corrosion is being developed based on micro-encapsulation technology. Corrosion indicators as well as corrosion inhibitors have been incorporated into microcapsules, blended into several paint systems, and tested for corrosion detection and protection effectiveness. This paper summarizes the development, optimization, and testing of microcapsules specifically designed to be incorporated into a smart coating that will deliver corrosion inhibitors to mitigate corrosion autonomously. Key words: smart coating, corrosion inhibition, microencapsulation, microcapsule, pH sensitive microcapsule, corrosion inhibitor, corrosion protection pain

Buhrow, Jerry↗