Enhanced latent thermal energy battery with additive manufacturing

The low thermal conductivity of Phase Change Materials (PCMs), such as paraffin waxes, hinders efficient latent heat storage, especially for rapid charging and discharging cycles. To address this issue, this study explores experimentally and numerically the use of metal additive manufacturing to create a latent heat storage system operating at medium temperatures (around 90°C). A 3D Cartesian metal lattice is manufactured through laser powder bed fusion to optimize heat conduction within the PCM. Experimental tests show impressive specific power densities (approximately 714 ± 17 W kg−1 during charging and 1310 ± 48 W kg−1 during discharging). Moreover, the device exhibits stability over multiple cycles. Finally, the validated finite-element model has the potential to provides a basis for general design guidelines to boost the system's performance further. Potential applications of this technology are highlighted in the automotive industry, where such systems could efficiently manage thermal energy, for instance, by capturing excess heat from an engine's cooling radiator to expedite the warm-up process during a cold start, which is a critical phase for reducing pollutant emissions.