PCM Composite Cold Plate

Thermal storage devices based on phase-change materials (PCMs) have traditionally been box-like structures with robust walls and PCM volume fractions <60%. The usefulness of such devices in aerospace thermal control applications is limited because of the bulkiness and weight. A far more useful configuration would be thin (1-5 mm) PCM plates that can be readily integrated into electronic racks, focal planes, panels for radar and photovoltaic arrays, and in laser-hardened radiators. LEO satellites abound with thermal transients driven by periodic environmental and traffic loads, and lightweight thermal inertia in a thin PCM plate format would be generally useful. Prior PCM art does not teach how to achieve both PCM containment and structural stability in thin plate structures. This project will use innovative design and non-woven fiber assembly methods to fabricate thin PCM composite plates that have high PCM fraction for heat capacity, integral small-gauge heat pipes for high thermal conductivity, and good mechanical strength and stability. In Phase I, plates will be fabricated and characterized both thermally and mechanically. Application to spacecraft thermal control, avionics and pulse power electronics will be pursued and the potential benefits quantified. Phase II would develop thermal control components based on thin-plate design and scale-up production capability.