K. Minor, P. Dimick, H. Wright
IntraMicron, Inc., Alabama, United States
Keywords: thermal management, heat transfer, metal microfibrous media, phase change material, lithium ion battery
Thermal management remains a significant challenge in applications such as lithium-ion batteries, reactive systems, electronics, and personal protective devices, where efficient heat dissipation is critical to performance and safety. Effective interfacial heat transfer is essential in these systems, and thermal buffering through the use of phase change materials helps maintain device temperatures at desired levels. IntraMicron’s metal microfibrous media with phase change material (MFM-PCM) offers a solution with up to four times the overall heat transfer coefficient (HTC) of conventional methods. This conformable, sintered, highly porous, nonwoven structure, made from metal fibers with 30-400% greater surface area than round fibers, enables exceptional heat removal and thermal buffering via phase transition. The structure can integrate active cooling elements, such as water tubes or heat pipes, to enhance thermal regulation without adding interfacial heat transfer resistance. Comprising 2-30% metals (e.g., copper, nickel, stainless steel) and phase change materials like hydrocarbon waxes or salt hydrates, MFM-PCM provides superior HTC while maintaining design flexibility. This adaptable structure can be tailored to meet specific HTC and density requirements across diverse high-performance applications. Demonstrations in high-energy Li-ion batteries have validated IntraMicron’s technology, confirming the potential of MFM-PCM to enhance thermal management across various configurations.