Thanks to their high energy density and thermal conductivity, metallic Phase Change Materials (mPCM) have shown great potential to improve the performance of thermal energy storage systems. However, the commercial application of mPCM is still limited due to their corrosion behavior with conventional container materials. This work first addresses on a fundamental level, whether carbon‐based composite‐ceramics are suitable for corrosion critical components in a thermal storage system. The compatibility between the mPCM AlSi12 and the Liquid Silicon Infiltration (LSI)‐based carbon fiber reinforced silicon carbide (C/C‐SiC) composite is then investigated via contact angle measurements, microstructure analysis, and mechanical testing after exposure. The results reveal that the C/C‐SiC composite maintains its mechanical properties and microstructure after exposure in the strongly corrosive mPCM. Based on these results, efforts were made to design and manufacture a container out of C/C‐SiC for the housing of mPCM in vehicle application. The stability of the component filled with mPCM was proven nondestructively via computer tomography (CT). Successful thermal input‐ and output as well as thermal storage ability were demonstrated using a system calorimeter under conditions similar to the application. The investigated C/C‐SiC composite has significant application potential as a structural material for thermal energy storage systems with mPCM.
To overcome the restrictions on electric vehicles ranges on winter term conditions, due to the heating demand of the interior, the use of a Thermal High Performance Storage with metallic Phase Change Materials is one possible solution. A new storage concept, using a so called Heat Transport System, enabling the heat transfer from the storage to a vehicles cooling fluid by evaporation and condensation of a working fluid within a closed circle, is introduced in this study. The influence of the storage on an electric vehicles range is exemplary shown for DLR´s Urban Modular Vehicle Concept for a motorway cycle by theoretical investigations. An increase of range by 36,3 km resp. 18,4 % for an ambient temperature of -10 °C and 46 km resp. 26,7 % for an ambient temperature of -20 °C could be reached. The energy densities of the designed storages reach values of more than 220 Wh/kg resp. more than 310 Wh/l. The cost estimations for those storage systems are approx. 445 € resp. 660 €. A comparison between the thermal energy storage and a conventional heating system consisting out of a PTC-Heater and a battery show, that the conventional heating system has a mass which is about two thirds higher, a volume which is more than one third higher and a quadrupled price compared to the thermal energy storage.
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