New Generation Smart Textiles Containing Phase Change Materials

Gagan Sachdeva and Surbhi Gupta

B.Tech, Textile Technology
Panipat Institute of Engineering & Technology,

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New Generation Smart Textiles Containing Phase Change Materials

Gagan Sachdeva and Surbhi Gupta,
B.Tech, Textile Technology,
Panipat Institute of Engineering and Technology, Samalkha, Panipat-132102

ABSTRACT Smart textiles are materials and structure that sense and react to environmental conditions or stimuli, such as those from mechanical, thermal, chemical, electrical, magnetic or other sources. The Phase Change Materials are those which change their phase from solid to liquid upon heating and back to solid from liquid when temperature is drop down. During their phase change from Solid to liquid they absorb, distribute and store the heat, and release it when going a phase change from liquid to solid. Thus it keeps the wearer skins temperature constant by absorbing the excess heat and releasing it when required. PCM possesses the ability to change their phase with a certain temperature range which can be controlled by choosing the various phase change material according to the end use of the product. This paper discuss about the principle of Phase Change Material, Its different type available. The different technology used for the incorporation of phase change materials into textile substrate and their application with limitation is also been discussed. Keywords: Phase Change Temperature, Technical textiles, Microclimate, Microencapsulation, Perspiration, Temperature, Thermocules and Thermal Regulation.

1. INTRODUCTION The textile industry has reached a highly advanced stage with the different types and qualities of fabrics that can be manufactured. The history of textiles and fibers spans thousands of years, beginning with the style change from animal skins to the first fabric used to clothe humanity. But during the relatively short period of the past 50 years, the fiber and textile industries have undergone the most revolutionary changes and seen the most remarkable innovations in their history. Technical textiles are reported to be the fastest growing sector of the textile industrial sector [6]. In recent years, significant progress has been achieved in the area of technical textiles, fibers, yarns, fabrics and other structures with added-value functionality have been successfully developed for technical and/or high performance end-uses. Technical textiles were promoted as alternative materials for a limitless range of applications, including civil engineering, the automotive industry, aerospace and the medical industry. The huge advancement in the Technical textiles industry and the accurate control on the mechanization process offer an innovative environment for new product, namely Smart textiles. Smart textiles are materials and structure that sense and react to environmental conditions or stimuli, such as those from mechanical, thermal, chemical, electrical, magnetic or other sources [15]. In the last decade one of emerging technologies is microencapsulated Phase Change Materials which are being

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developed to provide significantly enhanced thermal management for fibers, foams and textiles with application to apparel and technical textiles. The different types of Smart textile materials are: 1) Phase Change Material, 2) Chromic Colors, 3) Shape memory materials, 4) Auxetic material, 5) HoIofiber, 6) Stomatex, 7) Stimuli-responsive hydrogels and membranes and 8) Electronic textile [1, 4]. Suitable technical equipment is becoming more and more important for authorities and the military. Not only are electronics, hard and software playing a large role, there are also increasing demands for apparel. The call for Smart fabrics is becoming more and more insistent. A new generation of these fabrics features Phase Change Materials (PCMs) which are being developed to provide significantly enhanced thermal management for fibers, foams and textiles. These Phase Change Materials are able to absorb, store and release excess body heat when the body needs it resulting in less sweating and freezing, while the micro climate of the skin is influenced in a positive way and efficiency and performance are enhanced. An Outlast Jacket Containing Phase Change Material is shown in Fig: 1, which maintain the wearer skin temperature in a comfortable zone. Fig: 1 Outlast Phase Change Jacket According to this definition textiles containing PCM are considered as smart because they react immediately to changes in environmental temperature and adapt to the prevailing hot or cold condition [2]. Phase change technology originates from the NASA (National Aeronautics and Space Administrations) research program of the 1970s.The aim of this program was to provide astronauts and instruments with better protection against extreme fluctuation of temperature in space and since then research work has been carried out by scientists and now textiles with phase change materials (PCMs) are used in numerous products and applications from apparel, underwear, socks, accessories and shoes to bedding and sleeping bags. PCMs can even be found in specialty items, such as antiballistic vests, automotive, medical or special industrial applications, where warmth and energy play a role.

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2. PRINCIPLE WORKING OF PCM FABRIC

The principal function of clothing assembly is to provide the wearer with protection against undesirable environments. Due to the fact that a human being is homeo thermal, the human body regulates temperature in narrow limits around 370C [2]. But Fabrics containing PCMs appear to be effective in contributing to apparel comfort by buffering and reducing overheating, the cause of perspiration. The fabrics with PCM react immediately to changes in environmental temperature and adapts to the prevailing hot or cold conditions. The Phase Change Materials changes their phase from solid to liquid upon heating and back to solid from liquid when temperature is drop down. During their phase change from Solid to liquid they absorb, distribute and store the heat, and release it when going a phase change from liquid to solid. When temperature rise occurs as a result of body activity or a higher environmental temperature, PCM reacts by absorbing the heat. Storing this surplus energy the PCM liquefies. This phase change produces a temporary cooling effect in the clothing layers. The Working of Phase Change Material is also shown in Fig: 2. Once the PCM has completely melted, the storage of heat stops. The PCM releases the stored heat with a drop of environmental temperature or when the body is at rest, and a temporary warming effect occurs in clothing layers. This heat exchange produces a buffering effect in clothing layers, minimizing changes in skin temperature.

Fig: 2 Working Principle of PCM The PCMs keep the wearer more comfortable by absorbing excess body heat when it creates too much heat and by releasing stored heat when the body needs it most. The Thermocules work with the body to regulate temperature and humidity better than fabrics or insulation alone.

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3. BENEFITS OF PCM:
The followings are the benefits that can be obtained by incorporation of PCM into a textile substrate: a) A cooling effect, caused by absorption of heat by the PCM. b) A heating effect, caused by release of heat from the PCM. c) A thermo-regulating effect, resulting from either absorption of heat or release of heat by the PCM which keeps the temperature of wearer constant in the comfort zone. d) An active thermal barrier effect resulting from either heat absorption or heat emission of the PCM and creating a thermal barrier in surrounding substrate, which, regulates through the substrate and adapts the heat flux to thermal needs. e) The cross-linked PEG treated fabric have antibacterial activity, resiliency/antiwrinkling, wear, toughness, absorbency and exsorbency of liquids, improved abrasion and linting resistance, decreased static propensity and increased oily soil release[5].

4. TYPES OF PHASE CHANGE MATERIALS

There are different types of phase change material which change their phase over a specific temperature range. So according the end use we can have different PCMs. Few example of phase change materials with their phase change temperature (PCT) and their Heat storage capacity:

4.1. Hydrated Inorganic Salt:

Hydrated inorganic salt is an inorganic salt crystal with n water molecules. The hydrated inorganic salt that can be used in the manufacture of heat-storage and thermo-regulated textiles and clothing usually has a heat-absorbing and -releasing temperature interval of about 20 to 40 C. Table: 1 shows some of the hydrated inorganic salts. Table: 1, Hydrated Inorganic Salts [5]

www.technicaltextile.net 4.2. Hydrocarbons:

The Phase Change Temperature (PCT) or Melting temperature for the hydrocarbons can be manipulated by selecting no. of carbon atoms. The PCT can be achieved from -5c to 60c by having no. of carbon atoms from 13-28. By selecting the no. of carbon atoms the PCT could be control as shown in Fig: 3. The Melting temperature of Hydrocarbons increases with increase in no. of carbon items. As shown in Fig: 3 the 20 number of carbons gives the Tm of 37.5 C which means the hydrocarbon which is having 20 number of carbon atom will change its phase from solid to liquid over 37.5 C temperature and back from liquid to solid below 37.5 C temperature.

Fig: 3, PCT vs No. of Carbon atoms [2]

4.3. Polyethylene glycol:

Paraffin waxes have the heat storage capacity of 150-200kj/kg with the PCT or melting temperature ranges from 35 C to 63 C. According to the end use of product different phase change temperature for PEG can be chosen as per Table: 2. The melting temperature for polyethylene glycol increases with increase in molecular weight. Table: 2, Molecular weight and melting temperature of Polyethylene glycol [2]

4.4. Fatty acids and Vegetable oils:

Fatty acid and mineral oils their heat Storage capacity range 153-182 kj/kg with Phase change temperature range(PCT)/Melting temperature of 30-60c.

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5. INCORPORATION OF PCM INTO FABRICS [2,5,7]: Since the process of phase change is dynamic; therefore, the materials are constantly changing from a state to another depending upon level of physical activity of the body and outside temperature. The thermo-regulating characteristic is possible in manmade fiber by adding PCM microcapsules to a polymer solution prior to fiber extrusion. In the process, PCM microcapsules are integrated inside the fiber itself. These PCM is first microencapsulated by a polymer coating in a sphere shape. The diameter of molecule is as small as 15-40m. Then these microcapsules can be applied to textile substrate by any of the following method. 5.1. Fiber technology The first step in any technology of PCM is Microencapsulation. The microencapsulated PCM fibers could store heat over long periods .Microencapsulation is the process of capturing small amounts of phase change materials in a shell material so that the phase change materials are permanently enclosed and protected. The protective polymer shell is very durable and designed to withstand textile production methods used in fiber, yarn spinning, weaving, knitting, and coating applications. 5.2. Coatings PCM could be incorporated into the textiles by coating using polymer such as acrylic, polyurethane, etc, and applied to the fabric. There are various coating processes available such as knife-over-roll, knife-over-air, pad-dry-cure, gravure, dip coating, and transfer coating. To prepare the coating composition, microspheres containing phase change material are wetted and dispersed in a dispersion of water solution containing a surfactant, a dispersant, an antifoam agent and a polymer mixture. The coating would be then applied to a textile substrate. In an alternative embodiment, an extensible fabric would be coated with an extensible binder containing microencapsulated phase change material to form an extensible, coated fabric. Preferred phase change materials include paraffinic hydrocarbons. 5.3. Lamination In this technology microcapsules would be mixed into a water-blown polyurethane foam mix and these foams are applied to a fabric in a lamination process, where the water is taken out of the system by drying process. The excellent honeycomb structure obtained during foam formation made considerable amount of still air trapping possibility, thus, leading to an increased passive insulation. Although the presence of PCM micelles in cells can easily be distinguished. Beside chemical protective suits the PCM can also improve the thermo-physiological wearing comfort of other protective garments made of nonwovens such as surgical gowns, uniforms, or garments worn in clean rooms. The cooling effect of the PCM can delay the temperature rise and, hence, the moisture rises in the microclimate substantially. As a result, the wearing time of the garments can be extended significantly without the occurrence of heat stress as a serious health risk.

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5.4. Microencapsulation:

Microencapsulation is a process in which tiny particles or droplets are surrounded by a coating to give small capsules many useful properties. In a relatively simplistic form, a microcapsule is a small sphere with a uniform wall around it. Microencapsulation is also known as micro packaging of solids and liquids. The material inside the microcapsule is referred to as the core, internal phase, or fill, whereas the wall is sometimes called a shell, coating, or membrane. The Fig: 4 show microencapsulated paraffin by a polymer. It is an innovative technology for packing of solids and liquids. Fig: 4 Microcapsule containing paraffin [2] The microcapsules are produced by depositing a thin polymer coating on small solid particles or liquid droplets, or on dispersion of solid in liquids. The core particles (active substance) from microcapsule can be released under controlled conditions to suit a specific purpose. The core substance from the microcapsule can be released by friction, by pressure, by dissolution through the polymer wall coating or by biodegradation. Most microcapsules have diameters between a few micrometers and a few millimeters.

6. APPLICATION OF PHASE CHANGE MATERIALS

Fabrics containing micro PCMs have been used in a variety of technical textile applications such as apparel, automotive textiles, domestic textiles, medical products, 6.1. Apparel: Major end-use of textile containing PCM in Apparel includes: 6.1.1. Life style apparel - Smart jackets, Vests, Men's and Women's hats, Gloves. Some peoples have jobs where they go to and from a cold storage facility or transport vehicle and a warm building or outside environment on an intermittent basis. PCM protective garments improve the comfort of workers as they go through these environmental step changes. It has been observed that garments made with PCMs or dynamic insulation will keep a person warm longer than conventional insulation when worn in cold environment. Fig: 5 Jacket Containing PCM

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6.1.2. Outdoor active wear apparel -jackets and jacket lining, boots, golf shoes, trekking shoes, socks, ski and snowboard gloves. Safety helmets have a thermal resistance of approximately 1.0 m2 k/w and due to their structure the heat generated by the wearer can be dissipated only by means of convection. But with the incorporation of micro PCM in the helmet liner leads to substantial reduction of the microclimate temperature in the head area. 6.1.3. Protective garments. In the case of chemical or biological protective clothing a conflict between the protective function of clothing and the physiological regulation of body temperature may occur. The conflict led to discomfort and physical strain and in extreme cases can put the person at risk from heat stress. The Outlast Protective garment (Body Armor) contains the microencapsulated PCM thus providing more comfortable Protective textile. The Outlast provide many kinds of protective clothing which contains the microencapsulated PCM ranges from Vest to Body Armor. The Fig: 6 show an Outlast Body armor containing Phase Change Material. Fig: 6 Outlast Body Armor 6.2. Automotive Textiles: A Car Interiors containing Phase Change Material is shown in Fig: 7. During the summer, the temperature inside the passenger compartment of an automobile can rise substantially-for instance, when the car is parked outside. In order to stabilize the interior temperature while driving the car, many models are equipped with air conditioning systems; however, providing sufficient cooling capacity requires a lot of energy. On the other side, during the winter months, the driver and the passengers are often confronted with low temperatures, especially as they first get in the car. Fig: 7 Car Interior containing PCM As result, some models have heating systems installed in the drivers seat which are supplied by the cars battery. Due to additional systems for monitoring and controlling various functions in cars, the power supply needed for their operation has steadily increased over the past years. In order to prevent further demands on the batterys capacity, manufacturers are searching for all kinds of energy savings.

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6.3. Aerospace:

Phase change technology originates from the NASA (National Aeronautics and Space Administrations) research program of the 1970s.The aim of this program was to provide astronauts and instruments with better protection against extreme fluctuation of temperature in space and since then research work has been carried out by scientists. In Aerospace the PCM is used in space suits and as a cover protection for instruments against the severe temperature changes of outer space. Fig: 8, Space Suit with PCM

6.4. Medical Products: PEG-treated fabric may be useful in medical and hygiene applications where both liquid transport and antibacterial properties are desirable, such as surgical gauze, nappies and incontinence products [5]. Textile containing PCM can keep the skin temperature within the comfort range, so they can be used as a bandage. If a therapeutic blanket made of a flexible PCM composite contains a micro PCM having a transition temperature below normal skin temperature, it can be used for cooling febrile patients in a careful and controlled manner. Fig: 9, Wound Care bandage A careful selection of the phase change temperature makes it possible to avoid the danger of overcooling the patient that is inherent with ice packs. Alternatively, a blanket with PCM can be useful for gently and controllably reheating hypothermia patients.

6.5. Others: There are numerous others application for textile containing Phase Change Material, Some of the popular uses of PCM in textile are: The PCM is used in tarpaulin cloth so that temperature of inside the tarpaulin can be maintained as shown in Fig: 10.

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Fig: 10 Tarpaulin fabrics with PCM The PCM is also used in the Covering cloth for some sensitive items which require a maintained and control temperature as shown in Fig: 11.

Fig: 11 Cover Fabric for sensitive items The PCM can also be used in baterry warmers, agriculture, building material and geotextile[17].

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7. LIMITATION
Besides the very important functions and application of Textile containing PCM, It posses few limitation due to which the textile containing phase change material are not so popular, the limitation of textile containing phase change materials are:

a) The limitation with phase change materials is that this phenomenon only occurs over a
specific temperature or temperature range for any specific PCM and When the Latent heat of the PCM is fully absorbed or released the thermo regulating effect stops. b) The clothing structure should be carefully engineered otherwise it can release the absorbed heat to the environment rather than to the wearers body. c) If the amount of PCM presence is more to get higher heat storage, the fabric become very stiff because of higher amount of PCM.

8. CONCLUSION
The intelligent textiles and smart clothing is emerging field in the world of textiles. The textile industry has already focused for several years on enhancing the functional properties of textiles. Phase Change Material, Chromic Colors, Shape memory materials, Auxetic material, HoIofiber, Stomatex, Stimuli-responsive Hydrogels and membranes and Electronic textile are examples of Smart textiles that are already commercially available in the market. The textiles containing phase change materials (PCMs) are used in many products and applications from apparel, underwear, socks, accessories and shoes to bedding, sleeping bags, car Seats, Wound care bandages, space suit and protective garment. PCMs are even find their application in some specialty items, such as antiballistic vests, automotive, medical or special industrial applications, where warmth and energy plays a vital role.

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9. REFERENCES 1) International Journal Of Clothing Science And Technology Vol.18 No.2,2006 pp. 108-128, An Overview of smart technologies for clothing design and engineering By: S Lam Po Tang and G.K.Stylios. 2) S.Mondal, Phase change materials for smart textiles-An overview, Appl. Them. Eng (2007), doi:10.1016/j.applthermaleng.2007.08.009. 3) Information on http://www.outlast.com 4) Smart and Intelligent Textile and fibres By: H MEINANDER, Tampere University of Technology, Finland 5) Smart Fibres, Fabrics and Clothing Edited by: Xiaoming Tao, Heat Storage and thermoregulated textile and clothing By: Xingxiang zhang, pp 34-57 6) Handbook of Technical Textile, Woodhead Publishing limited, Edited By: A.R Horrocks and S.C Ananad 7) Phase Change Materials: Overview By: Aravine Prince, http://www.fibre2fashion.com 8) Information on http://en.wikipedia.org/wiki/Phase_change_material 9) PCM Thermal Solutions, http://www.pcm-solutions.com 10) Smart Textiles & Clothing, Synergies for innovation By: Miloslav Ohlidal-Brno University of Technology & Pavel Malcik-textile Testing Institute, Brno www.czelo.cz/dokums_raw/Ohlidal.pdf 11) http://www.textileworld.com/Articles/2004/March/Features/Phase_Change_Materials.html 12) Advances in Technolgy: Smart & Engineered Textile Jose A. Gonzalez, Protective Clothing Research Group, Department of Human Ecology,University of Alberta www.ualberta.ca/~jag3/smart_textiles/Page_5.html 13) Information on http://en.wikipedia.org/wiki/Micro-encapsulation 14) Journal of Technical textiles international, Berbara Pause of textile Testing, March 2002 International Newsletter. 15) Smart Textiles: The Innovative Road to the future by: Sungmee park and Sundaresan Jayaraman, Textile & Fiber Engineering, Atlanta, USA 16) Technical Textiles, volume 44, February 2001. 17) Phase Change Materials (PCMs) and Applications, Space Hardware Design Final Project by: Benn Mottinger, University of Colorado, Aerospace engineering