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DOE OSTI · 2532475

Additive manufacturing for electrocaloric terpolymer thin films

Ruan, Wei [University of Connecticut, Storrs, CT (United States)]·Ritchey, Zachary [University of Connecticut, Storrs, CT (United States)]·Wang, Fei [University of Connecticut, Storrs, CT (United States)]·Huey, Bryan D. [University of Connecticut, Storrs, CT (United States)]·Jain, Menka [University of Connecticut, Storrs, CT (United States)]·McCutcheon, Jeffrey R. [University of Connecticut, Storrs, CT (United States)]·Burke, Kelly A. [University of Connecticut, Storrs, CT (United States)] (ORCID:0000000267410114)
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Abstract

Current heating, venting, and air conditioning (HVAC) systems have drawbacks of high energy consumption, large CO 2 emissions, and low efficiency. Electrocaloric (EC) cycles present an eco-friendly alternative by converting thermal energy to electrical energy. Defect-free thin films with uniform thickness are required to achieve optimal EC performance. A scalable thin film fabrication process is essential for integrating EC cycles into HVAC systems. This study introduces EC thin films prepared by electrospray (ES) processing, a manufacturing method that deposits EC polymer layer by layer using high voltage. The resulting films show superior thickness control, smoother surfaces, and improved thermal and electrical properties compared with solution casting. In addition, post-annealing at 120°C enhances the thermal and EC performance, with films achieving a temperature change (ΔT) of 3.6°C at 100 MV/m when tested near room temperature. With the potential for future scalability, the ES method offers a promising approach for fabricating EC thin films.

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36 MATERIALS SCIENCE42 ENGINEERINGadditive manufacturingelectrocaloricelectrosprayrelaxor ferroelectricsolid-state coolingthin film

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Ruan, Wei [University of Connecticut, Storrs, CT (United States)], Ritchey, Zachary [University of Connecticut, Storrs, CT (United States)], Wang, Fei [University of Connecticut, Storrs, CT (United States)], Huey, Bryan D. [University of Connecticut, Storrs, CT (United States)], Jain, Menka [University of Connecticut, Storrs, CT (United States)], McCutcheon, Jeffrey R. [University of Connecticut, Storrs, CT (United States)], Burke, Kelly A. [University of Connecticut, Storrs, CT (United States)] (ORCID:0000000267410114). 2025-03-19. Additive manufacturing for electrocaloric terpolymer thin films. https://doi.org/10.1016/j.xcrp.2025.102503

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The transition to a flexible and reliable energy infrastructure, using electro-thermal energy generation technologies such as geothermal, concentrated solar power, and nuclear, usually demands simultaneous advancement of thermal energy storage (TES) to support on-demand electricity generation and industrial applications while mitigating the inherent intermittency of renewable energy sources and power outages from direct energy generation. Among TES technologies, thermochemical energy storage (TCES) based on calcium looping emerges as a compelling high-power energy storage candidate due to its high reaction enthalpy, compatibility with elevated operating temperatures, and abundance of low-cost materials. However, the long-term durability of calcium-based sorbents for TCES is hindered by surface sintering and particle aggregation, leading to performance degradation over repeated thermal cycles. This study explores a moisture hydration-based strategy to regenerate a degraded calcium sorbent and mitigate performance degradation for long duration TCES. The addition of moisture transforms calcium oxide into calcium hydroxide and produces intercalation water layers, associated with a regenerated surface area and reduced calcium oxide crystallite size. Both these effects are beneficial in restoring the sorbents' reactivity for carbonization. Additionally, an optimized hydration-assisted reactivation protocol balances the recovered energy storage capacity with heating penalty required for moisture removal from hydrated samples, resulting in an enhanced energy storage capacity up to 176% compared to benchmark sorbents that undergo cycling without reactivation after 60 cycles. In conclusion, these results highlight the potential of hydration-assisted reactivation to enhance the long-term performance of TCES, providing an effective pathway to advancing electro-thermal storage technologies.

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