U.S. patent application number 15/367172 was filed with the patent office on 2018-06-07 for thermal energy storage system with enhanced transition array.
The applicant listed for this patent is Abdel-Rahman N. Naser, Amna N. Naser, Najih naser. Invention is credited to Abdel-Rahman N. Naser, Amna N. Naser, Najih naser.
Application Number | 20180156546 15/367172 |
Document ID | / |
Family ID | 62242973 |
Filed Date | 2018-06-07 |
United States Patent
Application |
20180156546 |
Kind Code |
A1 |
naser; Najih ; et
al. |
June 7, 2018 |
Thermal Energy storage system with enhanced transition array
Abstract
This invention describes the design and applications of a
thermal storage system with desirable thermo physical and kinetic
properties for various applications including architectural design,
increasing thermal mass of building envelops and climate
control.
Inventors: |
naser; Najih; (Cary, NC)
; Naser; Abdel-Rahman N.; (Cary, NC) ; Naser; Amna
N.; (Cary, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
naser; Najih
Naser; Abdel-Rahman N.
Naser; Amna N. |
Cary
Cary
Cary |
NC
NC
NC |
US
US
US |
|
|
Family ID: |
62242973 |
Appl. No.: |
15/367172 |
Filed: |
December 1, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 20/023 20130101;
C09K 5/063 20130101; Y02E 60/145 20130101; E04B 2001/742 20130101;
F28D 2021/0035 20130101; F28D 2021/008 20130101; Y02E 60/14
20130101; E04B 1/80 20130101 |
International
Class: |
F28D 20/02 20060101
F28D020/02 |
Claims
1. A thermal energy storage system comprising a three dimensional
holding media and contained within it phase change materials or
energy receptors and crystallization cofactors for enhanced thermal
response comprising: a). A porous absorbent or reticulated network
surface of about 1 mm to a bout 1000 mm thickness and of large
surface area and void volume capacity to permanently hold and
maintain thermal energy compositions or receptors. b). a thermal
energy material or receptor composition to store and release energy
upon its phase transition in repetitive cycles and to be fully
contained by the media matrix member. c). an anchor site network
and stabilizing cofactors of the phase change material distributed
in and/or onto the holding media components to serve as crystal
core growth site and stabilizer of the thermal storage
composition.
2. The support and holding matrix of claim 1 comprises a structure
of cellulosic material, natural or synthetic fibers, reticulated
vitreous carbon, melt blown fibers and the likes randomly or
uniformly integrated and networked to form a three dimensional
absorbing or reticulated pad structure with affinity to aqueous and
non-aqueous compositions.
3. The energy storage receptor and phase change material comprises
of inorganic salts and crystalline hydrates, molten salts,
inorganic eutectic mixtures, fatty acids/esters, fatty alcohols,
fatty salts, organic eutectic mixture or aliphatic
hydrocarbons.
4. The composition of claim 1 where the anchoring site and crystal
landing sites may be of cellulosic nature, woven or nonwoven
fibers, carbon fibers, polypropylene, graphene oxide, polyethylene,
polyester and melt blown fibers in mono and multi filaments or
combinations thereof, weaved or integrated in a panel open geometry
to contain phase change energy storage receptors, enhance thermal
conductivity and/or reduce subcooling effect during solidification
cycle.
5. The composition of claims 1 and 4 including impregnating media
matrix modifying surfactants and crystal stabilizers selected from
ionic compounds, salts, fatty acid and ester salts, magnesium
stearate, metal oxides, silicon dioxide or fine silica, aluminum,
iron, copper, carbon fiber, carbon nanotubes, carbon black, to
increase active crystal site, thermal conductivity and absorption
capacity for rapid reversible crystallization.
6. The composition of claims 4 and 5, wherein the additive and
nucleating agent is selected from H.sub.2O, FeO, CuO, Cu.sub.2O,
ZnO, SrO, Al.sub.2O.sub.3, Fe.sub.2O.sub.3, SiO.sub.2, BaO, NaCl,
KCl, LiCl, StCl, Na.sub.2CO.sub.3, CaCl.sub.2, MgCl.sub.2,
ZnCl.sub.2, FeCl.sub.3, BaCl.sub.2, MgSO.sub.4, CuSO.sub.4,
BaSO.sub.4, CaCO.sub.3, Na.sub.2SO.sub.4, Na.sub.2B.sub.4O.sub.7,
Sr.sub.3(PO.sub.4).sub.2, CaB.sub.4O.sub.7,
Na.sub.5P.sub.3O.sub.10, BaS.sub.2O.sub.3, BaCO.sub.3, BaCl.sub.2,
Sr(OH).sub.2, SrCO.sub.3, K.sub.2PO.sub.4, Magnesium stearate,
palmitic acid, stearic acid, bentonite, ethylene oxide, propylene
oxide, or mixtures thereof.
7. The composition of claim 6, wherein additional thermal
conductors and crystal core seeding are distributed within and onto
the large network area of the media matrix in amounts ranging from
0.01 to about 10 percent by weight.
8. The energy storage compositions and the media matrix of claim
1-7 further comprising an array of cells serially or in parallel
and of one or more PCM composition and transition temperature.
9. The configuration and compositions of claims 1-8 encapsulated in
a film barrier forming a sealed enclosure comprising of one or more
materials with vapor barrier and radiant film quality.
10. The compositions of claim 1-9 may be configured to produce
thermal energy storage system for efficient charging and
discharging of energy and use in building structures, walls,
ceilings, floor boards, underlayment flooring, strategic heat
storage walls (fireplaces and kitchen areas), overcome low thermal
mass of light weight buildings, exterior thermal envelope, siding
boards and stone veneer.
11. The compositions and construct of claim 1-9 for body cooling
applications and as thermal guard panels in automobile liners,
shipping vessels and storing temperature sensitive products.
12. The compositions and construct of claim 1-9 where thermal
energy storage panels may be assembled as liners or flow through
thermal energy store or batteries for charging and discharging
thermal energy in large stationary operations as well as portable
thermal store applications.
Description
CROSS REFERENCES OF RELATED APPLICATION
[0001] This patent application claims the benefit of U.S.
Provisional Patent Application No. 62/261,959, filed on Dec. 2,
2015, the specifications of which are hereby incorporated.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates to a phase change thermal energy
storage system for climate control environments, building
structures, energy management and safe transport of temperature
sensitive materials and application thereof.
BACKGROUND
[0003] The present invention relates to the field of thermal energy
storage and use of materials that can capture and release energy
upon phase transition.
[0004] Phase change materials (PCMs) or phase change energy
receptors are materials that store/release heat during phase
transition without a rise in their own temperature. These features
make PCMs ideal to capture and store heat for many applications
including architectural design, increasing thermal mass of building
envelops, thermal underlayment, climate control and shipping
enclosures for temperature sensitive products.
[0005] PCMs can be used to construct building materials due to
their latent heat storage capacity. It is based on enthalpy
conversion when PCMs absorb heat and transition from solid to
liquid. They continue to absorb heat without a significant rise in
their temperature until all material is converted to liquid phase.
The absorbed energy is released to the environment as PCM
solidifies and transition from liquid to solid due to a fall in the
environment temperature. This process is very useful to keep a
building temperature within a constant comfortable range. PCMs
store more heat per unit volume than many conventional building
materials such as masonry, wood or rock.
[0006] There are two main classes of PCMs, organic and inorganic
with a wide range of melting temperatures. Organic PCMs include
paraffin compounds and non-paraffin compounds such as fatty acids,
fatty alcohols and fatty esters that melt and solidify congruently
with little subcooling. Organic PCMs have low density per volume,
low thermal conductivity and are generally flammable.
[0007] Inorganic phase change materials such as salt hydrates are
known for their heat of high fusion and storage density but suffer
from congruent melting and irreversible processes. Most have slow
or poor nucleating properties which result in subcooling where they
solidify at much lower temperature than their general melting
point. There are different crystal forms that may be produced
causing stratification on repeated melting and crystallization.
Unfortunately the formation of lower hydrate forms lead to severe
stratification and water phase separation causing solid salts to
fall to the bottom of the enclosure. Such undesired process
deprives the top layer from the useful phase change material
originally introduced and induces subcooling at temperatures below
its congealing crystallization temperature. Several remedies were
suggested to solve this problem including mechanical stirring, use
of gelling and thickening materials or addition of other salts and
nucleating agents to make the mixture congruent. The admixing of
nucleating agents such as strontium, potassium and barium salts
have been proposed to stabilize the compositions. U.S. Pat. No.
4,613,444, U.S. Pat. No. 4,690,769 and U.S. Pat. No. 6,402,982.
[0008] The performance of PCMs is also dependent on their
environmental exposure conditions such as enclosure, humidity and
surrounding temperature. PCMs enclosures describing plastic films
or sheets forming sealed pockets were used to contain the PCM
material from drying or absorbing excessive moisture as described
in U.S. Pat. No. 5,626,936. The sealed confinement prevents
material from escaping the enclosure and leaking into walls or
ceiling structures. It is a significant benefit to minimize
potential corrosion or damage caused by leaked PCM compounds.
Additional steps were proposed to stabilize the compositions by
using thickening adsorbents such as diatomaceous earth as described
in U.S. Pat. No. 7,641,812 and U.S. Pat. No. 8,741,169. Additional
superabsorbents and hydrophobic sorbents as viscosity modifiers
were also proposed in U.S. 2009/0191408 A1 and U.S. 2014/0339460 A1
including chemical crosslinking PCM compounds with isocynate
polymers which affect its thermal storage capacity and conductivity
in comparison with native PCM compounds.
[0009] Although, these steps are helpful in attenuating the
problem, they suffer from alteration in thermal conductivity and
slow rates of crystallization when temperature changes are small
thus lack to produce a total solution. Mechanical stirring or
agitation is limited in use and inconvenient in most phase change
energy storage applications. Thickeners may increase the viscosity
of phase change materials but may increase the flammability of
organic PCMs forming flammable gels. Also, for salt hydrates
thickening agents absorb and share the water molecules necessary to
maintain the salt hydrate at a higher hydration level, a phenomenon
requiring all water molecules to be available to solubilize the
desired salt form. Viscosity modifiers and cross linkers are
thermally inert materials and reduce the thermal storage loading of
the PCM composition and it negatively affect thermal conductivity.
Additional improvements are therefore desired. The present
disclosure offers thermal energy storage compositions and construct
with enhanced reversible phase change transition while maintaining
the original thermal storage properties of organic and inorganic
PCMs.
SUMMARY OF THE INVENTION
[0010] This invention represents a significant improvement and
solution to slow crystallization rates and phase transition of
thermal storage materials. The primary objective is to produce
highly responsive, thin, light weight storage panels with high
thermal mass and efficient thermal charging and discharging of
energy for use in building spaces, walls, ceilings, floor boards,
underlayment flooring, strategic heat storage walls (fireplaces and
kitchen areas), positively impact low thermal mass and light weight
buildings as well as the exterior thermal envelope including siding
boards and stone veneer. Such applications can reduce costs of
heating and air conditioning while enhancing occupant comfort with
a cooling effect and reduction in temperature swings.
[0011] For this purpose, for example the inventive heat storage
compositions can be used advantageously as latent heat energy
panels. They may be encased in walls, ceilings, doors, warehouses,
storage structures and barns. In addition, the disclosed system can
be used to prevent excessive heating from various sources or from
people and equipment in buildings and vessels. For example it can
be integrated into window coverings or encased into office modules,
furniture, automobile liners and in the walls of transport
vehicles, caravans, trailers or vessels.
[0012] In some embodiments, for example, the thin three dimensional
(3-D) media matrix with high absorption affinity and tremendous
active surface network acting as nucleating sites enables a
reversible phase change transition and rapid melting and
crystallization rate. The media's high absorption capacity allows
the immobilization of organic and inorganic phase change materials
and cofactors for enhancing thermal conductivity and rapid response
to changes in the environment temperature. Additionally, the media
matrix retains water molecules in intimate contact with the phase
change material molecules to maintain effective solubility,
segregation and formation of lower hydrated salt forms. The
disclosure describes the embodiment of large solvating and
nucleation active site dispersed onto and within the media network.
The encapsulated energy storage array employs neat, high energy
storage PCMs in a self-contained, leak proof, flexible and
efficient matrix capable of storing and discharging energy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is a schematic illustration of one design of a fiber
network made from fibers selected from cellulosic ingredients,
bamboo fibers, polypropylene, melt blown synthetic polymers and the
like.
[0014] FIG. 1B shows the networking for two or more fiber formation
scheme patterns.
[0015] FIG. 1C shows the integration of a high absorbing capacity
support component integrated between layers of fine fibers.
[0016] FIG. 2 is a schematic view illustrating one media matrix
loaded with phase change energy composition and crystal cores and
is encapsulated in a sealed flexible barrier film forming thermal
energy storage Cell.
[0017] FIG. 3 is a schematic of a cross section of various
temperature transition phase change materials. A dual PCM energy
storage 1 and 2 is used to store and release energy at different
temperatures during melting and crystallization phases.
[0018] FIG. 4 shows a cross section of the energy storage system
configured as a flow through cell where hot or cold energy input is
processed in various applications.
DETAILED DESCRIPTION
[0019] This disclosure is generally described to illustrate a
construct, compositions and method to produce thermal energy
storage system using Phase Change Materials for many applications
where thermal energy and temperature management is necessary.
Various embodiments are presented; some embodiments describe
amplified crystallization and efficient molecular hydration by
using an inert 3-D fiber network media as the support matrix for
the PCM and crystal core stabilizing cofactors. The media matrix
and method presented herein offer total composition containment to
prevent leakage and phase separation or segregation on repeated
melting and crystallization while enhancing thermal stability. The
embedded PCM compositions represent an array of thermal storage
islands in one platform. These pseudo conjugated PCM islands
increase thermal conductivity resulting in high heat of fusion
turnover and specific heat per unit volume and weight. This
decreases the necessary time needed for nucleation to occur in a
recrystallization cycle and the subsequent stored energy
release.
[0020] Another advantage of the invention is the high loading of
phase change material receptor in the large area network of the
holding media matrix where neat liquid PCM is directly loaded
forming an array of crystallization islands within the media layer.
Furthermore, the high density and higher stability of pure PCM
compositions (without thickening agents, polymerization and
molecular modification) provide high thermal storage per unit
volume and reduces volume changes during the melting and
solidification cycles at reduced cost.
[0021] The 3-D media member is an inert media matrix of large
surface area and high absorption affinity towards aqueous and
non-aqueous compositions and is used to contain PCMs of varying
temperatures ranging from subzero to 150.degree. C. FIG. 1A
illustrates one fiber network 1 made from fibers selected from
cellulosic ingredients, bamboo fibers, polypropylene, melt blown
synthetic polymers and the like. Alternatively, FIG. 1B shows the
networking for two or more fibers 2, 3 and formation scheme while
FIG. 1C shows the integration of a high absorbing capacity
component 4 or an air blown fibrous composition sandwiched between
layers of fine fibers 1 and 3 used as the holding matrix for the
phase change material. FIG. 2 illustrates one media matrix 4 loaded
with phase change energy composition and crystal cores 5, and the
layers 1-5 are encapsulated in a sealed flexible barrier film 6, 7
forming thermal energy storage Cell. The cell configuration may be
replicated over various lengths and widths as energy storage
panels. Selected temperatures of phase change materials are
generally designed to create a cooling effect of a few degrees
Celsius as heat storage medium. In some embodiments and as mere
examples, the preferred transition temperatures include 4, 6, 10,
15, 18, 21, 23, 25, 27, 28, 29, 32, 35, 37, 49.degree. C.
[0022] A simplified representation of the invention comprises a
absorbent support or continuous three dimensional fibrous media
member impregnated with additive crystal core nucleating sites and
PCM selected from inorganic salts and crystalline hydrates, molten
salts, inorganic eutectic mixtures, fatty acids/esters, alcohols,
organic eutectics, aliphatic hydrocarbons and combinations thereof.
Various compositions may be loaded into the media's matrix
separately or as mixtures of the phase change material.
Alternatively, PCM additives may be added with the phase change
material and within the support media matrix. The addition of
nucleating agents serves as crystal core and anchoring sites for
crystal growth while distributed within the media microstructures
as well as within the fibrous matrix construct. In addition, the
large media's surface area and PCM distribution ensures high
nucleation array to avoid subcooling while the high rate of crystal
growth speeds the recovery of heat from the PCM. Furthermore, the
uniform density and high volumetric thermal density minimizes
volume variation during phase change solidification
[0023] Thermal conductivity is a measure of a materials ability to
conduct heat. It is generally measure by heat flow meters, the
greater the thermal conductivity indicate a more efficient heat
transfer and phase change transition. The present disclosure uses
thermal conductor materials including fine fibers, flakes, layers,
and particles in the media matrix. The thin layer and 3-D media
structure maintains the PCM and thermal conductors in close contact
during the molten state when thermal conductivity is at higher
value. This additional feature of the invention facilitates an
efficient heat transfer and rapid crystallization rate.
[0024] In another embodiment, the generally low thermal
conductivity of phase change material may be improved by the media
matrix comprising highly conductive sites or particles selected
from aluminum, iron, copper, silica, carbon black, carbon fibers,
carbon nanotubes, metal oxides and grapheme/oxides. Additionally,
the integration of these materials within the media matrix
structure plays a dual purpose as active a thermal conductor and
crystal core for enhanced crystallization and efficient phase
transition rate.
[0025] It should be recognized that the various embodiments and
illustration are merely described for illustrative fulfillment of
the various objectives of the present invention. In another
embodiment and of further advantage of the use of the media's role
to contain PCMs and cofactors, it plays a major role to contain
organic PCM molecules (fatty acids/esters and alcohols) entrapped
within the media's open structure. For example, methyl palmitate
crystallizes faster within the media's network and microstructures
than in bulk volume. Conjugated methyl palmitate crystal islands
make energy recovery more efficient and enhance phase change
transition turnover rate. In addition, the ability of the media to
retain water molecules in close proximity helps prevent inorganic
PCM degradations associated with water molecule loss during heating
cycles. This is especially important for crystalline hydrates and
eutectic mixtures where water loss drops the PCM to lower hydration
states and induced phase separation. This high hydration proximity
prevents PCM salting out and promotes rapid charging and
discharging of energy during both solid and liquid phases.
[0026] In another embodiment, dual energy storage panels are
produced to represent the use of PCMs of different melting
temperatures. FIG. 3 illustrates the employment of this invention
to produce thermal energy storage systems responsive to seasonal
climate conditions. The brief illustration shows the potential use
of two or more phase change materials 5 and 8 of different melting
temperature serially produced as in FIG. 2 and placed in parallel
to generate proactive energy storage systems that are responsive to
seasonal conditions.
[0027] For example, a PCM that melts at 23.degree. C. for cooler
days of the year while using a 29.degree. C. PCM for the warmer
days delivering comfort while saving energy.
[0028] The diversity of the storage system provided in this
invention allows its use in various configurations to produce an
array of thermal cells for inline use utilizing a flow through cell
design application as in FIG. 4. including but not limited to HVAC
ductwork, suspended floor platforms and use in active mode PCM
activation and recycling. This also demonstrates the wide
applicability of the flexible and easily formed energy storage
panels to various shapes from planar, sheets, cylindrical and
rectangular shapes depending on the application.
[0029] The examples described herein are non-limiting and represent
some embodiments as further illustrations of the disclosure.
Example 1
[0030] This example illustrates the 3-D media matrix and fiber
network capable of absorbing aqueous and non-aqueous materials. The
continuous media and/or its components is modified with crystal
modifiers selected from Al, Cu, Fe, FeO, CuO, Cu.sub.2O, ZnO, SrO,
Al.sub.2O.sub.3, Fe.sub.2O.sub.3, SiO.sub.2, BaO, NaCl, KCl, LiCl,
StCl, Na.sub.2CO.sub.3, MgCl.sub.2, ZnCl.sub.2, FeCl.sub.3,
BaCl.sub.2, MgSO.sub.4, CuSO.sub.4, BaSO.sub.4, CaCO.sub.3,
Na.sub.2SO.sub.4, Na.sub.2B.sub.4O.sub.7, Sr.sub.3(PO.sub.4).sub.2,
CaB.sub.4O.sub.7, Na.sub.5P.sub.3O.sub.10, BaS.sub.2O.sub.3,
BaCO.sub.3, SrCO.sub.3, carbon fibers, carbon black, Magnesium
stearate, bentonite, ethylene oxide, propylene oxide, or mixtures
thereof in amounts of less than 30 percent by weight. The thermal
storage PCM used with the media matrix is selected from inorganic
salts and crystalline hydrates for example and not limited to
calcium chloride hexahydrate, sodium carbonate dodecahydrate,
eutectic mixtures, fatty acids/esters, alcohols, organic eutectics,
aliphatic hydrocarbons and combinations thereof.
[0031] Compositions are loaded into the media's components or
admixed with the phase change material and contained by the media
matrix.
Example 2
[0032] This example illustrates the preparation of a salt hydrate
PCM composition and loading of the media support. A feed stock
calcium chloride is dissolved in an aqueous solvent at moderate
temperatures (under 40.degree. C.) to allow a much higher
concentration to be achieved. The concentrated brine solution is
stripped in purification steps such as filtration or settled
particle separation while at elevated temperatures. The
concentrated brine solution is cooled to less than 20.degree. C. to
crystalize calcium chloride hexahydrate crystals. The resulting
crystals are separated and placed in a closed temperature
controlled dissolution vessel. The temperature is set to
35-37.degree. C. for the crystals to melt and the temperature is
maintained at this level while stirring. The vessel is kept close
to prevent water loss. Association of alkali metals made up of
Group 1 and group 2 are added to the melted crystals at a total
percent weight not to exceed 10%. In one embodiment of a formula,
calcium chloride hexahydrate is paired with two alkali metal salts
of group 1 for a total percent weight of less than 7 and two alkali
metal salts of group 2 for a combined percent weight of less than 3
percent weight. While stirring, the molten complex is modified with
one or combinations of CuO, Cu.sub.2O, ZnO, TiO.sub.2, SiO.sub.2,
BaO, carbon black or graphene in an amount of less than 4 percent
by weight. The Composition is loaded into the media member and
allowed to be absorbed by the media matrix. The loaded media member
is sealed between film layers with vapor barrier quality film
preferably with aluminum film component to produce the thermal
energy storage panel to store and release heat.
Example 3
[0033] A saturated solution of calcium chloride is prepared in an
aqueous solvent at 40 C while stirring. The concentrated brine
solution is purified to produce the mother liquor. The concentrated
brine solution is cooled to less than 20.degree. C. to crystalize
calcium chloride hexahydrate crystals. The resulting crystals are
separated and placed in a closed temperature controlled dissolution
vessel and heated to 35-37.degree. C. An alkali metal salt from
group 1 was added to the mix while stirring in amounts of less than
5 percent weight. A 2 percent weight magnesium chloride and 2
percent weight strontium chloride are added to the calcium chloride
mixture. Barium sulfate and Titanium oxide are added while stirring
in less than 1 percent weight. The formula is added to the media
matrix and allowed to be absorbed and distributed in the support
media. The loaded media matrix is then placed in a sealed moisture
barrier film preferably with aluminum film component to produce the
thermal energy storage panel to store and release heat.
Example 4
[0034] This example illustrates the use of media matrix to hold and
disperse within its micro structures a non-aqueous PCM composition.
The organic PCM is selected from fatty acids/ester, methyl laurate,
methyl palmitate, methyl stearate, fatty alcohols or aliphatic
carbon. The material is gently melted at a heat setting slightly
above melting temperature. In a preferred embodiment, a fire
retardant additive, calcium carbonate or sodium triphosphate is
added while mixing. The composition is loaded into the media matrix
and allowed to be absorbed and distributed to produce the phase
change thermal energy storage panel. The loaded media matrix is
sealed between sheets of barrier film.
Example 5
[0035] This example describes one application of the use thermal
storage loaded media matrix with enhanced thermal conductivity. A
low melting temperature PCM methyl Laurate is melted at a few
degrees above its melting point. A crystal promoter and thermal
conductor may be selected from Al, Cu, Fe, FeO, CuO, Cu.sub.2O,
ZnO, Fe.sub.2O.sub.3, SiO.sub.2, CaCO.sub.3, Na.sub.2SO.sub.4,
Na.sub.2B.sub.4O.sub.7, CaB.sub.4O.sub.7, Na.sub.5P.sub.3O.sub.10,
carbon fibers, carbon black, Magnesium stearate or bentonite in
less than 10 percent weight. The melted methyl laurate composition
is then used to impregnate the 3-D media matrix and the composition
is allowed to be absorbed and contained to produce a fully loaded
media member which is then sealed between film layers.
* * * * *