Ultraflexible, cost-effective and scalable polymer-based phase change composites via chemical cross-linking for wearable thermal management

Phase change materials (PCMs) offer great potential for realizing zero-energy thermal management due to superior thermal storage and stable phase-change temperatures. However, liquid leakage and solid rigidity of PCMs are long-standing challenges for PCM-based wearable thermal regulation. Here, we report a facile and cost-effective chemical cross-linking strategy to develop ultraflexible polymer-based phase change composites with a dual 3D crosslinked network of olefin block copolymers (OBC) and styrene-ethylene-butylene-styrene (SEBS) in paraffin wax (PW). The C-C bond-enhanced OBC-SEBS networks synergistically improve the mechanical, thermal, and leakage-proof properties of PW@OBC-SEBS. Notably, the proposed peroxide-initiated chemical cross-linking method overcomes the limitations of conventional physical blending methods and thus can be applicable across diverse polymer matrices. We further demonstrate a portable and flexible PW@OBC-SEBS module that maintains a comfortable temperature range of 39–42 °C for personal thermotherapy. Our work provides a promising route to fabricate scalable polymer-based phase change composite for wearable thermal management. Jing et al. report a cost-effective chemical cross-linking method for synthesizing ultraflexible polymer-based phase change composites with 3D crosslinked networks and further demonstrate portable applications for wearable thermal management.