Stretchable Elastomer–Phase Change Composites for Passive Thermal Management in Wearable Electronics

Year : 2026 | Volume : 14 | Issue : 02 | Page : 30 41
    By

    M. Chennakesavulu,

  • S. John Leon,

  • P Joel Josephson,

  • V.Parimala,

  • DVSSSV Prasad,

  • D. Priya Matharasi,

  • Hirald Dwaraka Praveena,

  • Sekar K,

  • S. Sheik Mydeen,

  1. Associate Professor, Department of Electronics and Communication Engineering, Rajeev Gandhi Memorial College of Engineering and Technology (Autonomous), Andhra Pradesh, India
  2. Associate Professor, Department of Marine Engineering, Noorul Islam Centre for Higher Education, Nagercoil, Tamil Nadu, India
  3. Associate Professor, Department of Electronics and Communication Engineering, Malla Reddy (MR) Deemed to be University, Secunderabad, Telangana, India
  4. Assistant Professor, Department of Electronics and Communication Engineering, Chennai Institute of Technology, Chennai, Tamil Nadu, India
  5. Professor, Department of Mechanical Engineering, Aditya University, Surampalem, Andhra Pradesh, India
  6. Associate Professor, Department of Chemistry, St. Joseph’s Institute of Technology, Chennai, Tamil Nadu, India
  7. Associate Professor, Department of Electronics and Communication Engineering, School of Engineering, Mohan Babu University, Tirupati, Andhra Pradesh, India
  8. Professor, Department of Electrical and Electronics Engineering, Adithya Institute of Technology, Coimbatore, Tamil Nadu, India
  9. Associate Professor, Department of chemistry, Sethu Institute of Technology, Pulloor, Tamil Nadu, India

Abstract

Elastomer-embedded phase change material (EPCM) composites are developed as stretchable, leakage-free, and electrically insulating thermal regulation layers for wearable electronics operating under stringent skin-safety requirements. The EPCM architecture comprises microencapsulated organic phase change materials (μPCM, 30–70 wt%) uniformly dispersed within soft elastomer matrices based on PDMS or SEBS-type thermoplastic elastomers, together with low loadings (1–8 wt%) of electrically insulating hexagonal boron nitride (h-BN) fillers to enhance lateral heat transport. Differential scanning calorimetry confirms a well-defined and stable phase transition within the targeted temperature range of 35–42°C, with negligible peak shift upon variation of μPCM content or h-BN incorporation, indicating preservation of the intrinsic phase-change behavior. The latent heat storage capacity increases monotonically with μPCM loading, providing effective thermal buffering at moderate contents (~40–50 wt%) and extended thermal regulation at higher loadings (60–70 wt%). Thermogravimetric analysis demonstrates excellent thermal stability, with negligible mass loss below ~200°C and delayed thermal degradation in h-BN-containing composites. Thermal conductivity shows a progressive increase from neat elastomer and μPCM-only systems to h-BN-filled EPCM composites, enabling efficient lateral heat spreading and mitigating localized PCM activation. Mechanical testing reveals a soft, nonlinear elastomeric response with sustained strains exceeding 150% without mechanical failure at μPCM contents up to ~50 wt%, along with excellent cyclic durability over 500 loading–unloading cycles. Leakage resistance tests, including prolonged isothermal holding at 50°C and blotting paper evaluation, confirm complete suppression of PCM leakage even at high μPCM loadings.

Keywords: Elastomer-embedded phase change materials (EPCM), Wearable thermal management, Microencapsulated PCM (μPCM), Stretchable composites, Hexagonal boron nitride (h-BN)

[This article belongs to Journal of Polymer & Composites ]

How to cite this article:
M. Chennakesavulu, S. John Leon, P Joel Josephson, V.Parimala, DVSSSV Prasad, D. Priya Matharasi, Hirald Dwaraka Praveena, Sekar K, S. Sheik Mydeen. Stretchable Elastomer–Phase Change Composites for Passive Thermal Management in Wearable Electronics. Journal of Polymer & Composites. 2026; 14(02):30-41.
How to cite this URL:
M. Chennakesavulu, S. John Leon, P Joel Josephson, V.Parimala, DVSSSV Prasad, D. Priya Matharasi, Hirald Dwaraka Praveena, Sekar K, S. Sheik Mydeen. Stretchable Elastomer–Phase Change Composites for Passive Thermal Management in Wearable Electronics. Journal of Polymer & Composites. 2026; 14(02):30-41. Available from: https://journals.stmjournals.com/jopc/article=2026/view=238612


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Regular Issue Subscription Original Research
Volume 14
Issue 02
Received 03/02/2026
Accepted 06/02/2026
Published 10/03/2026
Publication Time 35 Days
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