OIL-IN-WATER MACRO-EMULSION PROCESS FOR FORMING SOLID GEL BEADS MELTABLE TO FORM A GEL PHASE CHANGE MATERIAL

Solid gel beads formed from a gel product of a 5 carbon to 60 carbon alkane phase change material, 5 carbon to 60 carbon alkene phase change material, or a combination thereof and a styrene-based polymer are homogeneous, has an uneven exterior surface, and a major axis length in a range of 1000 μm to 100 mm. Methods for making the solid gel bead include providing water having a preselected temperature based on a linear relationship to the melting point of a phase change material composition, mixing the phase change material composition with the styrene-based polymer at or below the preselected temperature with stirring to form a pulp, and mixing the pulp into the water with turbulent mixing while maintaining the temperature of the mixture at the preselected temperature.