Impact of pressure drop oscillations on surface temperature and critical heat flux during flow boiling in a microchannel

Flow boiling in microchannel heat sinks is capable of providing the high-heat-flux dissipation required for thermal management of next-generation wide bandgap power electronics at low pumping power and uniform surface temperatures. One of the primary issues preventing implementation of these technologies is the presence of flow boiling instabilities, which may reduce the heat transfer performance. However, the effect of individual instabilities, such as the parallel channel instability or pressure drop oscillations, on the overall heat transfer coefficient and critical heat flux in microchannel heat sinks has not been fully quantified. The primary cause of these dynamic flow boiling instabilities is the interaction between the inertia of a two-phase mixture in a heated channel and sources of compressibility located upstream of the inlet. In order to isolate the effect of pressure drop oscillations on flow boiling heat transfer performance, experiments are performed in a single square microchannel cut into a copper heat sink, with a controlled level of upstream compressibility. The impact of pressure drop oscillations on the heat transfer coefficient and critical heat flux is characterized through analysis of both time-averaged steady-state data as well as high-frequency pressure signals synchronized with high-speed visualization. The dielectric working fluid HFE-7100 is used in all experiments with a saturation temperature of 60°C at the channel outlet pressure. The occurrence and effect of pressure drop oscillations in 20 mm long microchannels of three different channel widths (0.5, 0.75, and 1 mm) are related to mass flux, the degree of two-phase flow confinement, and the severity of pressure drop oscillations

Optimization of permeable membrane microchannel heat sinks for additive manufacturing

The design freedom brought by additive manufacturing (AM) can be leveraged in the design of microchannel heat sinks to improve their cooling performance. The permeable membrane microchannel (PMM) heat sink geometry was inspired by the ability of powder bed AM processes to fabricate partially porous metal parts having small internal flow features on the order of the powder size. The design routes coolant through a parallel array of thin permeable membranes arranged in a single-layer-manifold configuration. The permeable membranes provide effective heat exchange surfaces and the manifold configuration yields a low flow resistance across the PMM heat sink, all incorporated in a single layer by the use of AM. Past work has introduced the PMM heat sink concept, but the optimal geometric feature sizes were not explored or identified. The n current study is first to explore design optimization of the PMM heat sink to identify target feature sizes for AM fabrication, assessment of the conditions under which the PMM geometry outperforms other standard microchannel heat sink designs, and inspection of the ability of metal 3D printing process to produce the optimal features. To this end, a reduced-order PMM heat sink model is developed, a gradient-based-multi-objective optimization is performed to identify the optimal feature sizes for different coolants (water and 48/52 water/ethylene glycol mixture) at different flow rates (100 – 500 mL/min), footprint areas (49 – 900 mm2), and channel heights (0.5 – 2.5 mm). The optimization results are benchmarked against an optimized straight microchannel (SMC) heat sink design. Optimized PMM designs offer up to 68% lower thermal resistance at a set pressure drop compared to optimized SMC designs. A pair of SMC and PMM heat sinks optimized for the same operating conditions are 3D printed using direct-metal-laser-sintering (DMLS) of AlSi10Mg. X-ray microtomography is used to characterize the geometry of the 3D-printed parts. The model identifies that optimal membrane gap sizes on the order of ~10s μm are required for the PMM to realize performance advantages compared to SMC heat sinks under the same operating conditions. The performance is predicted to be highly sensitive to this pore size, and even though DMLS is shown to produce parts with gaps as small as 26.7 microns, morphological deviations between the design and as-printed part are shown to lead to noticeable performance differences. Albeit excellent performance potential reinforced by this work, these findings call for further AM process development to ensure reliable, as-predicted PMM heat sinks to realize this potential

Investigation of boiling behaviors in vapor chambers in response to transient heat input profiles

Vapor chambers are being increasingly utilized as passive heat spreaders in various high-power density thermal management architectures. Particularly, in applications involving power electronics packaging, there is a need to understand and predict thermal performance of vapor chambers under different transient heat loads. It is known that boiling could occur in the wick structure of a vapor chamber at the location of heat input if sufficiently high heat fluxes are directly imposed on the chamber wall. Prior experimental studies that characterize the steady state thermal resistance of vapor chambers versus input power can only identify the behavior before and after the transition to boiling. However, because the initiation of boiling is a discrete event that occurs during the transient powering up, it is critical to understand how boiling behaviors will affect the performance of the vapor chamber in response to the transient heat input profile characteristics. Furthermore, currently available transient vapor chamber modeling efforts do not consider the occurrence of nucleate boiling, precluding their usage for applications where boiling is likely to occur. In this paper, we experimentally characterize the occurrence and effect of nucleate boiling in a vapor chamber coupled with an air-cooled heat sink, subject to various transient heat input profiles. The long-time step response behaviors are first studied for ten on-off cycles, at different on-powers, to illustrate the complete temperature response to a steady state in each cycle. For a range of intermediate powers, an interesting phenomenon is observed, where boiling occurs in every alternate cycle; we identify this range as the transition regime of boiling incipience in the vapor chamber. We further investigate the transient response to a pulsed heat input for various on-times ranging three orders of magnitude from 0.1 s to 400 s, and with two duty cycles (0.25 and 0.5), while keeping either the on-power or the average power constant. For a fixed on-power, lower on-times (0.1 s – 2 s) do not cause any boiling, but for longer on-times (≥ 20 s), cases with lower duty cycles led to occurrences of boiling incipience. Furthermore, for a fixed average power, a higher on-power at a lower duty cycle is more likely to cause boiling, which interestingly leads to an even lower mean steady temperature compared to cases with lower on-power and larger duty cycle. These studies provide insights into the nature of boiling incipience in vapor chambers for their usage under realistic transient input powers mimicking power electronics

A semi-empirical model for thermal resistance and dryout during boiling in thin porous evaporators fed by capillary action

Two-phase passive heat transport devices such as vapor chambers, loop heat pipes, and capillary pumped loops utilize porous evaporators for phase change and to drive fluid transport. Nucleate boiling can occur within such capillary-fed porous evaporators, especially under high-heat-flux operation, as has been visually observed in various experimental studies in the literature. However, prior modeling efforts have typically only considered single-phase flow of liquid through a completely saturated porous medium for characterizing the dryout limit and thermal performance. The present work offers a new semi-empirical model for prediction of thermal resistance and dryout during boiling in capillary-fed evaporators. Thermal conduction across the solid and volumetric evaporation within the pores are solved to obtain the temperature distribution in the porous structure. Capillary-driven lateral liquid flow from the outer periphery of the evaporator to its center, with vapor flow across the thickness, is considered to obtain the local liquid and vapor pressures. The capillary pressure and the relative permeabilities (fraction of single-phase permeabilities) for two-phase flow in the porous medium are modeled as a function of the local liquid saturation. The heat flux at which the liquid saturation at the center of the evaporator becomes zero is defined as the dryout limit of the evaporator. Experiments are conducted on sintered copper particle evaporators of different particle sizes and heater areas to collect data for model calibration. To demonstrate the wider applicability of the model for other types of porous evaporators, the model is further calibrated against a variety of dryout limit and thermal resistance data collected from the literature. The model is shown to predict the experimentally observed trends in the dryout limit with mean particle/pore size, heater size, and evaporator thicknesses

Comparative analysis of battery electric vehicle thermal management systems under long-range drive cycles

Due to increasing regulation on emissions and shifting consumer preferences, the wide adoption of battery electric vehicles (BEV) hinges on research and development of technologies that can extend system range. This can be accomplished either by increasing the battery size or via more efficient operation of the electrical and thermal systems. This study endeavours to accomplish the latter through comparative investigation of BEV integrated thermal management system (ITMS) performance across a range of ambient conditions (-20 °C to 40 °C), cabin setpoints (18 °C to 24 °C), and six different ITMS architectures. A dynamic ITMS modelling framework for a long-range electric vehicle is established with comprehensive sub models for the operation of the drive train, power electronics, battery, vapor compression cycle components, and cabin conditioning in a comprehensive transient thermal system modelling environment. A baseline thermal management system is studied using this modelling framework, as well as four common thermal management systems found in literature. This study is novel for its combination of comprehensive BEV characterization, broad parametric analysis, and the long range BEV that is studied. Additionally, a novel low-temperature waste heat recovery (LT WHR) system is proposed and has shown achieve up to a 15% range increase at low temperatures compared to the baseline system, through the reduction of the necessary cabin ventilation loading. While this system shows performance improvements, the regular WHR system offers the greatest benefit, a 13.5% increase in cold climate range, for long-range BEV drive cycles in terms of system range and transient response without the need for additional thermal system equipment

A figure of merit to characterize the efficacy of evaporation from porous microstructured surfaces

Evaporation from porous structured surfaces is encountered in a variety of applications including electronics cooling, desalination, and solar energy generation. Of major interest in the design of thermal systems for such applications is a prediction of the heat and mass transfer rates during evaporation from these surfaces. The present study develops a figure of merit (FOM) that characterizes the efficacy of evaporative heat transfer from microstructured surfaces. Geometric quantities such as the contact line length per unit area, porosity, and contact angle that are independent of details of the surface structure are utilized to develop the FOM, allowing for flexibility in its application to a variety of structured surfaces. This metric is calibrated against an evaporative heat transfer model and further benchmarked with evaporation heat transfer data from the literature. The FOM successfully captures the variation in evaporation heat transfer coefficient across different structures as well as the optimum dimensions for a given structure, and therefore can serve as a tool to survey available structures and also optimize their dimensions for heat and mass transfer enhancement

Transient flow boiling and maldistribution characteristics in heated parallel channels induced by flow regime oscillations

Flow boiling provides an effective means of heat removal but can suffer from thermal and hydrodynamic transients that compromise heat transfer performance and trigger device failure. In this study, the transient flow boiling characteristics in two thermally isolated, hydrodynamically coupled parallel microchannels are investigated experimentally. High-speed flow visualization is synchronized to high-frequency heat flux, wall temperature, pressure drop, and mass flux measurements to provide time-resolved characterization. Two constant and two transient heating conditions are presented. For a constant heat flux of 63 kW/m2 into each channel, boiling occurs continuously in both channels and the parallel channel instability is observed to occur at 15 Hz. Time-periodic oscillations in the pressure drop and average mass flux are observed, but corresponding oscillations in the wall temperatures are virtually non-existent at this condition. At a slightly lower constant heat flux of 60 kW/m2, boiling remains continuous in one of the channels, but the other channel experiences time-periodic flow regime oscillations between single-phase and two-phase flow. At this condition, extreme time-periodic wall temperature oscillations are observed in both channels with a long period (~7 s) due to oscillations in the severity of the flow maldistribution. For the transient heating conditions, square wave heating profiles oscillating between different heat flux levels are applied to the channels. Because of their relatively high frequency, the heating transients are attenuated by the microchannel walls, resulting in effectively constant heating conditions and flow boiling characteristics like that of the aforementioned constant heating conditions. This study illustrates the susceptibility of parallel two-phase heat sinks to flow maldistribution, particularly when undergoing transient flow regime oscillations

The effect of uneven heating on the flow distribution between parallel microchannels undergoing boiling

As the size, weight, and performance requirements of electronic devices grow increasingly demanding, their packaging has become more compact. As a result of thinning or removing the intermediate heat spreading layers, non-uniform heat generation from the chip-scale and component-level variations may be imposed directly on the attached microchannel heat sink. Despite the important heat transfer performance implications, the effect of uneven heating on the flow distribution in parallel microchannels undergoing boiling has been largely unexplored. In this study, a two-phase flow distribution model is used to investigate the impact of uneven heating on the flow distribution behavior of parallel microchannels undergoing boiling. Under lateral uneven heating (i.e., the channels are each heated to different levels, but the power input is uniform along the length of any given channel), it is found that the flow is significantly more maldistributed compared to the even heating condition. Specifically, the range of total flow rates over which the flow is maldistributed is broader and the maximum severity of flow maldistribution is higher. These trends are assessed as a function of the total input power, degree of uneven heating, and the extent of thermal connectedness between the channels. The model predictions are validated against experiments for a representative case of thermally isolated and coupled channels subjected to even heating and extreme lateral uneven heating conditions and show excellent agreement

Maturation, Peer Context, and Indigenous Girls\u27 Early-Onset Substance Use

This paper examines a biosocial model of the impact of puberty on Indigenous girls\u27 early-onset substance use by considering the potential mediating role of peer context (i.e. mixed-sex peer groups and substance use prototypes) on the puberty and substance use relationship. Data include responses from 360 girls of a common Indigenous cultural group residing on reservations/reserves in the upper Midwest and Canada. Results of structural equation modeling revealed that the statistically significant relationship between girls\u27 pubertal development and early-onset substance use was mediated by both mixed-sex/romantic peer groups and favorable social definitions of substance use. Implications for substance use prevention work include addressing the multiple and overlapping effects of peer influence from culturally-relevant perspectives

Compressed-Liquid Energy Storage with an Adsorption-based Vapor Accumulator for Solar-Driven Vapor Compression Systems in Residential Cooling

A cycle-integrated energy storage strategy for vapor-compression refrigeration is proposed wherein thermo-mechanical energy is stored as compressed liquid.A compressed-liquid tank is integrated into the liquid line of the system by means of an adsorption-based vapor accumulator in the vapor line. Energy is retrieved through expansion of the compressed liquid, which allows for a tunable evaporator temperature. A thermodynamic model is developed to assess the system performance, with storage incorporated, for solar residential cooling in two locations with contrasting ambient temperature profiles. Ammonia, R134a, and propane, all paired with activated carbon as adsorbent, are evaluated.A high cold thermal energy storage density is achieved when operated with ammonia. However, the accumulator suppresses the coefficient of performance of the system because work is required to extract refrigerant from the adsorbent. Practical feasibility of the proposed storage strategy calls for the development of nontoxic refrigerant–adsorbent pairs with more favorable adsorption behavior