高效微小通道热沉散热系统设计及其实验研究
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摘要
微通道热沉由于结构紧凑,比表面积大,换热能力强,易于集成和工作安全可靠等优点,使其成为高热流密度电子器件散热和飞行器热控领域的有效装置。本文综合介绍和分析了微小通道热沉散热系统的工作原理及其特性,针对几种不同结构的微小通道热沉散热系统进行了一系列实验和理论研究。
本文针对不同的应用空间场合,设计了微小通道热沉散热系统整体方案和系统各部件结构型式。采用机械加工方式设计和加工了矩形平行直列通道和交错肋片扰流通道结构热沉,实验研究了其在不同结构型式和加热功率下的系统运行特性。实验和数值模拟对比分析表明交错肋片布置结构中由于交错肋对流体的不断扰动,抑制了边界层沿流动方向的充分发展,从而增强了换热效果,较矩形直列热沉结构具有更好的散热性能,其平均换热能力提高了19.4%以上,但在每列的交错肋片的前后端处有流动涡形成,带来了阻力增大的问题。此外,从场协同的角度出发分析了交错肋片结构强化传热和流动阻力增加的机理。流体沿其流动方向在每个肋片的前后端都受到新的扰动,在这些位置上热流和速度矢量之间的β协同角呈周期性地变化,其数值远小于矩形直列通道的场协同角β大小,提高了对流换热强度。但在流体扰动的同时,带来了阻力增加的问题,其速度矢量和速度梯度矢量之间的α协同角较平行直流通道要大。综合考虑两种结构的传热和流动情况,引入温度梯度矢量(?)T和速度梯度矢量(?)υ之间的γ协同角关系,显示交错肋片结构具有相对较优的综合性能。
结合增大微小通道散热器比表面积和削弱热边界层发展以强化传热的目的,本文设计了一种新型多层交错蜂窝板叠合微小通道热沉结构。采用光化学刻蚀方法加工的蜂窝微小通道板通过层层叠加的方式,在热沉内部形成微肋交错扰动的流体通道。该方法通过层叠方式在有限的封装空间内形成较单层流道更大的比表面积,构建了交错扰流的三维立体结构,解决了整体加工难度大及制造成本高等问题。针对该新型结构微小通道热沉设计,在不同流量,不同加热功率,不同工质,不同热沉设计尺寸等实验情况下对其散热系统进行了性能测试实验,对影响该系统性能的因素进行了分析和讨论。实验发现流量对系统性能影响很大,为得到较大的系统流量,在微泵泵功受限的情况下,必须对系统结构进行优化以减少系统阻力,为此改进了系统结构方案,采用了系统管路与微泵管路大小匹配,加大热沉进出口管径,设置热沉多进出口布置等方式进行系统减阻,并对此做了对比实验。单进单出热沉进出口管尺寸为φ4mm的热沉结构较进出管尺寸为φ2mm的热沉结构,在同样加热140W情况下,基板壁面温度下降了14.9℃。实验发现工质对系统的运行特性也有一定的影响,本文实验对比了多层交错蜂窝板叠合微小通道热沉结构分别以水和无水乙醇为工质的运行特性,由于水的比热容较大,其系统性能较无水乙醇系统要好。
通过将多层交错蜂窝板叠合微小通道热沉结构抽象成多孔介质模型,利用修正的达西方程和双能量方程模型对其进行了整体模拟和性能分析,数值计算结果和实验结果相一致。并针对各种不同的进出口布置方式,对热沉基板温度分布和压降情况进行了对比分析。分析结果指出多进出口设计方式在一定流量条件下由于减小了内部流速,从而降低了热沉压降,其流动与换热的综合效果较好。而交叉进出布置方式由于流体从距离较近的出口直接流出,减少了流动距离,其进出口压差最小,但中心区域由于流量的减少出现了局部高温情况。该数值模型为系统的设计和优化提供了指导,为微小通道热沉散热系统的应用奠定了基础。
The microchannel heatsink has been widely used in the field of thermal control of spacecraft and cooling of electronics with high heat flux because of the advantages of compact structures, high surface-to-volume ratio in limited space, strong cooling abilities, easily implementation and safe working. The thesis introduced the operating principles and analyzed the working characteristics of the minichannel heatsink cooling systems. A series of experimental and numerical works are conduced to several different minichannel heatsink structures.
According to different application requirements, the overall designs of the cooling system and the components structures are proposed in the thesis. Using the wire-cut method, the parallel rectangular-shaped minichannel array and the offset-fin minichannel structure heatsinks are fabricated. An experimental investigation is conducted to determine the heat transfer characteristics and cooling performance of the two kinds of minichannel structures machined into brass plates. The influence of minichannel in/outlet configuration, input heating power and property variations on the heat transfer behavior are analyzed experimentally. The experimental and numerical results show that the offset-fin structure obtains better cooling performance because the fluid flow disturbance restricts the development of the thermal boundary. The cooling fins are arranged into a staggered construction, when fluid flows in these alternating minichannels, the thermal boundary layer up-and downstream from the cooling fins. A new thermal boundary layer is restarted along the small pieces, resulting in a thinner thermal boundary layer. A high heat transfer coefficient is therefore obtained. The analytical results indicate that cooling performance increases to up 19.4% compared with the conventional straight ones. However, the vortex flow regions are found near the front and the rear edges of cooling fins, bringing the problem of larger pressure loss than the conventional straight ones. From the field synergy point, the heat transfer enhancement and flow resistance increment mechanisms of the offset-fin structures are also analyzed. The intersection angle between velocity and temperature gradient periodically changes along the up-and downstream from the cooling fins, and its value is far less than the conventional straight ones, improving heat transfer intensity. However, disturbances in the fluid simultaneously bring the issue of increased resistance, the intersection angle between velocity and velocity gradient is larger than the conventional straight ones. Both considering the heat transfer and flow conditions, the synergy relationship between temperature gradient and velocity gradient shows that staggered fin structure has a relatively optimum overall performance.
Combined the purposes of extending the surface-to-volume ratio in heatsink and restricts the development of the thermal boundary for heat transfer enhancement. A novel multilayer staggered honeycomb minichannel heatsink is designed in the cost-effective way in the thesis. Multilayered metal plates each with rows of etched honeycomb cells in are stacked to form the well-designed staggered minichannels in the heatsink. Better cooling performance is obtains based on the fluid hydrodynamic mixing improvement for periodic breakup of the thermal boundary layer. At the same time, the stacking structure design is also an easily implemental way to obtain higher surface-to-volume ratio in limited space simultaneously reducing the fabrication difficulty for 3D structure. Experimental investigation is conducted to determine the heat transfer characteristics and cooling performance of the honeycomb minichannel cooling system. The system heat transfer performance is evaluated under various operation situations, which includes different flow rate, input heating power, working fluid medium, minichannel heatsink parameters and test system configurations. The influence factors for the system performance are analyzed and discussed experimentally. It finds the flow rate has a large influence for the system performance from the experiments. In order to obtain larger flow rate for better cooling performance under the limited pumping power condition, the system configurations and structures must be optimized to reduce flow resistance. Several improvements such the agreement of the connection pipe size between micropump and heat sink, increasing the pipe size of heatsink in/outlet entrance holes and the multi-inlets and outlets arrangement are taken to reduce the system resistance for the comparison experiments. It finds that the substrate temperature of the singleφ4mm inner diameter in/outlet heatsink design decreases 14.9℃compared to the 02mm inner diameter in/outlet ones under the same 140W input heating power. The effects of working fluid to the cooling system are also studied by comparing water and ethanol as working fluid. It shows that the fluid with high specific heat is more suited for the heat transfer application.
By modeling the multilayer staggered honeycomb minichannel structures as porous media, the coupled heat transfer and flow characteristics of the heatsink are simulated and analyzed with the extended Darcy equation and the two-energy equation. The numerical results are in good accordance with the experimental ones. For the different in/outlet arrangements, the heatsink substrate temperature distribution and pressure drop are compared using the porous media model. The results show that the multi-inlets and outlets arrangement gets better cooling performance because the lower flow velocity under the constant flow rate reduces the pressure drop through the heatsink. However, although the cross multi-inlets and outlets design obtains the least pressure drop because of the reduction of flow length in the minichannels, there is found a local high temperature region in the center of the substrate also as the reduction of the flow rate through the minichannels. The experimental and numerical work is the fundament of developing the minichannel heatsink cooling system for high heat flux removal applications.
本文针对不同的应用空间场合,设计了微小通道热沉散热系统整体方案和系统各部件结构型式。采用机械加工方式设计和加工了矩形平行直列通道和交错肋片扰流通道结构热沉,实验研究了其在不同结构型式和加热功率下的系统运行特性。实验和数值模拟对比分析表明交错肋片布置结构中由于交错肋对流体的不断扰动,抑制了边界层沿流动方向的充分发展,从而增强了换热效果,较矩形直列热沉结构具有更好的散热性能,其平均换热能力提高了19.4%以上,但在每列的交错肋片的前后端处有流动涡形成,带来了阻力增大的问题。此外,从场协同的角度出发分析了交错肋片结构强化传热和流动阻力增加的机理。流体沿其流动方向在每个肋片的前后端都受到新的扰动,在这些位置上热流和速度矢量之间的β协同角呈周期性地变化,其数值远小于矩形直列通道的场协同角β大小,提高了对流换热强度。但在流体扰动的同时,带来了阻力增加的问题,其速度矢量和速度梯度矢量之间的α协同角较平行直流通道要大。综合考虑两种结构的传热和流动情况,引入温度梯度矢量(?)T和速度梯度矢量(?)υ之间的γ协同角关系,显示交错肋片结构具有相对较优的综合性能。
结合增大微小通道散热器比表面积和削弱热边界层发展以强化传热的目的,本文设计了一种新型多层交错蜂窝板叠合微小通道热沉结构。采用光化学刻蚀方法加工的蜂窝微小通道板通过层层叠加的方式,在热沉内部形成微肋交错扰动的流体通道。该方法通过层叠方式在有限的封装空间内形成较单层流道更大的比表面积,构建了交错扰流的三维立体结构,解决了整体加工难度大及制造成本高等问题。针对该新型结构微小通道热沉设计,在不同流量,不同加热功率,不同工质,不同热沉设计尺寸等实验情况下对其散热系统进行了性能测试实验,对影响该系统性能的因素进行了分析和讨论。实验发现流量对系统性能影响很大,为得到较大的系统流量,在微泵泵功受限的情况下,必须对系统结构进行优化以减少系统阻力,为此改进了系统结构方案,采用了系统管路与微泵管路大小匹配,加大热沉进出口管径,设置热沉多进出口布置等方式进行系统减阻,并对此做了对比实验。单进单出热沉进出口管尺寸为φ4mm的热沉结构较进出管尺寸为φ2mm的热沉结构,在同样加热140W情况下,基板壁面温度下降了14.9℃。实验发现工质对系统的运行特性也有一定的影响,本文实验对比了多层交错蜂窝板叠合微小通道热沉结构分别以水和无水乙醇为工质的运行特性,由于水的比热容较大,其系统性能较无水乙醇系统要好。
通过将多层交错蜂窝板叠合微小通道热沉结构抽象成多孔介质模型,利用修正的达西方程和双能量方程模型对其进行了整体模拟和性能分析,数值计算结果和实验结果相一致。并针对各种不同的进出口布置方式,对热沉基板温度分布和压降情况进行了对比分析。分析结果指出多进出口设计方式在一定流量条件下由于减小了内部流速,从而降低了热沉压降,其流动与换热的综合效果较好。而交叉进出布置方式由于流体从距离较近的出口直接流出,减少了流动距离,其进出口压差最小,但中心区域由于流量的减少出现了局部高温情况。该数值模型为系统的设计和优化提供了指导,为微小通道热沉散热系统的应用奠定了基础。
The microchannel heatsink has been widely used in the field of thermal control of spacecraft and cooling of electronics with high heat flux because of the advantages of compact structures, high surface-to-volume ratio in limited space, strong cooling abilities, easily implementation and safe working. The thesis introduced the operating principles and analyzed the working characteristics of the minichannel heatsink cooling systems. A series of experimental and numerical works are conduced to several different minichannel heatsink structures.
According to different application requirements, the overall designs of the cooling system and the components structures are proposed in the thesis. Using the wire-cut method, the parallel rectangular-shaped minichannel array and the offset-fin minichannel structure heatsinks are fabricated. An experimental investigation is conducted to determine the heat transfer characteristics and cooling performance of the two kinds of minichannel structures machined into brass plates. The influence of minichannel in/outlet configuration, input heating power and property variations on the heat transfer behavior are analyzed experimentally. The experimental and numerical results show that the offset-fin structure obtains better cooling performance because the fluid flow disturbance restricts the development of the thermal boundary. The cooling fins are arranged into a staggered construction, when fluid flows in these alternating minichannels, the thermal boundary layer up-and downstream from the cooling fins. A new thermal boundary layer is restarted along the small pieces, resulting in a thinner thermal boundary layer. A high heat transfer coefficient is therefore obtained. The analytical results indicate that cooling performance increases to up 19.4% compared with the conventional straight ones. However, the vortex flow regions are found near the front and the rear edges of cooling fins, bringing the problem of larger pressure loss than the conventional straight ones. From the field synergy point, the heat transfer enhancement and flow resistance increment mechanisms of the offset-fin structures are also analyzed. The intersection angle between velocity and temperature gradient periodically changes along the up-and downstream from the cooling fins, and its value is far less than the conventional straight ones, improving heat transfer intensity. However, disturbances in the fluid simultaneously bring the issue of increased resistance, the intersection angle between velocity and velocity gradient is larger than the conventional straight ones. Both considering the heat transfer and flow conditions, the synergy relationship between temperature gradient and velocity gradient shows that staggered fin structure has a relatively optimum overall performance.
Combined the purposes of extending the surface-to-volume ratio in heatsink and restricts the development of the thermal boundary for heat transfer enhancement. A novel multilayer staggered honeycomb minichannel heatsink is designed in the cost-effective way in the thesis. Multilayered metal plates each with rows of etched honeycomb cells in are stacked to form the well-designed staggered minichannels in the heatsink. Better cooling performance is obtains based on the fluid hydrodynamic mixing improvement for periodic breakup of the thermal boundary layer. At the same time, the stacking structure design is also an easily implemental way to obtain higher surface-to-volume ratio in limited space simultaneously reducing the fabrication difficulty for 3D structure. Experimental investigation is conducted to determine the heat transfer characteristics and cooling performance of the honeycomb minichannel cooling system. The system heat transfer performance is evaluated under various operation situations, which includes different flow rate, input heating power, working fluid medium, minichannel heatsink parameters and test system configurations. The influence factors for the system performance are analyzed and discussed experimentally. It finds the flow rate has a large influence for the system performance from the experiments. In order to obtain larger flow rate for better cooling performance under the limited pumping power condition, the system configurations and structures must be optimized to reduce flow resistance. Several improvements such the agreement of the connection pipe size between micropump and heat sink, increasing the pipe size of heatsink in/outlet entrance holes and the multi-inlets and outlets arrangement are taken to reduce the system resistance for the comparison experiments. It finds that the substrate temperature of the singleφ4mm inner diameter in/outlet heatsink design decreases 14.9℃compared to the 02mm inner diameter in/outlet ones under the same 140W input heating power. The effects of working fluid to the cooling system are also studied by comparing water and ethanol as working fluid. It shows that the fluid with high specific heat is more suited for the heat transfer application.
By modeling the multilayer staggered honeycomb minichannel structures as porous media, the coupled heat transfer and flow characteristics of the heatsink are simulated and analyzed with the extended Darcy equation and the two-energy equation. The numerical results are in good accordance with the experimental ones. For the different in/outlet arrangements, the heatsink substrate temperature distribution and pressure drop are compared using the porous media model. The results show that the multi-inlets and outlets arrangement gets better cooling performance because the lower flow velocity under the constant flow rate reduces the pressure drop through the heatsink. However, although the cross multi-inlets and outlets design obtains the least pressure drop because of the reduction of flow length in the minichannels, there is found a local high temperature region in the center of the substrate also as the reduction of the flow rate through the minichannels. The experimental and numerical work is the fundament of developing the minichannel heatsink cooling system for high heat flux removal applications.
引文
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