Polymers with highly conductive fillers could possibly replace standardly used materials, such as aluminum and copper alloys, for passive cooling purposes. The main problem of the composite polymer-based heat sinks is that their high thermal conductivity is uneven. The orientation of this anisotropy is set according to the position of the highly thermally conductive filler. Its orientation is influenced by the melt flow during the polymer heat sink molding process. This article shows that change of the melt flow inside the mold cavity can improve the overall cooling efficiency of a polymer heat sink, which leads to lower temperatures on the heat source used. Two polymer heat sinks of identical geometries were produced. Their high thermal conductivity was given by the use of graphite flakes as the filler. The only difference between the heat sinks was in the position of the fan gate during their production. Different temperatures of the heat source between the two heat sinks were observed for the same measurement conditions. The measurements were conducted at Heatlab, BUT/Brno.
In the past decade, the condensation of internal air humidity in automotive headlamps has become more prevalent than ever due to the increased usage of a new light source—LEDs. LEDs emit far less heat than previously-used halogen lamps, which makes them far more susceptible to fogging. This fogging occurs when the internal parts of the headlamp fall to a temperature below the dew point. The front glass is most vulnerable to condensation due to its direct exposure to ambient conditions. Headlamp fogging leads to a decrease in performance and the possibility of malfunctions, which has an impact not only on the functional aspect of the product’s use but also on traffic safety. There are currently several technical solutions available which can determine the effectivity of ventilation systems applied for headlamp defogging. Another approach to this problem may be to use a numerical simulation. This paper proposes a CFD (computational fluid dynamics) simulation with a slightly simplified 3D model of an actual headlamp, which allows simulation of all the phenomena closely connected with fluid flow and phase change. The results were validated by real experiments on a special fogging–defogging test rig. This paper compares three different simulations and their compliance with real experiments.
Miniaturization of electronic devices leads to new heat dissipation challenges and traditional cooling methods need to be replaced by new better ones. Polymer heat sinks may, thanks to their unique properties, replace standardly used heat sink materials in certain applications, especially in applications with high ambient temperature. Polymers natively dispose of high surface emissivity in comparison with glossy metals. This high emissivity allows a larger amount of heat to be dissipated to the ambient with the fourth power of its absolute surface temperature. This paper shows the change in radiative and convective heat transfer from polymer heat sinks used in different ambient temperatures. Furthermore, the observed polymer heat sinks have differently oriented graphite filler caused by their molding process differences, therefore their thermal conductivity anisotropies and overall cooling efficiencies also differ. Furthermore, it is also shown that a high radiative heat transfer leads to minimizing these cooling efficiency differences between these polymer heat sinks of the same geometry. The measurements were conducted at HEATLAB, Brno University of Technology.
The use of polymer composites as a replacement for commonly applied materials in industry has been on the rise in recent decades. Along with the development of computer software, the desire to predict the behavior of new products is thus increasing. Traditional additives in the form of fibers cause anisotropic properties of the whole product. The subject of the presented study is a polymer heat sink prototype with a thermally conductive filler in the form of graphite flakes, which differs from the commonly used fibers. Three simplified approaches are introduced to model the thermal conductivity anisotropy of an entire heat sink. Each model is subjected to an inverse heat conduction problem, the output of which are thermal conductivity values. These are optimized to minimize the difference between simulated and experimental temperatures at selected locations in the model. The approaches are compared with each other with respect to their error against the experimentally obtained results. The goal is to find a sufficiently simplified approach that can be applied to products of various geometries. This would remove the costly and time-consuming need for mold production and experimental testing.
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