Performance Characterization of a Novel Cross-Media Composite Heat Exchanger for Air-to-Liquid Applications

Arie, Martinus; Hymas, David; Singer, Farah; Shooshtari, Amir; Ohadi, Michael M.

doi:10.1109/itherm.2019.8757258

Cited by 6 publications

(7 citation statements)

References 14 publications

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“…Furthermore, conductive resistance is computed analytically from Equation ( 20), and R total can now be obtained from Equation (8): R walls = t wall k wire A CS wire (20) where A CS wire = (2…”

Section: Analytical Model For the Entire Hxmentioning

confidence: 99%

“…The current paper meets the above challenges by utilizing a novel, entirely additively manufactured, low-cost, and lightweight metal-polymer composite HX [20][21][22], with effective thermal conductivity in the range of 130 W/m-K [21]. High thermal conductivity metal wires contribute towards effective thermal conductivity while polymer media contribute to a lightweight and low-cost unit.…”

Section: Introductionmentioning

confidence: 99%

“…The heat exchanger can also include additively manufactured integrated liquid manifolds of polymer. Customized 3D printing processes utilize a polymer and a metal head based on a hybrid and innovative approach [25] designed and developed by a few of the co-authors, as described in [20,26]. The polymer head prints layers of polymer media to build air-side and liquid-side channels using FDM while the metal head prints bare metal wires that continuously lay over the polymer media using EFCAM such that they form a direct heat transfer route between the air-side and liquid-side channels.…”

Section: Introductionmentioning

confidence: 99%

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Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

Mandel¹,

Shooshtari²,

Ohadi³

2022

Energies

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In order to meet increasing power-dissipation requirements of the electronics industry, compact, low-cost, and lightweight heat exchangers (HXs) are desired. With proper design, materials, and manufacture, polymer composite heat exchangers could meet these requirements. This paper presents a novel crossflow air-to-water, low-cost, and lightweight metal-polymer composite HX. This HX, which is entirely additively manufactured, utilizes a novel cross-media approach that provides direct heat exchange between air and liquid sides by using connecting fins. A robust numerical model was developed, which includes the dimensional effects of additive manufacturing. The study consists of a simplified 3D CFD model based on ellipsoidal-shaped staggered tube banks for the laminar range. It then uses an analytical approach to compute entire HX performance. The model is validated experimentally within 8% for thermal performance, 12% for air-side impedance, and 18% for water-side impedance. Finally, HX is compared with a conventional CPU radiator and performs within 10% of the conventional unit for reasonable flow rates and pressure-drop ranges. Moreover, HX also provides added design and cost advantages over the conventional unit, which makes the HX a potential candidate for electronic cooling applications.

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Section: Analytical Model For the Entire Hxmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

Mandel¹,

Shooshtari²,

Ohadi³

2022

Energies

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“…The heat then continuously conducts through the wires axially, up to t wall length, until it reaches the PCM side. In this so-called cross-media approach, small-diameter continuous metal wires of high thermal conductivity, such as copper, are laid across all the fluid and PCM channels, providing a direct heat transfer route between the hot fluid and the PCM (see Figure 1c,e) [10][11][12][13][14]. Since the heat transfer route is independent of the thermal conductivity of the polymer, the resulting TES system is a low-resistance unit.…”

Section: Design Of a Novel Tes Systemmentioning

confidence: 99%

“…The present study overcomes these challenges by utilizing a low-cost, metal-polymer composite heat exchanger (HX), consisting of metal wires embedded in the polymer structure and integrated with a PCM to yield a compact, durable, and lightweight storage device. The proposed technology leverages the results from the authors' past work on a patented cross-media approach capable of producing entirely additively manufactured, low-cost and lightweight metal-polymer composite heat exchangers [10][11][12][13][14]. The TES units based on these HXs utilize high thermal-conductivity continuous metal wires that act as fins in a tube-bank geometry, separated by lightweight and low-cost alternate polymer channels.…”

Section: Introductionmentioning

confidence: 99%

A 1D Reduced-Order Model (ROM) for a Novel Latent Thermal Energy Storage System

2022

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Phase change material (PCM)-based thermal energy storage (TES) systems are widely used for repeated intermittent heating and cooling applications. However, such systems typically face some challenges due to the low thermal conductivity and expensive encapsulation process of PCMs. The present study overcomes these challenges by proposing a lightweight, low-cost, and low thermal resistance TES system that realizes a fluid-to-PCM additively manufactured metal-polymer composite heat exchanger (HX), based on our previously developed cross-media approach. A robust and simplified, analytical-based, 1D reduced-order model (ROM) was developed to compute the TES system performance, saving computational time compared to modeling the entire TES system using PCM-related transient CFD modeling. The TES model was reduced to a segment-level model comprising a single PCM-wire cylindrical domain based on the tube-bank geometry formed by the metal fin-wires. A detailed study on the geometric behavior of the cylindrical domain and the effect of overlapped areas, where the overlapped areas represent a deviation from 1D assumption on the TES performance, was conducted. An optimum geometric range of wire-spacings and size was identified. The 1D ROM assumes 1D radial conduction inside the PCM and analytically computes latent energy stored in the single PCM-wire cylindrical domain using thermal resistance and energy conservation principles. The latent energy is then time-integrated for the entire TES, making the 1D ROM computationally efficient. The 1D ROM neglects sensible thermal capacity and is thus applicable for the low Stefan number applications in the present study. The performance parameters of the 1D ROM were then validated with a 2D axisymmetric model, typically used in the literature, using commercially available CFD tools. For validation, a parametric study of a wide range of non-dimensionalized parameters, depending on applications ranging from pulsed-power cooling to peak-load shifting for building cooling application, is included in this paper. The 1D ROM appears to correlate well with the 2D axisymmetric model to within 10%, except at some extreme ranges of a few of the non-dimensional parameters, which lead to the condition of axial conduction inside the PCM, deviating from the 1D ROM.

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Error Performance Index Based PID Tuning Methods for Temperature Control of Heat Exchanger System

Kumar

Sampath

Praneeth

et al. 2021

2021 IEEE International IOT, Electronics and Mechatronics Conference (IEMTRONICS)

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Performance Characterization of a Novel Cross-Media Composite Heat Exchanger for Air-to-Liquid Applications

Cited by 6 publications

References 14 publications

Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

A 1D Reduced-Order Model (ROM) for a Novel Latent Thermal Energy Storage System

Error Performance Index Based PID Tuning Methods for Temperature Control of Heat Exchanger System

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