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

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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 ORG GREEN TEA of a simplified 3D CFD Canes/Cane Accessories 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.