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 Hoodie 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 Rollators 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.