Ultra-stable counter flow diverging minichannel heat sink with integrated microstructures for superior cooling performance

• Published in: Applied thermal engineering 2025-01, Vol.258, p.124560, Article 124560
• Main Authors: Waqar Ali Shah, Syed, Jiang, Xingchi, Li, Yuen Kit Howard, Chen, Gong, Liu, Jian, Gao, Yuan, Zhang, Shiwei, Pan, Chin
• Format: Article
• Language: English
• Subjects: Advanced cooling applications; Counter flow diverging minichannels; Gradient micro pin-fins; Gradient microcavities; Lower pressure drop; Stable two-phase flow
• ISSN: 1359-4311
• DOI: 10.1016/j.applthermaleng.2024.124560

[Display omitted] •Proposing the counter flow diverging minichannels with integrated microstructures.•A synergy of gradient micro pin-fins and cavities is the primary mechanism.•Attained heat flux of 746.14 W/cm2 and heat transfer coefficient of 28.18 W/cm2K.•Offered a very small pressure drop of 2.35 kPa with a stable two-phase flow. Efficient thermal management of miniaturized electronic devices is quite challenging nowadays. It requires dissipation of very high heat flux without considerable elevation of surface temperature. To address this issue, this study proposes the counter flow diverging minichannel heat sink in a compact size of 3 cm2. Additionally, two innovative microstructures have been developed and integrated into the bottom surface of the proposed minichannel heat sink: one with gradient micro pin-fins and another combining gradient microcavities with micro pin-fins. Comprehensive flow boiling experiments are conducted under various operating conditions to identify the best configuration with the most appropriate operating condition to dissipate the highest heat flux with minimal pressure drop and stable two-phase flow patterns. The current study reveals that the synergistic effects of gradient micro pin-fins and optimized gradient microcavities achieve a very high heat flux of 746.14 W/cm2 and a two-phase heat transfer coefficient of 28.18 W/cm2K under the limitation of wall temperature lower than 132 °C. Additionally, it maintains an exceptionally low pressure drop of 2.35 kPa with stable two-phase flow patterns under a mass flux of 600 kg/m2s and a degree of subcooling of 40 °C. Compared to the bare surface, counter flow diverging minichannels with gradient micro pin-fins and optimized gradient microcavities show excellent enhancements of 201.12 % in the effective heat flux and 124 % in the two-phase heat transfer coefficient, suggesting it is the best design in the present study for advanced cooling applications.