Development of Power Electronic Building Block (PEBB) modules, initiated through the Office of Naval Research (ONR), is a promising enabling technology which will promote future electrical power systems. Key in this development is the thermal design of a PEBB packaging scheme that will manage the module's high heat dissipation levels. As temperatures in electronics are closely associated with operating efficiency and failure rates, management of thermal loads is necessary to ensure proper and reliable device performance. The current work investigates the thermal design requirements for a preliminary PEBB module developed by the NSF Center for Power Electronics Systems (CPES) at Virginia Tech. This module locates four primary heat-generating devices onto a copper bonded substrate in a multi-chip module format. The thermal impact of several design variables (including heat sink quality, substrate material, device spacing, and substrate and metallization thickness) are modeled within the multi-layer thermal analysis software TAMSä. Model results are in the form of metal layer surface temperatures that closely represent the device junction temperatures. Other design constraints such as electrical and material characteristics are also considered in the thermal design. Design results indicate for the device heat dissipation levels that a low resistance heat sink coupled with a high conductivity substrate, such as aluminum nitride, are required for acceptable device junction temperatures. Substrate performance, in the form of a spreading resistance component, will be negatively affected by a lower quality heat sink. Both forced air and cold plate cooling methods were found acceptable; factors such as environment, cost and integration will determine which solution is most feasible. Maximum surface temperatures can be lowered somewhat through adjustment of device spacing. However, this reduction was small compared to the impact on parasitic capacitance. Additionally, there is some thermal benefit to thicker high-conductivity substrates, whereas lower conductivity substrates will increase the maximum surface temperature. Thicker copper layers will prove beneficial though this benefit is not as great for higher conductivity substrates. Also discussed are the on-going and future development efforts that are expected to require thermal consideration. These consist of a top-level thermal bus for additional heat removal, the use of metal matrix composites and concepts for multi-module integration. / Master of Science

Sustaining high performance demand has led to the development of manycore processors. These manycore processors have thermal properties which are different from conventional processors. In order to understand the thermal characteristics of such manycore processors, we have developed a modeling environment with a rich set of features which can be used to used to model different scenarios in manycore processors. Using this modeling framework, we have developed a thermal management policy called 'Weight based management policy'. We have also developed a GUI based modeling tool which can be integrated into the computer architecture curriculum so as to enable students to understand the importance of thermal limitations right during the design phase.

No description available.

Les problématiques liées à la gestion de la chaleur sous capot sont importantes lors du développement de nouveaux véhicules terrestres. Jusqu’à maintenant, les approches les plus courantes pour les caractériser et s’assurer du bon comportement des véhicules étaient principalement expérimentales. Les test sont de plus en plus remplacés par des modèles numériques permettant un gain financier et de temps considérable. L’approche numérique est désormais répandue dans l’industrie automobile, et on l’applique ici dans le cas d’une motoneige afin de caractériser son comportement aérothermique, à l’aide de l’outil CFD. L’utilisation du modèle, validé à l’aide d’essais sur le terrain, permet alors l’optimisation des paramètres influençant la gestion thermique, et ainsi l’harmonisation des traitements acoustiques appliqués en vue d’une réduction de bruit tout en respectant les besoins de refroidissement de ces appareils.

This thesis describes the processing and characterisation of Al-70Si alloys manufactured by gas atomised spray forming at Sandvik-Osprey (Neath, UK) and Oxford University using a newly commissioned spray forming pilot-plant facility. Spray formed Al-70Si (CE7) provides an attractive balance of thermophysical properties making it suitable for thermal management applications. Microstructural characterisation of CE7 was conducted using optical microscopy, image analysis, electron probe micro analysis (EPMA) and electron backscatter diffraction (EBSD). Microscopy revealed an interpenetrating network microstructure consisting of fine, randomly oriented polycrystalline primary Si interpenetrated by large, α-Al grains devoid of eutectic Si. Mechanical testing and thermal cycling simulated a service environment and revealed for the first time crack initiation, growth and blunting mechanisms, the effect of intermetallic phases on the bulk mechanical properties, and anisotropy effects resulting from macrosegregation of Al during solidification. A relationship between the inter-phase interface length and the fracture toughness has been proposed and methods of interface length refinement have been investigated, including chill casting and spray forming. Spray formed CE7 modified with separate additions of B, P, P+Ce and Sr have been microstructurally and mechanically characterised and compared with binary CE7. While alloy additions were effective in refining primary and eutectic Si in chill cast alloys, spray formed alloys showed little change in interface length. Particle injection of Si-Al powder was effective in refining the scale of the spray formed microstructure, and improving mechanical properties. The deleterious effect of intermetallic phases on bulk mechanical properties has been demonstrated and highlighted the importance of melt cleanliness and materials control during manufacturing.

Proton Exchange Membrane Fuel Cells (PEMFCs) present a promising alternative to the conventional internal combustion engine for automotive applications because of zero harmful exhaust emissions, fast refuelling times and possibility to be powered by hydrogen generated through renewable energy. However, several issues need to be addressed before the widespread adoption of PEMFCs, one such problem is the removal of waste heat from the fuel cell electrochemical reaction at high ambient temperatures. Automotive scale fuel cells are most commonly liquid cooled, evaporative cooling is an alternative cooling method where liquid water is added directly into the fuel cell flow channels. The liquid water evaporates within the flow channel, both cooling and humidifying the cell. The evaporated water, along with some of the product water, is then condensed from the fuel cell exhaust, stored, and re-used in cooling the fuel cell. This work produces a system level model of an evaporatively cooled fuel cell vehicle suitable for the study of water balance and heat exchanger requirements across steady state operation and transient drive cycles. Modelling results demonstrate the ability of evaporatively cooled fuel cells to self regulate temperature within a narrow region (±2°C) across a wide operating range, provided humidity is maintained within the flow channels through sufficient liquid water addition. The heat exchanger requirements to maintain a self sufficient water supply are investigated, demonstrating that overall heat exchange area can be reduced up to 40% compared to a liquid cooled system due to the presence of phase change within the vehicle radiator improving heat transfer coefficients. For evaporative cooling to remain beneficial in terms of heat exchange area, over 90% of the condensed liquid water needs to be extracted from the exhaust stream. Experimental tests are conducted to investigate the condensation of water vapour from a saturated air stream in a compact plate heat exchanger with chevron flow enhancements. Thermocouples placed within the condensing flow allow the local heat transfer coefficient to be determined and an empirical correlation obtained. The corresponding correlation is used to produce a heat exchanger model and study the influence different heat exchanger layouts have on the overall required heat transfer area for an evaporatively cooled fuel cell vehicle. A one-dimensional, non-isothermal model is also developed to study the distribution of species, current density and temperature along the flow channel of an evaporatively cooled fuel cell using different methods of liquid water addition. Results show that good performance can be achieved with cathode inlet humidities as low as 20%, although some anode liquid water addition may be required at high current densities due to increased electro-osmotic drag. It is also demonstrated that both good membrane hydration and temperature regulation can be managed by uniform addition of liquid water across the cell to maintain a target exhaust relative humidity.

<div>The continued miniaturization and demand for improved performance of electronic devices has resulted in the need for transformative thermal management strategies. Flow boiling is an attractive approach for the thermal management of devices generating high heat fluxes. However, designing heat sinks for two-phase operation and predicting their performance is difficult because of, in part, commonly encountered flow boiling instabilities and a lack of experimentally validated physics-based phase change models. This work aims to advance the state of the art by furthering our understanding of flow boiling instabilities and their implications on the operating characteristics of electronic devices. This is of particular interest under transient and non-uniform heating conditions because of recent advancements in embedded cooling techniques, which exacerbate spatial non-uniformities, and the demand for cooling solutions for next-generation electronic devices. Additionally, this work aims to provide a high-fidelity experimental characterization technique for slug flow boiling to enable the validation of physics-based phase change models.</div><div><br></div><div>To provide a foundation for which the effects of transient and non-uniform heating can be studied, flow boiling instabilities are first studied experimentally in a single, 500 μm-diameter borosilicate glass microchannel. A thin layer of optically transparent and electrically conductive indium tin oxide coated on the outside surface of the microchannel provides a spatially uniform and temporally constant heat flux via Joule heating. The working fluid is degassed, dielectric HFE-7100. Simultaneous high-frequency measurement of reservoir, inlet, and outlet pressures, pressure drop, mass flux, inlet and outlet fluid temperatures, and wall temperature is synchronized to high-speed flow visualizations enabling transient characterization of the thermal-fluidic behavior.</div><div><br></div><div>The effect of flow inertia and inlet liquid subcooling on the rapid-bubble-growth instability at the onset of boiling is assessed first. The mechanisms underlying the rapid-bubble-growth instability, namely, a large liquid superheat and a large pressure spike, are quantified. This instability is shown to cause flow reversal and can result in large temperature spikes due to starving the heated channel of liquid, which is especially severe at low flow inertia.</div><div><br></div><div>Next, the effect of flow inertia, inlet liquid subcooling, and heat flux on the hydrodynamic and thermal oscillations and time-averaged performance is assessed. Two predominant dynamic instabilities are observed: a time-periodic series of rapid-bubble-growth instabilities and the pressure drop instability. The heat flux, ratio of flow inertia to upstream compressibility, and degree of inlet liquid subcooling significantly affect the thermal-fluidic characteristics. High inlet liquid subcoolings and low heat fluxes result in time-periodic transitions between single-phase flow and flow boiling that cause large-amplitude wall temperature oscillations and a time-periodic series of rapid-bubble-growth instabilities. Low inlet liquid subcoolings result in small-amplitude thermal-fluidic oscillations and the pressure drop instability. Low flow inertia exacerbates the pressure drop instability and results in large-amplitude thermal-fluidic oscillations whereas high flow inertia reduces their severity.</div><div><br></div><div>Flow boiling experiments are then performed in a parallel channel test section consisting of two thermally isolated, heated microchannels to study the Ledinegg instability. When the flow in both channels is in the single-phase regime, they have equal wall temperatures due to evenly distributed mass flux delivered to each channel. Boiling incipience in one of the channels triggers the Ledinegg instability which induces a temperature difference between the two channels due to flow maldistribution. The temperature difference between the two channels grows with increasing power. The experimentally observed temperature excursion between the channels due to the Ledinegg instability is reported here for the first time.</div><div><br></div><div>Time-resolved characterization of flow boiling in a single microchannel is then performed during transient heating conditions. For transient heating tests, three different heat flux levels are selected that exhibit highly contrasting flow behavior during constant heating conditions: a low heat flux corresponding to single-phase flow (15 kW/m²), an intermediate heat flux corresponding to continuous flow boiling (75 kW/m²), and a very high heat flux which would cause critical heat flux if operated at this heat flux continuously (150 kW/m²). Transient testing is first conducted using a single heat flux pulse between these heat flux levels and varying the pulse time. It is observed that any step up/down in the heat flux level that induces/ceases boiling, causes the temperature to temporarily over/under-shoot the eventual steady temperature. Following the single heat flux pulse experiments, a time-periodic series of heat flux pulses is applied. A square wave heating profile is used with pulse frequencies ranging from 0.1 to 100 Hz and three different heat fluxes levels (15, 75, and 150 kW/m²). Three different time-periodic flow boiling fluctuations are observed: flow regime transitions, pressure drop oscillations, and heating pulse propagation. For heating pulse frequencies between approximately 1 and 10 Hz, the thermal and flow fluctuations are heavily coupled to the heating characteristics, forcing the pressure drop instability frequency to match the heating frequency. For heating pulse frequencies above 25 Hz, the microchannel wall attenuates the transient heating profile and the fluid essentially experiences a constant heat flux.</div><div><br></div><div>To improve our ability to predict the performance of heat sinks for two-phase operation, high-fidelity characterization of key hydrodynamic and heat transfer parameters during microchannel slug flow boiling is performed using a novel experimental test facility that generates an archetypal flow regime, devoid of flow instabilities and flow regime transitions. High-speed flow visualization images are analyzed to quantify the uniformity of the vapor bubbles and liquid slugs generated, as well as the growth of vapor bubbles over a range of heat fluxes. A method is demonstrated for measuring liquid film thickness from the visualizations using a ray-tracing procedure to correct for optical distortions. Characterization of the slug flow boiling regime that is generated demonstrates the unique ability of the facility to precisely control and quantify hydrodynamic and heat transfer characteristics.</div><div><br></div><div>This work has advanced state-of-the-art technologies for the thermal management of high-heat-flux-dissipation devices by providing an improved understanding on the effects of transient and non-uniform heating on flow boiling and an experimental method for the validation of physics-based flow boiling modeling.</div>

No description available.

The effects of climate change along with shifts in social demands have opened up commercial possibilities for new and innovative green technology. At the head of this trend is research into new technologies for Hybrid Electric Vehicles (HEVs) and Battery Electric Vehicles (BEVs). These technologies would provide for more environmentally friendly transportation; however their current performance when compared to Internal Combustion Engine (ICE) Vehicles has led to slow adoption rates. One of the key factors that could help to increase the performance of HEVs and BEVs lies in improvement of the battery systems. Through proper thermal management of the batteries the range and performance of these vehicles can be improved, helping to increase the performance of the vehicles. This study looks at improving the thermal management of the battery system by generating more efficient cooling plates. These cooling plates are set between battery cells and contain channels that coolant is pumped through. Through optimization of these cooling channels, the efficiency of the cooling plates with regards to the average temperature and standard deviation of temperature of the battery cell can both be increased. The power required to run the cooling system can also be reduced by reducing the pressure losses associated with the cooling plate. Numerical optimization on three models of cooling plates was performed. The models were based on multi-inlet and outlet curved channel systems, with one model constructed using arcs and the other two using 90 degree angles. Results showed that improvements of up to 80% could be made depending on the objective functions when compared to an initial design through optimization, with straight channels providing 8% more efficient designs in terms of pressure losses over curved designs, and curved designs providing 6% more efficient designs in terms of average temperature. Analysis on the effects of varying the mass flow rate, heat flux and inlet temperature was also conducted to evaluate their effects on the optimized geometries. This study has practical applications in helping to develop new cooling plates for commercial use through implementation of the generated design features and optimization algorithms. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2012-09-27 15:09:12.261

This thesis examines the development of a high efficiency heat pump system using thermoelectric (TE) and reticulated metal foam (RMF) technologies to power a vehicle`s battery thermal management system. The focus is split into two areas: first a review of TE???s sourcing or removing heat, second an examination of compact heat exchanger (HX) design. Five TE suppliers were investigated to understand the performance and limitations of their TE modules. Testing showed the Kyrotherm product to be superior so it was used as a design basis. RMF???s are known to be an effective means to improve the performance of compact heat exchangers, thus HX???s were evaluated with RMF foams compressed to varying densities in order to understand their potential in conjunction with thermoelectric devices. Experimental results showed performance was limited due to adequate bonding, yet still on par with the highest efficiency technologies currently on the market.