Aggressive demands for high power density and low-cost power modules in the automotive sector pose significant challenges to the thermal management systems. These challenges necessitate adopting highly effective cooling technologies in power modules to remain competitive in the semiconductor industry. Furthermore, the thermal management strategy must be simple, easy to integrate, compact, effective, efficient, reliable, and economical.
This thesis is an effort to investigate the impact of fin geometry on the overall performance of finned-type liquid-cooled power electronic modules in electrified transportation. The cooling system's performance metrics, including thermal resistance, pressure drop, pumping power, and mass, are discussed in depth. Various cooling technologies are benchmarked. The finned-type cooling technique is chosen over other methods due to simplicity and low pressure drop. Integrated cooling or direct cooling of the module’s baseplate is selected due to considerable thermal resistance reduction because of thermal grease elimination. Potential fabrication techniques are thoroughly explored and compared in terms of mass production and prototyping suitability.
Four different fin shapes, including circular (baseline), drop-shaped, symmetric convex lens, and offset strip in the staggered arrangement, are studied herein. The cooling agent is Water and Ethylene Glycol 50% volumetric mixture (WEG 50%). Typical operating conditions in electrified vehicles (EVs) such as flow rate and inlet temperature are assumed for the numerical analysis. A grid convergence study is carried out to ensure numerical solutions are within an acceptable error band.
The thermal performance evaluation results showed that, on average, offset strip, drop-shaped, and the convex lens performed 39%, 20%, and 6% better than the baseline design, respectively. Additionally, the design candidates are compared in terms of mass and estimated machining cost. The results of the baseline case are verified against empirical correlations from the literature. The maximum deviation is less than 1% and 1.2% for finned-surface temperature and pressure drop, respectively. The difference is attributed to the end-wall effects. / Thesis / Master of Applied Science (MASc)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/26369 |
| Date | January 2021 |
| Creators | Kashfi, Seyed Sobhan |
| Contributors | Emadi, Ali, Mechanical Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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