Impingement Air Cooled Plate Fin Heat Sinks Part II– Thermal Resistance Model Zhipeng Duan* and Yuri S. Muzychka+ Faculty of Engineering and Applied Science Memorial University of Newfoundland St. John’s, Newfoundland, Canada, A1B 3X5 Email: zpduan@engr.mun.ca, yuri@engr.mun.ca ABSTRACT Impingement air cooling with heat sinks is one attractive solution in thermal management of electronic components. A simple impingement flow thermal resistance model based on developing laminar flow in rectangular channels is proposed. Experimental measurements of thermal resistance are performed with heat sinks of various impingement inlet widths, fin spacings, fin heights and airflow velocities to test the validity of the model. The accuracy of the predicted thermal resistance was found to be within 20% of the experimental data at channel Reynolds numbers less than 1200. The simple model is suitable for parametric design studies. KEY WORDS: Impingement Flow, Heat Sink, Thermal Resistance, Model, Plate Fin, Airflow NOMENCLATURE Ab As b h heff hrad H I k ka L Leff Ls Nf Nu Pr Q Q Qloss R R1D Rbare Rbase Rfins Rrad Rsink base plate area, m2 heat source area, m2 fin spacing, m heat transfer coefficient , W/m2 K effective heat transfer coefficient , W/m2 K radiation heat transfer coefficient, W/m2 K fin height, m current, A thermal conductivity of heat sink, W/mK thermal conductivity of air, W/mK length of heat sink base, m effective length, m length of heat source, m number of fins Nusselt number Prandtl number total electrical power input, W air volume flow rate, m3/s ambient heat loss, W thermal resistance, K/W one-dimensional thermal resistance, K/W prime surface thermal resistance, K/W conduction thermal resistance of heat sink base, K/W fin surface thermal resistance, K/W radiation thermal resistance, K/W overall heat sink thermal resistance, K/W Rsp Rtotal Reb* s t tb T Ts Tamb Tsource Tbase U W Ws spreading thermal resistance, K/W total thermal resistance, K/W modified channel Reynolds number = (bVch/ν)(b/L) impinging inlet width, m fin thickness, m base plate thickness, m temperature, °C heat source temperature, K ambient temperature, K mean heat source temperature, K mean heat sink base temperature, K voltage, V width of heat sink base, m width of heat source, m Greek symbols eigenvalues, =(δm2+λn2)1/2 βm,n δm eigenvalues, =mπ/c ζ dummy variable, m-1 λn eigenvalues, = nπ/d φ spreading function Subscripts 1 based upon vertical channel 2 based upon horizontal channel amb ambient b base ch channel Dh based upon hydraulic diameter eff effective f fin s heat source INTRODUCTION The heat dissipated in electronic components is increasing with advances in the performance of modern computers. Furthermore, the structure of these components is becoming ever more compact. Therefore, thermal management in the electronics environment is becoming increasingly difficult due to high heat load and dimensional constraints. Impingement air cooling with heat sinks is one attractive solution to these problems. Nottage [1] suggested that the heat sink fin and channel may be thought of as a type of heat exchanger in which the hot fluid stream is replaced with the solid fin. The counterflow __________________________________________ ∗ + Graduate Research Assistant Assistant Professor 0-7803-8357-5/04/$20.00 ©2004 IEEE 436 2004 Inter Society Conference on Thermal Phenomena arrangement has the greatest potential to achieve high effectiveness. This requires an airflow direction normal to the heat sink base, however, heat sinks with airflow directed normal to the base have received little attention. Since the impingement airflow in a heat sink is intermediate between counterflow and crossflow, its thermal performance is expected to exceed that of a crossflow heat sink. The present work is focused on the impingement flow plate fin geometry. The research objectives are to develop a robust model for predicting thermal resistance of plate fin heat sinks for impingement air cooling. Experimental measurements of thermal resistance are performed with heat sinks of various dimensions and airflow velocities to test the validity of the model. LITERATURE REVIEW Teertstra et al. [2] developed an analytical model to predict the average heat transfer rate for air cooled plate fin heat sinks. The Nusselt number is a function of the heat sink geometry and fluid velocity. The model is asymptotic between two limiting cases - fully developed and developing flow in parallel plate channels. They validated the model with experiments and found 2.1% RMS error and 6% maximum error. Copeland [3] suggested using a laminar flow heat transfer model for parallel flow in isothermal rectangular channels to model the heat sink. The Nusselt number data was taken from Shah and London [4] and fitted to an equation of the Churchill-Usagi form. s Air inflow Air outflow t b p Air outflow Plane Fin H W Hf Hf tb L Fig. 1 Geometry of a plate fin heat sink in impingement flow. There have been few studies specifically on impingement cooling with heat sinks. The geometry of a heat sink in impingement flow is shown schematically in Figure 1. In this flow arrangement the air enters at the top and exits out the sides, i.e. TISE (top inlet side exit). Biskeborn et al. [5] reported experimental results for a TISE design using unique “serpentine” square pin fins. Sparrow et al. [6] performed heat transfer experiments on an isothermal TISE type single channel passage. Hilbert et al. [7] reported a novel laminar flow heat sink with two sets of triangular or trapezoidal shaped fins on the two inclined faces of a base. This design is efficient because the downward flow increases the air speed near the base of the fins where the fin temperatures are highest. By having the cool air enter at the center of the heat sink and exit at the sides, the length of the fins in the flow direction is reduced so that the heat transfer coefficient is increased. Sathe et al. [8] conducted a numerical and experimental study of a TISE plate fin heat sink that was notched in the center to reduce flow stagnation. A combination of fin thickness of the order of 0.5 mm and channel spacings of 0.8 mm with appropriate central cut-out yielded heat transfer coefficients over 1500 W/m2K at a pressure drop of less than 100 Pa. Copeland [9] performed theoretical, experimental and numerical analyses on a manifold microchannel heat sink with multiple top inlets alternated with top outlets. At a given pumping power, increasing the number of inlet/outlet channels requires an increase in the volume flow rate, but permits higher flow velocity, provides lower thermal resistance. Kang and Holahan [10] developed a one dimensional thermal resistance model of impingement air cooled plate fin heat sinks to understand how the heat sink performance depends on the different geometry variables. This simple model provides only an order of magnitude estimate of the thermal resistance. Holahan et al. [11] modeled the impingement flow field in the channel between the fins as a Hele-Shaw flow. Conduction within the fin is modeled by superposition of a kernel function derived from the method of images. Convective heat transfer coefficients are adapted from existing parallel plate correlations. Kondo et al. [12] completed an experimental study and reported a zonal model of a thermal resistance prediction for impingement cooling heat sinks with plate fins. The impingement flow over the plate fins was divided into six regions. A set of correlations are proposed between the thermal resistance of the heat sink and the geometry of the plate fins. Dividing the heat sink into regions requires a large number of equations and makes the model very complicated. The accuracy of the predicted thermal resistance was found to be within ±25% of the experimental data. Sathe et al. [13] presented a computational analysis for three dimensional flow and heat transfer in the IBM 4381 heat sink. Biber [14] carried out a numerical study to determine the thermal performance of a single isothermal channel with variable width impinging flow. She numerically studied many different combinations of channel parameters and presented the correlation for channel average Nusselt number. Sasao et al. [15] developed a numerical method for simulating impingement air flow and heat transfer in plate fin heat sinks. Saini and Webb [16] presented a modified Biber [15] model and validated this model by experiments. THEORETICAL MODELLING Heat sink thermal circuit analysis Heat sink models typically assume a uniform airflow at the heat sink inlet. The flow in typical plate fin heat sinks used in cooling electronic modules is laminar, because of the small fin spacing and low airflow rates. The thermal resistance circuit for heat flow from the electronic module surface temperature (Ts) to ambient temperature (Tamb) is depicted in Figure 2. Heat generated from an electronic module can be approximated as 437 2004 Inter Society Conference on Thermal Phenomena constant heat flux over area As. The electronic module surface area (As) is usually too small to dissipate the heat, so a heat sink is typically required. Since heat sink base area (Ab) is usually larger than As, thermal spreading resistance (Rsp) occurs when heat leaves a heat source of finite dimensions (As) and enters into a larger region (Ab). Heat flux is assumed uniform over the base of fins. Heat is conducted from the base to the tip of the fins and it is convected from the fin surface (Rfins). Heat is also convected from the prime surface (the exposed portion of the base) (Rbare). The thermal resistance from the fins and prime surface to the ambient air is the total convection resistance of heat sink. The heat sink total convection resistance is usually the dominant thermal resistance in the thermal circuit for the electronic module cooling. Figure 2 illustrates the thermal circuit corresponding to the heat transfer from a plate fin heat sink. The total heat sink thermal resistance is Rtotal = Ts − Tamb Q Rbare Electronic Module As Rfins Tamb tb 1 + kAb heff Ab Rsp = Ts Rrad 8 ∞ sin2 (δm Ls 2) 8 ∞ sin2 (λn Ws 2) φ δ ( ) ⋅ + ∑ ∑ λ 3 ⋅φ(λn ) m 2 3 2 Ls LWkm=1 Ls LWkn=1 δm n + (2) ∞ ∞ sin2 (δm Ls 2)sin2 (λn Ws 2) 16 ⋅φ(βm,n ) ∑∑ 2 2 2 Ls Ws LWkm=1 n=1 δm λ2 βm,n (5) where (3) φ (ζ ) = The thermal spreading resistance will depend on several geometric and thermal parameters R sp = f ( L, W , Ls , W s , t b , k , heff ) Rsp Fig. 2 Thermal resistance circuit. where R1D is the one dimensional resistance given by R1D = Rbase Heat sink base Ab (1) The total thermal resistance may be modelled by considering the heat sink as bare plate with effective film coefficient as shown in Figure 3. The thermal resistance is now: Rtotal = R1D + Rsp Heat Sink (4) The spreading resistance vanishes when the heat flux is distributed uniformily over the entire heat sink base surface. The Rtotal is known from experimental measurements, therefore, the effective heat transfer coefficient heff can be calculated from Eq.(2). Lee et al. [17] developed an analytical model for predicting thermal spreading resistance in a circular plate with a uniform heat flux on one surface and a convective boundary condition over the other surface. Yovanovich et al. [18] reviewed the previously published spreading resistance models and presented simple correlation equations for ease of computation. Yovanovich et al. [19] presented the thermal spreading resistance of an isoflux, rectangular heat source on a two layer rectangular flux channel with convective or conductive boundary conditions at one boundary. The thermal spreading resistance for the present research is obtained from the following expression developed by Yovanovich et al. [19]. ( e 2 t bζ + 1)ζ − (1 − e 2 t bζ ) h eff k ( e 2 t bζ − 1)ζ − (1 + e 2 t bζ ) h eff k (6) In all summations φ(ζ) is evaluated in each series using ζ=δm, λn, and βm,n. The general expression for spreading resistance consists of three terms. The single summations account for two-dimensional spreading in the x and y directions, respectively, and the double summation term accounts for three-dimensional spreading from the rectangular heat source. The eigenvalues are δm=2mπ/L, λn=2nπ/W, βm,n=(δm2+λn2)1/2. The eigenvalues δm and λn, corresponding to the two strip solutions, depend on the flux channel dimensions and the indices m and n, respectively. The eigenvalues βm,n for the rectangular solution are functions of the other two eigenvalues. Spreading resistance is important in heat sink applications. The value of effective heat transfer coefficient heff is an effective value which accounts for both the heat transfer coefficient on the fin surface and the increased surface area, as shown in Figure 3. 438 2004 Inter Society Conference on Thermal Phenomena Heat Sink We need only study one half of the heat sink since the flow field and temperature contours on the other half are a mirror image due to symmetry. One half of the impingement cooling heat sink channel is considered as two connected rectangular channels; one is vertical and the other is horizontal. Their effective lengths are Leff1 and Leff2, as illustrated in Figure 3. This consideration is justifiable if one imagines a typical streamline, for example near the middle of the impingement slot. This streamline length is better approximated by the Lshaped path of height 0.5H and length 0.5L-0.25s after a 90° turn. tb Tsource Heat sink base Electronic Module Tbase Ab As heff shroud Tbase Tsource 0.5s Heat sink base Ab Electronic Module As Leff1 Vch2 Vch1 H Leff2 Fig. 3 Schematic showing the effective heat transfer coefficient. heff = 0.5L Fig. 4 Impingement flow geometric configuration. 1 Ab Rsin k (7) The average heat transfer coefficient for the heat sink is modelled as The overall heat sink resistance is given by Rsin k = b 1 Nf + h( Nf −1)bL + hrad Arad R fin h = hch1 (8) s L−s + hch 2 L L (13) As s→0 the flow is nearly parallel through the entire sink, while s→L the flow is fully perpendicular through the sink. Thus, the total heat resistance can be expressed as Rtotal = Rsp + Rbase + Rsink (9) EXPERIMENTAL FACILITY Heat transfer model The heat transfer coefficient, h, will be computed using the following model developed by Teertstra et al. (1999). This model is applicable to both fully developed and developing flows. −3 −3 3.65 Reb * Pr 1/ 3 Nub = + 0.664 Reb *Pr 1+ 2 Reb * h ⋅b Nu b = ka Reb * = Reb ⋅ b L −1/ 3 (10) Figure 5 shows a schematic of the thermal tester. Two electrical heaters were used to simulate an electronic module. These electrical heaters were put into a 76.2 mm square cross section 12 mm high copper block. Insulation was applied to the bottom and the periphery of the copper block. The heat loss was estimated to be less than 5 % of the heat input, and a correction was applied in the data reduction. The heat input to the heat sink was determined at the time of test by the product of measured voltage and current (UI) corrected for ambient heat loss (Qloss). (11) (12) 439 2004 Inter Society Conference on Thermal Phenomena Air in flow and Holman [21]. The uncertainty in the total measured thermal resistance (Rtotal) was a maximum of 2.6 % for the validation test data. Further details on uncertainty analysis and experimental data can be found in Duan [22]. Heat Sink RESULTS AND DISCUSSION Thermocouples at copper block The model is validated with the experimental data taken on four heat sinks and other experimental data from the published literature. Figure 6 – 9 shows the measured and predicted thermal resistance of Heat Sink #1 – #4 for different impingement inlet widths. The highest Reynolds number in the experimental data was 1270, which is in the laminar regime. The differences between predictions and test results increase slightly with increasing flow rate. upper surface Heat sink base Insulation Thermocouples at copper block Copper lower surface block Heater Fig. 5 Schematic of the thermal tester. 0.6 Table 1 Geometry of the heat sinks used in the experiments. Configur ation L (mm) W (mm) tb (mm) t (mm) b (mm) H (mm) Nf Heat Sink #1 127 122 12.7 1.2 2.25 26.5 36 Heat Sink #2 127 122 12.7 1.2 2.25 50.0 36 Heat Sink #3 127 116 12.7 1.2 4.27 34.0 22 Heat Sink #4 127 116 12.7 1.2 4.27 50.0 22 s=10%L, experiment s=10%L, model s=25%L, experiment s=25%L, model s=50%L, experiment s=50%L, model s=75%L, experiment s=75%L, model s=100%L, experiment s=100%L, model Thermal resistance Rtotal (K/W) 0.5 0.4 0.3 0.2 0.1 1 2 3 Channel velocity Vch2 (m/s) 4 5 Fig. 6 Thermal resistance comparison for Heat Sink #1. 0.6 s=10%L, experiment s=10%L, model s=25%L, experiment s=25%L, model s=50%L, experiment s=50%L, model s=75%L, experiment s=75%L, model s=100%L, experiment s=100%L, model 0.5 Thermal resistance Rtotal (K/W) Five copper-constantan thermocouples were attached to the upper surface of the copper block to measure the upper surface average temperature. Another five thermocouples were attached to the lower surface of copper block to measure the lower surface average temperature. The upper and lower surfaces are divided into four equal areas. The five thermocouples are placed at the centroids of the four equal areas and the center of the whole surface, respectively. The mean temperature of the heat source was represented as the average of the ten readings of thermocouples. The ambient temperature was measured with three other thermocouples. The three thermocouple readings were averaged to give the average ambient temperature. The measurement includes the spreading resistance. Tests were conducted for four heat sink geometries for impingement flow. Heat sink thermal resistance data were taken for different flow rate conditions and different impingement inlet widths. For each heat sink, the experimental measurements were carried out at seven different velocities in the plenum chamber (Vd), 0.4 m/s, 0.5 m/s, 0.6 m/s, 0.7 m/s, 0.8 m/s, 0.9 m/s, 1.0 m/s, and six different impingement inlet widths, 5%L, 10%L, 25%L, 50%L, 75%L, 100%L, respectively. In total, 168 data points were collected for thermal resistance. The details of the heat sinks used for the tests are summarized in Table 1. 0.4 0.3 0.2 0.4 The uncertainty analysis for the test data was conducted using the root sum square method described in Moffat [20] 440 0.8 1.2 1.6 Channel velocity Vch2 (m/s) 2 2.4 Fig. 7 Thermal resistance comparison for Heat Sink #2. 2004 Inter Society Conference on Thermal Phenomena 0.6 0.3 Thermal resistance Rtotal (K/W) Thermal resistance Rtotal (K/W) 0.4 s=10%L, experiment s=10%L, model s=25%L, experiment s=25%L, model s=50%L, experiment s=50%L, model s=75%L, experiment s=75%L, model s=100%L, experiment s=100%L, model 0.4 0.2 Saini and Webb test data Analytical model 0.1 0.2 0.8 0 1.2 1.6 2 2.4 Channel velocity Vch2 (m/s) 2 2.8 4 5 6 Channel velocity Vch2 (m/s) 7 Fig. 10 Thermal resistance comparison for Saini and Webb [17] test data. Fig. 8 Thermal resistance comparison for Heat Sink #3. 0.7 0.14 s=10%L, experiment s=10%L, model s=25%L, experiment s=25%L, model s=50%L, experiment s=50%L, model s=75%L, experiment s=75%L, model s=100%L, experiment s=100%L, model 0.5 Holahan et al. test data Analytical model 0.12 Thermal resistance Rtotal (K/W) 0.6 Thermal resistance Rtotal (K/W) 3 0.4 0.1 0.08 0.06 0.3 0.04 0.4 0.8 1.2 Channel velocity Vch2 (m/s) 1.6 0 2 3 6 9 12 Channel velocity Vch2 (m/s) Fig. 11 Thermal resistance comparison for Holahan et al. [11] test data. Fig. 9 Thermal resistance comparison for Heat Sink #4. Figure 10 shows the comparison between the Saini and Webb [16] experimental data and the analytical model predictions of total thermal resistance. Overall, the trend is very good. Figure 11 shows the comparison between the Holahan et al. [11] experimental data and the predictions of total thermal resistance. The experimental data and predictions are in excellent agreement. It was found that all experimental data errors are within ±20% with an RMS errors of 11.1%. Although the thermal resistance prediction algorithm is based on a very simple model, it succeeds in representing the trends of the experimental values fairly well. The agreement is quite satisfying in view of the simplicity of the model. Given the uncertainties of thermal resistance measurements, the model is reasonably well validated. The effects of impingement inlet width on thermal resistance are shown in Figures 6 – 9. From these figures it can be seen that, for the same flow rate, the total thermal resistance decreases when the impingement inlet width 441 2004 Inter Society Conference on Thermal Phenomena becomes smaller. This is due to the high impingement channel velocity, which makes the impingement heat transfer coefficient large in the case of small inlet widths. increases. Thus, the impingement heat transfer coefficient decreases and thermal resistance increases. 0.5 0.6 Thermal resistance Rtotal (K/W) 0.5 sink #2 sink #4 sink #2 sink #4 s=10%L s=10%L s=25%L s=25%L test test test test Heat Heat Heat Heat data data data data Thermal resistance Rtotal (K/W) Heat Heat Heat Heat 0.4 sink sink sink sink #1 #2 #1 #2 s=10%L s=10%L s=25%L s=25%L test data test data test data test data 0.4 0.3 0.3 0.2 0.004 0.2 0.004 0.008 0.012 Air flow rate Q (m3/s) 0.016 Fig. 13 Effects of fin spacing on thermal resistance. The effects of fin spacing on thermal resistance are illustrated by the results for Heat Sinks #2 and #4, which have the same dimensions except for fin spacing (b). Figure 12 shows the experimental values of the thermal resistance with changes in the spacing between fins for impingement inlet widths of 10% and 25%L. The experimental values increase with an increase in fin spacing for the same volumetric flow rate. This is due to the fact that channel velocity decreases when the fin spacing increases. Thus, the impingement heat transfer coefficient decreases and thermal resistance increases. When the fins are closely spaced, the surface area of the heat sink increases, the contraction pressure loss at the impingement inlet and the expansion pressure loss at outlet of the heat sink increase, and this effect dominates. When the fin spacing becomes larger, although the pressure drop decreases, the surface area of the heat sink also decreases and this makes the rate of heat transfer lower. Furthermore, the pressure drop increases remarkably and volumetric flow rate decreases as the spacing between the fins becomes smaller, if the performance of the cooling fan is taken into account. The effects of fin height on thermal resistance are illustrated by comparison of the results for Heat Sinks #1 and #2, and Heat Sinks #3 and #4. Heat Sinks #1 and #2 have the same dimensions except for fin height (H). Heat Sinks #3 and #4 have the same dimensions except for fin height (H). Figure 13 depicts the experimental values of thermal resistance for Heat Sinks #1 and #2, and Figure 14 demonstrates the experimental values of thermal resistance for Heat Sinks #3 and #4 for impingement inlet widths of 10% and 25%L. As shown in the figures the thermal resistance increases with an increase in fin height for the same volumetric flow rate. This is due to the fact that the channel velocity decreases when the fin height 0.012 0.016 Air flow rate Q (m3 /s) 0.02 Effects of fin height on thermal resistance for Heat Sinks #1 and #2. 0.6 Heat Heat Heat Heat Thermal resistance Rtotal (K/W) Fig. 12 0.008 0.02 sink sink sink sink #3 #4 #3 #4 s=10%L s=10%L s=25%L s=25%L test test test test data data data data 0.5 0.4 0.3 0.004 Fig. 14 0.008 0.012 Air flow rate Q (m3 /s) 0.016 0.02 Effects of fin height on thermal resistance for Heat Sinks #3 and #4. CONCLUSIONS This paper investigated thermal resistance of impingement air cooled plate fin heat sinks for a variety of impingement inlet widths, fin spacings and fin heights. The analytic model is developed for the low Reynolds number laminar flow and heat transfer in the interfin channels of impingement flow plate fin heat sinks. The simple model is suitable for heat sink parametric design studies. The accuracy range of the analytical model was established by comparison with experimental 442 2004 Inter Society Conference on Thermal Phenomena measurements of four actual heat sinks and other obtainable experimental data. The major thermal resistance in the thermal circuit is the fin surface resistance. Research on impingement flow plate fin heat sink modelling was pursued to obtain tools for parametric design studies and optimization of heat sinks. The analytical thermal resistance model predictions agree with experimentally measured values within ±20% and 11.1% RMS for the range 300<Re<1200. In general, the thermal resistance model tends to underpredict. The thermal resistance model includes the spreading resistance for a smaller module attached to a larger heat sink. The complicated zonal model [13] predictions are in agreement with the experimental data within ±25%. The thermal resistance model is implemented for laminar flow, since the expected practical operating range of this type of high performance heat sink would typically produce flows in the range of Re < 1200. The thermal resistance decreases when the impingement inlet width becomes smaller for the same flow rate. Thermal resistance is very sensitive to changes in fin spacing. The thermal resistance increases significantly with an increase in fin spacing for the same volumetric flow rate. Increasing fin height slightly increases the heat sink thermal resistance for the same flow rate. The fin efficiencies were almost the same for the heat sinks tested, therefore, fin efficiency did not pose a problem in the present study. ACKNOWLEGEMENTS The authors acknowledge the support of the Natural Sciences and Engineering Research Council of Canada (NSERC), and R-Theta Inc. for providing heat sinks for the present study. REFERENCE [1] Nottage, H.B., 1945, in discussion of Gardner, K.A., 1945. “Efficiency of Extended Surface,” Transaction of the ASME, Vol. 67, pp. 621-631. [2] Teertstra, P., Yovanovich, M.M, Culham, J.R., and Lemczyk, T., 1999. “Analytical Forced Convection Modeling of Plate Fin Heat Sinks,” Proc. Fifteenth Semi-Therm Symposium, pp. 34-41. [3] Copeland, D., 2000. “Optimization of Parallel Plate Heat Sinks for Forced Convection,” Proc. Sixteenth Semi-Therm, pp. 266-272. [4] Shah, R.K., and London A.L., 1978. 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