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Numerical and experimental studies of ultra low profile three-dimensional heat sinks (3DHS) made using a novel manufacturing approach

The continued increase in electronic device packaging densities is placing ever more challenging performance requirements on air-cooled heat sinks. In cases where the state-of-the-art heat sink technology is unable of to meet these requirements, this often results in either a relaxation of design specifications, or the exploration of other thermal management technologies better able to handle high heat density applications, such as liquid cooling. Both of these approaches provide challenges to equipment designers, as relaxing requirements does not allow for a scale-able path to increased device densities and their associated functionality, while incorporating new thermal management technologies often requires major hardware redesigns, which has significant cost implications. In this work, we explore the use of air-cooled heat sinks incorporating three-dimensional features, so-called three-dimensional heat sinks (3DHS), that enhance heat transfer through a number of different physical mechanisms, as an approach to further extending the limits of air cooling. An ultra low profile (5.7 mm) heat sink application is targeted due to the significant thermal challenges associated with restrictions on heat sink height. We also present details on a novel manufacturing method that has significant cost advantages over other fabrication methods such as investment casting and direct metal printing. Experiments on 3DHS and conventional heat sink are conducted in a wind tunnel test apparatus as a function of inlet air mass flow rate and flow bypass above the heat sinks. The experimental results show a strong correlation between heat sink permeability and thermal performance, as measured by heat sink thermal resistance versus ideal pumping power. The results also illustrate the important effects of flow bypass on heat sink performance. The best performing 3DHS design is observed to have up to a 19% improvement in thermal performance relative to a conventional parallel fin heat sink of the same form factor. Comparison of the experimental results with finite-volume simulations of the laminar, steady equations for mass, momentum and energy transport shows good agreement for heat sink thermal resistance and pressure drop across the heat sink. For the case where the fluid flow is modeled as transitional and steady, there is a greater discrepancy between simulations and experiments, suggesting that the experimental flow conditions are predominantly laminar.