Session: K16-02: HEAT TRANSFER IN ELECTRONIC EQUIPMENT II

Paper Number: 131195

131195 - Assessment of Optimal Fin Structure and Shroud Size in Fan-Cooled Heat Sinks for Next-Generation EV Battery Chargers 

Abstract: 

As next-generation battery chargers become more compact yet offer higher power outputs, efficient cooling methods are crucial. Air-cooled heat sinks are gaining prominence due to the growing demand for high-performance battery chargers. This study delves into the influence of shroud size and optimal fin configuration in the axial fan impingement cooling technique. Experimental evaluations were performed on the Delta-Q XV3300 battery charger, with four distinct configurations tested, reflective of current market trends: i) no shroud, ii) half-size shroud, iii) full shroud, and iv) a Delta-Q production shroud. Results indicated that the shroud size subtly affects the heat sink's thermal performance, with shrouds directing airflow through the fin array, resulting in up to a 5% temperature decrease on the heat sink's periphery, in contrast to the no-shroud scenario. Notably, the Delta-Q production shroud lagged in performance, primarily due to its integrated "fan guards."

Furthermore, a numerical comparison of fin structures beneath the fan—specifically bare fin, pin fin, and vane-shaped designs—was conducted. Under assumptions of a level heatsink skyline and a consistent heat flux boundary condition, both pin fin and vane-shaped designs surpassed the bare fin configuration in thermal efficiency by 7.3% and 5.1% respectively.

In conclusion, recommendations are provided for enhancing the heat sink's cooling efficiency, especially when a protective wall shields connectors. A proposed design introduces an additional wall on the opposite side to curb excessive airflow escape. Additionally, integrating converging radial fins that gradually transition to parallel orientations reduces air circulation, thereby decreasing temperature variances by 7% to 25% across various heat-intensive regions.Top of Form

Presenting Author: Sahand Najafpour Simon Fraser University

Presenting Author Biography: Sahand Najafpour is a PhD student at Simon Fraser University with a background in Mechanical Engineering. He did his Bachelor's and Master's studies at the Sharif University of Technology, Iran. He focused on heat transfer enhancement techniques in single-phase and phase change heat transfer. Currently, he is working on fluid-induced vibrations of flexible flags to unravel the underlying physics and the role of vibrations in heat transfer improvement.
In addition, he is interested in the thermal management of battery chargers and the optimization of cooling solutions.

Authors:

Sahand Najafpour Simon Fraser University
Chris Botting Delta-Q Technologies
Majid Bahrami Simon Fraser University