Effect of Source-Sink Misalignment and Sink Cavity Aspect Ratio on the Thermal Performance of Gallium Heat Sinks

Abstract

Herein, we numerically investigated methods to improve heat dissipation from the base of a phase-change material (PCM) heat sink exposed to high heat flux (15 W/cm2). The sink cavity exhibited a rectangular cross-section with two opposite vertical walls of high thermal conductivity. These walls serve as heat-dissipating fins. We used gallium, a metallic PCM with high thermal conductivity and a low melting point to improve heat dissipation by leveraging buoyancy-driven circulations within the molten gallium. We adopted a method to position the sink base on top of the heat source surface in such a way to augment temperature gradients within the liquid to induce imbalances in gallium density and consequent internal circulations. In this technique, one vertical wall is subjected to forced-convective heat exchange with the surroundings, while the other remains adiabatic. Subsequently, for the case which showed optimum performance, we relaxed the adiabatic thermal boundary condition applied at one of the vertical walls and replaced it with convective heat transfer condition, and assessed the sink performance based on that. Further, we analyzed the impact of various aspect ratios of the sink cavity on the induced internal circulations and base cooling. Sink cavities with aspect ratios of 1.33, 0.96, and 0.64 corresponding to sink heights of 20, 17, and 14 mm, respectively, were examined under a consistent heat flux applied across a 15-mm base length. We also investigated the precise positioning of the sink base relative to the heat source surface and explored its influence on temperature gradients and gallium density imbalances crucial for induced internal circulations. Results indicate that a sink cavity aspect ratio of 0.96 yields the optimal heat dissipation from the base. Further, aligning the left bottom edge of the sink base with the left edge of the heat source surface maximizes heat dissipation to the ambient surroundings, thereby prolonging latent-heat dumping into the sink before the gallium completely melts. Any misalignment between the sink base and the surface of the heat source may have a profound impact on the temporal evolution of induced internal circulations within the molten gallium, essentially affecting heat dissipation from the sink base.