Thermal Management Research Articles

Thermal uniformity analysis of a hybrid battery pack using integrated phase change material, metal foam, and counterflow minichannels

This study investigates the thermal performance and temperature uniformity of a hybrid battery thermal management system (BTMS) that integrates phase change material (PCM), metal foam, and minichannels. Computational fluid dynamics is used to model the PCM melting process and heat transfer between all components. The primary goal of the work is to investigate BTMS architectures which can enhance thermal uniformity and prevent critical temperature rise in a high-voltage battery pack under fast discharging and real-world driving cycle. Four BTMS designs are compared. The design that integrates PCM, metal foam, and counterflow minichannels is shown to have the best performance. At low pumping power (coolant Reynolds number Re = 10), this design reduces the peak battery temperature by 11.5 K compared to a design employing pure PCM only. This configuration also ensures a temperature difference of less than 5 K among individual battery cells, addressing thermal safety considerations and extending battery lifespan. Further analysis revealed that the inclusion of metal foam delays PCM melting, enhances both system and battery thermal uniformity, and offers a higher performance-to-weight ratio compared to designs without metal foam. Although wavy-shaped minichannels offer minimal temperature improvement (0.3 K) over straight minichannels, their higher cost and increased pumping power requirements do not justify their practicality. Under both fast discharging and real driving conditions, the first design with pure PCM provides uniform heat distribution within batteries but fails to maintain the maximum battery temperature within the optimal range. Overall, this study highlights the effectiveness of the proposed hybrid BTMS design in providing uniform temperature distribution and maintaining the maximum battery temperature within the optimal range under harsh environmental conditions, fast discharging, and the Urban Dynamometer Driving Schedule (UDDS) drive cycle.

Novel design of centralized square array of pin-fins in microchannels heat sink for thermal management of high concentrator photovoltaic system

Novel design of centralized square array of pin-fins in microchannels heat sink for thermal management of high concentrator photovoltaic system

An experimental study to evaluate the performance of variable-width channel cold plates for cooling rectangular Li-ion batteries

The limited cooling capacity of cold plates employing conventional channel designs represents a key obstacle in thermal management systems. The persistent growth of the thermal boundary layer and the uneven distribution of flow across the channels are the principal challenges encountered in this context. To overcome these challenges, this study aims to analyse a modified cold plate of obstructed variable-width channels that can improve the hydrothermal performance and temperature uniformity. Different shapes of pin fins and grooves with variable sizes that match the width of the variable-width channels are proposed. Specifically, four types of pin fins–grooves were used: ellipse, drop, rhombus and trapezoid. The traditional cold plate served as a basis for evaluating the performance of new designs of cold plates. In addition to the traditional cold plate, the four proposed designs of cold plates were manufactured from copper. Experiments were conducted with water as a working fluid under a laminar flow for a flow rate range of 0.004–0.04 kg/s and a discharge C-rate range of 1C–2C. Results indicated that the use of variable-width channels with all shapes of fins–grooves effectively contributed to improving the heat dissipation of the cold plate, accompanied with an increase in hydraulic pumping power. At the highest flow rate, the best improvement percentage in the Nusselt number of 82.5% was achieved when trapezoidal pin fins–grooves were used; by contrast, the lowest pumping power increasing percentage of 33.2% was obtained when elliptical pin fins–grooves were adopted. The best hydraulic/thermal performance was achieved when trapezoidal pin fins were utilised, with the highest figure of merit of 1.685.

Comparative analysis on the radiative time-dependent water/kerosene-based Cu nanofluid through squeezing Riga plates with heat dissipation: Spectral quasilinearization technique

The time-dependent thermal management along with convective flows are vital in various heat transfer applications in engineering systems such as in automotive cooling systems, and industrial heat exchangers. Because of enhanced thermal conductivity, nanofluids are widely considered for advanced cooling systems such as electronics, aerospace, geothermal energy extraction, etc. The current analysis presents comparative results of the radiative, time-dependent flow of water/kerosene-based Copper nanofluids between squeezing Riga plates focusing on heat dissipation. Both the plates are embedded within a porous matrix and the influence of non-uniform heat source/sink and thermal convective boundary conditions is examined. Riga plates, generally utilized for their ability to generate electromagnetic fields provide greater control over the fluid flow. The problem designed with the inclusion of aforesaid factors is transformed into a non-dimensional form for the utilization of appropriate similarity functions. Further, the impacts of several effective terms on the flow profiles are presented followed by the numerical solution of the profile obtained using the spectral quasilinearization method. Moreover, some of the outstanding findings are; an increase in the fluid velocity is marked for the separation of the plates but the rate of enhancement in the case of kerosene is more pronounced than that of water. Further, irrespective to the type of fluids, the heat transfer rate enhances for the increasing heat fluid which provides the variation of thermal radiation.

Optimized Design of Multilayer Embedded Micro-Fins for Enhanced Thermal Management in three-dimensional stacked chips with Heterogeneous Heat Source

Optimized Design of Multilayer Embedded Micro-Fins for Enhanced Thermal Management in three-dimensional stacked chips with Heterogeneous Heat Source

Multifunctional Smart Fabrics with Integration of Self-Cleaning, Energy Harvesting, and Thermal Management Properties.

Due to their good wearability, smart fabrics have gradually developed into one of the important components of multifunctional flexible electronics. Nevertheless, function integration is typically accomplished through the intricate stacking of diverse modules, which inevitably compromises comfort and elevates processing complexities. The integration of these discrete functional modules into a unified design for smart fabrics represents a superior solution. Here, we put forward a rational approach to functional integration for the typical challenges of thermal management, energy supply, and surface contamination in smart fabrics. This sandwich-structured multilayer fabric (MLF) is obtained by continuous electrospinning of two layer P(VDF-HFP) fabric and one layer P(VDF-HFP) fabric functionalized with core-shell SiO2/ZnO/ZIF-8 (SZZ) nanoparticles. Specifically, MLFs achieve effective and stable energy harvesting in triboelectric nanogenerators (TENGs) with hydrophobicity and antibacterial properties. Meanwhile, MLFs also have high mid-infrared emissivity and sunlight reflectivity, successfully realizing radiative cooling under different climates, and have been applied in wearing clothing, roof shading, and car covers. This work may contribute to the design and manufacturing of next-generation thermal comfort smart fabrics and wearable electronics, particularly in terms of the rational design of multifunctional devices.

Tunable Graphene‐Based Absorber Using Nanoscale Grooved Metal Film at Telecommunication Wavelengths

Graphene‐based absorbers have various modern applications across industries due to their exceptional properties. Some common applications include: thermal management and energy storage. Herein, the design and simulation of a broadband tunable absorber based on graphene with perfect absorption spectra in the near‐infrared region are reported. The proposed structure consists of an MgF2 layer and golden disc surrounded by L‐shaped golden arms placed on single layer of graphene. The structure guarantees polarization‐insensitive (PI) performance under normal incident due to the symmetrical design. The investigation of the PI of the structure reveals almost similar absorption for oblique incident angles up to 55° for TM and up to 60° for TE polarization. The desirable resonance wavelength is achievable by tuning the geometrical parameters. By changing the chemical potential of graphene, the absorption and bandwidth of absorber are controllable. A full width at half maximum of 330 nm is another superiority of this absorber. These considerable aspects of the proposed structure make it practical for varieties of applications such as cloaking, sensing, switching, and so on.

Effect of Water-based Alumina-Copper MHD Hybrid Nanofluid on a Power-Law Form Stretching/Shrinking Sheet with Joule Heating and Slip condition: Dual Solutions Study

The application of hybrid nanofluid is now being employed to augment the efficiency of heat transfer rates. A numerical study was conducted to investigate the flow characteristics of water-based-alumina copper hybrid nanofluids towards a power-law form stretching/shrinking sheet. This study also considered the influence of magnetic, Joule heating, and thermal slip parameters. This study is significant because it advances our understanding of hybrid nanofluids in the presence of magnetic fields, power-law form stretching/shrinking sheet, and heat transfer mechanisms, providing valuable insights for optimizing and innovating thermal management systems in various industrial applications such as polymers, biological fluids, and manufacturing processes like extrusion, plastic and metal forming, and coating processes. The main objective of this study is to examine the impact of specific attributes, including suction and thermal slip parameters on temperature and velocity profiles. In addition, this exploration examined the reduced skin friction and reduced heat transfer in relation to the solid volume fraction copper and magnetic effects on shrinkage sheet and thermal slip parameter on suction effect. To facilitate the conversion of a nonlinear partial differential equation into a collection of ordinary differential equations, it is necessary to incorporate suitable similarity variables into the transformation procedure. The MATLAB bvp4c solver application is utilized in the conclusion process to solve ordinary differential equations. No solution was found in the sort of when , and . As the intensity of the Eckert number increases, the temperature profile and boundary layer thickness also increase. The reduced heat transfer rate upsurged in both solutions for solid volume fraction copper for shrinking sheet, while the opposite actions can be noticed in both solutions for thermal slip parameter for suction effect. Finally, the study conducted an analysis to identify two distinct solutions for shrinking sheet and suction zone, while considering different parameter values for the copper volume fractions, magnetic and thermal slip condition effect.

Design of ION Thruster

Ion thrusters represent a significant advancement in electric propulsion, enhancing fuel efficiency by accelerating ions for thrust generation. These systems, demonstrated in missions such as Deep Space 1 and Dawn, facilitate substantial velocity changes with minimal propellant, making them suitable for long-duration space missions. This paper outlines the design of an ion thruster aimed at achieving a thrust of 0.2 Newton, focusing on the use of xenon as the propellant and employing highvoltage grids for ion acceleration. Key design aspects include an efficient power supply delivering at least 26 W, effective thermal management, and the integration of control systems. Performance metrics target a specific impulse of 3,000 seconds and a thrust-to-power efficiency ratio greater than 0.5. Through detailed calculations, including arc distance, flow configuration and velocity analyses and testing using different materials, this study identifies optimal configurations for thrust generation. The developed ion thruster is tailored for small satellites (700-800 kg) to enhance trajectory control and station-keeping, underscoring the importance of ion propulsion in modern space exploration

Evaluation of Thermal and Mechanical Properties of Bi-In-Sn/WO3 Composites for Efficient Heat Dissipation.

Phase change materials (PCMs) offer promising solutions for efficient thermal management in electronic devices, energy storage systems, and renewable energy applications due to their capacity to store and release significant thermal energy during phase transitions. This study investigates the thermal and physical properties of Bi-In-Sn/WO3 composites, specifically for their use as phase change thermal interface materials (PCM-TIMs). The Bi-In-Sn/WO3 composite was synthesized through mechanochemical grinding, which enabled the uniform dispersion of WO3 particles within the Bi-In-Sn alloy matrix. The addition of WO3 particles markedly improved the composite's thermal conductivity and transformed its physical form into a putty-like consistency, addressing leakage issues typically associated with pure Bi-In-Sn alloys. Microstructural analyses demonstrated the existence of a continuous interface between the liquid metal and WO3 phases, with no gaps, ensuring structural stability. Thermal performance tests demonstrated that the Bi-In-Sn/WO3 composite achieved improved thermal conductivity, and reduced volumetric latent heat, and there was a slight increase in thermal contact resistance with higher WO3 content. These findings highlight the potential of Bi-In-Sn/WO3 composites for utilization as advanced PCM-TIMs, offering enhanced heat dissipation, stability, and physical integrity for high-performance electronic and energy systems.

A Review of Advanced Thermal Interface Materials with Oriented Structures for Electronic Devices

In high-power electronic devices, the rapid accumulation of heat presents significant thermal management challenges that necessitate the development of advanced thermal interface materials (TIMs) to ensure the performance and reliability of electronic devices. TIMs are employed to facilitate an effective and stable heat dissipation pathway between heat-generating components and heat sinks. In recent years, anisotropic one-dimensional and two-dimensional materials, including carbon fibers, graphene, and boron nitride, have been introduced as fillers in polymer-based TIMs due to their high thermal conductivity in specific directions. The orientation of the fillers in the polymer matrix has become an important issue in the development of a new generation of high-performance TIMs. To provide a systematic understanding of this field, this paper mainly discusses recent advances in advanced oriented TIMs with high thermal conductivity (>10 W/(m·K)). For each filler, its preparation strategies and enhancement mechanisms are analyzed separately, with a focus on the construction of oriented structures. Notably, there are few reviews related to carbon fiber TIMs, and this paper details recent research results in this field. Finally, the challenges, prospects, and future development directions of advanced TIMs are summarized in the hope of stimulating future research efforts.

Insights into Chemical Bonding Modes and Heat Transport at the Molecular Level.

Despite the demand for nanoscale thermal management technologies of material surfaces and interfaces using organic molecules, heat transport properties at the single molecular level remain elusive due to the experimental difficulty of measuring temperature at the nanoscopic scale. Here we show how chemical bonding modes can affect the heat transport properties of single molecules. We focused on four molecular systems: benzylthiol linked to another phenyl group by either a triple (compound 1), double (3), or amide (4) bond and a common linear alkanethiol (2), all of which are nearly identical in molecular length. We prepared binary self-assembled monolayers (SAMs) using 1 as a common reference in combination with 2-4 and investigated their relative heat transport properties using scanning thermal microscopy (SThM). Two-dimensional temperature mapping of the binary SAMs showed that C≡C and C=C bonds provide more effective pathways for heat transport compared to C-C bonds. Since the amide molecule has resonance structures with C=N double bond character, we expected that its heat transport properties would be comparable to those of the thiols containing triple or double bonds. However, the heat transport properties of this molecule prevailed over the others, most likely due to the formation of additional heat transport pathways caused by intermolecular hydrogen bonding. These findings may provide important guidelines for the design of organic materials for nanoscale thermal management.

Thermal management of lithium-ion batteries based on the coupling of liquid cooling and composite phase change materials

ABSTRACT Effective thermal management techniques for lithium-ion batteries are crucial to ensure their optimal efficiency. This paper proposes a thermal management system that combines liquid cooling with composite phase change materials (PCM) to enhance the cooling performance of these lithium-ion batteries. A numerical study was conducted to examine the impact of various factors on the battery module’s thermal management performance, including the number of flow channels, the distance between these flow channels and the upper and front surfaces, fluid flow rate, coolant inlet temperature, and material’s phase change temperature. The simulation results indicate that at a discharge rate of 6C and a flow channel count of 5, the maximum temperature and the maximum temperature difference of the battery module decrease by 6.44% and 34.35%, respectively, when PCM is coupled with liquid cooling, compared to the pure liquid cooling. However, as the flow rate increases, the rate of temperature reduction slows down, while the pressure drop increases. When the flow rate reaches 0.4 m/s, the maximum temperature only drops by 0.57°C while the pressure drop increases by nearly two times. Furthermore, an increase in the PCM’s melting temperature leads to a larger maximum temperature difference in the battery module. This effect is more pronounced with higher coolant inlet temperatures. Therefore, careful consideration of both flow rate and coolant inlet temperature is essential for designing an effective thermal management system for batteries.

Workpiece temperature control in friction stir welding of Inconel 718 through integrated numerical analysis and process control

Friction stir welding (FSW) offers significant advantages over fusion welding, particularly for high-strength alloys like Inconel 718. However, achieving optimal surface quality in Inconel 718 FSW remains challenging due to its sensitivity to temperature fluctuations during welding. This study integrates finite element simulations, statistical analysis, and advanced control methodologies to enhance weld surface quality through adequate thermal management. High-fidelity simulations of the FSW process were conducted using a validated 3D transient COMSOL Multiphysics model, producing a comprehensive dataset correlating process parameters (rotational speed, axial force, and welding speed) with workpiece temperature. This dataset facilitated statistical analysis and parameter optimization through Analysis of variance (ANOVA) method, leading to a deeper understanding of process variables. A nonlinear state-space system model was subsequently developed using experimental data and the system identification toolbox in Matlab, incorporating domain-specific insights. This model was rigorously validated with an independent dataset to ensure predictive accuracy. Utilizing the validated model, tailored control strategies, including proportional-integral-derivative (PID) and model predictive control (MPC) in both single and multivariable configurations, were designed and evaluated. These control strategies excelled in maintaining welding temperatures within optimal ranges, demonstrating robustness in response times and disturbance handling. This precision in thermal management is poised to significantly refine the FSW process, enhancing both surface integrity and microstructural uniformity. The strategic implementation of these controls is anticipated to substantially improve the quality and consistency of welding outcomes.

Phase change material performance in chamfered dual enclosures: Exploring the roles of geometry, inclination angles and heat flux

This study presents a comprehensive thermal performance analysis of phase change materials (PCMs) within a chamfered dual enclosures subjected to constant heat flux. Utilizing numerical simulations, we investigate the impact of various PCM types, inclination angles (α = 0°, 15°, 30°, 45°, 60°, 75°, 90°), and heat flux levels (Q = 500, 1000, 1500, 2000 W/m²) on melting rates, temperature distribution, and energy storage efficiency. The study examines commercially available PCMs, including RT-25, RT-27, RT-31, RT-35, RT-38, RT-42, RT-47, and RT-50. Our findings reveal that the inclination angle significantly influences thermal performance, with optimal performance observed at angles between 45° and 90° The PCM at 45° exhibited the fastest melting rate and demonstrating the highest energy storage efficiency. Among the PCMs, RT-27 showed the slowest temperature increase, while RT-50 exhibited the highest heat absorption efficiency and rapid temperature rise, making it suitable for applications requiring quick thermal management. Additionally, higher heat flux levels accelerated the phase transition process, with melting rates increases higher at 2000 W/m² compared to 500 W/m². The energy storage capacity varied, with RT-47 and RT-50 demonstrating the highest storage rates, while RT-27 was effective for sustained thermal energy release despite its slower phase change rate. This research bridges gaps in the existing literature by integrating various parameters and providing a holistic understanding of PCM behaviour in thermal energy storage systems. The insights gained from this study can inform the design and optimization of PCM-based thermal management solutions across various applications, including solar heating systems, electronic device cooling, and industrial waste heat recovery.

Influence of functionalized and non-functionalized 2D graphene nanomaterial with organic phase change materials: Thermal performance comparison

Thermal energy storage and harvesting using phase change materials (PCMs) is a crucial aspect of solar thermal utilisation and energy management. However, the intrinsic limitations associated with PCMs, such as their relatively lower thermal conductivity and sluggish thermal transport pose significant obstacles in the advancement of thermal energy harvesting and storage systems reliant on PCMs. Research explored by inclusion of nanomaterial with the PCM matrix is predominant depending on uniform diffusion and stability of the developed nanocomposite. In this research endeavour, we introduce a novel and synergistic approach to synthesis a functionalized graphene nanomaterials and compare its performance with non-functionalized graphene nanomaterial at various concentrations within organic PCMs, operating at a phase change temperature of 54 °C. The formulated nanocomposite’s thermophysical properties morphology, chemical stability, optical absorbance & transmittance, melting enthalpy, thermal stability and thermal reliability were investigated using sensitive instruments. The findings unveil a remarkable enhancement in thermal conductivity with functionalized graphene dispersed PCM exhibiting an astonishing surge of 106.7 % at a mere 0.8 wt% loading, when contrasted with conventional PCM. The optical transmittance of RT54-0.8fGr was significantly reduced from 56 % to 17.2 %, which enabled the effectiveness for solar thermal energy harnessing; meanwhile the melting enthalpy was energised to 193.4 J/g from 182.6 J/g. The developed nanocomposite with better optical property and melting enthalpy were tested for 500 numbers of accelerated thermal cycles and its chemical stability and thermal property were compared with PCM. Furthermore, a heat transfer analysis is numerically simulated to exhibit the thermal conductance performance of functionalized nanocomposite PCM over base PCM. The findings suggest that the functionalized graphene dispersed PCM matrix to exhibit highly favourable attributes for renewable thermal energy storage due to their exceptional comprehensive features.

Perspective on Dual‐Tower Concentrated Solar Power Plants

ABSTRACTThis paper presents a comprehensive analysis of dual‐tower concentrated solar power (CSP) plants, highlighting their key technical advantages, including improved efficiency and enhanced heat distribution. The novel dual‐tower design, implemented at Guazhou, Gansu Province by Three Gorges Renewables, significantly enhances optical efficiency and reduces spillage losses compared to traditional single‐tower systems. Utilizing molten salts or particle receivers, the dual‐tower configuration offers a more efficient thermal management approach. A comparative analysis of various designs underscores the trade‐offs between increased efficiency and capital costs. The paper also discusses the economic and environmental benefits, technical challenges, and future research directions associated with dual‐tower systems, providing valuable insights into their potential to advance solar thermal technology.

Nanomaterials in electronics: Advancements and challenges in high-performance devices

Nanomaterials, such as graphene, carbon nanotubes, and metal oxides, are revolutionizing the field of electronics by enabling the development of high-performance devices. This study provides a comprehensive overview of the synthesis, characterization, and application of these nanostructured materials. The unique properties of nanomaterials, including exceptional electrical conductivity, thermal management capabilities, and potential for device miniaturization, offer significant advantages over traditional materials. Graphene, for instance, exhibits remarkable electrical and thermal conductivity, making it an ideal candidate for applications in transistors and sensors. Carbon nanotubes, known for their strength and conductivity, enhance the performance of various electronic components, while metal oxides play a crucial role in semiconductor applications. Despite these advancements, several challenges remain. Issues related to scalability hinder the large-scale production of nanomaterials, while reproducibility concerns affect the reliability of devices fabricated from these materials. Moreover, the environmental impact of synthesizing and disposing of nanomaterials raises significant ethical considerations that must be addressed as the field progresses. This paper aims to provide insights into the current research trends and potential future directions, highlighting the need for sustainable practices in the synthesis and application of nanomaterials in electronics. By addressing these challenges, we can pave the way for the next generation of high-performance electronic devices that are not only efficient but also environmentally responsible.

Nanosized boron nitride-incorporated polyvinyl alcohol composites with TEMPO-oxidized cellulose nanofibers as ultrathin thermal interface materials

With the miniaturization and dense packing of electrical devices and mobility platforms, the effective thermal management at the interfaces of components in compact form factors is essential to overcome the performance limits and ensure the stability. Herein, we report the development of assembly of nanosized boron nitrides (BN) and TEMPO-oxidized cellulose nanofibers (T-CNFs) in polyvinyl alcohol (PVA) composites as ultrathin thermal interface materials (TIMs). BN nanoparticles (average thickness of 3.8–4.0 nm, lateral size of 90–100 nm, and aspect ratio of 25) were produced with a yield exceeding 80 % from the chemical treatment of hexagonal BN with NaOH and subsequent ball milling. TEMPO-oxidized cellulose nanofibers (T-CNFs) were added to mechanically reinforce the PVA-based matrix, while by the functionalization with OH– groups, the BN particles dispersed readily in the PVA solution, obtaining ultrathin nanosized BN/PVA/T-CNF composite films (∼50 µm). In contrast to the expected low thermal conductivity due to surface defects and high contact resistances typical of nanosized BN, composite films containing 50 wt% nanosized BN exhibited significantly high in-plane and through-plane thermal conductivities of 11.13 and 1.22 W/mK, respectively. Comparative analysis based on the Lewis–Nielsen model revealed that the size, shape, and agglomeration state of the BN particles could highly influence the thermal conductivity of composite films. Furthermore, heat dissipation experiments reflecting practical conditions demonstrated the outstanding performance and thermal stability of nanosized BN/PVA/T-CNF films as TIMs. This study will inspire rational strategies to facilely incorporate nanosized BN to diverse composites, offering advanced thermal characteristics with mechanical robustness.

General Approach to Hydrolysis Resistive Aluminum Nitride and Its High-Performance Thermal Interface Materials.

Aluminum nitride (AlN), noted for its excellent thermal conductivity and exceptional electrical insulation, presents a promising alternative to traditional ceramic particles in thermal interface materials (TIMs). However, its broader adoption in practical applications is limited by performance degradation due to the vulnerability of its crystal structure to ubiquitous moisture. This study introduces a dual solution, utilizing a mechanochemical method to design a dense outer layer of Galinstan liquid metal (LM) that simultaneously enhances AlN's resistance to hydrolysis and improves its thermal performance in TIM applications. The high surface free energy of the LM layer imparts hydrophobic properties to the AlN surface and, combined with outer metal oxides, forms a dual-layer protective barrier that prevents water penetration, significantly enhancing the TIM's long-term stability in high-humidity conditions. Additionally, the LM layer at the interface improves the thixotropic properties of the TIM and enhances interfacial heat transport through the bridging effect of the LM, resulting in improved rheological mobility and thermal conductivity of the composite material. This win-win surface modification strategy opens opportunities for the practical and durable application of AlN in widespread electronic thermal management.