Numerical Analysis of the Thermal Performance of a Hybrid Heat Sink Comprised of Perforated Foam Fins Embedded Within a Phase Change Material

Abstract

This study presented a numerical model to evaluate a novel design of a hybrid heat sink incorporating perforated foam fins (PFFs) instead of solid fins (SFs) within a phase change material (PCM). This innovation is designed to enhance thermal performance in electronic cooling applications. The base of the heat sink was subjected to constant heat fluxes of 2, 3, and 4 kW/m². The effect of the perforation location (top, center, and bottom) within the foam fin and foam porosities (0.85, 0.90, and 0.95) were investigated. The results showed that the hybrid PFF design demonstrably improved thermal efficiency compared to the SF configuration. This innovative approach offered three benefits: a significant reduction in overall heat sink weight, an augmentation of the thermal conductivity of PCM, and the intermixed molten PCM between the fins passages through perforations. The PFF heat sink extended the operational time by 6%–8% for the range of heat fluxes at SPT of 70°C and led to a 24.5% increase in PCM volume, compared to the SF configuration. Complete melting of the PCM in the PFF heat sink is observed at 29 min for the highest heat flux of 4 kW/m², while the melting rates are 25% and 62% for the applied heat flux of 2 and 3 kW/m². Perforation location within the foam fin (top, center, and bottom) achieved equivalent heat transfer capabilities, enabling design flexibility for perforation location. The PFF with a porosity of 0.85 demonstrated superior thermal performance.