Applied Thermal Engineering最新文献

{"title":"Two-bed adsorption refrigeration cycle integration into a hybrid biomass-gasification multigeneration system for sustainable energy production: comprehensive 4E analysis, and machine learning optimization","authors":"Ming Fu ,&nbsp;Ali Basem ,&nbsp;Sarminah Samad ,&nbsp;Dyana Aziz Bayz ,&nbsp;Saleh Alhumaid ,&nbsp;Ashit Kumar Dutta ,&nbsp;H. Elhosiny Ali ,&nbsp;Zuhair Jastaneyah ,&nbsp;Salem Alkhalaf ,&nbsp;Ibrahim Mahariq","doi":"10.1016/j.applthermaleng.2025.128615","DOIUrl":"10.1016/j.applthermaleng.2025.128615","url":null,"abstract":"<div><div>This paper presents an integrated biomass-driven multigeneration energy system incorporating advanced thermodynamic cycles and a two-bed adsorption refrigeration cycle (ARC) for efficient cooling, heating, power generation, and hydrogen production. The key novelty of this study is the first-time integration of a dual-bed ARC into a biomass-driven system for simultaneous multi-output generation, complemented by a novel computational framework combining artificial neural networks and genetic algorithms for efficient multi-objective optimization. A detailed analysis of the system’s performance was conducted, focusing on exergy destruction, cost rates, and various system outputs. Key subsystems, including the gasifier, PEME, and ARC, were evaluated for their exergy efficiency and economic viability. The gasifier subsystem exhibited the highest exergy destruction, amounting to 4322.24 kW, with a cost rate of 20.47 $/h. The power cycle, responsible for significant energy conversion, incurred the highest cost of 260.49 $/h with an exergy destruction of 18,448.60 kW. In comparison, the PEME unit demonstrated a relatively low exergy destruction of 440.26 kW and a cost rate of 23.91 $/h. Parametric studies revealed that the increased moisture content reduced hydrogen production and heating load, while raising the cooling capacity. In contrast, higher gasifier temperatures and optimized biomass flow rates enhanced hydrogen generation and heating load. Furthermore, a multi-objective optimization framework, combining artificial neural networks (ANN) with genetic algorithms (GA), was applied to maximize exergy efficiency, minimize levelized total emission (LTE), and reduce total cost. The optimization revealed a set of Pareto-optimal solutions, with the best compromise achieving an exergy efficiency of 64.57 %, a total cost rate of 43.90 $/h, and an LTE of 1.21 Ton/GJ.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128615"},"PeriodicalIF":6.9,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145265127","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effect of carbonization/silver plating double modification on the thermal properties of PEG/wood-based composite phase change materials: experiments and molecular dynamics simulations","authors":"Zhiwen Yin,&nbsp;Chaohua Zhang","doi":"10.1016/j.applthermaleng.2025.128621","DOIUrl":"10.1016/j.applthermaleng.2025.128621","url":null,"abstract":"<div><div>To overcome the bottleneck of single modification methods for composite phase change materials struggling to balance high thermal conductivity and high phase change enthalpy, this study employed poplar wood as the raw material to fabricate a wood-based porous carrier through a dual-modulation strategy involving carbonization and silver-plating. This modified carrier was then impregnated with polyethylene glycol phase change material to synthesize a shape-stable composite phase change material with integrated structure and function. A combined experimental and modeling approach was used to investigate the thermal properties and underlying mechanisms of the composite. Experimental results demonstrate that the silver-enhanced carbonized wood/polyethylene glycol composite phase change material achieved 93.2 % photothermal conversion efficiency and its thermal conductivity reached 0.632 W·m⁻¹·K⁻¹, representing a 2.64-fold enhancement compared to pure polyethylene glycol. The material exhibited effective temperature control capability in electronic device thermal management scenarios and maintained stable phase change behavior over 100 heating–cooling cycles. Molecular dynamics simulations elucidated the synergistic mechanism between the silver nanoparticle-modified three-dimensional porous network and polyethylene glycol. Vibrational density of states spectra confirmed that enhanced interfacial phonon coupling reduced interfacial thermal resistance to 3.459 × 10⁻⁹ m²·K·W⁻¹, corresponding to a 56.23 % reduction relative to non-modified wood/polyethylene glycol composites. This work innovatively combines wood cell wall engineering with interfacial phonon engineering, revealing atomic-scale heat transfer mechanisms at the microscopic level. The integrated experimental and simulation approach provides valuable insights for developing wood-based multifunctional composite phase change materials.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128621"},"PeriodicalIF":6.9,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227662","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Cooling capacity characteristics of a simplified JT cryocooler working at liquid hydrogen temperature","authors":"Yunwei Shen ,&nbsp;Ziyun Luo ,&nbsp;Changxu Qiu ,&nbsp;Zhichao Chen ,&nbsp;Shaoshuai Liu ,&nbsp;Qinyu Zhao ,&nbsp;Bo Wang ,&nbsp;Zhihua Gan","doi":"10.1016/j.applthermaleng.2025.128612","DOIUrl":"10.1016/j.applthermaleng.2025.128612","url":null,"abstract":"<div><div>Characterized by high reliability, low-level vibration and no moving parts in the cold end, the precooled Joule-Thomson (JT) cryocooler working at liquid hydrogen temperature has potential applications in cooling electronic devices and liquid hydrogen zero boil-off systems in space. In order to reduce complexity, a simplified JT cryocooler has been proposed, successfully achieving liquid hydrogen refrigeration. However, its cooling capacity characteristics have not been systematically studied yet. Consequently, in this study, steady working states of the simplified JT cryocooler at different precooling temperatures are analyzed based on thermodynamic analysis. At a fixed precooling temperature, the temperature behaviors of this JT cryocooler under various heat loads are explained. The inlet temperature of the precooling heat exchanger demonstrates distinct variations under different heat load conditions. The effects of the heat load and the precooling temperature on cooling capacity characteristics are verified with experimental results.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128612"},"PeriodicalIF":6.9,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264391","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Argon-induced thermal field optimization and oxygen volatilization for vacancy-oxygen defect control in CZ silicon growth","authors":"Qitao Zhang ,&nbsp;Ai Wang ,&nbsp;Junxian Chai ,&nbsp;Tai Li ,&nbsp;Peilin He ,&nbsp;Xiang Zhou ,&nbsp;Guoqiang Lv ,&nbsp;Xingwei Yang ,&nbsp;Wenhui Ma","doi":"10.1016/j.applthermaleng.2025.128610","DOIUrl":"10.1016/j.applthermaleng.2025.128610","url":null,"abstract":"<div><div>During the Czochralski growth of monocrystalline silicon, oxygen-related volatile species are closely associated with the formation of vacancy–oxygen (VO_x) complexes. In this study, a comprehensive multiphysics simulation was carried out to investigate the coupled influence of argon flow rates (90–180 L/min) on gas-phase volatile transport (SiO/CO), thermal field distribution, and the evolution of VO_x complexes. The results demonstrate that increasing the argon flow rate markedly enhances convective mass transfer at the melt surface, reducing the surface concentrations of SiO and CO by 35.47 % and 27.54 %, respectively. As a consequence, the effective oxygen concentration in the melt decreases by 7.16–55.83 %, leading to a corresponding suppression of VO_x complex formation by 8.78–16.69 %. However, when the flow rate exceeds 150 L/min, excessive convection enhances surface turbulence and induces localized thermal gradients, vacancy accumulation, and elevated stress near the solid–liquid interface. These effects cause oxygen inhomogeneities and partially offset the benefits of further volatile removal, so that 180 L/min does not represent an optimal condition despite the lowest melt oxygen concentration. Therefore, an optimal argon flow range of 90–120 L/min is identified, balancing efficient volatile evacuation with interfacial stability and effective suppression of VO_x complexes. This study establishes a quantitative correlation between gas-phase transport behavior and defect formation mechanisms, providing a practical gas flow regulation strategy for minimizing oxygen-related defects in industrial-scale Czochralski silicon crystal growth.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128610"},"PeriodicalIF":6.9,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227721","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Performance evaluation and optimization of CO2-based binary mixture closed-Brayton-cycle at high turbine inlet temperature for hypersonic vehicles under finite cold source","authors":"Lei Lang ,&nbsp;Fangyan Jiang ,&nbsp;Hao Zhu ,&nbsp;Xinyan Xiu ,&nbsp;Weibo Gu ,&nbsp;Zhuo Xue ,&nbsp;Kunlin Cheng ,&nbsp;Cong Wang ,&nbsp;Chaolei Dang ,&nbsp;Zhijie Liu ,&nbsp;Song Wang ,&nbsp;Jiang Qin ,&nbsp;Hongyan Huang ,&nbsp;Xin Zhang","doi":"10.1016/j.applthermaleng.2025.128601","DOIUrl":"10.1016/j.applthermaleng.2025.128601","url":null,"abstract":"<div><div>Closed Brayton cycle (CBC) has a promising development prospect in the field of airborne power generation (APG), but limited cold source limits its power output and constrains its minimum cycle conditions. To meet the requirements of long-endurance and high-power tasks for hypersonic vehicles, this paper establishes a CBC optimization model considering the fuel cracking by balancing the thermal efficiency and the heat absorption of cold source. The thermodynamic performance of different CO₂-based binary mixtures is evaluated at high turbine inlet temperatures (TITs). Results indicate that rapid increase in fuel enthalpy value caused by fuel cracking will significantly change the temperature distribution in the precooler. Both using the CO₂-based binary mixture and improving TIT can be an effective way to enhance the APG system performance. The maximum electric power per unit mass flowrate of fuel for CO₂-Kr, SCO₂ and CO₂-SO₂ at the TIT of 2000 K can reach 1116 kJ/kg, 1439 kJ/kg and 1636 kJ/kg, respectively, all of which have the potential to achieve megawatt-level power generation. However, an ultra-high TIT may not be the most appropriate, as the enhanced power generation performance it brings comes at the cost of cold source. In addition, the optimal compressor inlet temperature for CO₂-SO₂ is lower than SCO₂ (385 K vs. 352 K), which greatly simplifies the difficulty of aerodynamic design. Therefore, considering power level, component optimization and working indicators, CO₂-SO₂ is more appropriate than SCO₂ for the long-endurance APG task at high TIT.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"280 ","pages":"Article 128601"},"PeriodicalIF":6.9,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217483","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of three-layer staggered liquid cooling system for high-rate charging of large cylindrical battery module in electric vehicles","authors":"Feifei Liu ,&nbsp;Yongkuan Sun ,&nbsp;Qilong Yang ,&nbsp;Wu Qin ,&nbsp;Xianfu Cheng ,&nbsp;Jianbang Zeng","doi":"10.1016/j.applthermaleng.2025.128585","DOIUrl":"10.1016/j.applthermaleng.2025.128585","url":null,"abstract":"<div><div>Efficient thermal management is essential for ensuring the safety and reliability of large cylindrical lithium-ion battery modules under ultra-fast charging. This study proposes a three-layer staggered liquid-cooled pipe (TSLP) design for a 37-cell (32700 type) module and evaluates its performance through combined computational fluid dynamics (CFD) simulation, experimental validation, and Box-Behnken design (BBD) optimization. Parametric analyses reveal that a staggered counter-flow layout with a middle-layer pipe height of 34 mm and wall thickness of 0.6 mm achieves favorable temperature control, with a peak module temperature of 36.17 °C and a maximum inter-cell temperature difference of 2.43 °C. A BBD response surface methodology was employed to optimize operating conditions, including inlet flow rate, ambient temperature, and coolant precooling rate. The optimal solutions at ambient temperatures of 35/40/45 °C correspond to inlet velocities of approximately 0.044/0.047/0.049 m·s⁻¹ and precooling rates of 3.6–3.9 °C·min⁻¹. Validation shows high consistency between experimental data, CFD simulations, and BBD predictions, with deviations below 0.4 °C. These results demonstrate that the TSLP system offers improved cooling uniformity and scalability for large-format cylindrical cells, providing practical guidance for high-power battery thermal management in electric vehicles.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"280 ","pages":"Article 128585"},"PeriodicalIF":6.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217041","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Assessment of methanol combustion engines in spark ignition, spark-, and glow plug-assisted compression ignition modes","authors":"Xinlei Liu ,&nbsp;Mohammad Raghib Shakeel ,&nbsp;Vallinayagam Raman ,&nbsp;Balaji Mohan ,&nbsp;Rafael Menaca ,&nbsp;Yoann Viollet ,&nbsp;Abdullah S. AlRamadan ,&nbsp;Emre Cenker ,&nbsp;Hong G. Im","doi":"10.1016/j.applthermaleng.2025.128538","DOIUrl":"10.1016/j.applthermaleng.2025.128538","url":null,"abstract":"<div><div>E-methanol is gaining attention as a clean, renewable fuel for future engine technologies. This study investigates three combustion modes, including spark ignition (SI), spark-assisted compression ignition (SACI), and glow plug-assisted compression ignition (GACI), in a light-duty engine using computational fluid dynamics. Combustion and emissions were analyzed under four speed/load conditions. The results show that stable combustion can be achieved across all loads, with the highest indicated thermal efficiency (ITE) at mid-load conditions due to reduced wall heat transfer losses. At high loads, delaying the combustion phasing mitigated excessive maximum pressure rise rates but reduced ITE due to increased exhaust losses. Among the three combustion modes, SI exhibited the highest incomplete combustion losses due to inhomogeneous in-cylinder mixture distribution. At idle, the GACI mode yielded the highest ITE, benefiting from prolonged auxiliary heating and a larger ignition area. For SACI and GACI, ignition and combustion processes were highly sensitive to injection strategies, influencing local thermal and mixing conditions. In GACI mode, ignition positions varied with operating conditions and fuel-jet interactions with the glow plug. Ignition occurred in regions with equivalence ratios below 0.3, where high local temperatures were maintained due to relatively low heat absorption, enabling stable and efficient combustion.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"280 ","pages":"Article 128538"},"PeriodicalIF":6.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217124","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Vibration-enhanced performance of asymmetric channel flat-plate pulsating heat pipes: Reducing thermal resistance and start-up time under dynamic loads","authors":"Qingliang Li ,&nbsp;Li Wang ,&nbsp;Dong Zhang ,&nbsp;Gang Cheng","doi":"10.1016/j.applthermaleng.2025.128588","DOIUrl":"10.1016/j.applthermaleng.2025.128588","url":null,"abstract":"<div><div>As a highly efficient heat transfer device, the pulsating heat pipe (PHP) has seen widespread application in recent years. However, the mechanisms by which its performance is affected by environmental factors such as vibration have not yet been fully clarified. To address this gap, the present study experimentally investigates the start-up and heat transfer performance of an asymmetric-channel flat-plate PHP under varying heating powers, vibration frequencies (0 Hz, 25 Hz, 50 Hz, 75 Hz), and vibration amplitudes (0 mm, 0.4 mm, 0.8 mm, 1.2 mm). The results show that the asymmetric microchannel structure leads to local liquid slug retention under non-vibrational conditions. Vibration enhances fluid circulation, reduces slug stagnation, and improves thermal transfer efficiency. This results in shorter start-up time and lower start-up temperature. With increasing vibration frequency, the start-up time of PHP is gradually reduced. At a heating power of 60 W, vibration frequency exhibits a positive effect on start-up performance, achieving optimal results at 75 Hz. Vibration amplitude exerts a stronger influence on the heat transfer performance of the PHP. An amplitude of 0.8 mm was found to be the most effective, as it facilitated gas–liquid two-phase flow and improved heat transfer efficiency. When the heating power was between 10 W and 30 W, the influence of vibration on thermal resistance was minimal. However, at 40 W to 60 W, vibration significantly reduced thermal resistance. At 60 W, the thermal resistance reached 0.53 K/W under vibration, a reduction of 30.26 % compared to the non-vibrational condition.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128588"},"PeriodicalIF":6.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental thermal and environmental impact performance evaluations of hydrogen-enriched fuels for power generation","authors":"Huseyin Karasu ,&nbsp;Dogan Erdemir ,&nbsp;Ibrahim Dincer","doi":"10.1016/j.applthermaleng.2025.128597","DOIUrl":"10.1016/j.applthermaleng.2025.128597","url":null,"abstract":"<div><div>The transition to a low-carbon energy future requires a multi-faceted approach, including the enhancement of existing power generation technologies. This study provides a comprehensive experimental evaluation of hydrogen enrichment as a strategy to improve the performance and reduce the emissions of a power generator. A 3.65 kW power generator that is equipped with spark-ignition engine is systematically tested with five distinct base fuels: gasoline, propane, methane, ethanol, and methanol. Each fuel is volumetrically blended with pure hydrogen in ratios of 5 %, 10 %, 15 %, and 20 % using a custom-developed dual-fuel carburetor. The key parameters, including exhaust emissions (CO₂, CO, HC, NO_x), cylinder exit temperature, electrical power output, and thermodynamic efficiencies (energy and exergy), are meticulously measured and analyzed. The results reveal that hydrogen enrichment is a powerful tool for decarbonization, consistently reducing carbon-based emissions across all fuels. At a 20 % hydrogen blend, CO₂ emissions are reduced by 22–31 %, CO emissions by 39–60 %, and HC emissions by 21–60 %. This environmental benefit, however, is accompanied by a critical trade-off: a severe increase in NO_x emissions, which rose by 200–420 % due to significantly elevated combustion temperatures. The power outputs are increased by 2–16 %, with hydrogen addition enabling lower-energy–density fuels like methane and propane to achieve performance parity with gasoline. Thermodynamic analysis confirms these gains, with energy efficiency showing marked improvement, particularly for methane, which has increased from 42.0 % to 49.9 %. While hydrogen enrichment presents a viable pathway for enhancing engine performance and reducing the carbon emissions of power generators, the profound increase in NO_x necessitates the integration of advanced control and after-treatment systems for its practical and environmentally responsible deployment.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128597"},"PeriodicalIF":6.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264406","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dual-embedded cooling for thermoelectric coolers in electronics thermal management","authors":"Xiangbin Du ,&nbsp;Yanmei Kong ,&nbsp;Yuxin Ye ,&nbsp;Hangtian Zhu ,&nbsp;Ruiwen Liu ,&nbsp;Guohe Zhang ,&nbsp;Shichang Yun ,&nbsp;Binbin Jiao","doi":"10.1016/j.applthermaleng.2025.128568","DOIUrl":"10.1016/j.applthermaleng.2025.128568","url":null,"abstract":"<div><div>Optimizing thermoelectric cooler (TECs) efficiency and cooling capacity requires minimizing the temperature difference between cold and hot sides. However, the parasitic thermal resistance induced by thermal interface materials in the conventional integration of TEC-based cooling systems elevates temperature difference, compromising their performance under rated power conditions. This study demonstrates a dual-embedded thermal module that integrates thermoelectric legs on the chip backside (serving as the TEC cold side) and embeds microfluidic channels into the substrate of hot side (functioning as the TEC hot side). A silicon test chip with integrated temperature sensors and heating functions was utilized to evaluate cooling performance. Compared to the TEC cooling module with conventional integration, the proposed design achieves a 33% enhancement in coefficient of performance (COP), a 61% reduction in total thermal resistance under equivalent cooling conditions, and a 47% decrease in the proportion of additional thermal resistance outside the TEC in the module. In addition, a prediction model was developed to quantify the impact of parasitic thermal resistance on the maximum achievable cooling power under varying loads. The dual-embedded cooling module demonstrates simultaneous enhancements of 66% in cooling power and 27.2% in temperature difference compared to conventional thermal solutions under equivalent thermal boundary conditions. This co-designed architecture eliminates thermal interface materials, slashing parasitic thermal resistance across heat transfer pathways, while bypassing complex heterogeneous integration challenges between TEC substrates and silicon chips, thereby ensuring reliable TEC performance maximization for high-flux electronics cooling.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"281 ","pages":"Article 128568"},"PeriodicalIF":6.9,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264360","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}