Numerical analysis of heat sink configurations and their impact on conjugate heat transfer in manifold systems

This study numerically analyzes the impact of heat sink designs, inlet fluid velocity, and heat flux on fluid flow and conjugate heat transport parameters. Four thermal sink configurations are examined: Type A, a conventional rectangular design serving as the baseline; Type B, featuring rectangular cavities on the walls; Type C, incorporating asymmetric triangular and trapezoidal cavities; and Type D, consisting of interconnected pin-like structures. The findings reveal that Type A creates large circulation zones, which limit heat transfer performance. In contrast, the modified designs (Types B, C, and D) significantly enhance conjugate heat transfer efficiency. At constant inlet velocity, increasing heat flux (Q) amplifies the performance differences among the heat sink types. Conversely, at constant heat flux, increasing inlet velocity diminishes these differences. At low inlet velocities, the average temperature (T_avg) of Types B, C, and D is similar, with Type D achieving the lowest temperature non-uniformity (δT). At higher inlet velocities, Type B exhibits the best conjugate heat transfer performance, followed by Types C, D, and A. These results underscore the importance of optimized heat sink geometries and flow conditions for improved thermal performance.