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研究生: 吳明璋
Ming-Chang Wu
論文名稱: 散熱座結合熱電致冷器之最佳化設計
Thermal Optimal Design for Heat Sinks Integrated with Thermoelectric Coolers
指導教授: 洪英輝
Ying-Huei Hung
口試委員:
學位類別: 博士
Doctor
系所名稱: 工學院 - 動力機械工程學系
Department of Power Mechanical Engineering
論文出版年: 2006
畢業學年度: 95
語文別: 中文
論文頁數: 1冊
中文關鍵詞: 散熱座熱電致冷器最佳化設計水平渠道流平面噴流衝擊
外文關鍵詞: Heat Sink, Thermoelectric Cooler, Thermal Optimal Design, Ducted Flow, Slot Jet Impingement
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  • 在本論文研究中,建立了一系列的實驗系統及方法,來分別探討散熱座或散熱座結合熱電致冷器之散熱模組應用於不同冷卻方法之熱傳特性與最佳化設計。冷卻方法分為(一)水平渠道流與(二)限制平面噴流衝擊兩種。在研究中探討影響水平渠道內及限制平面噴流衝擊的熱傳性能之相關參數分別列之如下:(一)水平渠道流-穩態晶片發熱量(Qc,s)、熱電致冷器輸入電流(I)、散熱座高度與渠道高度比(Hs/Hc)與渠道雷諾數(ReD)。這些參數的探討範圍是Qc,s=10-50 W,I=2-10 A,Hs/Hc=0.42-1與ReD=7351-30055。(二)限制平面噴流衝擊-穩態晶片發熱量(Qc,s)、熱電致冷器輸入電流(I)、噴流間距與噴嘴寬度比(H/Wj) 、散熱座高度與噴嘴寬度比(Hs/Wj)與噴流雷諾數(Rej)。這些參數的探討範圍是Qc,s=8-18 W,I=2-6 A,H/Wj=2-10,Hs/Wj=0.74-3.40 與 Rej=194-1685。
    在水平渠道內分別針對散熱座或散熱座結合熱電致冷器之散熱模組的暫態/穩態局部和平均熱傳特性作探討。研究結果顯示Hs/Hc和ReD皆對暫態/穩態局部和平均紐賽數以及外界熱阻有顯著影響。另外,平均外界熱阻、I與Qc,s皆對散熱模組之局部和平均總熱阻有顯著影響。利用變異數分析F檢測法針對相關參數作統計敏感度分析,發現ReD對穩態平均紐賽數與平均外界熱阻具有最顯著的影響;對於平均總熱阻而言, 重要的影響參數包括平均外界熱阻、I與Qc,s。在研究中亦針對在水平渠道內散熱座或散熱座結合熱電致冷器之散熱模組的對流熱傳特性建立反應曲面模型並且提出新的經驗公式。
    關於限制平面噴流衝擊於散熱座或散熱座結合熱電致冷器散熱模組的對流熱傳特性方面,本研究先後針對暫態/穩態局部和平均熱傳特性作探討。研究結果顯示Hs/Wj和Rej皆對暫態/穩態局部和平均紐賽數以及外界熱阻有顯著影響。另外,平均外界熱阻、I與Qc,s皆對散熱模組之局部和平均總熱阻有顯著影響。利用變異數分析F檢測法針對相關參數作統計敏感度分析,發現Rej對穩態平均紐賽數與平均外界熱阻具有最顯著的影響;對於平均總熱阻而言, 重要的影響參數包括平均外界熱阻、I與Qc,s。在研究中亦針對在限制平面噴流衝擊於散熱座或散熱座結合熱電致冷器散熱模組的對流熱傳特性建立反應曲面模型並且提出新的經驗公式。
    為了評估散熱座結合熱電致冷器應用於不同冷卻方法下之熱傳特性,本研究中提出了一個結合熱網路理論模型及熱電致冷器實驗性能曲線的半經驗方法。此方法可準確地預測散熱座結合熱電致冷器熱傳模組在不同外界熱阻下相關的實驗熱傳結果。對於熱端與冷端溫差(□T)與性能係數(COP)而言,理論預測結果與實驗數據比較之平均誤差分別為3.6%與1.5%,而最大誤差分別為18.7%與13.1%。
    本研究中更成功地發展出一套應用於在不同外界熱阻下,散熱座或散熱座結合熱電致冷器散熱模組的最佳化散熱方法,此方法可使設計者有效且快速地在多個限制條件下找出最佳化的散熱設計。首先,利用工程統計分析所作出的敏感度測試可定量地分析出系統中相關參數影響之重要性;接著應用反應曲面法搭配實驗計劃法來得到迴歸曲面模型;最後再藉由數值最佳化方法來有效的求出在各種限制條件下的最佳化散熱設計。應用此最佳化方法及流程,可以成功地對於不同外界熱阻下之散熱座或散熱座結合熱電致冷器散熱模組得到各種限制條件的最佳化設計。


    In the present study, a series of theoretical and experimental studies on the heat transfer characteristics from heat sinks and Heat Sink/TEC assemblies by using different cooling methods have been performed. Two types of cooling methods such as ducted flow and slot jet impingement are employed in the present study. The relevant parameters influencing heat transfer performance in ducted flow and slot jet impingement studies are listed, respectively. They are: (1) ducted flow - the steady-state heat loads, the input current of TEC, ratio of heat sink height to channel height (Hs/Hc) and channel Reynolds number (ReD). The ranges of parameters studied are Qc,s=10~50 W, I=2~10 A, Hs/Hc=0.42~1, ReD=7351~30055 (or Ui=1.95~7.98 m/s). (2) slot jet impingement -the steady-state heat loads, the input current of TEC, ratio of jet separation distance to nozzle width (H/Wj), ratio of heat sink height to nozzle width (Hs/Wj) and jet Reynolds number (Rej). The ranges of above-mentioned parameters studied at steady state are Qc,s=8~18 W, I=2~6 A, H/Wj=2~10, Hs/Wj=0.74~3.40 and Rej=194~1693. Their effects on heat transfer characteristics in ducted flow and slot jet impingement have been systematically explored.
    For heat sinks and HS/TEC assemblies in a ducted flow, the transient-/steady-state local and average heat transfer characteristics are studied. The results manifest the effects of ReD and Hs/Hc on transient-/steady-state local and average Nusselt Number are more significant as compared with qcv,s (or Qt,s) and I. Similar trend can be found for external thermal resistance. Moreover, the effects of , Qc,s and I on local and average overall thermal resistance are significant. By the statistical sensitivity analysis of ANOVA F-test, ReD has the most significant effect on steady-state average Nusselt number and average external thermal resistance, and is significantly affected by any one of , I and Qc,s in the present parametric studies. In addition, new correlations as well as RSM models of steady-state average Nusselt number, average external thermal resistance and average overall thermal resistance in terms of relevant influencing parameters for heat sinks and HS/TEC assemblies are presented.
    For heat sinks and HS/TEC assemblies with slot jet impingement, the transient-/steady-state local and average heat transfer characteristics are studied. The results manifest the effects of Rej and Hs/Wj on transient-/steady-state local and average Nusselt Number are more significant as compared with H/Wj, Qc,s (or Qt,s) and I. Similar trend can be found for external thermal resistance. Moreover, the effects of , Qc,s and I on local and average overall thermal resistance are significant. By the statistical sensitivity analysis of ANOVA F-test, Rej has the most significant effect on steady-state average Nusselt number and average external thermal resistance, and is significantly affected by any one of , I and Qc,s in the present parametric studies. In addition, new correlations as well as RSM models of steady-state average Nusselt number, average external thermal resistance and average overall thermal resistance in terms of relevant influencing parameters for heat sinks and HS/TEC assemblies are presented.
    In addition, an effective semi-empirical method combines thermal network models and empirical correlations for exploring the thermal performance of heat sinks and HS/TEC assemblies are successfully established. Comparisons of the predicted parameters such as ΔT, Tc, Th and COP evaluated by this method with the experimental data are made with the average deviations of 3.6%, 1.3%, 0.3% and 1.5%, respectively; as well as with the maximum deviations of 18.7%, 5.8%, 2.2% and 13.1%, respectively.
    Furthermore, a systematical design optimization method, which allows the thermal engineer to meet several design objectives and constraints simultaneously and effectively, has been successfully presented and applied to the optimal designs for heat sinks and HS/TEC assemblies with various external thermal resistances in the present study. First of all, a statistical method for the sensitivity analysis is performed to determine the key factors that are critical to the design; and a response surface methodology (RSM) is applied to establish explicit regression models in terms of the design factors with an well-organized design of experiments (DOE). By employing the gradient-based numerical optimization technique, a series of constrained optimal designs can be efficiently performed. With this design optimization method, optimal designs for heat sinks and HS/TEC assemblies under different external thermal resistances are successfully explored with design constraints.

    ABSTRACT i ACKNOWLEDGEMENTS iv LIST OF TABLES xvii LIST OF FIGURES xxi NOMENCLATURE xliv CHAPTER 1 INTRODUCTION AND BACKGROUND 1 1.1 RATIONALE 1 1.2 FUNDAMENTAL MECHANISM OF COOLING METHODS 5 1.2.1 Ducted Flow 5 1.2.2 Slot Jet Impingement 7 1.2.3 Thermoelectric Cooling 9 1.3 LITERATURE SURVEY 12 1.3.1 Convective Heat Transfer from Heat Sinks in a Ducted Flow 12 1.3.2 Convective Heat Transfer from Heat Sinks with Slot Jet Impingement 14 1.3.3 Thermal Performance of Thermoelectric Coolers 18 1.3.4 Design Optimization Techniques 20 1.4 RESEARCH TOPICS AND OBJECTIVES 22 1.5 THESIS ORGANIZATION 26 CHAPTER 2 THE EXPERIMENTS 31 2.1 HEAT TRANSFER BEHAVIOR OF HEAT SINKS OR HEAT SINK/TEC ASSEMBLIES IN A DUCTED FLOW 31 2.1.1 Description of Experimental Facilities 32 (A) Air Supply Facility 32 (B) Pressure Load Unit 32 (C) Test Section 33 (D) Types of Test Assembly 34 (E) Apparatus and Instrumentation 35 2.1.2 Data Acquisition and Control 37 2.1.3 Experimental Procedures 38 (A) Start-Up and Operating Procedures 38 (B) Shutdown Procedure 39 2.1.4 Data Reduction 40 2.1.5 Test Matrix 44 (A) Heat Transfer Characteristics of Heat Sinks in a Ducted Flow 44 (B) Heat Transfer Characteristics of Heat Sink/TEC assemblies in a Ducted Flow 45 2.2 HEAT TRANSFER BEHAVIOR OF HEAT SINKS OR HEAT SINK/TEC ASSEMBLIES WITH SLOT JET IMPINGING 45 2.2.1 Description of Experimental Facilities 46 (A) Air Supply Facility 46 (B) Test Section 47 (C) Types of Test Assembly 49 (D) Apparatus and Instrumentation 50 2.2.2 Data Acquisition and Control 52 2.2.3 Experimental Procedures 53 (A) Start-Up and Operating Procedures 53 (B) Shutdown Procedure 54 2.2.4 Data Reduction 55 (A) Fluid Flow Characteristics 55 (B) Heat Transfer Characteristics 56 2.2.5 Test Matrix 61 (A) Heat Transfer Characteristics of Heat Sinks with Slot Jet Impingement 61 (B) Heat Transfer Characteristics of Heat Sink/TEC Assemblies with Slot Jet Impingement 62 2.3 SENSITIVITY ANALYSIS 63 2.4 UNCERTAINTY ANALYSIS 65 CHAPTER 3 OPTIMAL DESIGN 97 3.1 DESIGN OF EXPERIMENTS 98 3.2 RESPONSE SURFACE METHODOLOGY 99 3.2.1 Response Surface Model 99 3.2.2 Central Composite Design 101 3.2.3 Least Squares Regression Analysis 102 3.2.4 Analysis of Response Surface Model 105 (A) Analysis of Variance 105 (B) Box-Cox Power Transformation 106 3.2.5 Accuracy of Response Surface Model 107 3.3 NUMERICAL OPTIMIZATION TECHNIQUES 107 3.3.1 Sequential Quadratic Programming 108 3.3.2 Globally Optimal Solution 110 CHAPTER 4 THERMAL OPTIMAL DESIGN FOR HEAT SINKS OR HEAT SINK/TEC ASSEMBLIES IN A DUCTED FLOW 112 4.1 HEAT TRANSFER CHARACTERISTICS OF HEAT SINKS IN A DUCTED FLOW 112 4.1.1 Temperature Distributions on Heat Sinks 113 4.1.2 Transient Heat Transfer Characteristics 114 (A) Transient Heat Flux Distributions of Input Power 114 (B) Transient Convective Heat Flux Distribution 115 (C) Transient Local Heat Transfer Characteristics 116 (D) Transient Average Heat Transfer Characteristics 118 4.1.3 Steady-state Heat Transfer Characteristics 119 (A) Steady-state Local and Average Nusselt Number 119 (B) Steady-state Local and Average External Thermal Resistance 121 (C) Empirical Correlations of Average Heat Transfer Characteristics 121 4.2 HEAT TRANSFER CHARACTERISTICS OF HEAT SINK/TEC ASSEMBLIES IN A DUCTED FLOW 123 4.2.1 Performance Testing of Thermoelectric Coolers 124 (A) Determination of Performance Parameters 124 (B) Determination of Physical Properties 129 (C) Measurement of New Performance Correlations 130 4.2.2 Temperature Distributions on HS/TEC Assemblies 131 4.2.3 Transient Heat Transfer Characteristics 132 (A) Transient Heat Flux Distributions of Input Power 132 (B) Transient Convective Heat Flux Distribution 133 (C) Transient Local Heat Transfer Characteristics 134 (D) Transient Average Heat Transfer Characteristics 136 4.2.4 Steady-state Heat Transfer Characteristics 137 (A) Steady-state Local and Average Nusselt Number 138 (B) Steady-state Local and Average External Thermal Resistances 139 (C) Steady-state Local and Average Overall Thermal Resistance 141 4.3 DESIGN OPTIMIZATION FOR HEAT SINKS AND HEAT SINK/TEC ASSEMBLIES IN A DUCTED FLOW 143 4.3.1 Design Optimization for Heat Sinks in a Ducted Flow 143 (A) Design Variables for Heat Sinks 143 (B) Model Establishment by Response Surface Methodology 143 (C) Numerical Optimization 145 4.3.2 Design Optimization for Heat Sink/TEC Assemblies in a Ducted Flow 146 (A) Design Variables for Heat Sink/TEC Assemblies 146 (B) Model Establishment by Response Surface Methodology 147 (C) Numerical Optimization 149 CHAPTER 5 THERMAL OPTIMAL DESIGN FOR HEAT SINKS OR HEAT SINK/TEC ASSEMBLIES WITH SLOT JET IMPINGEMENT 211 5.1 HEAT TRANSFER CHARACTERISTICS OF HEAT SINKS WITH SLOT JET IMPINGEMENT 211 5.1.1 Transient Heat Transfer Characteristics of Heat Sinks with Slot Jet Impingement 213 5.1.2 Steady-state Heat Transfer Characteristics of Heat Sinks with Slot Jet Impingement 214 (A) Steady-state Local Nusselt Number 214 (B) Steady-state Average Nusselt Number 215 (C) Steady-state Local and Average External Thermal Resistance 218 5.1.3 Semi-empirically Modeling of Heat Sinks with Slot Jet Impingement under Various Hs/H Ratios 220 (A) Theoretical Modeling for Heat Sinks at Hs/H=1 221 (B) Empirical Correlations of Average Heat Transfer Characteristics for Heat Sinks under Various Hs/H Ratios 226 5.2 HEAT TRANSFER CHARACTERISTICS OF HEAT SINK/TEC ASSEMBLIES WITH SLOT JET IMPINGEMENT 229 5.2.1 Performance Testing of Thermoelectric Coolers 230 5.2.2 Temperature Distributions on Heat Sink/TEC Assemblies 231 5.2.3 Transient Heat Transfer Characteristics 232 (A) Transient Heat Flux Distributions of Input Power 232 (B) Transient Convective Heat Flux Distribution 233 (C) Transient Local Heat Transfer Characteristics 235 (D) Transient Average Heat Transfer Characteristics 237 5.2.4 Steady-state Heat Transfer Characteristics 238 (A) Steady-state Local Nusselt Number 239 (B) Steady-state Average Nusselt Number 240 (C) Steady-state Local and Average External Thermal Resistance 241 (D) Steady-state Local and Average Overall Thermal Resistance 243 (E) Empirical Correlations of Average Overall Thermal Resistance 244 5.3 DESIGN OPTIMIZATION FOR HEAT SINK AND HEAT SINK/TEC ASSEMBLY WITH SLOT JET IMPINGEMENT 246 5.3.1 Design Optimization for Heat Sinks with Slot Jet Impingement 246 (A) Design Variables for Heat Sinks 246 (B) Model Establishment by Response Surface Methodology 246 (C) Numerical Optimization 248 5.3.2 Design Optimization for Heat Sink/TEC Assemblies with Slot Jet Impingement 249 (A) Design Variables for Heat Sink/TEC Assemblies 249 (B) Model Establishment by Response Surface Methodology 249 (C) Numerical Optimization 251 CHAPTER 6 A SEMI-EMPIRICALLY THERMAL OPTIMIZATION FOR HEAT SINK/TEC ASSEMBLIES WITH VARIOUS EXTERNAL THERMAL RESISTANCES 320 6.1 SEMI-EMPIRICALLY THERMAL ANALYSIS FOR HEAT SINK/TEC ASSEMBLIES UNDER DIFFERENT EXTERNAL THERMAL RESISTANCES 320 6.1.1 Theoretical Thermal Network Model for Heat Sink/TEC Assemblies 320 6.1.2 Semi-Empirically Methods for Heat Sink/TEC Assemblies 323 (A) Method I 323 (B) Method II 325 (C) Method III 327 6.2 THERMAL PERFORMANCE EVALUATION FOR HEAT SINK/TEC ASSEMBLIES UNDER DIFFERENT EXTERNAL THERMAL RESISTANCES 328 6.2.1 Thermal Evaluation for Heat Sink/TEC Assemblies with Reduction of Thermal Resistances 329 (A) Thermal Evaluation for Heat Sink/TEC Assemblies in a Ducted Flow 330 (B) Thermal Evaluation for Heat Sink/TEC Assemblies with Slot Jet Impingement 331 6.2.2 Thermal Evaluation for Heat Sink/TEC Assemblies with Enhancement of Module Heat Loads 333 (A) Thermal Evaluation for Heat Sink/TEC Assemblies in a Ducted Flow 334 (B) Thermal Evaluation for Heat Sink/TEC Assemblies with Slot Jet Impingement 335 6.2.3 Thermal Evaluation for Heat Sink/TEC Assemblies with Improvement of External Thermal Resistances 337 (A) Thermal Evaluation for Heat Sink/TEC Assemblies in a Ducted Flow 337 (B) Thermal Evaluation for Heat Sink/TEC Assemblies with Slot Jet Impingement 339 6.3 DESIGN OPTIMIZATION FOR THERMAL PERFORMANCE OF HEAT SINK/TEC ASSEMBLIES UNDER DIFFERENT EXTERNAL THERMAL RESISTANCES 341 6.3.1 Design Optimization for HEAT SINK/TEC Assemblies with Reduction of Thermal Resistance 341 (A) Design Optimization for Heat Sink/TEC Assemblies in a Ducted Flow 341 (B) Design Optimization for Heat Sink/TEC Assemblies with Slot Jet Impingement 345 6.3.2 Design Optimization for HEAT SINK/TEC Assemblies with Enhancement of Module Heat Loads 349 (A) Design Optimization for Heat Sink/TEC Assemblies in a Ducted Flow 349 (B) Design Optimization for Heat Sink/TEC Assemblies with Slot Jet Impingement 352 6.3.3 Design Optimization for Heat Sink/TEC Assemblies with Improvement of External Thermal Resistance 355 (A) Design Optimization for Heat Sink/TEC Assemblies in a Ducted Flow 355 (B) Design Optimization for Heat Sink/TEC Assemblies with Slot Jet Impingement 359 CHAPTER 7 CONCLUSIONS AND RECOMMENDATIONS 435 7.1 CONCLUSIONS 435 7.1.1 Thermal Optimal Design for Heat Sinks or Heat Sink/TEC Assemblies in a Ducted Flow 435 7.1.2 Thermal Optimal Design for Heat Sinks or Heat Sink/TEC Assemblies with Slot Jet Impingement 437 7.1.3 A Semi-Empirically Thermal Optimization for Heat Sink/TEC Assemblies with Various External Thermal Resistances 440 7.2 RECOMMANDATIONS 441 REFERENCES 443 APPENDIX A CALIBRATION OF AIR VELOCITY 450 APPENDIX B CALIBRATION OF AIR FLOW RATE 455 APPENDIX C EMISSIVITY DETERMINATION OF HEATED TARGET SURFACE 462 APPENDIX D EMPIRICAL CORRELATIONS FOR AIR PROPERTIES 465 APPENDIX E CALCULATIONS FOR HEAT TRANSFER MODES 472 APPENDIX F DETERMINATION OF THERMAL CONDUCTIVITY OF BALSA SLAB 482 APPENDIX G COMPARISION OF DATA REDUCTION METHOD 483 APPENDIX H UNCERTAINTY ANALYSIS 487 VITA 500 LIST OF PUBLICATIONS 501

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