Binghuan Huang

Due to the large surface-area-to-volume ratio, microchannel heat exchangers have a higher heat transfer rate compared with traditional scale heat exchangers. In this study, the optimum microchannel cavity with high heat transfer and low flow resistance is designed to further improve microchannel exchangers’ thermal performance. A three-dimensional laminar flow model, consisting of Navier–Stokes equations and an energy conservation equation is solved and the conjugate heat transfer between the silicon basement and deionized water is taken into consideration. The impact of the shape, aspect ratio, size and spacing of the cavity on the thermal performance of microchannel exchangers are numerically investigated, respectively. The results indicated that the cavity on the sidewall can enhance heat transfer and reduce flow resistance simultaneously, and cavities with a relatively small expansion angle and streamlined edge could enhance thermal performance the most. Based on the conclusions, a new cavity shape is proposed, and the simulation results verify its excellent thermal performance as expected. Furthermore, investigation is performed to figure out the optimum design of the new cavity and the optimal geometric parameters of the cavity under different flow conditions have been obtained in principle for microchannel exchangers’ design.

The application of microchannel heat exchangers is of great significance in industrial fields due to their advantages of miniaturized scale, large surface-area-to-volume ratio, and high heat transfer rate. In this study, microchannel heat exchangers with and without fan-shaped reentrant cavities were designed and manufactured, and experiments were conducted to investigate the flow and heat-transfer characteristics. The impact rising from the radius of reentrant cavities, as well as the Reynolds number on the heat transfer and the pressure drop, is also analyzed. The results indicate that, compared with straight microchannels, microchannels with reentrant cavities could enhance the heat transfer and, more importantly, reduce the pressure drop at the same time. For the ranges of parameters studied, increasing the radius of reentrant cavities could augment the effect of pressure-drop reduction, while the corresponding variation of heat transfer is complicated. It is considered that adding reentrant cavities in microchannel heat exchangers is an ideal approach to improve performance.

Flow characteristics within entrance regions in microchannels are important due to their effect on heat and mass transfer. However, relevant research is limited and some conclusions are controversial. In order to reveal flow characteristics within entrance regions and to provide empiric correlation estimating hydrodynamic entrance length, experimental and numerical investigations were conducted in microchannels with square cross-sections. The inlet configuration was elaborately designed in a more common pattern for microdevices to diminish errors caused by separation flow near the inlet and fabrication faults so that conclusions which were more applicable to microchannels could be drawn. Three different microchannels with hydraulic diameters of 100 μm, 150 μm, and 200 μm were investigated with Reynolds (Re) number ranging from 0.5 to 50. For the experiment, deionized water was chosen as the working fluid and microscopic particle image velocimetry (micro-PIV) was adopted to record and analyze velocity profiles. For numerical simulation, the test-sections were modeled and incompressible laminar Navier–Stokes equations were solved with commercial software. Strong agreement was achieved between the experimental data and the simulated data. According to the results of both the experiments and the simulations, new correlations were proposed to estimate entrance length. Re numbers ranging from 12.5 to 15 was considered as the transition region where the relationship between entrance length and Re number converted. For the microchannels and the Reynolds number range investigated compared with correlations for conventional channels, noticeable deviation was observed for lower Re numbers (Re < 12.5) and strong agreement was found for higher Re numbers (Re > 15).