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142 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 24, NO.

2, JUNE 2001

Modeling of the Thermal and Hydraulic Performance


of Plate Fin, Strip Fin, and Pin Fin Heat
Sinks—Influence of Flow Bypass
Hans Jonsson and Bahram Moshfegh

Abstract—Tests have been conducted in a wind tunnel with seven codes. However, in order to reduce computational time, interest
types of heat sinks including plate fin, strip fin, and pin fin heat has also turned to development of compact models of the dif-
sinks. In the case of strip fin, and pin fin heat sinks, both in-line ferent heat sink types.
and staggered arrays have been studied. The pin fin heat sinks had
circular and square cross-sections. For each type, tests were run The performance of plate fin heat sinks have been studied
with fin heights ( ) of 10, 15, and 20 mm while the heat sink width extensively by Sparrow and co-workers [1]–[3], Kadle and
( ) was kept constant and equal to 52.8 mm. In total, 42 different Sparrow [4], Lau and Mahajan [5], Wirtz and co-workers [6],
heat sinks were tested. The width of the wind tunnel duct ( ) [7], Iwasaki et al. [8], Sata et al. [9], and Jonsson and Moshfegh
was varied in such a way that results were obtained for = [10], [11]. The investigators have utilized experimental and/or
0 84, 0.53, and 0.33. The wind tunnel height ( ) was varied sim-
ilarly, and data were recorded for = 1, 0.67, and 0.33 numerical methods for both laminar and turbulent flow regimes.
while the duct Reynolds number was varied between 2 000 through The heat transfer enhancement by introducing strip fins
16 500. has been treated by Sparrow and co-workers [12], [13], who
An empirical bypass correlation has been developed for the dif- treated laminar flow cases numerically. Boesmans et al. [14],
ferent fin designs. The correlation predicts the Nusselt number performed an experimental comparison between plate fin heat
and the dimensionless pressure drop and takes into account the
influence of duct height, duct width, fin height, fin thickness, and sinks and staggered strip fin heat sinks. Chapman et al. [15],
fin-to-fin distance. The correlation parameters are individual for compared a strip fin heat sink with a continuous fin heat sink
each fin design. Further, a physical bypass model for plate fin heat in open and confined configurations. Sathyamurthy et al. [16]
sinks has been developed to describe the bypass effect. compared a plate fin heat sink with a staggered strip fin heat
Index Terms—Bypass, circular, experimental, heat sink, physical sink both numerically and experimentally.
model, pin fin, plate fin, pressure drop, square, strip fin, thermal The performance of pin fin heat sinks has also been treated in
resistance. the literature. Kameoka et al. [17], Metzger et al. [18], Shaukat-
ullah and Gaynes [19] and Azar and Mandrone [20], Maudgal
I. INTRODUCTION and Sunderland [21], and Chyu et al. [22] have all treated their
thermal performance. However, the effect of airflow bypass was

T HE performance of passive heat sinks in bypass situations


has been the focus of many investigations in recent years,
and the subject has been treated both theoretically, numerically,
not treated primarily. Sparrow and Ramsey [23], and Chapman
et al. [15], investigated the bypass influence on pin fin heat sink
performance. Jonsson and Moshfegh [24], investigated the per-
and experimentally. Most of the theoretical investigations have formance of pin fin heat sinks numerically.
treated laminar flow cases for plate fin heat sinks, while inves- In previous publications the first author has developed two
tigations of strip fin and pin fin heat sinks have been mainly empirical bypass correlations, Jonsson and Palm [25], [26].
numerical, and experimental. The increased number of numer- Generally, the agreement between experimental data and the
ical investigations is of course due to the evolution of the many correlations were good, the thermal resistance was within
and powerful commercial computational fluid dynamics (CFD) and the pressure drop was within from experi-
mental data respectively. The correlations were developed for
plate fin and pin fin heat sinks. However, in the case of pin
Manuscript received October 16, 2000; revised February 26, 2001. This work fin heat sinks (Jonsson and Palm [25]) the influence of fin
was recommended for publication by Associate Editor J. R. Culham upon eval-
uation of the reviewers’ comments. This work was presented at the 7th Interso- height, and staggered arrays was not included, and in the case
ciety Conference on Thermal, Mechanical, and Thermomechanical Phenomena of plate fin and strip fin heat sinks (Jonsson and Palm [26]) the
in Electronic Systems (ITHERM 2000), Las Vegas, NV, May 23-26, 2000. This influence of the fin-to-fin distance was not studied.
work was supported by Ericsson Telecom, Ericsson Radio Systems, Ericsson
Components, Stockholm, Sweden, the Swedish National Board for Industrial In this paper, experimental data for plate fin, strip fin, and
and Technical Development (NUTEK), Stockholm, Sweden, and KK-stiftelsen, pin fin heat sinks is presented. In total, 42 different heat sinks
Stockholm, Sweden. were tested (see Table I). By varying the fin height, fin-to-fin
H. Jonsson is with the Department of Energy Technology, Division of Applied
Thermodynamics and Refrigeration, Royal Institute of Technology, Stockholm distance, and the tip and lateral clearance, a substantial data base
SE-100 44, Sweden (e-mail: hansj@thermo.kth.se). has been established, each heat sink was tested in seven different
H. Jonsson and B. Moshfegh are with the Division of Energy and Mechanical wind tunnel ducts. From this database, empirical correlations of
Engineering, Department of Technology, University of Gävle, Gävle SE-801 76,
Sweden. how the thermal and hydraulic performance of the heat sinks is
Publisher Item Identifier S 1521-3331(01)04790-0. affected by (mainly) the above mentioned parameters have been
1521–3331/01$10.00 ©2001 IEEE
JONSSON AND MOSHFEGH: THERMAL AND HYDRAULIC PERFORMANCE OF PLATE FIN, STRIP FIN, AND PIN FIN HEAT SINKS 143

TABLE I
DIMENSIONS OF TESTED HEAT SINKS

derived. Further, a physical bypass model for plate fin heat sinks with three different fin heights and two different fin-to-fin dis-
has been developed to describe the bypass effect. tances of each fin height. In total, 42 heat sinks were tested. The
base area, and the fin thickness were the same for all tested heat
sinks. The dimensions of the heat sinks are shown in Table I.
II. EXPERIMENTAL SETUP The tested heat sinks were milled from solid aluminum
(thermal conductivity W/(m K)) and no additional surface
A. Heat Sinks
treatment was applied. The heat sinks were heated by electrical
Seven different fin designs have been tested including plate heaters (MINCO aluminum-backed Thermofoil™ heaters with
fin heat sinks, strip fin heat sinks in both in-line and staggered #10 pressure-sensitive adhesive). The bottom of the heated foil
arrays, circular pin fin and square pin fin heat sinks (both in-line was insulated with 25 mm of Polystyrene (thermal conductivity
and staggered arrays) Fig. 1. For each fin design, tests were run W/(m K)). The heat sinks were mounted at the bottom
144 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 24, NO. 2, JUNE 2001

Fig. 2. Vertical cut view of heat sink, heated foil, and insulation.

Fig. 1. Plate fin heat sink (a), strip fin heat sinks with in-line, (b) and staggered,
(c) arrays, circular pin fin heat sinks, (in-line (d) and staggered (e) arrays), and
square pin fin heat sinks (in-line (f) and staggered (g) arrays).

of the wind tunnel duct in such a way that the fin base was flush
with the duct wall (Fig. 2). The reason for not using two heat
sinks mounted back-to-back is that all heat sinks were custom
made, and the cost for manufacturing twice as many heat sinks
would have been too large.
Fig. 3. Top view of wind tunnel.
B. Wind Tunnel
The general layout of the wind tunnel is shown in Figs. 3
and 4. The wind tunnel walls are made of Plexiglass [thermal
conductivity W/(m K)]. The air velocity is controlled by
frequency regulation of the electric power driving the fan.
The wind tunnel cross-sectional area at the measurement
section can be varied by moving the side walls and the ceiling
(Fig. 5). Tests were performed with duct configurations ac-
cording to Table II. For some of the heat sinks the values
of and 1 deviated slightly from the values in

Table II due to small deviations in and (see Table I).


The conduction heat losses through the wind tunnel bottom
wall (Fig. 2), i.e., the heat which was not dissipated through
Fig. 4. Side view of measurement section.
the heat sink, were estimated by a finite element calculation for
which the ANSYS 5.6 code was used. For this estimation, the
heat transfer coefficient (HTC) on the inside of the wind tunnel
wall was calculated as the average HTC for forced convection
over a plane surface. The HTC on the outside of the wind tunnel
wall was calculated as the average HTC for free convection from
a heated horizontal plate facing downward. The uncertainty in
the heat loss estimation was assumed to 5%.
Fig. 5. Front view of measurement section.
C. Measurement Equipment
All temperatures were measured with type thermocou- TABLE II
ples with a specified accuracy of C. However, when WIND TUNNEL DUCT CONFIGURATIONS
calibrating the thermocouples, an accuracy in temperature
1where
B base width of heat sink [m], see Table I;
CB width of wind tunnel duct [m];
H fin height [m], see Table I;
CH height of wind tunnel duct [m].
JONSSON AND MOSHFEGH: THERMAL AND HYDRAULIC PERFORMANCE OF PLATE FIN, STRIP FIN, AND PIN FIN HEAT SINKS 145

difference of less than C was observed. The heat sink TABLE III
base temperature was measured by averaging the reading of ERROR LIMITS FOR ALL THE EXPERIMENTAL DATA
four symmetrically positioned thermocouples (placed at each
corner of the heat sink, 10 mm from the edges).
The pressure drop over the heat sinks was measured using
two pressure taps positioned 50 mm upstream and downstream
of the heat sink respectively. The taps were connected to Au-
totran 700D pressure transducers. Three different transducers where
were used with the full scale readings of 100, 62, and 25 Pa de- heat dissipation [W];
pending on the occurring pressure drop. The maximum error, ac- total heat transfer area of heat sink [m ];
cording to the manufacturer, is of the full scale reading. temperature at heat sink base [ C];
The volumetric air flow rate was measured by a laminar flow temperature at the wind tunnel inlet [ C].
element with a total maximum error (including the pressure The thermal resistance, can be calculated by
transducer) of of reading.
The supplied heat was calculated by measuring the voltage K
(2)
over, and the current through, the electrically heated foil. For W
these measurements a Fluke 45 dual multimeter was used, and
In order to better reflect the actual velocity in the wind tunnel
the maximum error was estimated to of reading.
duct, the velocity is calculated using the effective fluid flow area,
The uncertainties in the experiments are discussed in detail
. The authors have investigated different definitions
in Jonsson [27], and for the experimental data presented here,
of the velocity and the present one was found to be the most
the maximum error , and the probable overall uncertainty ,
suitable. The average air velocity is hence calculated as
i.e., the error limits for a 95% confidence level, are shown in
Table III. m
The large error limits for the pressure drop are due to the in- (3)
s
accuracy in measuring small pressure drops. In fact, all pressure
drop readings smaller than 0.5 Pa have been discarded. where
volumetric air flow rate at standard conditions (101.3
kPa, 21.2 C) [m /s];
III. TEST PROCEDURE
wind tunnel cross sectional area at the test section
The tests were started by adjusting the velocity to a value cor- ( ) [m ];
responding to ( defined by (4), then the frontal area of the fins (see Table I, [m ]).
electrical circuit supplying the heated foil was closed, producing The duct Reynolds number, , is defined as
a heat load of 10 W. The temperatures were monitored at 30-s in-
tervals until conditions were at steady state. The conditions were - (4)
assumed steady state when the temperatures of each of the four
thermocouples in the heat sink base changed less than 0.05 C where
between two consecutive readings. The error in heat dissipation hydraulic diameter of the wind tunnel (
due to this assumption is very small, for the worst case it is less ) [m];
than 0.5%. At steady state, five sets of data were acquired auto- kinematic viscosity of air [m /s].
matically at 30-second intervals. The velocity was then reduced In order to represent the heat transfer coefficient in a dimen-
to a value corresponding to and the temperatures sionless way, the Nusselt number, , is defined as
were monitored until conditions were at steady state; at this time
the data acquisition procedure was repeated. The procedure of - (5)
reducing the velocity was repeated until the data corresponding
to equal to 6700, 5000, and 3350 was recorded as well. where
(The above mentioned Reynolds numbers roughly corresponds heat sink base plate length in flow direction [m];
to the velocities of 4, 3, 2, 1.5, and 1 m/s for a duct having a thermal conductivity of air [W/(m K)].
height of 30 mm and a width of 160 mm.) The air temperature The choice of as the characteristic length scale for the Nus-
at the wind tunnel inlet was held at approximately 20 C. During selt number, Nu, was made due to the fact that was almost
tests, deviations from the above mentioned Reynolds numbers equal for all heat sinks. Hence, represents the variation in
occurred due to practical reasons. the heat transfer coefficient only.
The dimensionless pressure drop is defined as
IV. DATA REDUCTION
The heat transfer coefficient, , (assuming 100% fin effi- - (6)
ciency) is calculated as
where
W pressure drop [Pa];
(1)
m K density of air [kg/m ].
146 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 24, NO. 2, JUNE 2001

Fig. 6. Fluid flow resistance net.

V. EMPIRICAL BYPASS CORRELATION


In order to describe the influence of airflow bypass on the per-
formance of heat sinks, the first author has developed two em- Fig. 7. Thermal behavior of heat sinks with H = 10 mm, B = 52:8 mm,
 = 5 mm in a wind tunnel duct with zero bypass (CH = 10 mm, CB =
pirical bypass correlations, Jonsson and Palm [25], [26]. These 63 mm).
correlations had generally good agreement to experimental data,
the thermal resistance was within and the pressure drop
was within from experimental data respectively. The cor-
relations were developed for plate fin, strip fin, and pin fin heat
sinks. However, in the case of pin fin heat sinks (Jonsson and
Palm [25]) the influence of fin height and staggered arrays was
not included, and in the case of plate fin and strip fin heat sinks
(Jonsson and Palm [26]) the influence of fin-to-fin distance was
not studied.
The present correlations predict the Nusselt number, ,
and the dimensionless pressure drop, , as functions of the in-
vestigated parameters: , , , , and .
Although the equations are the same for all types of heat sinks,
the correlation parameters (constants and exponents) are spe-
cific for each type of heat sink. Further, the correlations are not
valid for the zero bypass ducts, i.e., , and Fig. 8. Hydraulic behavior of heat sinks with H = 10 mm, B = 52:8 mm,
 = 5 mm in a wind tunnel duct with zero bypass (CH = 10 mm, CB =
63 mm).

, at the inlet; Frictional pressure drop, ; and Expansion


pressure drop, , at the outlet. The duct pressure drop up-
- (7) stream and downstream of the heat sink has been included to
enable comparison with experimental data.
The frictional pressure drop is calculated

[Pa] (10)
- (8)
where
It should also be observed that there is a relation between , eensity of air [kg/m ];
, and velocity [m/s];
duct length [m];
m (9) hydraulic diameter [m];
friction factor.
where is the number of fins in the spanwise direction. The hydraulic diameters are given by

VI. PHYSICAL BYPASS MODEL (wind tunnel duct)


(heat sink channel)
Described below is a simplified and slightly modified version
(bypass channel).
of the bypass model as presented by Butterbaugh and Kang [28].
In this model, valid for plate fin heat sinks, the airflow by- The friction factor is calculated as
pass is calculated by balancing the pressure drop for the interfin
flow path to that of the bypass flow path, Fig. 6. Each flow path for
has three pressure drop mechanisms: Contraction pressure drop, for .
JONSSON AND MOSHFEGH: THERMAL AND HYDRAULIC PERFORMANCE OF PLATE FIN, STRIP FIN, AND PIN FIN HEAT SINKS 147

TABLE IV
LIMITS WITHIN WHICH THE CORRELATIONS ARE VALID [Pa]
(12)

where

number of fins.

The expressions for the contraction and expansion pressure


drops are derived from diagrams in Kays and London [29]. The
expressions are valid for “short” plate fin heat sinks, where the
boundary layers are developing; for interrupted wall heat ex-
changers, where the boundary layers seldom are fully devel-
oped; and for “long” plate fin heat sinks under fully developed
conditions.

VII. RESULTS AND DISCUSSION


A. Performance in Ducts with Zero Bypass
As can be seen in Fig. 7, the thermal resistance for all heat
sinks are converging at high Reynolds numbers except for the
plate fin heat sink. At the same time, the pressure drop for all
heat sinks are diverging with increasing Reynolds numbers, see
Fig. 8. For increasing Reynolds number the increase in pressure
drop is larger for the pin fin heat sinks as compared to the strip
fin and plate fin heat sinks while the decrease in thermal resis-
tance is marginal. Consequently it is not beneficial to use pin fin
heat sinks at high Reynolds numbers.
Fig. 9. Evaluation of the Nusselt number correlation.
Further, three important observations can be made in Fig. 8.
First, the length of the fins in the flow direction have a strong
influence on the pressure drop. Longer fins results in lower pres-
sure drop. This is explained by the fact that the plate fin heat sink
only have one inlet contraction and one outlet expansion while
all the other heat sink types have multiple contractions and ex-
pansions as well as redevelopment of the boundary layers thus
causing a higher pressure drop. The second observation regards
the orientation of the fins. Generally, a staggered array results
in a larger pressure drop than an in-line array. Third, the shape
of the pins have some influence. The circular pins have lower
pressure drop compared to the square pins. This is very apparent
when comparing the staggered arrays for the square pin and the
circular pin fin heat sinks. For in-line array, this behavior is not
as pronounced.

B. Evaluation of the Empirical Bypass Correlation


The constants and exponents in (7) and (8) (the correlation pa-
rameters) were estimated using nonlinear regression for which
the code STATISTICA 4.5 [30] was utilized. The convergence
criteria was set to a relative error of and convergence was
Fig. 10. Evaluation of the dimensionless pressure drop correlation. reached after 100 iterations typically. The correlations are valid
within the ranges given in Table IV.
The correlation parameters are provided in Table V. The per-
The contraction pressure drop, , and the expansion pres-
formance of the correlations are shown in Figs. 9 and 10. As can
sure drop, , are calculated
be seen, the Nusselt number, , is predicted quite well. The
correlation yield predictions that are almost as good as the
[Pa] correlation. This is probably due to the inaccuracy in pres-
(11) sure drop measurement at low pressure drops. In fact, the experi-
148 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 24, NO. 2, JUNE 2001

TABLE V also shown in Table V. The performance of the correlations can


CORRELATION PARAMETERS also be studied in Figs. 9 and 10.

C. Evaluation of the Physical Bypass Model


In Figs. 11 and 12 the physical bypass model is compared
with experimental data for plate fin heat sinks. From an en-
gineering point of view the agreement with experimental data
is rather good considering the simplicity of the model. As can
be seen, the model underpredicts the experimental data and at
present, these differences are not quite clear to the authors. One
possible explanation is that the model utilizes friction factors
for fully developed flow while the flow in the experiments most
likely is developing. Generally, the agreement is best at large
pressure drops which probably is due to the inaccuracy in mea-
suring small pressure drops.

VIII. CONCLUSIONS
An empirical bypass correlation has been developed for seven
different fin designs including plate fin, in-line and staggered
strip fin heat sinks, and circular and square pin fin heat sinks ar-
ranged in both in-line and staggered arrays. The correlation pre-
dicts the Nusselt number and the dimensionless pressure drop
and takes into account the influence of duct height, duct width,
fin height, fin thickness, and fin-to-fin distance. The correlation
parameters are specific for each fin type. Further, a physical by-
pass model for plate fin heat sinks has been developed to de-
scribe the bypass effect.
Fig. 11. Comparison between experimental data for a plate fin heat sink with
At high Reynolds numbers in zero bypass ducts, the pressure
 = 5 mm and the physical bypass model H=CH = 0:67. drop is larger for the pin fin heat sinks as compared to the strip
fin heat sinks while the difference in thermal resistance is mar-
ginal. Consequently it is not beneficial to use pin fin heat sinks
at high Reynolds Numbers.
The empirical correlations give reasonably good agreement.
The Nusselt number is predicted with quite good accuracy.
The prediction of the dimensionless pressure drop should be
improved somewhat in order to make it useful in the design
process. The Reynolds number and the relative duct height,
, have the largest influence on the prediction of the
Nusselt number while all investigated parameters are important
for the prediction of the dimensionless pressure drop.
The physical bypass model for plate fin heat sinks is in rather
good agreement with experimental data considering the sim-
plicity of the model. A further extension of the physical bypass
model will incorporate other fin designs.
Fig. 12. Comparison between experimental data for a plate fin heat sink with
 = 5 mm and the physical bypass model H=CH = 0:33.
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multi-chip modules,” in Proc. Eurotherm Seminar 29 “Thermal Manag. from the Royal Institute of Technology, Stockholm, Sweden, in 1995 and 2000,
of Electron. Syst.”, Delft, The Netherlands, June 14–16, 1993. respectively.
[15] C. L. Chapman, S. Lee, and B. L. Schmidt, “Thermal performance of Since 1998, he has also been with the Division of Energy and Mechanical
an elliptical pin fin heat sink,” in Proc. 10th IEEE Semi-Therm Symp., Engineering, University of Gävle, Gävle, Sweden. His research interests are in
1994, pp. 24–31. turbulent forced convection air cooling of electronics, focusing on heat sink de-
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array orientation on heat transfer and pressure loss in pin fin arrays,” ment of Mechanical Engineering, Linköping University, Linköping, Sweden, in
ASME J. Eng. Gas Turbines Power, vol. 106, pp. 252–257, Jan. 1984. 1992.
[19] H. Shaukatullah and M. A. Gaynes, “Effect of pin fin heat sink size Presently, he is head of Division of Energy and Mechanical Engineering, De-
on thermal performance of surface mount plastic quad flat packs,” in partment of Technology, University of Gävle, Gävle, Sweden. He has rather
Proc. 1994 Int. Electron. Packag. Conf., Atlanta, GA, Sept. 25–28, pp. wide research interests, and has been active in many areas of fluid flow and heat
232–241. transfer, e.g., heat conduction, super insulation, phase change process, contact
[20] K. Azar and C. D. Mandrone, “Effect of pin fin density of the thermal heat transfer, natural and forced convection, as well as radiation heat transfer.
performance of unshrouded pin fin heat sinks,” ASME J. Electron. His main research interests are mathematical modeling of fluid flow and heat
Packag., vol. 116, pp. 306–309, Dec. 1994. transfer in closed spaces and channels with applications to heat transfer in build-
[21] V. K. Maudgal and J. E. Sunderland, “Forced convection heat transfer ings, air movement in spaces, cooling of electronic components and renewable
from staggered pin fin arrays,” in Proc. Nat. Heat Transf. Conf., vol. 7, energy as well as validation of numerical results by means of applying different
1996, HTD-Vol. 329, pp. 35–44. advanced experimental techniques for velocity and temperature measurements.
[22] M. K. Chyu, Y. Hsing, V. Natarajan, and J. S. Chiou, “Effects of per- He is involved in many scientific tasks such as referee for international journals
pendicular flow entry on convective heat (mass) transfer from pin-fin and conferences, as well as being a frequent invited speaker, visiting professor,
arrays,” in Proc. Nat. Heat Transf. Conf., vol. 7, 1996, pp. 45–52. member of examination committees, and varoius advisory committees.

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