In this work, density-based topology optimization is applied to the design of the air-side surface of dry-cooled power plant condensers. A topology optimization model assuming a steady-state, thermally and fluid dynamically fully developed internal flow is developed and used for this application. The conductance of the heat exchanger is maximized for a prescribed pressure drop and prescribed air-side temperature change across the heat exchanger. Polymer with infilled thermally conducting metal filaments is considered as the heat exchanger material which allows cost effective additive manufacturing techniques to be used to fabricate the obtained designs. Parametric studies are presented that analyze the effect of the material thermal conductivity and the heat exchanger unit cell height on the system's performance. The designs obtained from topology optimization are benchmarked against a simple optimized slot channel model in order to demonstrate the superior performance of the topology optimized designs. Thus, this work demonstrates the usefulness of topology optimization to fully exploit the design freedom afforded by additive manufacturing technologies.

This paper investigates the application of density-based topology optimization to the design of air-cooled forced convection heat sinks. To reduce the computational burden that is associated with a full 3D optimization, a pseudo 3D optimization model comprising a 2D modeled conducting metal base layer and a thermally coupled 2D modeled thermofluid design layer is used. Symmetry conditions perpendicular to the flow direction are applied to generate periodic heat sink designs. The optimization objective is to minimize the heat sink heat transfer resistance for a fixed pressure drop over the heat sink and a fixed heat production rate in the base plate. Optimized designs are presented and the resulting fin geometry is discussed from a thermal engineering point of view and compared to fin shapes resulting from a pressure drop minimization objective. Parametric studies are conducted to analyze the influence of the pressure drop on the heat sink heat transfer resistance. To quantify the influence of the assumptions made in the pseudo 3D optimization model, validation simulations with a body-fitted mesh in 2D and 3D are conducted. A good agreement between optimization model and validation simulations is found, confirming the physical validity of the utilized optimization model. Two topology optimized designs are exemplarily benchmarked against a size optimized parallel fin heat sink and an up to 13.6% lower thermal resistance is found to be realized by the topology optimization.

Engelbrecht, K. (2016). A design approach for integrating thermoelectric devices using topology optimization. Applied Energy, 176,[49][50][51][52][53][54][55][56][57][58][59][60][61][62][63][64] ABSTRACT Efficient operation of thermoelectric devices strongly relies on the thermal integration into the energy conversion system in which they operate. Effective thermal integration reduces the temperature differences between the thermoelectric module and its thermal reservoirs, allowing the system to operate more efficiently. This work proposes and experimentally demonstrates a topology optimization approach as a design tool for efficient integration of thermoelectric modules into systems with specific design constraints. The approach allows thermal layout optimization of thermoelectric systems for different operating conditions and objective functions, such as temperature span, efficiency, and power recovery rate. As a specific application, the integration of a thermoelectric cooler into the electronics section of a downhole oil well intervention tool is investigated, with the objective of minimizing the temperature of the cooled electronics. Several challenges are addressed: ensuring effective heat transfer from the load, minimizing the thermal resistances within the integrated system, maximizing the thermal protection of the cooled zone, and enhancing the conduction of the rejected heat to the oil well. The design method incorporates temperature dependent properties of the thermoelectric device and other materials. The 3D topology optimization model developed in this work was used to design a thermoelectric system, complete with insulation and heat sink, that was produced and tested. Good agreement between experimental results and model forecasts was obtained and the system was able to maintain the load at more than 33 K below the oil well temperature. Results of this study support topology optimization as a powerful design tool for thermal design of thermoelectric systems.

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 Users may download and print one copy of any publication from the public portal for the purpose of private study or research.  You may not further distribute the material or use it for any profit-making activity or commercial gain  You may freely distribute the URL identifying the publication in the public portal If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim.