Thermal-Hydraulic characterization in Manifold-microchannel heat sinks for Energy-efficient cooling of HEV/EV power modules

Electric vehicles (EVs) require efficient cooling solutions for power modules to ensure optimal performance, reliability, and driving range. In this study, we present a comprehensive thermohydraulic analysis of manifold microchannel (MMC) heat sinks to address the unique thermal demands of EV power module cooling. We conducted a numerical analysis of the MMC geometry to evaluate its geometric variations, including manifold height (6–12 mm), inlet-to-outlet manifold width ratios (1:3–3:1), and microchannel height (1–3 mm). Their effects on pressure drop and thermal resistance were evaluated by analyzing non-uniform flow characteristics, such as flow distribution, streamwise velocity, and vorticity. This study highlights the importance of mitigating non-uniform flow effects in large-scale coolers to effectively manage the localized hotspots in EV power modules. The optimized MMC heat sink design reduced the thermal resistance and pumping power by 2.8 % and 27.3 %, respectively, when compared to traditional microchannel heat sinks (TMC). Thus, it presents an effective solution for enhancing the energy efficiency and thermal performance in EV power modules.