Numerical investigation of the effect of central inlet–dual outlet arrangement and sidewall fin shapes on the thermal-hydraulic performance of multi-channels cold plate

This study numerically investigates the effects of novel side-fin arrangements on the thermal and hydraulic performance of a multi-channel cold plate with a vertical inlet and dual horizontal outlets. The proposed designs are compared to a traditional multi-channel cold plate (T-MCCP) to determine the most efficient configuration. The research numerically studied six channel designs, validating the results with experiments, under laminar flow ( Re 500–1700). The traditional control model (T-MCCP) measured 100 mm × 70 mm × 8 mm and consisted of nine straight minichannels (4 mm wide, 3 mm high), separated by 2 mm fins. The baseline for the study is a central-inlet, dual-side-outlet multi-channel cold plate, designated as Design B1. The subsequent four designs (B2–B5) are modifications of the B1 design, each incorporating staggered side fins of a different geometric shape to enhance thermal performance and flow distribution: B1: The Baseline (Central-inlet, dual-side-outlet multi-channel cold plate), B2: Design B1 enhanced with staggered circular side fins, B3: Design B1 enhanced with staggered triangular side fins, B4: Design B1 enhanced with staggered trapezoidal side fins, B5: Design B1 enhanced with staggered square side fins. The results clearly indicate that the integration of side fins leads to a significant enhancement in the heat transfer rate and a corresponding reduction in thermal resistance. This is accomplished by optimizing flow distribution and promoting internal mixing within the system. Furthermore, these modified designs exhibit a lower pressure drop compared to the traditional setup, particularly under high flow conditions, thereby successfully balancing high thermal performance with hydraulic efficiency. The research emphasizes that the specific side fin arrangement is a critical determinant of overall cooling performance. The optimal design, designated as the B4 configuration, positions the side fins in a consistent order across all cold plate channels, yielding the highest performance evaluation factor (PEC) of 1.80 at a Reynolds number of 1700. Specific improvements include a 36.84% increase in the Nusselt number (B5 configuration) and a 66.88% decrease in the friction factor (B1 configuration).