The design of mini/micro heat exchangers: A world of opportunities and constraints

Micro heat exchangers and heat sinks broadened their use in many technological fields during the last two decades. The reduction of the dimensions of the channels allows to obtain ultra-compact heat exchangers characterized by higher surface-to-volume ratio and overall heat transfer coefficients but, in general, with large pressure losses. Many imaginative configurations have been proposed and tested, by changing the geometry of the manifolds, the position of the inlet/outlet ports, the structure of the heat transfer core, the structural materials and others more. Unfortunately, these efforts were not coordinated and a complete overview of the results accumulated up to now is not available. However, some general conclusions can be made by using the published results and the main scope of this paper is to summarize these milestones. Some shared conclusion are the following: (i) the design of micro heat exchangers can be obtained by using the classical methods developed for conventional heat exchangers even if the presence of non- negligible scaling effects (i.e. compressibility effects, conjugate wall-fluid effects, viscous dissipation) must be always verified; (ii) the performances of micro heat exchangers and heat sinks is strongly influenced by the proper distribution of the flow rate within the heat transfer core and a series of different solutions is available in order to solve this problem, as summarized in this paper; (iii) the presence of strong conjugate wall-fluid heat transfer effects can become an opportunity for the use of miniaturized heat exchangers made with inexpensive materials having low thermal conductivity values, especially in presence of counter-current flow and cross-flow configurations.