Lightweighting strategies for optimized thermal energy Storage: Topology optimization of heat exchanger fins

Abstract

This study presents a novel method for optimizing fin structures in Thermal Energy Storage Systems (TESS) to enhance the thermal performance of Phase Change Materials (PCM) through Topology Optimization (TO). For the first time, the study incorporates the mass factor and weight ratio (γ) into the TESS optimization process, which is particularly crucial for applications requiring lightweight design, such as in the aerospace industry. Utilizing the “Y + T” fin design derived from TO outcomes and combining it with the “Parameter Sensitivity Analysis + Entropy Weighted-TOPSIS” method for multi-objective optimization, the research elucidates the thermal storage mechanisms and achieves rapid fin structure optimization. The results indicate that the optimal fin model with three branches at angles (θ) of 90° significantly improves the melting efficiency by 36.5 % and reduces the melting time of PCM by 375.9 s compared to the model without fins. Further re-optimization of the fin root length and width ratio led to an additional reduction of 15.2 s in PCM melting time. In summary, the study successfully realizes a lightweight TESS design through fin optimization, substantially enhancing energy efficiency and system adaptability. It clarifies the thermal storage mechanisms, facilitating rapid optimization, and provides insights for fin optimization and lightweight design in TESS applications.