Cooling compact electronics, such as laptops, is challenging due to strict size limitations and the low thermal capacity of air. While rectangular fins are commonly used, dovetail fins with tip clearance may offer improved thermal performance. This study investigates the thermal–hydraulic behaviour of rectangular and dovetail fin heat sinks under these constraints. Initially, a rectangular channel heat sink was designed and later modified to a channel heat sink incorporating a rectangular fin with tip clearance. This fin was further adapted into three dovetail fin variants by varying the root and tip thicknesses to evaluate the feasibility of replacing rectangular fins. CFD analyses were conducted in ANSYS Fluent for inlet air velocities ranging from 1 to 6 m/s (corresponding Reynolds number varies from 2054–12323), with the top surface of the heat sink maintained at a constant temperature of 360 K. Temperature distribution, heat transfer, pressure drop, and effectiveness were evaluated, considering weight in the performance comparison. Dovetail fins outperformed the rectangular fin, enhancing heat convection by up to 20.6% but with a 66.7% increase in weight and substantially higher pressure drops. The dovetail variant with weight equal to the rectangular fin achieved up to 2.2% higher performance with only a marginal increase in pressure drop, indicating its potential as a promising alternative.
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