Application of micro-channel heat sinks for thermal management of electric vehicle components: A comprehensive review
Bijan Darbari, Gholamreza Kefayati, Xiaolin Wang, Kambiz Vafai
Abstract
The rapid development of electric vehicle (EV) technology has intensified the need for efficient thermal management of critical components, including insulated-gate bipolar transistor (IGBT) traction inverters, batteries, and fuel cells. These components are compact yet generate substantial heat, which can reduce performance, reliability, and lifespan if not effectively managed. This review systematically examines the application of micro-channel heat sinks (MCHSs) for cooling these EV components. The literature synthesis follows a structured methodology, including the collection, categorization, and comparative analysis of experimental, numerical, and hybrid studies on MCHS designs, configurations, and thermal performance. The scope of this review encompasses the cooling principles, design innovations, and practical applications of MCHSs for IGBTs, batteries, and fuel cells. Key comparative findings reveal that MCHSs can significantly reduce peak temperatures and temperature non-uniformity, enhancing component reliability, lifespan, and performance. Among different MCHS configurations, hybrid jet-microchannel and two-phase micro heat sinks consistently demonstrate superior thermal performance across multiple EV components. The review also identifies current challenges in fabrication, integration, and optimization, highlighting research gaps that require further investigation. By explicitly defining the review scope, applying a systematic synthesis methodology, and providing comparative insights across various EV components and MCHS designs, this study offers a comprehensive reference for researchers and engineers seeking to optimize thermal management solutions in electric vehicles. • This study systematically reviews micro-channel heat sinks for EV components. • A novel comparative framework is applied to IGBTs, batteries, and fuel cells. • Hybrid jet-microchannel and two-phase MCHSs show superior thermal performance. • Key research gaps are identified in integration, PCM use, and geometry design. • The review provides a comprehensive reference for optimized EV thermal control.