Heatsinks to Cool Batteries for Unmanned Aerial Vehicles

This study aims to develop several different models of heatsinks, designed to cool a vertical take-off and landing unmanned aerial vehicle (UAV) battery, through topology optimization, aimed at being manufactured through selective laser melting (SLM) technology. A battery’s temperature must be properly managed for a safe and efficient operation. The methodology developed was with the support of software to carry out several simulations which, starting from several scenarios and restrictions imposed by the small space available to accommodate these small batteries in this type of aircraft. The conception resulted in several battery thermal management systems (BTMS) models, with different applications and efficiency degrees. A relevant aspect is the topology optimization being coupled to computational thermal analysis to reduce the mass of the heatsink whilst ensuring a maximum battery temperature threshold. Together with the use of topology optimization, the SLM process was selected to manufacture the heat sinks, under conditions of geometric freedom, using several high thermal conductivity metal alloys, such as, aluminium and copper to obtain the designed models.