Jet impingement cooling with multi-stage ducted electroaerodynamic actuators

Quinna Nguyen, C. Luke Nelson, Daniel S. Drew

Modern high-performance mobile electronics impose extreme constraints on thermal management, and traditional cooling methods often fail to meet requirements for power density, form factor, and durability. Jet impingement cooling offers a compelling solution but is typically hindered by the need for bulky ancillary hardware. Here, we demonstrate that compact arrays of reduced-scale electroaerodynamic (EAD) plasma actuators, which are silent, solid-state devices with no moving parts, can be used for direct jet impingement cooling of electronics. The main contribution is the first rigorous experimental demonstration and system-level validation of multi-stage, ducted electroaerodynamic jet arrays as a compact, fan-replacement impingement cooling solution for mobile electronics. We characterize the performance of both single- and multi-stage ducted actuators, including thermographic analysis of heat transfer coefficients and spatial cooling profiles. We also quantify the relationship between actuator stage count and cooling efficiency, showing that increasing the number of ion acceleration stages enhances jet velocity and heat transfer performance at a reduced efficiency. The actuators are then assembled into an array and directly compared to a conventional fan with similar coverage area, showing competitive performance at a fraction of the volume, weight, and power. Finally, we integrate the array onto a commercial edge AI system and show that thermal regulation during extended inference workloads matches that of a stock fan, without any moving mechanical components or noise. These results confirm that multi-stage EAD jet arrays are not only viable but advantageous for thermal management in mobile and high-performance systems, paving the way toward silent and miniaturized solid-state cooling solutions.