Multi-layer thermo-mechanical architectures for compact energy extraction systems

A thermal management cartridge assembly comprising:

• an outer shell comprising an aluminum substrate having a multi-layer surface treatment including an aluminum oxide layer, a micro-textured surface morphology, and a tetradecane hydrocarbon conformal coating, wherein said multi-layer surface treatment increases effective surface area relative to nominal geometric surface area and reduces junction-to-case thermal resistance compared to anodized-only surface preparations;
• a cartridge insert positioned within said outer shell, said cartridge insert comprising High Density Polyethylene having a specified molecular density range and thermal conductivity value, wherein said cartridge insert is engaged with an interior surface of said outer shell through press-fit interference engagement, and wherein said High Density Polyethylene exhibits a thermal expansion coefficient substantially higher than that of said aluminum substrate;
• a top cover comprising Acrylonitrile Butadiene Styrene thermoplastic polymer, said top cover configured to engage with said cartridge insert and said outer shell to provide environmental sealing;
• and
• wherein said outer shell, said cartridge insert, and said top cover are arranged in coaxial alignment along a central longitudinal axis to form a cylindrical cartridge assembly configured for single-handed manual operation and portable transport.