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Experimental and Numerical Study on Various Liquid-Cooled Heat Sinks Including Topology Optimization
Ge Shi1,2, Yanwei Dai1, Zhongjun Yu2
1Institute of Electronics Packaging Technology and Reliability, School of Mathematics, Statistics and Mechanics, Beijing University of Technology, Beijing 100124, China.
Micromachines
|November 27, 2025
Summary
Topology optimization significantly improves liquid-cooled heat sinks for millimeter-wave antennas. Optimized designs offer better thermal uniformity and lower pressure drop, enhancing performance and reliability in high-power applications.
Area of Science:
- Engineering
- Thermal Management
- Electromagnetics
Background:
- Millimeter-wave antennas require efficient thermal management due to increasing power density and miniaturization demands.
- Traditional heat sink designs struggle to meet the stringent thermal requirements of high-power millimeter-wave applications.
- Effective heat dissipation is critical for ensuring the reliability and performance of these advanced antenna systems.
Purpose of the Study:
- To investigate and design an efficient liquid-cooled heat sink for millimeter-wave antenna array heat sources using topology optimization.
- To minimize both average temperature and fluid dissipation in the heat sink design.
- To compare the performance of the optimized heat sink with conventional designs.
Main Methods:
- Topology optimization method was employed to design novel liquid-cooled heat sink channels with same-side inlet and outlet.
- Experimental and numerical simulations were conducted to evaluate thermal and fluid characteristics.
- A dedicated liquid-cooled experimental platform was developed to test designs under various flow rates.
Main Results:
- Topology optimization channels demonstrated superior thermal uniformity and reduced pressure drop compared to series, parallel, pin rib, and tree channel designs.
- Average heat source temperatures were 6% (Topology I) and 4% (Topology II) lower than conventional channels.
- Topology I channels showed a 9% lower pressure drop than parallel channels, indicating balanced heat dissipation and flow resistance.
Conclusions:
- Topology optimization provides an effective method for designing high-performance liquid-cooled heat sinks for millimeter-wave antennas.
- The optimized designs offer significant improvements in thermal management, enhancing system reliability and performance.
- This approach presents a practical solution for thermal challenges in miniaturized, high-power electronic systems.
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