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Heat Transfer Modulation of Micro-Textured Interfaces: A Multi-Scale Topology Optimization and Numerical Simulation
Qing Rao1, Benben Guo1, Jiafu Ruan2
1No. 6 Engineering (Xiamen), CCCC Third Harbor Engineering Co., Ltd., No. 189 Huachang Road, Huli District, Xiamen 361006, China.
Micromachines
|June 26, 2026
Summary
This study introduces a hybrid thermal management system for deep-sea LED Fish-Attracting Lamps (FALs) to reduce excessive junction temperatures. The novel design enhances heat dissipation and maintains pressure resistance for high-power illumination systems.
Area of Science:
- Thermal Management
- Optical Engineering
- Materials Science
Background:
- Deep-sea LED Fish-Attracting Lamps (FALs) face challenges with ultra-high heat flux densities (>100 W/cm²), leading to excessive junction temperatures.
- Effective thermal management is crucial for the reliability and performance of high-power deep-sea illumination systems.
Purpose of the Study:
- To propose and validate a hybrid thermal management scheme for deep-sea FALs that integrates interfacial micro-texturing, chimney-effect convection, and heat pipe phase-change heat transfer.
- To achieve passive high-efficiency heat dissipation and pressure-resistant sealing for deep-sea LED arrays.
Main Methods:
- Topology optimization of FAL housing to create chimney-effect enhanced flow channels integrated with heat pipe bundles.
- Fabrication of Micro-Element Texture (MET) arrays at the Phenolic Resin Substrate (PRS) thermal interface to improve thermal conductance.
- Multi-physics coupled numerical simulation and response surface methodology for parametric optimization of micro-texture configurations.
- Construction of a thermal interface performance testing platform for model validation.
Main Results:
- The integrated heat pipe technology effectively suppresses LED junction temperature rise.
- Groove-type MET arrays, oriented perpendicular to gravity, increased effective heat dissipation area and optimized natural convection.
- The proposed hybrid scheme reduced the maximum operating temperature of deep-sea FALs by 6.70% compared to conventional structures.
Conclusions:
- The developed hybrid thermal management scheme offers an effective engineering solution for the thermal-structural design of high-power deep-sea illumination systems.
- The integration of micro-texturing, chimney-effect convection, and heat pipes successfully addresses the thermal challenges in demanding deep-sea environments.
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