Thermal performance regulation of micro-textured interfaces via multi-scale topology optimization and numerical simulation

The critical challenge of excessive junction temperature caused by ultra-high heat flux densities (> 100 W cm −2 ) in deep-sea LED fish-attracting lamp (FAL) arrays is addressed. This study proposes a hybrid thermal management scheme integrating interfacial micro-texturing, chimney effect convection, and heat pipe phase change heat transfer, achieving the unification of passive high-efficiency heat dissipation and pressure-resistant sealing. The FAL housing structure is reconfigured using topology optimization to construct chimney effect enhanced flow channels integrated with heat pipe bundle arrays, thereby establishing efficient heat conduction pathways from the phenolic resin substrate (PRS) to the structural periphery. Micro-element texture (MET) arrays are fabricated at the PRS thermal interface to enhance interfacial thermal conductance. Based on multi-physics coupled numerical simulation, a parametric mapping model correlating geometric topology with thermal performance is established through response interface methodology, enabling the parametric optimization of micro-texture configurations. A thermal interface performance-testing platform is constructed to validate the accuracy and reliability of the numerical model. Experimental results demonstrate that the integrated heat pipe technology effectively suppresses LED junction temperature rise; moreover, groove-type MET arrays oriented perpendicular to the gravity direction not only significantly increase the effective heat dissipation area but also optimize the dynamic characteristics of natural convection. This proposed solution reduces the maximum operating temperature of deep-sea FALs by 6.73 % compared with conventional structures, providing an effective engineering solution for thermal structural design of high-power illumination systems.