Design and Multi-Objective Optimization of LED Plastic-Clad Aluminum Heat Sinks Based on NSGA-Ⅱ and Entropy-Weighted TOPSIS
LI Zixuan
WU Xiaolan
TANG Yaming
WANG Tengyue
Abstract：To address the industry challenges of traditional metal heat sinks being heavy and costly,and plastic heat sinks having insufficient thermal conductivity,this paper proposes an aluminum-plate-reinforced thermally conductive plastic composite heat sink(hereafter referred to as plastic-clad aluminum heat sink)design.Using finite element simulation combined with Box-Behnken experimental design within the response surface methodology(RSM),the effects of fin thickness,number,height,and embedded aluminum plate thickness on maximum junction temperature and heat sink mass were systematically analyzed,and a multi-objective optimization model was established.The NSGA-II multi-objective genetic algorithm coupled with the entropy weight TOPSIS decision method was applied to construct a comprehensive parameter selection system for the heat sink.Experimental results show that under high-power automotive lamp conditions,the optimized heat sink maintains LED junction temperatures at 74.19℃,with thermal performance approaching that of metal aluminum heat sinks;its mass is only 119.38 g(measured 120.00 g),representing a 60.85%reduction compared with the initial all-aluminum design,achieving a synergistic optimization of thermal efficiency and lightweight performance.Compared with traditional studies that focus on low-power LED modules,this plastic-aluminum composite structure innovatively addresses the thermal management challenges of thermally conductive plastic heat sinks in high-power automotive lighting scenarios,providing an engineering reference for efficient thermal design and lightweight development in smart lighting systems.
Keywords：LED heat sinkplastic-clad aluminumresponse surface methodologyNSGA-Ⅱentropy-weighted TOPSIS methodmulti-objective optimization
Publication Date：2026-02-28
Online Publishing Date：2026-03-19(First online date of this platform, not the publication date of the document)
Pages：9( 87-95 )