Thermal Optimization and Cooling-Channel Design for a 2-kW Fiber-Laser Cold Plate Considering Distributed Heat Sources and Mechanical Integration Constraints

This study evaluates cooling-channel configurations for a 2-kW fiber-laser cold plate designed to manage both dominant and distributed heat sources under operational and mechanical-integration constraints. Using CFD analysis, two design concepts were examined: model A, which prioritizes pump laser diode(PLD) cooling, and model B, which enhances cooling performance for peripheral distributed heat sources. The results show that both configurations effectively regulate the temperatures of multiple heterogeneous heat sources while maintaining thermal uniformity across the PLD array. Model A achieves lower and more uniform PLD temperatures through increased central-zone flow allocation, whereas model B improves the cooling of outer heat sources via enhanced peripheral-channel flow distribution. The integrated fin–fastener design effectively suppresses recirculation zones, and the application of a variable cross-sectional(VCS) inlet/outlet reduces pressure loss by 60 % locally and 23 % overall. These findings demonstrate an effective thermal-management strategy for fiber-laser cold plates with diverse heat-source layouts, providing a balanced design approach that accommodates cooling priority, flow distribution, and structural constraints inherent to fiber-laser assembly.