Graphite-based heat sink

Abstract

The present invention relates to a system for managing the heat from a heat source like an electronic component. More particularly, the present invention relates to a system effective for dissipating the heat generated by an electronic component using a heat sink formed from a compressed, comminuted particles of resin-impregnated flexible graphite mat or sheet.

What is claimed is:  
     
         1 . A heat sink comprising a graphite article shaped so as to provide a heat collection surface and at least one heat dissipation surface, wherein arranging the heat collection surface of the graphite article in operative connection with a heat source causes dissipation of heat from the heat source through the at least one heat dissipation surface of the graphite article, and further wherein the graphite article is formed from comminuted resin-impregnated flexible graphite sheet compressed into the desired shape.  
     
     
         2 . The heat sink of  claim 1  wherein the at least one heat dissipation surface of the graphite article comprises fins formed at a surface of the graphite article opposite the heat collection surface.  
     
     
         3 . The heat sink of  claim 1  wherein the graphite article has structural features comprising cavities therein, holes therethrough or combinations of cavities therein and holes therethrough, the at least one heat dissipation surface of the graphite article comprising surfaces of the structural features.  
     
     
         4 . The heat sink of  claim 1  wherein the graphite article comprises resin-impregnated flexible sheets of compressed particles of exfoliated graphite comminuted and then compressed into a desired shape.  
     
     
         5 . The heat sink of  claim 4  wherein the resin comprises an epoxy resin or a mixture of epoxy resins.  
     
     
         6 . A process of producing a heat sink, the process comprising: 
 a. compressing exfoliated graphite particles into a mat having a thickness of about 4.5 to about 25 mm;    b. impregnatins the mat with resin to form an impregnated body;    c. comminuting the impregnated body into particles; and    d. compressing the particles of impregnated body into a graphite article.    
     
     
         7 . The process of  claim 6  wherein the exfoliated graphite particles are formed by exposing intercalated flakes of graphite to sufficient heat to exfoliate the flakes into exfoliated graphite particles.  
     
     
         8 . The process of  claim 6  wherein the mat is compressed into a flexible graphite sheet having a thickness of about 0.025 to about 4 mm prior to impregnation with the resin.  
     
     
         9 . The process of  claim 6  wherein the impregnated body is compressed into a flexible graphite sheet having a thickness of about 0.025 to about 4 mm prior to being comminuted.  
     
     
         10 . The process of  claim 6  wherein the impregnated body is comminuted into particles to form particles of impregnated body having an average diameter such that a majority of the particles will pass through a 20 U.S. mesh.  
     
     
         11 . The process of  claim 6  wherein the particles of impregnated body are compressed by die-molding.  
     
     
         12 . The process of  claim 6  wherein the particles of impregnated body are compressed by isomolding.  
     
     
         13 . The process of  claim 6  wherein the graphite article is machined into a desired shape.  
     
     
         14 . The process of  claim 6  wherein the resin comprises an epoxy resin.  
     
     
         15 . A heat sink produced in accordance with the process of  claim 6 .  
     
     
         16 . A heat sink produced in accordance with the process of  claim 8 .  
     
     
         17 . A heat sink produced in accordance with the process of  claim 9 .  
     
     
         18 . A heat sink produced in accordance with the process of  claim 10 .  
     
     
         19 . A heat sink produced in accordance with the process of claim  13 .