Thermal interface apparatus, systems, and fabrication methods

Abstract

A method and machine may operate to fabricate a unitary, substantially uniformly distributed transfer material that can be coupled to a carrier material.

1 . A method, comprising: 
 forming a unitary, substantially uniformly distributed transfer material as a mesh including a plurality geometric objects forming a substantially repeating pattern; and    coupling a carrier material to the unitary, substantially uniformly distributed transfer material.    
   
   
       2 . The method of  claim 1 , wherein forming the unitary, substantially uniformly distributed transfer material further comprises: 
 impressing at least one patterned roller against a sheet of solderable material.    
   
   
       3 . The method of  claim 1 , wherein forming the unitary, substantially uniformly distributed transfer material comprises: 
 forming the unitary, substantially uniformly distributed transfer material comprising at least one of a component transfer material including bismuth, copper, gold, indium, zinc, antimony, magnesium, lead, silver, tin, and alloys thereof.    
   
   
       4 . The method of  claim 1 , wherein forming the unitary, substantially uniformly distributed transfer material comprises: 
 forming the unitary, substantially uniformly distributed transfer material with the plurality of geometric objects distributed on a grid pattern.    
   
   
       5 . The method of  claim 1 , wherein forming the unitary, substantially uniformly distributed transfer material comprises: 
 forming the unitary, substantially uniformly distributed transfer material including a plurality of connecting elements to couple the plurality of geometric objects to each other.    
   
   
       6 . The method of  claim 5 , wherein the plurality of connecting elements are arranged in a substantially repeating pattern.  
   
   
       7 . The method of  claim 1 , wherein the plurality of geometric objects includes a plurality of regular geometric objects.  
   
   
       8 . The method of  claim 1 , wherein the plurality of geometric objects includes a plurality of irregular geometric objects.  
   
   
       9 . The method of  claim 1 , comprising: 
 selecting at least one of a height, a shape, and a spacing of the plurality of geometric objects based on a desired volume of the unitary, substantially uniformly distributed transfer material.    
   
   
       10 . The method of  claim 1 , wherein coupling the carrier material comprises: 
 coupling the carrier material comprising at least one of a component carrier material including a polymer, an elastomer, a hardener, a catalyst, a reactive diluent, an adhesion promoter, a surfactant, a deforming agent, a fluxing agent, a toughening agent, a coupling agent, an epoxy, an ester, a siloxane, a polyamide, a silicone, a rubber, and a wetting agent.    
   
   
       11 . The method of  claim 1 , wherein coupling the carrier material comprises: 
 curing the carrier material.    
   
   
       12 . The method of  claim 1 , wherein coupling the carrier material comprises: 
 at least partially embedding the unitary, substantially uniformly distributed transfer material in the carrier material.    
   
   
       13 . The method of  claim 1 , further comprising: 
 placing the unitary, substantially uniformly distributed transfer material and the carrier material between a die and a heat dissipating element.    
   
   
       14 . The method of  claim 1 , further comprising: 
 heating the unitary, substantially uniformly distributed transfer material so as to break connecting elements coupling the plurality of geometric objects.    
   
   
       15 . A machine, comprising: 
 a transport element; and    a pair of rollers, at least one of which is to couple to the transport element, and at least one of which comprises a roller pattern to form a corresponding pattern in a solderable material, the roller pattern comprising an array of elements arranged in a substantially repetitive manner.    
   
   
       16 . The machine of  claim 15 , wherein selected elements included in the array of elements are interconnected by a plurality of connecting elements.  
   
   
       17 . The machine of  claim 15 , wherein the array of elements includes a plurality of substantially similar geometric objects.  
   
   
       18 . The machine of  claim 15 , wherein the array of elements are distributed on a grid pattern.  
   
   
       19 . The machine of  claim 15 , wherein the array of elements comprises a plurality of substantially similar geometric objects including regular geometric objects.  
   
   
       20 . The machine of  claim 19 , wherein the array of elements comprises a plurality of substantially similar geometric objects including irregular geometric objects.