Method of forming a thermo pyrolytic graphite-embedded heatsink

Abstract

The present disclosure is related to creating blocks of aluminum and/or copper material having embedded TPG elements for forming heatsinks. The metal blocks have an improved thermal conductivity in the X-Y plane. Furthermore, the TPG-embedded heatsinks can be created using methods capable of being performed using various machines and equipment in many various facilities.

1 . A method for forming a thermo pyrolytic graphite (TPG) therein according to a first embodiment of the present disclosure-embedded heatsink, the method comprising:
 suspending at least one TPG element in a form;   filling the form with a metal material;   heating the form to bond the at least one TPG element within the metal material to produce a TPG-embedded heatsink; and   cooling the bonded TPG-embedded heatsink.   
   
   
       2 . A method in accordance with  claim 1 , comprising suspending at least one planar TPG strip in the form. 
   
   
       3 . A method in accordance with  claim 1 , comprising suspending the at least one TPG element using a metal peg. 
   
   
       4 . A method in accordance with  claim 1 , comprising filling the form with a metal material selected from the group consisting of aluminum, copper, and combinations thereof. 
   
   
       5 . A method in accordance with  claim 4 , comprising filling the form with a powdered metal material. 
   
   
       6 . A method in accordance with  claim 4 , comprising filling the form with a liquid metal material. 
   
   
       7 . A method in accordance with  claim 1 , wherein filling the form comprises metal injection molding. 
   
   
       8 . A method in accordance with  claim 1 , wherein heating the form comprises a sintering process. 
   
   
       9 . A method in accordance with  claim 1 , further comprising plating the at least one TPG element with a metal. 
   
   
       10 . A method in accordance with  claim 9 , comprising plating the at least one TPG element with the metal selected from the group consisting of aluminum, copper, and combinations thereof. 
   
   
       11 . A method in accordance with  claim 1 , wherein the form is designed further contain at least one of fin features and complex details to reduce machining of the TPG-embedded heatsink. 
   
   
       12 . A method for forming an thermo pyrolytic graphite (TPG) therein according to a second embodiment of the present disclosure-embedded heatsink, the method comprising:
 obtaining a foam block;   depositing at least one TPG element into the foam block;   depositing the foam block with the at least one TPG element into a container; and   filling the container with molding sand; and   filling the foam block with a molten metal material.   
   
   
       13 . A method in accordance with  claim 12 , comprising depositing at least one planar TPG strip into the foam block. 
   
   
       14 . A method in accordance with  claim 12 , comprising filling the container with the molten metal material being selected from the group consisting of aluminum, copper, and combinations thereof. 
   
   
       15 . A method in accordance with  claim 12 , further comprising removing the metal block with the at least one TPG element embedded therein from the container. 
   
   
       16 . A method in accordance with  claim 15 , further comprising machining the metal block. 
   
   
       17 . A method for forming a thermo pyrolytic graphite (TPG) therein according to a third embodiment of the present disclosure-embedded heatsink, the method comprising:
 separating a foam block into at least two portions;   depositing at least one TPG element between the at least two portions of the foam block;   coupling the at least two portions of the foam block together to form a single block with the at least one TPG element;   depositing the single block with the at least one TPG element into a container; and   filling the container molding sand; and   filling the foam block with a molten metal material.   
   
   
       18 . A method in accordance with  claim 17 , comprising depositing at least one planar TPG strip. 
   
   
       19 . A method in accordance with  claim 17 , coupling the at least two portions using an adhesive composition. 
   
   
       20 . A method in accordance with  claim 17 , comprising filling the container with the molten metal material being selected from the group consisting of aluminum, copper, and combinations thereof. 
   
   
       21 . A method in accordance with  claim 17 , further comprising removing the metal block with the at least one TPG element embedded therein from the container. 
   
   
       22 . The method as set forth in  claim 21 , further comprising machining the metal block.