Monolithic structurally complex heat sink designs

Abstract

A heat sink includes a base and a heat exchange element monolithically connected to the base. The heat exchange element has a surface that at least partially bounds first and second paths through the heat exchange element. The surface forms an upper boundary of the first and second paths and includes an opening therethrough connecting the first and second paths.

1 . A heat sink, comprising:
 a base; and   a heat exchange element monolithically connected to said base and having a surface that at least partially bounds first and second paths through said heat exchange element,   wherein said surface forms an upper boundary of said first and second paths and includes an opening therethrough connecting said first and second paths.   
   
   
       2 . The heat sink as recited in  claim 1 , wherein said first and second paths are unobstructed paths about parallel to said base. 
   
   
       3 . The heat sink as recited in  claim 1 , wherein said heat exchange element is a portion of a foam structure. 
   
   
       4 . The heat sink as recited in  claim 1 , wherein said heat exchange element defines a closed channel that is about parallel to said base and has a closed circular or polygonal cross-section. 
   
   
       5 . The heat sink as recited in  claim 4 , wherein said polygonal cross-section is a hexagon. 
   
   
       6 . The heat sink as recited in  claim 1 , wherein said heat exchange element divides space into two congruent labyrinths. 
   
   
       7 . The heat sink as recited in  claim 6 , wherein said heat exchange element forms a minimum area surface. 
   
   
       8 . The heat sink as recited in  claim 1 , wherein said heat exchange element includes a re-entrant void. 
   
   
       9 . The heat sink as recited in  claim 1 , wherein a width of said path varies along said path. 
   
   
       10 . The heat sink as recited in  claim 1  formed by a process comprising the steps of:
 forming a sacrificial pattern of said heat sink using stereolithography, and   providing said pattern to an investment casting process to form a heat sink.   
   
   
       11 . A method comprising:
 providing a sacrificial heat sink pattern comprising:   a base form; and   a heat exchange element form connected to said base form and having a surface that at least partially bounds first and second paths through said heat sink pattern,
 wherein said surface forms an upper boundary of said first and second paths and includes an opening therethrough connecting said first and said second paths; and 
   providing said pattern to an investment casting process to form a monolithic heat sink.   
   
   
       12 . The method as recited in  claim 11 , wherein said first and second paths are unobstructed paths about parallel to said base form. 
   
   
       13 . The method as recited in  claim 11 , wherein said heat exchange element form is a portion of a form of a foam structure. 
   
   
       14 . The method as recited in  claim 11 , wherein said heat exchange element form defines a closed channel that is about parallel to said base form and has a closed circular or polygonal cross-section. 
   
   
       15 . The method as recited in  claim 14 , wherein said polygonal cross-section is a hexagon. 
   
   
       16 . The method as recited in  claim 11 , wherein said heat exchange element form divides space into two congruent labyrinths. 
   
   
       17 . The method as recited in  claim 16 , wherein said heat exchange element form is a minimum area surface. 
   
   
       18 . The method as recited in  claim 11 , wherein said heat exchange element form includes a re-entrant void. 
   
   
       19 . The method as recited in  claim 11 , wherein a width of said path varies along said path. 
   
   
       20 . The method as recited in  claim 11 , further comprising the step of forming said heat sink using stereolithography.