Ultrasonic additive manufacturing of cold plates with pre-formed fins

Abstract

A method for making a cold plate includes the steps of positioning a finstock structure in a cavity of a substrate; and applying a cover to the finstock structure and substrate, wherein the applying step comprises ultrasonically additive manufacturing the cover to the substrate and the finstock structure, whereby the cover joins with the substrate and the finstock structure. The resulting cold plate assembly includes a substrate having a cavity, a finstock structure within the cavity, and a cover closing the finstock structure within the cavity, the cover being integrally joined to the substrate and to the finstock structure.

What is claimed is: 
     
         1 - 12 . (canceled) 
     
     
         13 . A cold plate assembly, comprising:
 a substrate having a cavity,   a finstock structure within the cavity, and   a cover closing the finstock structure within the cavity, the cover being integrally joined to the substrate and to the finstock structure.   
     
     
         14 . The assembly of  claim 13 , wherein the finstock structure comprises material formed into a plurality of substantially parallel walls connected by folds, and wherein the cover is joined to the finstock structure along the folds. 
     
     
         15 . The assembly of  claim 13 , wherein the substrate comprises an aluminum plate. 
     
     
         16 . The assembly of  claim 13 , wherein the cavity has a floor, and further comprising structure on the floor to hold the finstock in position relative to the floor. 
     
     
         17 . The assembly of  claim 13 , wherein the cover comprises multiple layers, and wherein a first layer joined to the substrate and the finstock structure has a softer temper than subsequent layers. 
     
     
         18 . The assembly of  claim 13 , wherein the finstock is in compression between the substrate and the cover. 
     
     
         19 . The assembly of  claim 16 , wherein the finstock structure is integrally joined to the floor. 
     
     
         20 . The assembly of  claim 13 , wherein the finstock structure comprises a material selected from the group consisting of aluminum, copper, stainless steel, titanium, and alloys and/or combinations thereof. 
     
     
         21 . The assembly of  claim 13 , wherein the substrate, finstock and cover each comprise compatible ultrasonic welding material.