Integrated heat spreader with mechanical interlock designs

Abstract

An integrated heat spreader is presented. The heat spreader is constructed and arranged to be adhesively affixed, with a sealant, to at least a portion of a component, such as a substrate. The heat spreader includes a body portion, a lip portion substantially vertically oriented and integrally formed with the body portion, and a step portion integrally formed with the lip portion. As such, adhesion of the heat spreader to the sealant is increased, and failure due to shear stresses at the heat spreader bonding surface is prevented.

What is claimed is:  
     
         1 . An integrated heat spreader constructed and arranged to be adhesively affixed, with a sealant, to at least a portion of a component, comprising: 
 a body portion;    a lip portion substantially vertically oriented relative to the body portion; and    a step portion adjacent to the lip portion.    
     
     
         2 . The integrated heat spreader of  claim 1 , wherein the step portion has a plurality of cutouts therein.  
     
     
         3 . The integrated heat spreader of  claim 1 , wherein the step portion has a plurality of holes or bores therein.  
     
     
         4 . The integrated heat spreader of  claim 1 , wherein the step portion is irregularly shaped.  
     
     
         5 . The integrated heat spreader of  claim 1 , wherein the step portion is formed of copper or aluminum.  
     
     
         6 . The integrated heat spreader of  claim 1 , wherein the step portion is formed of a carbon/carbon composite.  
     
     
         7 . The integrated heat spreader of  claim 1 , wherein the step portion is formed of a carbon/metal composite.  
     
     
         8 . The integrated heat spreader of  claim 7 , wherein the carbon/metal composite comprises a matrix fiber reinforced composite.  
     
     
         9 . The integrated heat spreader of  claim 7 , wherein the carbon/metal composite comprises a carbon/copper composite.  
     
     
         10 . The integrated heat spreader of  claim 1 , further comprising a coating applied to the step portion.  
     
     
         11 . The integrated heat spreader of  claim 10 , wherein the coating comprises nickel.  
     
     
         12 . The integrated heat spreader of  claim 1 , further comprising a plated portion integrally formed with the step portion.  
     
     
         13 . The integrated heat spreader of  claim 12 , wherein the plated portion is formed of gold, silver, tin, nickel, or a metal composite.  
     
     
         14 . The integrated heat spreader of  claim 1 , wherein the sealant is silicone-based or epoxy-based.  
     
     
         15 . The integrated heat spreader of  claim 1 , wherein the component comprises a substrate.  
     
     
         16 . The integrated heat spreader of  claim 1 , wherein the body portion comprises a substantially rectangular or square frame.  
     
     
         17 . The integrated heat spreader of  claim 1 , further comprising a thermal interface material (TIM) interposing a die and the body portion, the TIM comprising one of solder, a polymer/solder composite, and a polymer.  
     
     
         18 . An integrated heat spreader constructed and arranged to be adhesively affixed, with a sealant, to at least a portion of a component, the sealant to act as an adhesive interface between the integrated heat spreader and the component, comprising: 
 a body portion; and    a lip portion vertically oriented relative to the body portion, the lip portion being constructed and arranged to define a channel in a face thereof.    
     
     
         19 . The integrated heat spreader of  claim 18 , wherein the channel is substantially concave.  
     
     
         20 . A method of making an integrated heat spreader, comprising: 
 forming a body portion;    forming a lip portion substantially vertically oriented relative to the body portion; and    forming a step portion adjacent to the lip portion.    
     
     
         21 . The method of  claim 20 , wherein the step portion has a plurality of cutouts therein.  
     
     
         22 . The method of  claim 20 , wherein the step portion has a plurality of holes or bores therein.  
     
     
         23 . The method of  claim 20 , wherein the step portion is irregularly shaped.  
     
     
         24 . A method of making an integrated heat spreader, comprising: 
 forming a body portion; and    forming a lip portion vertically oriented relative to the body portion, wherein the lip portion defines a channel in a face thereof.    
     
     
         25 . The method of  claim 24 , wherein the channel is substantially concave.