Integrated heat spreader with downset edge, and method of making same

Abstract

A downset edge integrated heat spreader is disclosed. The downset edge can be formed to an industrially accepted flatness with a single stamping operation. The downset edge can provide a surface for fastening the downset edge integrated heat spreader to a mounting substrate. The downset edge can also provide a component recess for mounting a component near a processor, but on the mounting substrate. The downset edge can also provide a warp and bend resistant structure during ordinary field use.

1 - 16 . (canceled)  
   
   
       17 . A process comprising: 
 forming an integrated heat spreader, including a heat spreader body including a first surface; and    forming a downset edge, including a downset edge wall and a downset edge surface which substantially surrounds the integrated heat spreader body, wherein the downset edge includes a second surface which is lower than the first surface.    
   
   
       18 . The process according to  claim 17 , wherein forming the downset edge is selected from a single stamping event, a plurality of stamping events, casting, injection molding, and consolidating a metal powder.  
   
   
       19 . The process according to  claim 17 , further including: 
 forming a cladding upon the downset edge integrated heat spreader.    
   
   
       20 . The process according to  claim 17 , further including: 
 forming a cladding upon the downset edge integrated heat spreader, wherein forming a cladding proceeds from one of before, during, and after forming the downset edge.    
   
   
       21 . A method comprising: 
 assembling a downset edge integrated heat spreader with a microelectronic die.    
   
   
       22 . The method according to  claim 21 , further including: 
 assembling the downset edge integrated heat spreader with a mounting substrate.    
   
   
       23 . The method according to  claim 21 , further including: 
 assembling the downset edge integrated heat spreader with a mounting substrate; and    affixing a fastener between the downset edge integrated heat spreader and the mounting substrate.    
   
   
       24 - 26 . (canceled)  
   
   
       27 . The process of  claim 17 , wherein forming includes stamping a notch by displacement of the downset edge away from the heat spreader body.  
   
   
       28 . The process of  claim 17 , wherein forming includes stamping a notch by displacement of the downset edge away from the heat spreader body by slip-shear of the downset edge away from the heat spreader body.  
   
   
       29 . The process of  claim 17 , wherein forming the downset edge is by molten casting.  
   
   
       30 . The process of  claim 17 , wherein forming the downset edge is by injection molding.  
   
   
       31 . The process of  claim 17 , wherein forming the downset edge is by dry casting a powdered metal composite.  
   
   
       32 . The process of  claim 17 , wherein forming the downset edge is by dry casting a powdered metal composite including a process selected from pressing, sintering, and a combination thereof.  
   
   
       33 . The process of  claim 17 , wherein forming includes stamping to form the downset edge surface downset from the heat spreader body bottom surface by a foot height, and wherein the foot height defines a container recess  
   
   
       34 . The process of  claim 17 , wherein forming includes forming a downset region disposed between the heat spreader body and the downset edge, wherein the downset region includes an inner wall and an outer wall.  
   
   
       35 . The process of  claim 17 , wherein forming includes: 
 forming a downset region disposed between the heat spreader body and the downset edge, wherein the downset region includes an inner wall and an outer wall; and    forming a channel in the downset edge wall which communicates between the inner wall and the outer wall.    
   
   
       36 . The process of  claim 17 , wherein forming includes: 
 machining a mass of material to a set of dimensions; followed by one or more stamping processes.    
   
   
       37 . The process of  claim 17 , wherein forming includes forming at least one of a lower cladding layer and an upper cladding layer upon the integrated heat spreader body, selected from pressure cladding, electroplating, electroless plating, and combinations thereof.  
   
   
       38 . The process of  claim 17 , wherein forming includes drawing an integrated heat spreader blank through a molten metal to form at least one of the lower cladding layer and an upper cladding layer upon the integrated heat spreader body.  
   
   
       39 . The process of  claim 17 , wherein forming includes forming one part of the downset edge as substantially asymmetrical with respect to the integrated heat spreader body.  
   
   
       40 . A process comprising: 
 forming a copper integrated heat spreader, including a heat spreader body including a first surface; and    forming a downset edge, including a downset edge wall and a downset edge surface which substantially surrounds the integrated heat spreader body, wherein the downset edge includes a second surface which is lower than the first surface.    
   
   
       41 . The process of  claim 40 , wherein forming includes stamping a notch in the copper by displacement of the downset edge away from the heat spreader body by slip-shear of the downset edge away from the heat spreader body.  
   
   
       42 . The process of  claim 40 , further including: 
 forming a cladding upon the downset edge integrated heat spreader, wherein forming a cladding proceeds from one of before, during, and after forming the downset edge.    
   
   
       43 . A process comprising: 
 forming an integrated heat spreader, including a heat spreader body including a first surface, wherein forming includes stamping a notch in the copper by displacement of the downset edge away from the heat spreader body by slip-shear of the downset edge away from the heat spreader body; and    forming a downset edge, including a downset edge wall and a downset edge surface which substantially surrounds the integrated heat spreader body, wherein the downset edge includes a second surface which is lower than the first surface, wherein forming includes forming one part of the downset edge as substantially asymmetrical with respect to the integrated heat spreader body.    
   
   
       44 . The process of  claim 43 , further including: 
 forming a cladding upon the downset edge integrated heat spreader, wherein forming a cladding proceeds from one of before, during, and after forming the downset edge.    
   
   
       45 . The process of  claim 43 , wherein forming includes: 
 machining a mass of material to a set of dimensions; followed by    one or more of the stamping processes.