Structured thermal transfer article

Abstract

Structured thermal transfer article comprising a plurality of metal bodies and a plurality of interstitial elements disposed between and connecting the plurality of metal bodies to one another. The metal bodies comprise an inner portion comprising a first metal and an outer portion comprising an alloy comprising the first metal and a second metal. The interstitial elements comprise the alloy of the outer portion.

1 . A method of forming a structured thermal transfer article comprising:
 providing a production tool having a predetermined array of mold cavities, depositing a composition comprising a binder and a plurality of metal bodies onto said production tool, said metal bodies comprising an inner portion comprising a first metal having a melting temperature T mp1 , and an outer portion comprising a second metal having a melting temperature T mp2 ; and   heating said composition to a temperature less than T mp1  and T mp2  to form an alloy comprising said first metal and said second metal that bonds said plurality of metal bodies to one another, wherein said bond forms a porous matrix.   
   
   
       2 . The method of  claim 1  wherein said first metal is selected from the group consisting of aluminum, copper, silver, and alloys thereof. 
   
   
       3 . The method of  claim 1  wherein said second metal is the group consisting of copper, silver, magnesium, and alloys thereof. 
   
   
       4 . The method of  claim 1  wherein said first metal comprises copper and said second metal comprises silver. 
   
   
       5 . The method of  claim 1  wherein said binder is selected from the group consisting of mineral oil, silicone oil, kerosene, and polyvinyl butyral. 
   
   
       6 . The method  claim 1  wherein said metal bodies further comprise diamond. 
   
   
       7 . The method of  claim 1  further comprising introducing a backing that said alloy comprising said first metal and said second metal form a bond with. 
   
   
       8 . The method of  claim 7 , wherein said metal bodies are deposited on a surface of said backing before heating the composition. 
   
   
       9 . The method of  claim 8 , wherein depositing said metal bodies on said surface of said backing comprises formation of said metal bodies by physical vapor deposition, plasma deposition, electroless plating, electrolytic plating, immersion plating, and combinations thereof. 
   
   
       10 . The method of  claim 1 , wherein said metal bodies are randomly shaped bodies, selected from polyhedrons, flakes, chips, fibers, plates, cylinders, needles, and combinations thereof.