Flexible heat sink

Abstract

A method of making a flexible heat sink is provided. The method includes the steps of (i) providing a first polymer composition having a multiplicity of thermally conductive particles; (ii) providing a second polymer composition having a multiplicity of non-spherical thermally conductive particles; (iii) forming a heat sink base from the first and/or second polymer; and (iv) forming a multiplicity of elongated protrusions contiguous with the heat sink base from the second polymer and optionally also from the first polymer

1 . A method of making a flexible heat sink comprising:
 providing a first polymer composition comprising a multiplicity of thermally conductive particles;   providing a second polymer composition comprising a multiplicity of non-spherical thermally conductive particles;   forming a heat sink base from the first and/or second polymer; and   forming a multiplicity of elongated protrusions contiguous with the heat sink base from the second polymer and optionally also from the first polymer; and   optionally providing a metallic layer contiguous with the second surface of the base; and   optionally providing a thermal interface material contiguous with the base or the metallic layer,   wherein the non-spherical thermally conductive particles are substantially aligned along the direction of elongation of the protrusions.   
   
   
       2 . The method of  claim 1  wherein the first and second polymer composition are substantially similar, which compositions optionally comprise one or more adhesive(s). 
   
   
       3 . The method of  claim 1  wherein the first and second polymer composition are provided in one step. 
   
   
       4 . The method of  claim 1  wherein the first and second polymer composition are provided in the form of a layered film. 
   
   
       5 . The method of  claim 1  wherein forming the base and protrusions is carried out by casting the layered film into a mold, the mold optionally having cavities in the shape of a rail and/or a post. 
   
   
       6 . The method of  claim 1  wherein forming the base and protrusions is carried out by extruding the layered film through a shaped die to form protrusions shaped as rails, and optionally separating the rail protrusions into posts. 
   
   
       7 . The method of  claim 1  wherein the thermal interface material layer is laminated to the base. 
   
   
       8 . The method of  claim 1  further comprising curing the first and/or second polymer composition and/or thermal interface material. 
   
   
       9 . The method of  claim 1  wherein the thermal interface material layer comprises an adhesive and the method further comprising a release liner adjacent to the thermal interface material layer. 
   
   
       10 . The method of  claim 1  wherein the first and/or second forming operations comprise profile extrusion and/or extrusion replication. 
   
   
       11 . The method of  claim 1  further comprising providing flexibility features adapted to increase the flexibility of the base, the flexibility features optionally selected from indentations, slits, channels, cut-outs, notches, holes, and any combination thereof. 
   
   
       12 . The method of  claim 1  further comprising forming a roll of the heat sink.