Molded heat sink and method of making same

Abstract

A heat sink for use with a heat generating component includes a molded cooling block including a molded cooling passage for receiving a cooling medium. The cooling block is configured to be positioned in sufficient heat transfer relationship with respect to the heat generating component so that the cooling medium is able to receive heat from the heat generating component. Furthermore, the cooling block includes first and second sections that are connected together and that each partially define the cooling passage.

What is claimed is: 
     
         1 . A heat sink for use with a heat generating component, the heat sink comprising:
 a molded cooling block including a molded cooling passage for receiving a cooling medium, wherein the cooling block is configured to be positioned in sufficient heat transfer relationship with respect to the heat generating component so that the cooling medium is able to receive heat from the heat generating component when the cooling medium is received in the cooling passage;   wherein the cooling block includes first and second sections that are connected together and that each partially define the cooling passage.   
     
     
         2 . The heat sink of  claim 1  wherein at least one of the sections of the cooling block comprises molded plastic. 
     
     
         3 . The heat sink of  claim 1  wherein at least one of the sections of the cooling block comprises a composite material. 
     
     
         4 . The heat sink of  claim 1  wherein at least one of the sections of the cooling block comprises molded metal. 
     
     
         5 . The heat sink of  claim 1  wherein at least one of the sections of the cooling block includes a molded body portion, and one or more alignment members that are insert molded with the body portion, and wherein the one or more alignment members are for aligning the at least one section with respect to the heat generating component. 
     
     
         6 . The heat sink of  claim 1  wherein at least one of the sections of the cooling block includes a molded body portion and one or more fastener members that are insert molded with the body portion, and wherein the fastener members are for fastening the at least one section to the heat generating component. 
     
     
         7 . The heat sink of  claim 1  wherein each of the first and second sections of the cooling block includes a molded body portion, an alignment member that is insert molded with the body portion, and a faster member that is insert molded with the body portion, and wherein the alignment members are for aligning the first and second sections with respect to the heat generating component, and the fastener members are for fastening the first and second sections to the heat generating component. 
     
     
         8 . The heat sink of  claim 1  wherein the first and second sections of the cooling block are configured to define the cooling passage such that the cooling medium is receivable in the cooling passage between the first and second sections of the cooling block. 
     
     
         9 . The heat sink of  claim 8  wherein the cooling passage is configured to be spaced away from the heat generating component when the heat sink is used with the heat generating component, and wherein the cooling passage is configured such that no cooling medium flows between the cooling block and the heat generating component when the heat sink is used with the heat generating component and the cooling medium is received in the cooling passage. 
     
     
         10 . An electronic circuit assembly comprising:
 a circuit assembly body; and   a molded cooling block attached to the circuit assembly body and including a molded cooling passage for receiving a cooling medium, wherein the cooling block is positioned in sufficient heat transfer relationship with respect to the circuit assembly body so that the cooling medium is able to receive heat from the circuit assembly body when the cooling medium is received in the molded cooling passage, and wherein the cooling block includes first and second sections that are connected together and that each partially define the cooling passage.   
     
     
         11 . The circuit assembly of  claim 10  wherein the first and second sections of the cooling block each comprise molded plastic. 
     
     
         12 . The circuit assembly of  claim 10  wherein the circuit assembly body includes an alignment member, and each of the first and second sections of the cooling block includes a molded body portion, and an alignment member that is insert molded with the body portion, and wherein the alignment member of the circuit assembly body cooperates with the alignment members of the first and second sections of the cooling block to align the first and second sections of the cooling block with respect to the circuit assembly body. 
     
     
         13 . The circuit assembly of  claim 10  wherein each of the first and second sections of the cooling block includes a molded body portion, and a fastener member that is insert molded with the body portion, and wherein the assembly further includes an additional fastener member that cooperates with the circuit assembly body and the fastener members of the first and second sections of the cooling block to fasten the first and second sections of the cooling block to the circuit assembly body. 
     
     
         14 . The circuit assembly of  claim 10  wherein the first and second sections of the cooling block are configured to define the cooling passage such that the cooling passage is spaced away from the circuit assembly body and such that the cooling medium is receivable in the cooling passage between the first and second sections of the cooling block, and wherein the cooling passage is configured such that no cooling medium flows between the cooling block and the circuit assembly body when the cooling medium is received in the cooling passage. 
     
     
         15 . A method for making a heat sink for use with a heat generating component, the method comprising:
 molding first and second sections of a cooling block such that each section partially defines a molded cooling passage; and   fastening the first and second sections together such that the first and second sections cooperate to define the cooling passage such that a cooling medium is receivable in the cooling passage between the first and second sections;   wherein the cooling block is configured to be positioned in sufficient heat transfer relationship with respect to the heat generating component so that the cooling medium is able to receive heat from the heat generating component when the cooling medium is received in the molded cooling passage.   
     
     
         16 . The method of  claim 15  wherein the molding step comprises molding plastic to form the first and second sections of the cooling block. 
     
     
         17 . The method of  claim 15  further comprising positioning one or more alignment members in a mold, and wherein the molding step comprises introducing moldable material into the mold to form at least one of the sections of the cooling block such that the at least one section includes the one or more alignment members. 
     
     
         18 . The method of  claim 15  further comprising positioning one or more fastener members in a mold, and wherein the molding step comprises introducing moldable material into the mold to form at least one of the sections of the cooling block such that the at least one section includes the one or more faster members. 
     
     
         19 . The method of  claim 18  wherein the fastening step comprises fastening the first and second sections together using the one or more faster members. 
     
     
         20 . The method of  claim 15  wherein the cooling passage is formed such that no cooling medium is flowable between the cooling block and the heat generating component when the heat sink is used with the heat generating component and the cooling medium is received in the cooling passage.