Patent ID: 8850704

Claim:
A method of manufacturing a heat sink, comprising: providing a first die body having a first wire forming region; providing a second die body opposite the first die body and having a second wire forming region; providing an elongate third die body; providing an elongate coiled wire having a plurality of contiguous loops, and then placing the elongate coiled wire over the third die body; positioning the third die body between the first and second die bodies; moving the first, second and third die bodies relative one another so as to compress and deform each of the plurality of contiguous loops of the elongate coiled wire simultaneously to form a wire fin comprising a plurality of contiguous loops and having an elongate body shaped to at least partially correspond to a shape defined between the first, second and third die bodies, the wire fin having first and second ends at opposing ends of the elongate body, each of the loops having first and second loop ends corresponding to the respective first and second ends of the wire fin; removing the formed wire fin from between the first and second die bodies; and attaching the first end of the wire fin to a heat sink base so that the wire fin is in thermal communication with the heat sink base.