Patent ID: 8296942

Claim:
A process for preparing a heatsink system for a heat generating electronic device, comprising the steps of: (a) providing a heat conducting substrate; (b) applying a thermoset powder polymer based binder material insulating layer on the heat conducting substrate; and (c) applying a printed circuit directly on the thermoset powder polymer based binder material insulating layer by means of a hot embossing system, wherein step (c) comprises: treating a first side of a copper foil to provide a fine voided structure; providing the treated copper foil on the insulating layer; stamping at least a portion of the copper foil on the insulating layer with a heated embossing tool, wherein the insulating layer flows into the fine voided structure of the copper foil to provide adhesion between the copper foil and the insulating layer, and removing residual copper which was not stamped on the insulating layer.