Patent ID: 7907410

Claim:
A thermal interface for coupling a first solid to a second solid, the thermal interface comprising: a patterned metal insert having a first exterior side positioned to contact the first solid and a second exterior side positioned to contact the second solid; a corrosion resistant layer coated directly onto at least one of the first exterior side and the second exterior side prior to the thermal interface being deployed between the first solid and the second solid, for protecting the patterned metal insert from corrosion, a metallic bond coupling the corrosion resistant layer to the patterned metal insert; and an organic layer coated directly onto the corrosion resistant layer prior to the thermal interface being deployed between the first solid and the second solid, for facilitating bonding of the patterned metal insert to one of the first solid and the second solid; wherein the at least one of the first exterior side and the second exterior side that is coated by the corrosion resistant layer is unpatterned, and wherein an interior volume of the patterned metal insert is patterned.