Patent ID: 7537151

Claim:
A method of manufacturing a heat sink, comprising the steps of, providing a base plate of metallic material having an upper surface formed with a series of parallel grooves, providing a folded fin of metallic material of sufficiently small wall thickness to be plastically deformable, and having a series of open crests sized to fit closely within the plate grooves, positioning a fin crest within each base plate groove so as to leave gaps G of predetermined width between the exterior surfaces of the crests and the internal surfaces of the grooves, placing the fin-base plate assembly in an evacuated chamber to remove substantially all air from the gaps G, after substantially all air is removed from the gaps G, forming a seal of polyvinyl alcohol (PVA) within and around the fin crests and above the upper surface of the base plate to a thickness “h” sufficient to cover and seal the gaps G and prevent the entry of material that forms the seal into the gaps G, to thereby form a work piece placing the work piece in a pressurized bath of hydraulic fluid and subjecting it to omni-directionally acting pressure sufficient to act on the seal material internal to the crests and plastically deform the exterior surfaces of the crests outwardly and into intimate contact with the internal surfaces of the base plate grooves, and, removing the seal of polyvinyl alcohol (PVA) by mechanical stripping, by water immersion, or by a combination thereof; in which said thickness “h” of said polyvinyl alcohol (PVA) is determined by the equation: h ≤ 2 ⁢ ⁢ g c ⁢ σ ρ ⁢ ⁢ g ⁢ ⁢ δ Where: h is thickness of said seal of PVA, ft g is the acceleration due to gravity=32.174 ft/s 2 g c is the constant of proportionality in Newton's second law of motion=32.174(lb m /lb f )·(ft/s 2 ) δ is the gap width (shown in FIG. 5 ), ft ρ is the density of PVA, lb m /ft 3 σ is the surface tension of PVA, lb f /ft.