Patent ID: 7421780

Claim:
A method for fabricating a thermal management system for a micro-component device, comprising: overlaying a target substrate as a first substrate with a blank in sheet form; providing a press tool having a predetermined relief structure with cutting blades for cutting the blank, the relief structure having an inner surface between adjacent cutting blades; stamping a microchannel structure having a plurality of outer walls enclosing a predefined area from the blank and defining an edge seal enclosing a predetermined area of the target substrate, comprises: pressing the press tool into the blank such that the cutting blades cut through the blank to the target substrate, cutting the blank into the microchannel structure and waste portions, and the inner surface of the release structure applying a predetermined compressive force onto the microchannel structure to facilitate a fluid-tight diffusion bond between the microchannel structure and the target substrate; removing the waste portions; bonding the microchannel structure to a heat dissipating side opposite from a micro-component device facing side of the first substrate, the micro-component device facing side for thermally engaging with the micro-component device; bonding the microchannel structure to a second substrate opposite the first substrate, defining a closed volume microchannel; and substantially filling the microchannel with a fluid thermal interface material.