Graphite-based heat sinks and method and apparatus for the manufacture thereof

Abstract

One embodiment of a heat sink comprises a metal support member having a groove disposed at a surface thereof and a fin disposed at the groove. The fin comprises a graphite-based material having a metal-based coating disposed thereon, and the fin is retained at the groove via a soldered joint at the metal-based coating and the groove. Another exemplary embodiment of a heat sink comprises a plurality of fins alternatingly arranged with a plurality of spacers. A method of fabricating a heat sink comprises preparing a surface of a graphite-based substrate, removing particulate matter generated from the preparation of the surface of the substrate, applying a metal-based coating at the surface of the substrate, and arranging the substrate to form a heat sink structure. An apparatus for cladding fins of a heat sink with a protective material comprises a first chamber that facilitates the preparation of substrate surfaces, a grit-removing apparatus disposed adjacent to the first chamber, a second chamber that facilitates the application of the protective material to the substrate surfaces, and a transport device configured to facilitate the movement of the substrates through the first chamber, to the grit-removing apparatus, and through the second chamber.