Electrical-circuit assembly with heat-sink

A heat-sink comprising:

• a base having a first-surface and a second-surface opposite the first-surface, the first-surface configured for thermal communication with an electrical-device;
• a lid having a third-surface and a fourth-surface opposite the third-surface, the lid arranged so the third-surface faces toward the second-surface;
• side-walls disposed between the base and the lid extending from the second-surface to the third-surface, wherein the base, the lid, and the side-walls cooperate to define a cavity;
• a single porous-structure formed integral to the base and extending from the second-surface toward the third-surface, the single porous-structure terminating a portion of a distance between the second-surface and the third-surface thereby defining a void between the single porous-structure and the third-surface;
• the void extending along the entire porous-structure and terminating on the side-walls;
• the single porous-structure having a contiguous-porosity network;
• and
• a heat-transfer-fluid disposed within the cavity.

A method of making a heat-sink, comprising:

• die-casting a base;
• the base having a first-surface and a second-surface opposite the first-surface, a single porous-structure, and side-walls;
• the first-surface, second-surface, single porous-structure, and side-walls formed integral to the base and defining a cavity;
• the first-surface configured for thermal communication with an electrical-device;
• the single porous-structure having a contiguous-porosity network;
• die-casting a lid;
• the lid having a third-surface and a fourth-surface opposite the third-surface;
• exposing a surface of the porous-structure;
• dispensing a heat-transfer-fluid within the cavity;
• and
• joining the lid to the side-walls;
• the lid arranged such that the third-surface faces toward the second-surface of the base;
• the single porous-structure extending from the second-surface of the base toward the third-surface of the lid;
• the single porous-structure terminating a portion of a distance between the second-surface and the third-surface thereby defining a void between the single porous-structure and the third-surface;
• the void extending along the entire porous-structure and terminating on the side-walls.