Heat sink and manufacturing process

Abstract

Corrugated fin components and base plates are stamped from coil-fed sheet in progressive dies. The corrugated component is staked to a primary base plate and the primary base plate is staked to a secondary base plate by plastically deforming conic posts into mushroom-shaped heads, thereby mechanically joining components without loose fasteners or adhesives. The manufacturing line may include multiple punch presses, staking stations, and positioning fixtures arranged about a rotary table or along a conveyor. Pick-and-place robots load the parts, and a PLC coordinates stamping, staking, inspection/sorting, and packaging. Vent apertures can be pierced in the corrugated component to promote omni-directional airflow. The approach enables high fin density and increased surface area relative to die-cast or extruded designs, supporting reduced weight, lower material usage, and high-throughput production.

Dependencies are inferred from the claim text.