Method of manufacturing bonded dual extruded, high fin density heat sinks

Method of manufacturing an extruded high fin density heat sink, comprising the steps of:

• (a) providing an extrusion die for extruding billets defined as first and second base elements;
• (b) extruding said first and second base elements, wherein said first base element has a plurality of spaced first fins and first recesses formed in a common first face, and wherein said second base element has a plurality of spaced second fins and second recesses formed in a common second face;
• (c) sizing said extruded first and second base elements to a predetermined dimension;
• (d) aligning said common first face of said first base element with said common second face of said second base element such that said first fins are aligned for being received by said second recesses and said second fins are aligned for being received by said first recesses;
• (e) applying a bonding layer to either of said first and second recesses and said first and second fins;
• and,
• (f) pressing each of said first and second fins into an aligned respective first and second recess thereby forming an extruded heat sink having gas passageways defined by spacing between nearest adjacent first and second fins bonded in the first and second elements.