Integrated heat spreader, heat sink or heat pipe with pre-attached phase change thermal interface material and method of making an electronic assembly

1. A method comprising:

providing a heat dissipating member having a surface;

providing a phase change thermal interface material that has the property of being a solid at room temperature, of becoming a liquid at a first elevated temperature above room temperature, wherein the phase change thermal interface material comprises fusible thermally conductive solder particles and particles of at least one thermally conductive filler dispersed throughout a polymer matrix that includes a cross-linking agent;

heating the phase change thermal interface material to the first elevated temperature;

applying the heated phase change thermal interface material to the surface of the heat dissipating member; and

allowing the phase change thermal interface material applied to the surface of the heat dissipating member to cool to room temperature.

2. The method of claim 1 wherein the heat dissipating member is a heat spreader, heat sink or heat pipe.

3. The method of claim 1 wherein the particles of the at least one thermally conductive filler are fusible particles, non-fusible particles or a combination of fusible particles and non-fusible particles.

4. The method of claim 1 wherein the phase change thermal interface material is applied to the surface of the heat dissipating member by screen printing.

5. A method comprising:

providing a heat dissipating member having a surface, the surface having a phase change thermal interface material pre-attached thereto, wherein the phase change thermal interface material has the property of being solid at room temperature, of becoming a liquid at a first elevated temperature above room temperature, wherein the phase change thermal interface material comprises fusible thermally conductive solder particles and particles of at least one thermally conductive filler dispersed throughout a polymer matrix that includes a cross-linking agent, and wherein the thermal interface material is pre-attached, including:

providing the phase change thermal interface,

heating the phase change thermal interface material to the first elevated temperature;

applying the heated phase change thermal interface material to the surface of the heat dissipating member;

providing a component that generates heat during operation, the component having a surface;

bringing the heat dissipating member and the component into proximity so that the phase change thermal interface material attached to the surface of the heat dissipating member contacts the surface of the component;

heating the phase change thermal interface material to the first elevated temperature, and

allowing the phase change thermal interface material to cool.

6. The method of claim 5 wherein the heat dissipating member is a heat spreader, heat sink or heat pipe, and wherein the component that generates heat during operation is a semiconductor die.

7. The method of claim 5 wherein the particles of the at least one thermally conductive filler are fusible particles, non-fusible particles or a combination of fusible particles and non-fusible particles.