Compliant Pin Fin heat sink with base integral pins

1. A compliant pin fin heat sink comprising:

a plurality of separate flexible base plates;

a plurality of elastomeric flow blockers joining the plurality of separate flexible base plates;

a plurality of pins extending from each of the flexible base plates and formed integral with each of the flexible base plates; and

a flexible top plate connected to and spaced from the flexible base plates, the plurality of pins disposed between the flexible base plates and the flexible top plate and the flexible base plates and flexible top plate having a thickness of from 0.2 mm to 0.5 mm;

wherein the compliant pin fin heat sink including the flexible top plate and the flexible base plates is flexible in an area of the compliant pin fin heat sink containing the plurality of pins to conform the compliant pin fin heat sink to contours of a contact surface under a load applied to the flexible top plate,

wherein the plurality of elastomeric flow blockers define flow channels that enclose the plurality of pins between the flexible base plates and the flexible top plate,

wherein each row of pins within each plurality of pins is offset from each adjacent row of pins within that plurality of pins.

2. The compliant pin fin heat sink of claim 1 , wherein the plurality of pins are forged in the flexible base plate.

3. The compliant pin fin heat sink of claim 1 , wherein the flexible base plates and the plurality of pins comprise copper.

4. The compliant pin fin heat sink of claim 1 , wherein the compliant pin fin heat sink is flexible under an applied load of from 50 pounds to 300 pounds in an area of the compliant pin fin heat sink containing the plurality of pins.

5. The compliant pin fin heat sink of claim 1 , wherein each pin in the plurality of pins extends from the flexible base plate a distance of from 1 mm to 5 mm.

6. The compliant pin fin heat sink of claim 1 , wherein the plurality of pins comprise a center to center spacing of from 0.8 mm to 2 mm and a diameter of from 0.4 mm to 1 mm.

7. The compliant pin fin heat sink of claim 1 , wherein:

each of the plurality of flexible base plates comprises a length of 50 mm and a width of 50 mm; and

the plurality of pins defines a rectangular area having 25 mm long sides.

8. The compliant pin fin heat sink of claim 1 , wherein the flexible top plate comprises a plurality of liquid inlets and a plurality of liquid outlets passing through the flexible top plate, each one of the plurality of separate flow channels in communication with one of the plurality of liquid inlets and one of the plurality of liquid outlets.

9. A method for forming a compliant pin fin heat sink, the method comprising:

forging a plurality of pins in a plurality of flexible base plates comprising copper and having a thickness of from 0.2 mm to 0.5 mm;

attaching elastomeric flow blocking structures joining each of the plurality of flexible base plates to an adjacent flexible base plate to form a corresponding flow channel that encloses the plurality of pins on that base plate; and

connecting to the base plate and to the pins a flexible top plate having a thickness of from 0.2 mm to 0.5 mm such that the plurality of pins is disposed between the flexible base plate and the flexible top plate;

wherein the compliant pin fin heat sink including the flexible top plate and the flexible base plates is flexible in an area of the compliant pin fin heat sink containing the plurality of pins to conform the compliant pin fin heat sink to contours of a contact surface under a load applied to the flexible top plate.

10. The method of claim 9 , wherein forging the plurality of fins further comprises forging the pins to have a length of from 1 mm to 5 mm, a diameter of 0.4 mm to 1 mm and a center to center spacing of 0.8 mm to 2 mm.