Method of making thermal attachment to porous metal surfaces

Claim 1

A process for the formation of useful heat transfer interfaces on and within localized areas of a porous metal heat sink, said process comprising the steps of, removing all traces of foreign matter from a porous metal panel by such method as vapor degreasing and/or sandblasting, disposing a removable mask over the porous metal panel to confine the process within the desired areas, providing surface cooling for the porous metal panel to prevent distortions due to excessive build up of heat from metallizing process, spraying molten, atomized, high thermal conductivity metal onto the unmasked areas and thereby building up slight surface projecting pads, wherein the temperature of said molten metal is near the melting point thereof, subsequently machining the pads smooth such that the maximum intimate contact may be obtained between the mounted heat dissipating device and pads, providing at least one hole extending through the built-up portion of the porous panel for attachment of devices which allow multiple paths of heat transfer and similarly providing an opposed pad on the opposite surface side of the metal panel.