Abstract: Embodiments of the present invention provide composite bodies having a discontinuous graphite preform and at least one silicon-bearing metal alloy infiltrant. Embodiments of the present invention also provide methods for producing such composite bodies. The metal alloy is preferably comprised of aluminum, copper, or magnesium, or combinations thereof. Certain preferred embodiments provide at least one aluminum alloy having from about 5% silicon to about 30% silicon, more preferably from about 11% to about 13% silicon, as an alloying element. Certain presently preferred embodiments provide an aluminum-silicon eutectic composition having about 12.5% silicon. Embodiments of the invention provide composite materials be “tuned” to more closely match thermal expansion characteristics of a number of semiconductor or integrated circuit materials such as, but not limited to, silicon, alumina, aluminum nitride, gallium nitride, and gallium arsenide while also providing high thermal conductivity.

Abstract: A heat sink including a composite material base plate that defines at least one through hole. At least one composite material insert is position into the at least one through hole prior to pressure infiltration. The composite material insert is oriented to increase thermal conductivity in the through-plan direction.

Abstract: A hybrid package for heat sinking a device is formed of a graphitic material that defines a plurality of cavities for cast-in-rivets and that defines at least one cavity for a cast-in-rivet via. The graphitic material is pressure infiltrated with a molten metal alloy so as to form a composite material with a plurality of cast-in rivets that increases at least one of the through-plane conductivity and the strength of the hybrid package and that forms at least one cast-in-rivet that increases an in-plane thermal conductivity of the hybrid package.

Abstract: A spray deposition apparatus comprises a source of aqueous fiber slurry that includes a mixture of milled graphite fibers in suspension. A slurry input of the spray deposition apparatus is coupled to the source of aqueous fiber slurry. The slurry input receives the mixture of aqueous fiber slurry. A gas pressure input receives pressurized gas. A nozzle aspirates the mixture of aqueous fiber slurry with the pressurized gas to produce a stream of fiber cluster droplets.