Channeled articles having very small diameter channels spaced very closely
can be made by packing elongated cores in a fixture, clamping them, and then introducing
matrix material around the cores. The matrix material is formed into a unitary
body and solidified. The cores are pulled out, leaving open channels where they
had been. Some core and matrix combinations will permit the cores to be pulled
out. Others require a core release coating to be applied to the cores. The cores
can be metal or ceramic or polymer, and the matrix can be metal or ceramic or polymer.
The cores can be solid, or hollow. Rather than pulling the cores out, if they are
polymer, they can be burned out. The matrix can be formed by liquid state, solid
state, or hybrid liquid/solid state techniques. A related technique uses hollow
cores, which are not pulled out, but which remain in the body after unification.
For such tube-walled articles, the matrix can be formed similarly. Rather than
insuring core release, core retention is required. Such may occur due to the nature
of the materials, or a specific core retention coating may be provided. Articles
made of such material include heat sinks for semiconductor devices, light-weight
structural components, thermally activated actuators, etc. Very small channel diameters
and very large length to opening aspect ratios can be achieved. Heat exchange fluid
can be compressed and pumped through such an article at very high efficiencies,
to cool semiconductor devices.