A segmented component for a housing includes a first shaped part, a first segment having a first cast metal region which is material-bonded to the first shaped part by a first bonding zone. The first shaped part is material-bonded to a second cast metal region of a second segment by a second bonding zone. At least one additional element is material-bonded to the second segment by a third bonding zone and material-bonded to the first segment by a fourth bonding zone, wherein the first shaped part, the first and second segments, and the at least one additional element defining an extension of an interior space of the housing in a cross-sectional plane.

In a heat sink module and a manufacturing method thereof, the method includes steps of: forming a heat dissipation fin set by aluminum extrusion process, wherein the heat dissipation fin set includes a plate, a plurality of fins extending from one side of the plate and being arranged spaced apart from one another, and a joint portion formed on the other side of the plate; placing the plate in a mold; injecting molten metal into the mold; forming a base by die-casting of the molten metal. The plate and the joint portion are wrapped by the base. The joint portion forms a connection structure including a bump and a notch fitted with the bump, so as to connect and fix the base and the heat dissipation fin set. The heat sink module has the strengthened connection structure and the fins with a superior aspect ratio.

The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.

The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.

The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.

In a heat sink module and a manufacturing method thereof, the method includes steps of: forming a heat dissipation fin set by aluminum extrusion process, wherein the heat dissipation fin set includes a plate, a plurality of fins extending from one side of the plate and being arranged spaced apart from one another, and a joint portion formed on the other side of the plate; placing the plate in a mold; injecting molten metal into the mold; forming a base by die-casting of the molten metal. The plate and the joint portion are wrapped by the base. The joint portion forms a connection structure including a bump and a notch fitted with the bump, so as to connect and fix the base and the heat dissipation fin set. The heat sink module has the strengthened connection structure and the fins with a superior aspect ratio.

The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.

A method of manufacturing a heat sink according to one aspect of the present disclosure is a method of manufacturing a heat sink including a base material having a surface on which a heat-radiation resin-coated film is formed, the method comprising: taking the base material out of a die-casting mold after the base material is die-cast; and forming the heat-radiation resin-coated film on the surface of the base material using residual heat of the base material taken out of the die-casting mold. In forming the heat-radiation resin-coated film, the heat-radiation resin-coated film is formed on the surface of the base material by bonding a heat-radiation resin film to the surface of the base material.