Methods for the manufacture of thermal interfaces, thermal interfaces, and articles comprising the same

A process for making a thermal interface, the process comprising:

• shaping a flowable composite comprising
• a flowable matrix composition,
• 1 to 80 volume percent of a plurality of magnetic, thermally conductive particles having an average length greater than a thickness or diameter, wherein the plurality of magnetic, thermally conductive particles have magnetic or superparamagnetic nanoparticles attached thereto, and
• optionally, an additional filler different from the plurality of magnetic, thermally conductive particles,
• to provide the flowable composite in a shape comprising a first surface and an opposing second surface, and having a Z-axis perpendicular to the first surface and the opposing second surface;
• subjecting the flowable composite to a rotating magnetic field and to a vibrational force along an X-direction, a Y-direction, and a Z-direction, or only the Z-direction, of the flowable composite in an amount and for a time effective to align the average length of the plurality of magnetic, thermally conductive particles along the Z-axis;
• and
• solidifying the flowable matrix composition to provide the thermal interface, wherein the thermal interface has a Z-direction thermal conductivity of at least 1.0 W/mK.