Two-component moisture curable thermal interface material for thermal management systems

A two-part curable composition which cures to form a thermally conductive cured product, comprising:

• a first part comprising:
• (1) a metal catalytic component for catalyzing the cure reaction, wherein the metal catalytic component is present from approximately 0.1 percent to approximately 0.5 percent by weight of the total weight of the first part and is
• a non-reactive diluent component, wherein the non-reactive diluent component is
• a wetting agent component, wherein the wetting agent component is present from approximately 0.1 percent to approximately 5.0 percent by weight of the total weight of the first part and comprises a copolymer with acidic groups;
• (4) a filler component, wherein the filler component of the first part is present from approximately 40 percent to approximately 95 percent by weight of the total weight of the first part;
• (5) a rheology modifier component, wherein the rheology modifier component is present from approximately 0.1 percent to approximately 5.0 percent by weight of the total weight of the first part and comprises fumed aluminum oxide;
• and (6) a pigment component wherein the pigment component of the first part is present from approximately 0.1 percent to approximately 2.0 percent by weight of the total weight of the first part;
• and
• a second part comprising:
• (1) a silane terminated polyurethane polymer, wherein the silane terminated polyurethane polymer is present from approximately 2 percent to approximately 15 percent by weight of the total weight of the second part and is
• wherein X comprises a polyurethane linkage containing at least two polyurethane repeating units;
• (2) a moisture scavenger, wherein the moisture scavenger is present from approximately 0.1 percent to approximately 5.0 percent by weight of the total weight of the second part and is
• a non-reactive diluent component, wherein the non-reactive diluent component is
• a filler component, wherein the filler component of the second part is present from approximately 40 percent to approximately 95 percent by weight of the total weight of the second part;
• and (5) a wetting agent component that is present from approximately 0.1 percent to approximately 5.0 percent by weight of the total weight of the second part, wherein at least one of the filler components of the first part and the second part comprises a thermally conductive filler selected from the group consisting of aluminum oxide, aluminum trihydrate, aluminum nitride, boron nitride, silicon carbide, and graphene nanoplatelet;
• wherein the non-reactive diluent component of the first part and the non-reactive diluent component of the second part is present from approximately 2 percent to approximately 15 percent by weight of the total weight of the first part and the second part;
• wherein the ratio of the first part to the second part is approximately 1:1 by volume;
• wherein the composition gels in between approximately 10 and approximately 240 minutes from the time the first part and the second part are brought together at room temperature;
• wherein the first part and second part comprise a pre-cured viscosity of approximately 75 to approximately 1,000 pascal-second at normal temperature and pressure;
• wherein the first part and second part comprise a pre-cured density of approximately 2.0 to approximately 3.2 grams per cubic centimeter;
• wherein the two-part curable composition cures to form a cured product with a Shore 00 durometer hardness ranging from approximately 50 to approximately 98;
• wherein the two-part curable composition cures to form a cured product with a thermal conductivity ranging from approximately 3.0 to approximately 5.0 watts per meter-kelvin;
• wherein the two-part curable composition cures to form a cured product that has a flammability rating of V-0 under UL94 standard;
• and
• wherein the two-part curable composition cures to form a cured product that has a minimum dielectric strength of 8 kV/mm.