Thermal interface materials having a combination of fillers and reduced squeeze force

A method of using a thermally conductive composition, comprising:

• combining an isocyanate component comprising a blocked isocyanate prepolymer and an isocyanate-reactive component comprising one or more polyetheramines to form the thermally conductive composition,
• wherein the isocyanate component and/or the isocyanate-reactive component comprise a polymodal filler composition at a percent by weight (wt %) of the thermally conductive composition in a range of 60 wt % to 95 wt %, the polymodal filler composition comprising a first thermally conductive filler of aluminum trihydrate (ATH) having a D50 particle size in the range of 0.1 μm to 10 μm, a second thermally conductive filler of ATH having a D50 in the range of 10 μm to 100 μm, wherein the first thermally conductive filler and the second thermally conductive filler are present at a percent by weight of the polymodal filler composition (wt %) in a range of 40 wt % to 90 wt %;
• and a third thermally conductive filler of alumina having a D50 in the range of 5 μm to 100 μm at a percent by weight of 10 wt % to 60 wt %;
• and
• emplacing the thermally conductive composition between a heat source and a heat sink in an EV battery.