Abstract: In an embodiment, a process for making a thermal interface article comprises shaping a flowable composite comprising a flowable matrix composition, 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, 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 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.

Abstract: A method of preparing a boron nitride foam includes flowing a gaseous medium along a flow path; introducing into the flow path a flowable composition that includes boron nitride sheets, a suspending agent, and optionally a surfactant to foam the flowable composition in the flow path; outputting the foamed flowable composition from the flow path; and solidifying the outputted flowable composition to provide the boron nitride foam; wherein the boron nitride foam has a structure defined by a three-dimensional network of interconnected cells defined by cell walls, wherein the cell walls include the boron nitride sheets.

Abstract: In an embodiment, a process for making a thermal interface article comprises shaping a flowable composite comprising a flowable matrix composition, 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, 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 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.