Patent ID: 7462309

Claim:
A method of making a net-shape molded, thermoplastic, thermally-conductive interface article, comprising the steps of: providing a molten composition comprising: about 40% to about 80% by weight of a thermoplastic elastomer matrix that is solid at the operational temperature range of the interface article of between about 10° C. to about 115° C.; about 20% to about 60% by weight of a thermally-conductive filler material including a mix of high aspect ratio fillers and low aspect ratio fillers; and about 5 to about 50% by weight of a phase change material dispersed throughout said elastomer matrix, said phase change material being capable of changing from a solid state to a liquid state and from a liquid state to a solid state within a temperature range of about 10° C. to about 115° C.; injecting the molten composition into a mold at a temperature greater than the melting point of the thermoplastic elastomer matrix; removing the composition from the mold to form a net-shape molded, thermoplastic, thermally-conductive interface article having an operational range of between about 10° C. to about 115° C., wherein said elastomer matrix in a solid state contains said phase change material in a liquid state.