A　thermal　conductive　structural　adhesive　(TCSA)　plays　a　crucial　role　in　battery　performance　and　safety.　TCSA　made　of　polyurethane　(PU)　has　not　only　a　good　thermal　conductivity　but　also　good　mechanical　strength　and　substrate　bonding　strength.　However,　it　has　to　be　cost-effective　and　easy　to　be　prepared.　This　work　aims　to　synthesize　a　series　of　castor　oil-based　PU　TCSAs　with　different　amounts　of　thermal　conductive　powder　using　commercially　available　castor　oil　polyols,　isocyanates,　Al2O3,　and　additives.　The　shear　strength　of　the　TCSA　containing　88%　thermally　conductivity　powder　reached　5.6　MPa,　which　was　similar　to　that　without　the　thermal　conductivity　fillers,　but　its　toughness　significantly　decreased.　Its　thermal　conductivity　was　as　high　as　1.8　W/mK,　and　it　was　thermally　stable　below　270°C.　©　2024　Wiley　Periodicals　LLC.