Composite material with thermal barrier properties, composite material layer and battery exhaust protection composite material

Abstract

The invention relates to a composite material with thermal barrier properties, a composite material layer and a battery exhaust protection composite material. The subject application relates to a composite material that can include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramized filler composition distributed within the silicone-based matrix component. The ceramized filler composition may include a ceramized filler component, a structure promoter component, a flux component, and a flame retardant component.

Description

Technical Field

[0001] The present disclosure relates to composite materials, composite layers, and battery exhaust protection composite materials. Specifically, it relates to composite materials, composite layers, and battery exhaust protection composite materials used as thermal barriers in various applications (such as battery packs), and methods for forming them. Background Art

[0002] Filler compositions, composite materials, and composite layers can be designed for high-temperature protection in various applications. For example, they can be used as thermal barriers in electric vehicle battery packs, thermal barrier coatings in high-temperature cable protection, thermal barrier containers for thermal spraying insulation, etc. However, in these and other applications, due to technological improvements, potential thermal growth continues to increase. Therefore, there is a continuing need for improved barrier designs that protect against such high heat potentials. Summary of the Invention

[0003] According to a first aspect, a composite material can include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifiable filler composition distributed within the silicone-based matrix component. The ceramifiable filler composition can include a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component. The composite material can have a compression set of no greater than about 5%, as measured at 100 °C with a 50% compression for 22 hours.

[0004] According to another aspect, a composite layer can include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifiable filler composition distributed within the silicone-based matrix component. The ceramifiable filler composition can include a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component. The composite layer can have a compression set of no greater than about 5%, as measured at 100 °C with a 50% compression for 22 hours.

[0005] According to yet another aspect, a battery exhaust protection composite material can include a composite material. The composite material can include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifiable filler composition distributed within the silicone-based matrix component. The ceramifiable filler composition can include a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component. The battery exhaust protection composite material can have a compression set of no greater than about 5%, as measured at 100 °C with a 50% compression for 22 hours.

[0006] According to another aspect, the battery exhaust protection composite material may include a composite layer. The composite layer may include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramizable filler composition distributed within the silicone-based matrix component. The ceramizable filler composition may include a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component. The battery exhaust protection composite material may have a compression set of no greater than about 5%, as measured at 100 °C at 50% compression for 22 hours. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The embodiments are shown by way of example and are not limited to the drawings.

[0008] Figure 1 Diagrams including exemplary composites according to certain embodiments described herein.

[0009] Those skilled in the art will appreciate that the elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. DETAILED DESCRIPTION

[0010] The following discussion will focus on specific implementations and embodiments of the present teachings. Providing this detailed description helps to describe certain embodiments and should not be construed as limiting the scope or applicability of the present disclosure or teachings. It should be understood that other embodiments may be used based on the disclosure and teachings provided herein.

[0011] The terms "comprising", "containing", "including", "having" or any other variation thereof are intended to cover non-exclusive inclusion. For example, a method, article, or apparatus that includes a series of features is not necessarily limited to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive or rather than an exclusive or. For example, condition A or B is satisfied by any of the following: A is true (or present) and B is false (or absent), A is false (or absent) and B is true (or present), and both A and B are true (or present).

[0012] Furthermore, the terms "a" or "an" are used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be understood to include one, at least one, or the singular also includes the plural, and vice versa, unless expressly stated otherwise. For example, when a single item is described herein, more than one item may be used in place of the single item. Similarly, where more than one item is described herein, a single item may be used in place of the more than one item.

[0013] The embodiments described herein generally relate to composite materials that may include a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifying filler composition distributed within the silicone-based matrix component.

[0014] For illustrative purposes, Figure 1 a composite material 100 according to the embodiments described herein is shown. As Figure 1 shown, the composite material 100 may include a silicone-based matrix component 110, a reinforcing filler component 115, and a ceramifying filler composition 120 distributed within the silicone-based matrix component 110.

[0015] According to certain embodiments, the silicone-based matrix component 110 in the composite material 100 may include specific materials. For example, the silicone-based matrix component 110 may include silicone. According to still further embodiments, the silicone-based matrix component 110 may consist of silicone.

[0016] According to still further embodiments, the silicone-based matrix component 110 may include a polydimethylsiloxane gum having an average molecular weight between 300,000 and 800,000, or a liquid polydimethylsiloxane polymer having a viscosity between 50 cst and 100,000 cst. According to still further embodiments, the silicone-based matrix component 110 may include vinyl and Si-hydrogen groups that may react with each other in the presence of a platinum catalyst.

[0017] According to yet further embodiments, the composite material 100 may include a specific content of the silicone-based matrix component 110. For example, the composite material 100 may have a silicone-based matrix component content of at least about 30 wt% of the total weight of the composite material 100, such as at least about 33 wt% or at least about 35 wt% or at least about 38 wt% or at least about 40 wt% or at least about 43 wt% or at least about 45 wt% or even at least about 48 wt%. According to yet further embodiments, the composite material 100 may have a silicone-based matrix component content of no greater than about 60 wt% of the total weight of the composite material 100, such as no greater than about 58 wt% or no greater than about 55 wt% or no greater than about 53 wt% or even no greater than about 50 wt%. It should be understood that the composite material 100 may have a silicone-based matrix component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a silicone-based matrix component content of any value within the range between any of the above minimum and maximum values.

[0018] According to some further embodiments, the reinforcing filler component 115 in the composite material 100 may comprise specific materials. For example, the reinforcing filler component 115 may comprise silica, silicone resin, carbon black, calcium carbonate, or any combination thereof. According to still further embodiments, the reinforcing filler component 115 may consist of silica, silicone resin, carbon black, calcium carbonate, or any combination thereof.

[0019] According to still further embodiments, the composite material 100 may comprise a specific content of the reinforcing filler component 115. For example, the composite material 100 may have a reinforcing filler component content of at least about 2.0 wt% of the total weight of the composite material 100, such as at least about 4.0 wt% or at least about 6.0 wt% or at least about 8.0 wt% or at least about 10.0 wt% or at least about 12.0 wt% or at least about 14.0 wt% or even at least about 16.0 wt%. According to still further embodiments, the composite material 100 may have a reinforcing filler component content of not more than about 20 wt% of the total weight of the composite material 100, such as not more than about 19 wt% or not more than about 18 wt% or even not more than about 17 wt%. It should be understood that the composite material 100 may have a reinforcing filler component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a reinforcing filler component content of any value within the range between any of the above minimum and maximum values.

[0020] According to still further embodiments, the composite material 100 may comprise a specific content of the ceramizing filler composition 120. For example, the composite material 100 may have a ceramizing filler composition content of at least about 40 wt% of the total weight of the composite material 100, such as at least about 43 wt% or at least about 45 wt% or at least about 48 wt% or at least about 50 wt% or at least about 53 wt% or at least about 55 wt% or even at least about 58 wt%. According to still further embodiments, the composite material 100 may have a ceramizing filler composition content of not more than about 70 wt% of the total weight of the composite material 100, such as not more than about 68 wt% or not more than about 65 wt% or not more than about 63 wt% or even not more than about 60 wt%. It should be understood that the composite material 100 may have a ceramizing filler composition content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a ceramizing filler composition content of any value within the range between any of the above minimum and maximum values.

[0021] According to certain embodiments, the ceramizing filler composition 120 may comprise a ceramizing filler component, a structure promoting agent component, a flux component, and a flame retardant component.

[0022] According to certain embodiments, the ceramifiable filler component of the ceramifiable filler composition 120 may comprise certain components. For example, the ceramifiable filler component may comprise a component selected from sepiolite, wollastonite, or any combination thereof. According to some further embodiments, the ceramifiable filler component may comprise sepiolite. According to some yet further embodiments, the ceramifiable filler component may consist of sepiolite. According to some further embodiments, the ceramifiable filler component may comprise wollastonite. According to some yet further embodiments, the ceramifiable filler component may consist of wollastonite. According to some further embodiments, the ceramifiable filler component may comprise a combination of sepiolite and wollastonite. According to some yet further embodiments, the ceramifiable filler component may consist of a combination of sepiolite and wollastonite.

[0023] According to some further embodiments, the ceramifiable filler component of the ceramifiable filler composition 120 may be a plurality of particles. According to some further embodiments, the ceramifiable filler component may have a specific aspect ratio. For the purposes of the embodiments described herein, the aspect ratio of the ceramifiable filler component may be defined as the average length of a statistically significant number of particles of the ceramifiable filler component divided by the average diameter (L / D) of a statistically significant number of particles of the ceramifiable filler component. For example, the ceramifiable filler component may have an aspect ratio of no greater than about 10.0, such as no greater than about 9.5 or no greater than about 9.0 or no greater than about 8.5 or no greater than about 8.0 or no greater than about 7.5 or no greater than about 7.0 or no greater than about 6.5 or no greater than about 6.0 or even no greater than about 5.5. According to some further embodiments, the ceramifiable filler component may have an aspect ratio of at least about 2.0, such as at least about 2.5 or at least about 3.0 or at least about 3.5 or at least about 4.0 or even at least about 4.5. It should be understood that the ceramifiable filler component may have an aspect ratio of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler component may have an aspect ratio of any value between any of the above minimum and maximum values.

[0024] According to some further embodiments, the ceramifiable filler composition 120 may comprise a specific content of ceramifiable filler components. For example, the ceramifiable filler composition 120 may have a ceramifiable filler component content of at least about 50 wt% of the total weight of the ceramifiable filler composition 120, such as at least about 55 wt% or at least about 60 wt% or at least about 65 wt% or at least about 70 wt or at least about 75 wt% or at least about 80 wt% or at least about 81 wt% or at least about 82 wt% or at least about 83 wt% or at least about 84 wt% or even at least about 85 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a ceramifiable filler component content of no greater than about 95 wt% of the total weight of the ceramifiable filler composition 120, such as no greater than about 94 wt% or no greater than about 93 wt% or no greater than about 92 wt% or no greater than about 91 wt% or no greater than about 90 wt% or no greater than about 89 wt% or no greater than about 88 wt% or no greater than about 88 wt% or even no greater than about 87 wt%. It should be understood that the ceramifiable filler composition 120 may have a ceramifiable filler component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler composition 120 may have a ceramifiable filler component content of any value within the range between any of the above minimum and maximum values.

[0025] According to some further embodiments, the composite material 100 may comprise a specific content of a ceramizable filler component. For example, the composite material 100 may have a ceramizable filler component content of at least about 40 wt% of the total weight of the composite material 100, such as at least about 41 wt% or at least about 42 wt% or at least about 43 wt% or at least about 44 wt% or at least about 45 wt% or at least about 46 wt% or at least about 47 wt% or at least about 48 wt% or at least about 49 wt% or at least about 50 wt% or at least about 51 wt% or at least about 52 wt% or at least about 53 wt% or at least about 54 wt% or at least about 55 wt% or at least about 56 wt% or at least about 57 wt% or at least about 58 wt% or at least about 59 wt% or even at least about 60 wt%. According to some further embodiments, the composite material 100 may have a ceramizable filler component content of no greater than about 70 wt% of the total weight of the composite material 100, such as no greater than about 69 wt% or no greater than about 68 wt% or no greater than about 67 wt% or no greater than about 66 wt% or no greater than about 65 wt% or no greater than about 64 wt% or no greater than about 63 wt% or no greater than about 62 wt% or no greater than about 61 wt% or even no greater than about 60 wt%. It should be understood that the composite material 100 may have a ceramizable filler component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a ceramizable filler component content of any value within the range between any of the above minimum and maximum values.

[0026] According to certain embodiments, the structure promoter component of the ceramizable filler composition 120 may comprise specific components. For example, the structure promoter component may comprise a component selected from crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof. According to some further embodiments, the structure promoter component may comprise crystalline silica. According to some other embodiments, the structure promoter component may consist of crystalline silica. According to some further embodiments, the structure promoter component may comprise diopside. According to some other embodiments, the structure promoter component may consist of diopside. According to some further embodiments, the structure promoter component may comprise spodumene. According to some other embodiments, the structure promoter component may consist of spodumene. According to some further embodiments, the structure promoter component may comprise lepidolite. According to some other embodiments, the structure promoter component may consist of lepidolite. According to some further embodiments, the structure promoter component may comprise lithium carbonate. According to some other embodiments, the structure promoter component may consist of lithium carbonate. According to some further embodiments, the structure promoter component may comprise lithium hydroxide. According to some other embodiments, the structure promoter component may consist of lithium hydroxide.

[0027] According to some further embodiments, the ceramifiable filler composition 120 may comprise a specific content of a structure promoting agent component. For example, the ceramifiable filler composition 120 may have a structure promoting agent component content of at least about 0.1 wt% of the total weight of the ceramifiable filler composition 120, such as at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or at least about 2.5 wt% or at least about 3.0 wt% or even at least about 3.5 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a structure promoting agent component content of not greater than about 7.0 wt% of the total weight of the ceramifiable filler composition 120, such as not greater than about 6.5 wt% or not greater than about 6.0 wt% or not greater than about 5.5 wt% or not greater than about 5.0 wt% or not greater than about 4.5 wt% or even not greater than about 4.0 wt%. It should be understood that the ceramifiable filler composition 120 may have a structure promoting agent component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler composition 120 may have a structure promoting agent component content of any value between any of the above minimum and maximum values.

[0028] According to some further embodiments, the composite material 100 may comprise a specific content of a structure promoting agent component. For example, the composite material 100 may have a structure promoting agent component content of at least about 0.05 wt% of the total weight of the composite material 100, such as at least about 0.1 wt% or at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or even at least about 2.5 wt%. According to some further embodiments, the composite material 100 may have a structure promoting agent component content of not greater than about 5.0 wt% of the total weight of the composite material 100, such as not greater than about 4.5 wt% or not greater than about 4.0 wt% or not greater than about 3.5 wt% or even not greater than about 3.0 wt%. It should be understood that the composite material 100 may have a structure promoting agent component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a structure promoting agent component content of any value between any of the above minimum and maximum values.

[0029] According to certain embodiments, the flux component of the ceramifiable filler composition 120 may comprise certain components. For example, the flux component may comprise a component selected from the group consisting of: a low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth(III) oxide, or any combination thereof. According to still further embodiments, the flux component may comprise a low-T frit. According to yet further embodiments, the flux component may consist of a low-T frit. According to still further embodiments, the flux component may comprise zinc oxide. According to yet further embodiments, the flux component may consist of zinc oxide. According to still further embodiments, the flux component may comprise zinc borate. According to yet further embodiments, the flux component may consist of zinc borate. According to still further embodiments, the flux component may comprise antimony(III) oxide. According to yet further embodiments, the flux component may consist of antimony(III) oxide. According to still further embodiments, the flux component may comprise bismuth(III) oxide. According to yet further embodiments, the flux component may consist of bismuth(III) oxide.

[0030] According to still further embodiments, the ceramifiable filler composition 120 may comprise a specific content of the flux component. For example, the ceramifiable filler composition 120 may have a flux component content of at least about 0.1 wt% of the total weight of the ceramifiable filler composition 120, such as at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or at least about 2.5 wt% or at least about 3.0 wt% or even at least about 3.5 wt%. According to still further embodiments, the ceramifiable filler composition 120 may have a flux component content of not greater than about 7.0 wt% of the total weight of the ceramifiable filler composition 120, such as not greater than about 6.5 wt% or not greater than about 6.0 wt% or not greater than about 5.5 wt% or not greater than about 5.0 wt% or not greater than about 4.5 wt% or even not greater than about 4.0 wt%. It should be understood that the ceramifiable filler composition 120 may have a flux component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler composition 120 may have a flux component content of any value within the range between any of the above minimum and maximum values.

[0031] According to some further embodiments, the composite material 100 may comprise a specific content of a flux component. For example, the composite material 100 may have a flux component content of at least about 0.01 wt% of the total weight of the composite material 100, such as at least about 0.05 wt% or at least about 0.1 wt% or at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or even at least about 2.5 wt%. According to some further embodiments, the composite material 100 may have a flux component content of no greater than about 5.0 wt% of the total weight of the composite material 100, such as no greater than about 4.5 wt% or no greater than about 4.0 wt% or no greater than about 3.5 wt% or even no greater than about 3.0 wt%. It should be understood that the composite material 100 may have a flux component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a flux component content of any value within the range between any of the above minimum and maximum values.

[0032] According to certain embodiments, the flame retardant component of the ceramizable filler composition 120 may comprise specific components. For example, the flame retardant component may comprise components selected from aluminum hydroxide, magnesium hydroxide, expanded graphite, platinum (Pt) complexes, or any combination thereof. According to some further embodiments, the flame retardant component may comprise aluminum hydroxide. According to some other embodiments, the flame retardant component may consist of aluminum hydroxide. According to some further embodiments, the flame retardant component may comprise magnesium hydroxide. According to some other embodiments, the flame retardant component may consist of magnesium hydroxide.

[0033] According to some further embodiments, the ceramifiable filler composition 120 may comprise a specific content of a flame retardant component. For example, the ceramifiable filler composition 120 may have a flame retardant component content of at least about 5.0 wt% of the total weight of the ceramifiable filler composition 120, such as at least about 6.0 wt% or at least about 7.0 wt% or at least about 8.0 wt% or at least about 9.0 wt% or at least about 10.0 wt% or at least about 11.0 wt% or even at least about 12.0 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a flame retardant component content of not more than about 20.0 wt% of the total weight of the ceramifiable filler composition 120, such as not more than about 19.0 wt% or not more than about 18.0 wt% or not more than about 17.0 wt% or not more than about 16.0 wt% or not more than about 15.0 wt% or even not more than about 14.0 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a flame retardant component content of at least about 4.0 ppm of the total weight of the ceramifiable filler composition 120, such as at least about 6.0 ppm or at least about 10.0 ppm or at least about 20.0 ppm or at least about 30.0 ppm or at least about 40.0 ppm or at least about 50.0 ppm or even at least about 60.0 ppm. According to some further embodiments, the ceramifiable filler composition 120 may have a flame retardant component content of not more than about 120.0 ppm of the total weight of the ceramifiable filler composition 120, such as not more than about 100.0 ppm or not more than about 80.0 ppm or not more than about 60.0 ppm or even not more than about 40.0 ppm. It should be understood that the ceramifiable filler composition 120 may have a flame retardant component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler composition 120 may have a flame retardant component content of any value within the range between any of the above minimum and maximum values.

[0034] According to some further embodiments, the composite material 100 may comprise a specific content of a flame retardant component. For example, the composite material 100 may have a flame retardant component content of at least about 2.5 wt% of the total weight of the composite material 100, such as at least about 3.0 wt% or at least about 3.5 wt% or at least about 4.0 wt% or at least about 4.5 wt% or at least about 5.0 wt% or at least about 5.5 wt% or even at least about 6.0 wt%. According to some further embodiments, the composite material 100 may have a flame retardant component content of not more than about 10.0 wt% of the total weight of the composite material 100, such as not more than about 9.5 wt% or not more than about 9.0 wt% or not more than about 8.5 wt% or not more than about 8.0 wt% or not more than about 7.5 wt% or even not more than about 7.0 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a flame retardant component content of at least about 3.0 ppm of the total weight of the composite material 100, such as at least about 6.0 ppm or at least about 10.0 ppm or at least about 15.0 ppm or at least about 20.0 ppm or at least about 25.0 ppm or at least about 30.0 ppm or even at least about 40.0 ppm. According to some further embodiments, the ceramifiable filler composition 120 may have a flame retardant component content of not more than about 50.0 ppm of the total weight of the composite material 100, such as not more than about 40.0 ppm or not more than about 30.0 ppm or not more than about 25.0 ppm or even not more than about 20.0 ppm. It should be understood that the composite material 100 may have a flame retardant component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a flame retardant component content of any value within the range between any of the above minimum and maximum values.

[0035] According to some further embodiments, the ceramifiable filler composition 120 may further comprise a functional additive. According to some other embodiments, the functional additive may comprise specific components. For example, the functional additive may comprise a component selected from iron(III) oxide, titanium oxide, or any combination thereof. According to some further embodiments, the functional additive component may comprise iron(III) oxide. According to some other embodiments, the functional additive component may consist of iron(III) oxide. According to some further embodiments, the functional additive component may comprise titanium oxide. According to some other embodiments, the functional additive component may consist of titanium oxide.

[0036] According to some further embodiments, the ceramifiable filler composition 120 may include a specific content of functional additives. For example, the ceramifiable filler composition 120 may have a functional additive content of at least about 0.1 wt% of the total weight of the ceramifiable filler composition 120, such as at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or at least about 2.5 wt% or at least about 3.0 wt% or even at least about 3.5 wt%. According to some further embodiments, the ceramifiable filler composition 120 may have a functional additive content of not greater than about 7.0 wt% of the total weight of the ceramifiable filler composition 120, such as not greater than about 6.5 wt% or not greater than about 6.0 wt% or not greater than about 5.5 wt% or not greater than about 5.0 wt% or not greater than about 4.5 wt% or even not greater than about 4.0 wt%. It should be understood that the ceramifiable filler composition 120 may have a functional additive content of any value within the range between any of the above minimum and maximum values. It should also be understood that the ceramifiable filler composition 120 may have a functional additive content of any value within the range between any of the above minimum and maximum values.

[0037] According to some further embodiments, the composite material 100 may include a specific content of functional additives. For example, the composite material 100 may have a functional additive content of at least about 0.05 wt% of the total weight of the composite material 100, such as at least about 0.1 wt% or at least about 0.5 wt% or at least about 1.0 wt% or at least about 1.5 wt% or at least about 2.0 wt% or even at least about 2.5 wt%. According to some further embodiments, the composite material 100 may have a functional additive content of not greater than about 5.0 wt% of the total weight of the composite material 100, such as not greater than about 4.5 wt% or not greater than about 4.0 wt% or not greater than about 3.5 wt% or even not greater than about 3.0 wt%. It should be understood that the composite material 100 may have a functional additive content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a functional additive content of any value within the range between any of the above minimum and maximum values.

[0038] According to some further embodiments, the composite material 100 may further include a foaming agent component. According to some further embodiments, the foaming agent component of the composite material 100 may include specific materials. For example, the composite material 100 may be selected from 2,2'-azobis(2-methylpropionitrile), N,N'-dinitrosopentamethylenetetramine, N,N'-dimethyl-N,N'-dinitrosoterephthalamide, 4,4'-oxybis(benzenesulfonylhydrazide), sodium bicarbonate, and any combination thereof.

[0039] According to some further embodiments, the composite material 100 may comprise a specific content of a foaming agent component. For example, the composite material 100 may have a foaming agent component content of at least about 0.1 wt% of the total weight of the composite material 100, such as at least about 0.2 wt% or at least about 0.3 wt% or at least about 0.4 wt% or at least about 0.5 wt or at least about 0.6 wt% or at least about 0.7 wt% or at least about 0.8 wt% or at least about 0.9 wt% or at least about 1.0 wt% or at least about 1.5 wt% or even at least about 2.0 wt%. According to some further embodiments, the composite material 100 may have a foaming agent component content of not greater than about 5.0 wt% of the total weight of the composite material 100, such as not greater than about 4.9 wt% or not greater than about 4.8 wt% or not greater than about 4.7 wt% or not greater than about 4.6 wt% or not greater than about 4.5 wt% or not greater than about 4.4 wt% or not greater than about 4.3 wt% or not greater than about 4.2 wt% or not greater than about 4.1 wt% or even not greater than about 4.0 wt%. It should be understood that the composite material 100 may have a foaming agent component content of any value within the range between any of the above minimum and maximum values. It should also be understood that the composite material 100 may have a foaming agent component content of any value within the range between any of the above minimum and maximum values.

[0040] According to certain embodiments, the composite material 100 may have a specific flammability rating as measured according to ASTM D3801. In particular, the composite material 100 may have a V-0 flammability rating as measured according to ASTM D3801.

[0041] According to some further embodiments, the composite material 100 may have a specific 5-minute hot plate exposure (HPE) cold side temperature, as measured using a hot plate test conducted at 800 °C for 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm sample of the composite material laminated to a layer of E-glass fabric with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite material side of the sample faces the hot plate. The temperature at the center point of the cold side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured at the specified time using an infrared (IR) thermometer. According to certain embodiments, the composite material 100 may have a 5-minute HPE cold side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 5-minute HPE cold side temperature of at least about 25 °C. It should be understood that the 5-minute HPE cold side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 5-minute HPE cold side temperature of the composite material 100 may be any value between any of the above values.

[0042] According to some further embodiments, the composite material 100 may have a specific 15-minute hot plate exposure (HPE) cold side temperature, as measured using a hot plate test conducted at 800 °C for 15 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm sample of the composite material laminated to a layer of E-glass fabric with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite material side of the sample faces the hot plate. The temperature at the center point of the cold side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured at the specified time using an infrared (IR) thermometer. According to certain embodiments, the composite material 100 may have a 15-minute HPE cold side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 15-minute HPE cold side temperature of at least about 25 °C. It should be understood that the 15-minute HPE cold side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 15-minute HPE cold side temperature of the composite material 100 may be any value between any of the above values.

[0043] According to some further embodiments, the composite material 100 may have a specific 30-minute hot plate exposure (HPE) cold side temperature, as measured using a hot plate test conducted at 800 °C for 30 minutes. For the purposes of the embodiments described herein, the hot plate test is conducted by preparing a 15 cm × 25 cm sample of the composite material laminated to a layer of E-glass fabric with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite material side of the sample faces the hot plate. The temperature at the center point of the cold side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured using an infrared (IR) thermometer at the specified time. According to certain embodiments, the composite material 100 may have a 30-minute HPE cold side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 30-minute HPE cold side temperature of at least about 25 °C. It should be understood that the 30-minute HPE cold side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 30-minute HPE cold side temperature of the composite material 100 may be any value between any of the above values.

[0044] According to some further embodiments, the composite material 100 may have a specific 5-minute torch exposure (TE) cold-side temperature, as measured using a torch test conducted at 1300 °C for 5 minutes, and a layer of fiberglass with a thickness of 100 microns is covered on the material or composite material layer. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to an E-glass fabric layer with a thickness of 100 microns, such that the total sample thickness is 1.5 mm. The sample is fixed to a holder. The torch is placed 7 cm from the surface of the sample fixed to the holder, and the composite material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold-side surface of the sample (i.e., the side of the sample opposite the torch) is measured using an infrared (IR) thermometer or a thermocouple at the specified time. According to some embodiments, the composite material 100 may have a 5-minute TE cold-side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 5-minute TE cold-side temperature of at least about 25 °C. It should be understood that the 5-minute TE cold-side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 5-minute TE cold-side temperature of the composite material 100 may be any value between any of the above values.

[0045] According to some further embodiments, the composite material 100 may have a specific 15 - minute torch exposure (TE) cold - side temperature, as measured using a torch test conducted at 1300 °C for 15 minutes, and a layer of fiberglass with a thickness of 100 microns is covered on the material or the composite material layer. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to an E - glass fabric layer with a thickness of 100 microns, such that the total sample thickness is 1.5 mm. The sample is fixed to a holder. The torch is placed 7 cm from the surface of the sample fixed to the holder, and the composite - material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite - material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold - side surface of the sample (i.e., the side of the sample opposite the torch) is measured at a specified time using an infrared (IR) thermometer or a thermocouple. According to certain embodiments, the composite material 100 may have a 15 - minute TE cold - side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 15 - minute TE cold - side temperature of at least about 25 °C. It should be understood that the 15 - minute TE cold - side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 15 - minute TE cold - side temperature of the composite material 100 may be any value between any of the above values.

[0046] According to some further embodiments, the composite material 100 may have a specific 30-minute torch exposure (TE) cold-side temperature, as measured using a torch test conducted at 1300 °C for 30 minutes, and a layer of glass fiber with a thickness of 100 microns is covered on the material or composite material layer. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to a layer of E-glass fabric with a thickness of 100 microns, such that the total sample thickness is 1.5 mm. The sample is fixed to a bracket. The torch is placed 7 cm from the surface of the sample fixed to the bracket, and the composite material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold-side surface of the sample (i.e., the side of the sample opposite the torch) is measured at a specified time using an infrared (IR) thermometer or a thermocouple. According to certain embodiments, the composite material 100 may have a 30-minute TE cold-side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material 100 may have a 30-minute TE cold-side temperature of at least about 25 °C. It should be understood that the 30-minute TE cold-side temperature of the composite material 100 may be within the range between any of the above values. It should also be understood that the 30-minute TE cold-side temperature of the composite material 100 may be any value between any of the above values.

[0047] According to yet some other embodiments, the composite material 100 may have a specific density. For the purposes of the embodiments described herein, the density of the composite material 100 may be determined according to ASTM D1056. According to certain embodiments, the composite material 100 may have a density of no greater than about 1700 kg / m 3 such as no greater than about 1600 kg / m 3 or no greater than about 1500 kg / m 3 or no greater than about 1400 kg / m 3 or no greater than about 1300 kg / m 3 or no greater than about 1200 kg / m 3 or no greater than about 1100 kg / m 3 or no greater than about 1000 kg / m 3 or no greater than about 900 kg / m 3 or no greater than about 800 kg / m 3 or no greater than about 700 kg / m 3 or no greater than about 600 kg / m 3 or no greater than about 500 kg / m3 or even not greater than about 400 kg / m 3 According to yet other embodiments, composite material 100 may have a density of at least about 200 kg / m 3 . It should be understood that the density of composite material 100 may be within the range between any of the above minimum and maximum values. It should also be understood that the density of composite material 100 may be any value between any of the above minimum and maximum values.

[0048] According to yet other embodiments, composite material 100 may have a specific weight. According to certain embodiments, composite material 100 may have a weight of at least about 0.04 kg / m 2 such as at least about 0.1 kg / m 2 or at least about 0.2 kg / m 2 or at least about 0.3 kg / m 2 or at least about 0.4 kg / m 2 or at least about 0.5 kg / m 2 or at least about 1.0 kg / m 2 or even at least about 1.5 kg / m 2 According to yet other embodiments, composite material 100 may have a weight not greater than about 17 kg / m 2 . It should be understood that the weight of composite material 100 may be within the range between any of the above minimum and maximum values. It should also be understood that the weight of composite material 100 may be any value between any of the above minimum and maximum values.

[0049] According to yet other embodiments, composite material 100 may have a specific hardness. For the purposes of the embodiments described herein, the hardness of composite material 100 may be determined according to ASTM D2240. According to certain embodiments, composite material 100 may have a hardness of at least about 20 Shore 00, such as at least about 22 Shore 00 or at least about 23 Shore 00 or at least about 24 Shore 00 or even at least about 25 Shore 00. According to yet other embodiments, composite material 100 may have a hardness not greater than about 71 Shore A, such as not greater than about 70 Shore A or not greater than about 69 Shore A or not greater than about 68 Shore A or not greater than about 67 Shore A or even not greater than about 66 Shore A. It should be understood that the hardness of composite material 100 may be within the range between any of the above minimum and maximum values. It should also be understood that the hardness of composite material 100 may be any value between any of the above minimum and maximum values.

[0050] According to some further embodiments, the composite material 100 may have a specific tensile strength. For the purposes of the embodiments described herein, the tensile strength of the composite material 100 may be determined in accordance with ASTM D412. According to certain embodiments, the composite material 100 may have a tensile strength of at least about 0.3 MPa, such as at least about 0.5 MPa or at least about 1.0 MPa or at least about 10 MPa or at least about 20 MPa or at least about 30 MPa or at least about 40 MPa or at least about 50 MPa or at least about 100 MPa or even at least about 150 MPa. According to some further embodiments, the composite material 100 may have a tensile strength of not greater than about 500 MPa. It should be understood that the tensile strength of the composite material 100 may be within the range between any of the above minimum and maximum values. It should also be understood that the tensile strength of the composite material 100 may be any value between any of the above minimum and maximum values.

[0051] Now referring to embodiments of the composite material layer, the composite materials described herein may be formed as a layer of material. It should be understood that, according to specific embodiments, the composite material layer described herein may comprise any of the components described herein with reference to the composite material 100. It should also be understood that, according to specific embodiments, the composite material layer described herein may have any of the properties described herein with reference to the composite material 100.

[0052] According to some further embodiments, the composite material layer may have a specific thickness. For example, the composite material layer may have a thickness of at least about 0.2 mm, such as at least about 0.5 mm or at least about 1.0 mm or at least about 1.5 mm or at least about 2.0 mm or at least about 2.5 mm or at least about 3.0 mm or at least about 3.5 mm or at least about 4.0 mm or at least about 4.5 mm or even at least about 5.0 mm. According to some further embodiments, the composite material layer may have a thickness of not greater than about 10 mm, such as not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8.0 mm or not greater than about 7.5 mm or not greater than about 7.0 mm or not greater than about 6.5 mm or even not greater than about 6.0 mm. It should be understood that the thickness of the composite material layer may be within the range between any of the above minimum and maximum values. It should also be understood that the thickness of the composite material layer may be any value between any of the above minimum and maximum values.

[0053] According to certain embodiments, the composite material layer may have a specific flammability rating as measured in accordance with ASTM D3801. In particular, the composite material layer may have a V-0 flammability rating as measured in accordance with ASTM D3801.

[0054] According to some further embodiments, the composite material layer may have a specific 5 - minute hot plate exposure (HPE) cold - side temperature, as measured using a hot plate test conducted at 800 °C for 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm sample of the composite material laminated to a non - alkali glass fabric layer with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite - material side of the sample faces the hot plate. The temperature at the center point of the cold - side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured using an infrared (IR) thermometer at the specified time. According to some embodiments, the composite material layer may have a 5 - minute HPE cold - side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 5 - minute HPE cold - side temperature of at least about 25 °C. It should be understood that the 5 - minute HPE cold - side temperature of the composite material layer may be within the range between any of the above values. It should also be understood that the 5 - minute HPE cold - side temperature of the composite material layer may be any value between any of the above values.

[0055] According to some further embodiments, the composite material layer may have a specific 15 - minute hot plate exposure (HPE) cold - side temperature, as measured using a hot plate test conducted at 800 °C for 15 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm sample of the composite material laminated to a non - alkali glass fabric layer with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite - material side of the sample faces the hot plate. The temperature at the center point of the cold - side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured using an infrared (IR) thermometer at the specified time. According to some embodiments, the composite material layer may have a 15 - minute HPE cold - side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 15 - minute HPE cold - side temperature of at least about 25 °C. It should be understood that the 15 - minute HPE cold - side temperature of the composite material layer may be within the range between any of the above values. It should also be understood that the 15 - minute HPE cold - side temperature of the composite material layer may be any value between any of the above values.

[0056] According to some further embodiments, the composite material layer may have a specific 30-minute hot plate exposure (HPE) cold side temperature, as measured using a hot plate test conducted at 800 °C for 30 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm sample of the composite material laminated to a layer of E-glass fabric with a thickness of 0.3 mm, such that the total sample thickness is 1.5 mm. The sample is placed on top of a hot plate adjusted to the desired temperature, and the composite material side of the sample faces the hot plate. The temperature at the center point of the cold side surface of the sample (i.e., the side of the sample opposite the hot plate) is measured at a specified time using an infrared (IR) thermometer. According to certain embodiments, the composite material layer may have a 30-minute HPE cold side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 30-minute HPE cold side temperature of at least about 25 °C. It should be understood that the 30-minute HPE cold side temperature of the composite material layer may be within the range between any of the above values. It should also be understood that the 30-minute HPE cold side temperature of the composite material layer may be any value between any of the above values.

[0057] According to some further embodiments, the composite material layer may have a specific 5-minute torch exposure (TE) cold side temperature, as measured using a torch test conducted at 1300 °C for 5 minutes, and the material or composite material layer is covered with a layer of fiberglass having a thickness of 100 microns. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to a layer of E-glass fabric having a thickness of 100 microns such that the total sample thickness is 1.5 mm. The sample is fixed to a holder. The torch is placed 7 cm from the surface of the sample fixed to the holder, and the composite material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold side surface of the sample (i.e., the side of the sample opposite the torch) is measured at the specified time using an infrared (IR) thermometer or a thermocouple. According to certain embodiments, the composite material layer may have a 5-minute TE cold side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 5-minute TE cold side temperature of at least about 25 °C. It should be understood that the 5-minute TE cold side temperature of the composite material layer may be within the range between any of the above values. It should also be understood that the 5-minute TE cold side temperature of the composite material layer may be any value between any of the above values.

[0058] According to some further embodiments, the composite material layer may have a specific 15-minute torch exposure (TE) cold-side temperature, as measured using a torch test conducted at 1300 °C for 15 minutes, and the material or composite material layer is covered with a layer of fiberglass having a thickness of 100 microns. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to a layer of E-glass fabric having a thickness of 100 microns such that the total sample thickness is 1.5 mm. The sample is fixed to a holder. The torch is placed 7 cm from the surface of the sample fixed to the holder, and the composite material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold-side surface of the sample (i.e., the side of the sample opposite the torch) is measured at a specified time using an infrared (IR) thermometer or a thermocouple. According to certain embodiments, the composite material layer may have a 15-minute TE cold-side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 15-minute TE cold-side temperature of at least about 25 °C. It should be understood that the 15-minute TE cold-side temperature of the composite material layer may be within a range between any of the above values. It should also be understood that the 15-minute TE cold-side temperature of the composite material layer may be any value between any of the above values.

[0059] According to some further embodiments, the composite material layer may have a specific 30-minute torch exposure (TE) cold-side temperature, as measured using a torch test conducted at 1300 °C for 30 minutes. For the purposes of the embodiments described herein, the torch test is performed on a 15 cm × 15 cm sample of the composite material laminated to a E-glass fabric layer having a thickness of 100 microns, such that the total sample thickness is 1.5 mm. The sample is fixed to a holder. The torch is placed 7 cm from the surface of the sample fixed to the holder, and the composite material side of the sample faces the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the sample, and the external flame reaches and stabilizes at the desired temperature, as measured using a thermometer at the point where the flame touches the sample. The temperature at the center point of the cold-side surface of the sample (i.e., the side of the sample opposite the torch) is measured at a specified time using an infrared (IR) thermometer or a thermocouple. According to certain embodiments, the composite material layer may have a 30-minute TE cold-side temperature of no greater than about 800 °C, such as no greater than about 775 °C or no greater than about 750 °C or no greater than about 725 °C or no greater than about 700 °C or no greater than about 675 °C or no greater than about 650 °C or no greater than about 625 °C or even no greater than about 600 °C. According to some further embodiments, the composite material layer may have a 30-minute TE cold-side temperature of at least about 25 °C. It should be understood that the 30-minute TE cold-side temperature of the composite material layer may be within the range between any of the above values. It should also be understood that the 30-minute TE cold-side temperature of the composite material layer may be any value between any of the above values.

[0060] According to yet some further embodiments, the composite material layer may have a specific density. For the purposes of the embodiments described herein, the density of the composite material layer may be determined in accordance with ASTM D1056. According to certain embodiments, the composite material layer may have a density of no greater than about 1700 kg / m 3 such as no greater than about 1600 kg / m 3 or no greater than about 1500 kg / m 3 or no greater than about 1400 kg / m 3 or no greater than about 1300 kg / m 3 or no greater than about 1200 kg / m 3 or no greater than about 1100 kg / m 3 or no greater than about 1000 kg / m 3 or no greater than about 900 kg / m 3 or no greater than about 800 kg / m 3 or no greater than about 700 kg / m 3 or no greater than about 600 kg / m 3 or no greater than about 500 kg / m 3 or even no greater than about 400 kg / m 3According to some further embodiments, the composite layer may have a density of at least about 200 kg / m 3 It should be understood that the density of the composite layer may be within the range between any of the above minimum and maximum values. It should also be understood that the density of the composite layer may be any value between any of the above minimum and maximum values.

[0061] According to some further embodiments, the composite layer may have a specific weight. According to certain embodiments, the composite layer may have a weight of at least about 0.04 kg / m 2 such as at least about 0.1 kg / m 2 or at least about 0.2 kg / m 2 or at least about 0.3 kg / m 2 or at least about 0.4 kg / m 2 or at least about 0.5 kg / m 2 or at least about 1.0 kg / m 2 or even at least about 1.5 kg / m 2 According to some further embodiments, the composite layer may have a weight not greater than about 17 kg / m 2 It should be understood that the weight of the composite layer may be within the range between any of the above minimum and maximum values. It should also be understood that the weight of the composite layer may be any value between any of the above minimum and maximum values.

[0062] According to some further embodiments, the composite layer may have a specific hardness. For the purposes of the embodiments described herein, the hardness of the composite layer may be determined according to ASTM D2240. According to certain embodiments, the composite layer may have a hardness of at least about 20 Shore 00, such as at least about 22 Shore 00 or at least about 23 Shore 00 or at least about 24 Shore 00 or even at least about 25 Shore 00. According to some further embodiments, the composite layer may have a hardness not greater than about 71 Shore A, such as not greater than about 70 Shore A or not greater than about 69 Shore A or not greater than about 68 Shore A or not greater than about 67 Shore A or even not greater than about 66 Shore A. It should be understood that the hardness of the composite layer may be within the range between any of the above minimum and maximum values. It should also be understood that the hardness of the composite layer may be any value between any of the above minimum and maximum values.

[0063] According to some further embodiments, the composite material layer may have a specific tensile strength. For the purposes of the embodiments described herein, the tensile strength of the composite material layer may be determined in accordance with ASTM D412. According to certain embodiments, the composite material layer may have a tensile strength of at least about 0.3 MPa, such as at least about 0.5 MPa or at least about 1.0 MPa or at least about 10 MPa or at least about 20 MPa or at least about 30 MPa or at least about 40 MPa or at least about 50 MPa or at least about 100 MPa or even at least about 150 MPa. According to some further embodiments, the composite material layer may have a tensile strength of not greater than about 500 MPa. It should be understood that the tensile strength of the composite material layer may be within the range between any of the above minimum and maximum values. It should also be understood that the tensile strength of the composite material layer may be any value between any of the above minimum and maximum values.

[0064] According to certain embodiments, the composite material layer described herein may be formed according to any acceptable forming process for the composite material layer.

[0065] Turning now to further embodiments described herein, such embodiments generally relate to a battery exhaust protection composite material that may comprise a composite material or a composite material layer as described herein. It should be understood that, according to specific embodiments, the battery exhaust protection composite material described herein may comprise any of the components referred to herein with reference to Composite Material 100. It should also be understood that, according to specific embodiments, the battery exhaust protection composite material described herein may have any of the properties referred to herein with reference to Composite Material 100.

[0066] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, those skilled in the art will recognize that those aspects and embodiments are merely illustrative and do not limit the scope of the invention. Embodiments may be according to any one or more of the embodiments listed below.

[0067] Embodiment 1. A composite material comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramizable filler composition distributed within the silicone-based matrix component, wherein the ceramizable filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of not greater than about 5%, as measured at 100 °C at 50% compression for 22 hours.

[0068] Embodiment 2. A composite material layer comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifying filler composition distributed within the silicone-based matrix component, wherein the ceramifying filler composition comprises: a ceramifying filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of no greater than about 5%, as measured at 100 °C at 50% compression for 22 hours.

[0069] Embodiment 3. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material further comprises a blowing agent component distributed within the silicone-based matrix component.

[0070] Embodiment 4. The composite material or composite material layer according to Embodiment 3, wherein the blowing agent composition comprises components selected from 2,2'-azobis(2-methylpropionitrile), N,N'-dinitrosopentamethylenetetramine, N,N'-dimethyl-N,N'-dinitrosoterephthalamide, 4,4'-oxybis(benzenesulfonylhydrazide), sodium bicarbonate, and any combination thereof.

[0071] Embodiment 5. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material further comprises a platinum complex hydrosilylation catalyst distributed within the silicone-based matrix component.

[0072] Embodiment 6. The composite material or composite material layer according to Embodiment 5, wherein the composite material has a platinum complex hydrosilylation catalyst content of at least about 3 ppm of the composite material.

[0073] Embodiment 7. The composite material or composite material layer according to Embodiment 5, wherein the composite material has a platinum complex hydrosilylation catalyst content and is no greater than about 50 ppm.

[0074] Embodiment 8. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the reinforcing filler component comprises silica, silicone resin, carbon black, calcium carbonate, or any combination thereof.

[0075] Embodiment 9. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a reinforcing filler component content of at least about 2.0% by weight of the total weight of the composite material.

[0076] Embodiment 10. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a reinforcing filler component content of no greater than about 20.0% by weight of the total weight of the composite material.

[0077] Embodiment 11. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the silicone-based matrix component comprises polydimethylsiloxane gum having an average molecular weight between 300,000 and 800,000, or a liquid polydimethylsiloxane polymer having a viscosity between 50 cst and 100,000 cst.

[0078] Embodiment 12. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the silicone-based matrix component comprises vinyl and Si-hydrogen groups, and the vinyl and Si-hydrogen groups can react with each other in the presence of a platinum catalyst.

[0079] Embodiment 13. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a silicone-based matrix component content of at least about 30% by weight of the total weight of the composite material.

[0080] Embodiment 14. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a silicone-based matrix component content of not more than about 60% by weight of the total weight of the composite material.

[0081] Embodiment 15. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a ceramizable filler composition content of at least about 40% by weight of the total weight of the composite material.

[0082] Embodiment 16. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a ceramizable filler composition component content of not more than about 70% by weight of the total weight of the composite material.

[0083] Embodiment 17. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler component comprises a component selected from sepiolite, wollastonite, or any combination thereof.

[0084] Embodiment 18. The composite material or composite material layer according to Embodiment 17, wherein the ceramizable filler component has an aspect ratio (length / diameter) of not more than about 10.

[0085] Embodiment 19. The composite material or composite material layer according to Embodiment 17, wherein the ceramizable filler component has an aspect ratio (length / diameter) of at least about 2.

[0086] Embodiment 20. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a ceramizable filler component content of at least about 50% by weight of the total weight of the ceramizable filler composition.

[0087] Embodiment 21. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a ceramizable filler component content of not more than about 95% by weight based on the total weight of the ceramizable filler composition.

[0088] Embodiment 22. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a ceramizable filler component content of at least about 40% by weight based on the total weight of the composite material.

[0089] Embodiment 23. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a ceramizable filler component content of not more than about 70% by weight based on the total weight of the composite material.

[0090] Embodiment 24. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the structure promoter component comprises a component selected from crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0091] Embodiment 25. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a structure promoter component content of at least about 0.1% by weight based on the total weight of the ceramizable filler composition.

[0092] Embodiment 26. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a structure promoter component content of not more than about 7.0% by weight based on the total weight of the ceramizable filler composition.

[0093] Embodiment 27. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a structure promoter component content of at least about 0.05% by weight based on the total weight of the composite material.

[0094] Embodiment 28. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a structure promoter component content of not more than about 5% by weight based on the total weight of the composite material.

[0095] Embodiment 29. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the flux component comprises a component selected from low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth trioxide, or any combination thereof.

[0096] Embodiment 30. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flux component content of at least about 0.1% by weight based on the total weight of the ceramizable filler composition.

[0097] Embodiment 31. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flux component content of not more than about 7.0% by weight based on the total weight of the ceramizable filler composition.

[0098] Embodiment 32. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flux component content of at least about 0.05% by weight based on the total weight of the composite material.

[0099] Embodiment 33. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flux component content of not more than about 5% by weight based on the total weight of the composite material.

[0100] Embodiment 34. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the flame retardant component comprises a component selected from aluminum hydroxide, magnesium hydroxide, expanded graphite, platinum (Pt) complex, or any combination thereof.

[0101] Embodiment 35. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flame retardant component content of at least about 5.0% by weight based on the total weight of the ceramizable filler composition.

[0102] Embodiment 36. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flame retardant component content of not more than about 20.0% by weight based on the total weight of the ceramizable filler composition.

[0103] Embodiment 37. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flame retardant component content of at least about 2.5% by weight based on the total weight of the composite material.

[0104] Embodiment 38. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition has a flame retardant component content of not more than 10% by weight based on the total weight of the composite material.

[0105] Embodiment 39. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the ceramizable filler composition further comprises a functional additive.

[0106] Embodiment 40. The composite material or composite material layer according to Embodiment 39, wherein the functional additive comprises a component selected from iron(III) oxide, titanium oxide, or any combination thereof.

[0107] Embodiment 41. The composite material or composite material layer according to Embodiment 39, wherein the ceramifiable filler composition has a functional additive content of at least about 0.1% by weight based on the total weight of the ceramifiable filler composition.

[0108] Embodiment 42. The composite material or composite material layer according to Embodiment 39, wherein the ceramifiable filler composition has a functional additive content of not more than about 7.0% by weight based on the total weight of the ceramifiable filler composition.

[0109] Embodiment 43. The composite material or composite material layer according to Embodiment 39, wherein the ceramifiable filler composition has a functional additive content of at least about 0.05% by weight based on the total weight of the composite material.

[0110] Embodiment 44. The composite material or composite material layer according to Embodiment 39, wherein the ceramifiable filler composition has a functional additive content of not more than about 5% by weight based on the total weight of the composite material.

[0111] Embodiment 45. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the material layer has a thickness of at least about 0.2 mm.

[0112] Embodiment 46. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the material layer has a thickness of not more than about 3.0 mm.

[0113] Embodiment 47. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a density of not more than about 1700 kg / m 3 of density.

[0114] Embodiment 48. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a density of at least about 200 kg / m 3 of density.

[0115] Embodiment 49. The composite material layer according to Embodiment 46, wherein the material layer has a density of not more than about 1700 kg / m 3 of density.

[0116] Embodiment 50. The composite material layer according to Embodiment 46, wherein the material layer has a density of at least about 200 kg / m3 Density.

[0117] Embodiment 51. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a weight of at least about 0.04 kg / m 2 Weight.

[0118] Embodiment 52. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a weight of not more than about 17 kg / m 2 Weight.

[0119] Embodiment 53. The composite material layer according to Embodiment 46, wherein the material layer has a weight of at least about 0.04 kg / m 2 Weight.

[0120] Embodiment 54. The composite material layer according to Embodiment 46, wherein the material layer has a weight of not more than about 17 kg / m 2 Weight.

[0121] Embodiment 55. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a hardness of at least about 20 Shore 00.

[0122] Embodiment 56. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a hardness of not more than about 71 Shore A.

[0123] Embodiment 57. The composite material layer according to Embodiment 46, wherein the material layer has a hardness of at least about 20 Shore 00.

[0124] Embodiment 58. The composite material layer according to Embodiment 46, wherein the material layer has a hardness of not more than about 71 Shore A.

[0125] Embodiment 59. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a tensile strength of at least about 0.3 MPa.

[0126] Embodiment 60. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material has a tensile strength of not more than about 500 MPa.

[0127] Embodiment 61. The composite material layer according to Embodiment 46, wherein the material layer has a tensile strength of at least about 0.3 MPa.

[0128] Embodiment 62. The composite material layer according to Embodiment 46, wherein the material layer has a tensile strength of not more than about 500 MPa.

[0129] Embodiment 63. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 5-minute HPE cold-side temperature of no greater than about 800 °C, as measured after a 5-minute hot plate test at 800 °C.

[0130] Embodiment 64. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 15-minute HPE cold-side temperature of no greater than about 800 °C, as measured after a 15-minute hot plate test at 800 °C.

[0131] Embodiment 65. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 30-minute HPE cold-side temperature of no greater than about 800 °C, as measured after a 30-minute hot plate test at 800 °C.

[0132] Embodiment 66. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 5-minute TE cold-side temperature of no greater than about 800 °C, as measured after a 5-minute torch test at 1300 °C, and the material or composite material layer is covered with a layer of glass fiber with a thickness of 100 microns.

[0133] Embodiment 67. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 15-minute TE cold-side temperature of no greater than about 800 °C, as measured after a 15-minute torch test at 1300 °C, and the material or composite material layer is covered with a layer of glass fiber with a thickness of 100 microns.

[0134] Embodiment 68. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a 30-minute TE cold-side temperature of no greater than about 800 °C, as measured after a 30-minute torch test at 1300 °C, and the material or composite material layer is covered with a layer of glass fiber with a thickness of 100 microns.

[0135] Embodiment 69. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a V-0 flammability rating as measured according to ASTM D3801.

[0136] Embodiment 70. The composite material or composite material layer according to any one of Embodiments 1 and 2, wherein the composite material or composite material layer has a thermal conductivity of no greater than about 0.20 W / mk.

[0137] Embodiment 71. A battery exhaust protection composite material, comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifiable filler composition distributed within the silicone-based matrix component, wherein the ceramifiable filler composition comprises: a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of no more than about 5%, as measured at 100 °C at 50% compression for 22 hours.

[0138] Embodiment 72. A battery exhaust protection composite material layer, comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramifiable filler composition distributed within the silicone-based matrix component, wherein the ceramifiable filler composition comprises: a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of no more than about 5%, as measured at 100 °C at 50% compression for 22 hours.

[0139] Embodiment 73. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material further comprises a blowing agent component distributed within the silicone-based matrix component.

[0140] Embodiment 74. The battery exhaust protection composite material or composite material layer according to Embodiment 73, wherein the blowing agent composition comprises components selected from 2,2'-azobis(2-methylpropionitrile), N,N'-dinitrosopentamethylenetetramine, N,N'-dimethyl-N,N'-dinitrosoterephthalamide, 4,4'-oxybis(benzenesulfonylhydrazide), sodium bicarbonate, and any combination thereof.

[0141] Embodiment 75. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material further comprises a platinum complex hydrosilylation catalyst distributed within the silicone-based matrix component.

[0142] Embodiment 76. The battery exhaust protection composite material or composite material layer according to Embodiment 75, wherein the composite material has a platinum complex hydrosilylation catalyst content of at least about 3 ppm of the composite material.

[0143] Embodiment 77. The battery exhaust protection composite material or composite material layer according to Embodiment 75, wherein the composite material has a platinum complex hydrosilylation catalyst content and is no more than about 50 ppm.

[0144] Embodiment 78. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the reinforcing filler component comprises silica, silicone resin, carbon black, calcium carbonate, or any combination thereof.

[0145] Embodiment 79. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a reinforcing filler component content of at least about 2.0% by weight of the total weight of the composite material.

[0146] Embodiment 80. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a reinforcing filler component content of not more than about 20.0% by weight of the total weight of the composite material.

[0147] Embodiment 81. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the silicone-based matrix component comprises polydimethylsiloxane gum having an average molecular weight between 300,000 and 800,000, or a liquid polydimethylsiloxane polymer having a viscosity between 50 cst and 100,000 cst.

[0148] Embodiment 82. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the silicone-based matrix component comprises vinyl and Si-hydrogen groups, and the vinyl and Si-hydrogen groups can react with each other in the presence of a platinum catalyst.

[0149] Embodiment 83. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a silicone-based matrix component content of at least about 30% by weight of the total weight of the composite material.

[0150] Embodiment 84. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a silicone-based matrix component content of not more than about 60% by weight of the total weight of the composite material.

[0151] Embodiment 85. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a ceramizable filler composition content of at least about 40% by weight of the total weight of the composite material.

[0152] Embodiment 86. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material has a ceramizable filler composition content of not more than about 70% by weight of the total weight of the composite material.

[0153] Embodiment 87. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler component comprises a component selected from sepiolite, wollastonite, or any combination thereof.

[0154] Embodiment 88. The battery exhaust protection composite material or composite material layer according to Embodiment 87, wherein the ceramizable filler component has an aspect ratio (length / diameter) of not greater than about 10.

[0155] Embodiment 89. The battery exhaust protection composite material or composite material layer according to Embodiment 87, wherein the ceramizable filler component has an aspect ratio (length / diameter) of at least about 2.

[0156] Embodiment 90. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a ceramizable filler component content of at least about 50% by weight based on the total weight of the ceramizable filler composition.

[0157] Embodiment 91. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a ceramizable filler component content of not greater than about 95% by weight based on the total weight of the ceramizable filler composition.

[0158] Embodiment 92. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a ceramizable filler component content of at least about 40% by weight based on the total weight of the composite material.

[0159] Embodiment 93. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a ceramizable filler component content of not greater than about 70% by weight based on the total weight of the composite material.

[0160] Embodiment 94. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the structure promoter component comprises a component selected from crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0161] Embodiment 95. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a structure promoter component content of at least about 0.1% by weight based on the total weight of the ceramizable filler composition.

[0162] Embodiment 96. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a structural promoter component content of not more than about 7.0% by weight of the total weight of the ceramizable filler composition.

[0163] Embodiment 97. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a structural promoter component content of at least about 0.05% by weight of the total weight of the composite material.

[0164] Embodiment 98. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a structural promoter component content of not more than about 5% by weight of the total weight of the composite material.

[0165] Embodiment 99. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the flux component comprises a component selected from low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth trioxide, or any combination thereof.

[0166] Embodiment 100. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flux component content of at least about 0.1% by weight of the total weight of the ceramizable filler composition.

[0167] Embodiment 101. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flux component content of not more than about 7.0% by weight of the total weight of the ceramizable filler composition.

[0168] Embodiment 102. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flux component content of at least about 0.05% by weight of the total weight of the composite material.

[0169] Embodiment 103. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flux component content of not more than about 5% by weight of the total weight of the composite material.

[0170] Embodiment 104. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the flame retardant component comprises a component selected from aluminum hydroxide, magnesium hydroxide, expanded graphite, platinum (Pt) complex, or any combination thereof.

[0171] Embodiment 105. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flame retardant component content of at least about 5.0% by weight based on the total weight of the ceramizable filler composition.

[0172] Embodiment 106. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flame retardant component content of not more than about 20.0% by weight based on the total weight of the ceramizable filler composition.

[0173] Embodiment 107. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flame retardant component content of at least about 2.5% by weight based on the total weight of the composite material.

[0174] Embodiment 108. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition has a flame retardant component content of not more than 10% by weight based on the total weight of the composite material.

[0175] Embodiment 109. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the ceramizable filler composition further comprises a functional additive.

[0176] Embodiment 110. The battery exhaust protection composite material or composite material layer according to Embodiment 109, wherein the functional additive comprises a component selected from iron(III) oxide, titanium oxide, or any combination thereof.

[0177] Embodiment 111. The battery exhaust protection composite material or composite material layer according to Embodiment 109, wherein the ceramizable filler composition has a functional additive content of at least about 0.1% by weight based on the total weight of the ceramizable filler composition.

[0178] Embodiment 112. The battery exhaust protection composite material or composite material layer according to Embodiment 109, wherein the ceramizable filler composition has a functional additive content of not more than about 7.0% by weight based on the total weight of the ceramizable filler composition.

[0179] Embodiment 113. The battery exhaust protection composite material or composite material layer according to Embodiment 109, wherein the ceramizable filler composition has a functional additive content of at least about 0.05% by weight based on the total weight of the composite material.

[0180] Embodiment 114. The battery exhaust protection composite material or composite material layer according to Embodiment 109, wherein the ceramizable filler composition has a functional additive content of not more than about 5% by weight based on the total weight of the composite material.

[0181] Embodiment 115. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the material layer has a thickness of at least about 0.2 mm.

[0182] Embodiment 116. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the material layer has a thickness of not more than about 3.0 mm.

[0183] Embodiment 117. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a density of not more than about 1700 kg / m 3 of density.

[0184] Embodiment 118. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a density of at least about 200 kg / m 3 of density.

[0185] Embodiment 119. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a density of not more than about 1700 kg / m 3 of density.

[0186] Embodiment 120. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a density of at least about 200 kg / m 3 of density.

[0187] Embodiment 121. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a weight of at least about 0.04 kg / m 2 of weight.

[0188] Embodiment 122. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a weight of not more than about 17 kg / m 2 of weight.

[0189] Embodiment 123. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a weight of at least about 0.04 kg / m 2 of weight.

[0190] Embodiment 124. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a weight of not greater than about 17 kg / m 2 of weight.

[0191] Embodiment 125. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a hardness of at least about 20 Shore 00.

[0192] Embodiment 126. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a hardness of not greater than about 71 Shore A.

[0193] Embodiment 127. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a hardness of at least about 20 Shore 00.

[0194] Embodiment 128. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a hardness of not greater than about 71 Shore A.

[0195] Embodiment 129. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a tensile strength of at least about 0.3 MPa.

[0196] Embodiment 130. The battery exhaust protection composite material layer according to Embodiment 71, wherein the composite material has a tensile strength of not greater than about 500 MPa.

[0197] Embodiment 131. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a tensile strength of at least about 0.3 MPa.

[0198] Embodiment 132. The battery exhaust protection composite material layer according to Embodiment 72, wherein the material layer has a tensile strength of not greater than about 500 MPa.

[0199] Embodiment 133. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 5-minute HPE cold side temperature of not greater than about 800 °C, as measured after a 5-minute hot plate test at 800 °C.

[0200] Embodiment 134. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 15-minute HPE cold-side temperature of no more than about 800 °C, as measured after a 15-minute hot plate test at 800 °C.

[0201] Embodiment 135. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 30-minute HPE cold-side temperature of no more than about 800 °C, as measured after a 30-minute hot plate test at 800 °C.

[0202] Embodiment 136. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 5-minute TE cold-side temperature of no more than about 800 °C, as measured after a 5-minute torch test at 1300 °C, and a layer of glass fiber with a thickness of 100 microns is covered on the material or composite material layer.

[0203] Embodiment 137. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 15-minute TE cold-side temperature of no more than about 800 °C, as measured after a 15-minute torch test at 1300 °C, and a layer of glass fiber with a thickness of 100 microns is covered on the material or composite material layer.

[0204] Embodiment 138. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a 30-minute TE cold-side temperature of no more than about 800 °C, as measured after a 30-minute torch test at 1300 °C, and a layer of glass fiber with a thickness of 100 microns is covered on the material or composite material layer.

[0205] Embodiment 139. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the battery exhaust protection composite material or composite material layer has a V-0 flammability rating as measured according to ASTM D3801.

[0206] Embodiment 140. The battery exhaust protection composite material or composite material layer according to any one of Embodiments 71 and 72, wherein the composite material or composite material layer has a thermal conductivity of no more than about 0.20 W / mk.

[0207] Note that not all activities described above in the general description or the examples are required, some of the specific activities may not be required, and one or more additional activities may be provided in addition to those described. Further, the order in which the activities are listed is not necessarily the order in which the activities are performed.

[0208] The benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, these benefits, advantages, solutions to problems, and any features that may cause any benefit, advantage, or solution to occur or become more pronounced should not be construed as critical, required, or essential features of any or all of the claims.

[0209] The description and illustration of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and illustration are not intended to be an exhaustive and comprehensive description of all elements and features of the apparatus and systems using the structures or methods described herein. The separate embodiments may also be provided in combination in a single embodiment, and conversely, the various features described in the context of a single embodiment may also be provided separately or in any sub-combination. In addition, references to values stated in ranges include each value within that range. Many other embodiments will be apparent to those skilled in the art only after they have read this specification. Other embodiments may be used and other embodiments may be derived from this disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the present invention. Accordingly, this disclosure should be considered illustrative and not restrictive.

Claims

1. A composite material, the composite material comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramizable filler composition distributed within the silicone-based matrix component, wherein the ceramizable filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of no more than about 5%, as measured at 100 °C at 50% compression for 22 hours.

2. A composite material layer, the composite material layer comprising: a silicone-based matrix component, a reinforcing filler component distributed within the silicone-based matrix component, and a ceramizable filler composition distributed within the silicone-based matrix component, wherein the ceramizable filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component, and wherein the composite material has a compression set of no more than about 5%, as measured at 100 °C at 50% compression for 22 hours.

3. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material further comprises a blowing agent component distributed within the silicone-based matrix component.

4. The composite material or composite material layer according to claim 3, wherein the blowing agent composition comprises components selected from 2,2'-azobis(2-methylpropionitrile), N,N'-dinitrosopentamethylenetetramine, N,N'-dimethyl-N,N'-dinitrosoterephthalamide, 4,4'-oxybis(benzenesulfonylhydrazide), sodium bicarbonate, and any combination thereof.

5. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material further comprises a platinum complex hydrosilylation catalyst distributed within the silicone-based matrix component.

6. The composite material or composite material layer according to claim 5, wherein the composite material has a platinum complex hydrosilylation catalyst content of at least about 3 ppm of the composite material.

7. The composite material or composite material layer according to claim 5, wherein the composite material has a platinum complex hydrosilylation catalyst content and is no more than about 50 ppm.

8. The composite material or composite material layer according to any one of claims 1 and 2, wherein the reinforcing filler component comprises silica, silicone resin, carbon black, calcium carbonate, or any combination thereof.

9. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material has a reinforcing filler component content of at least about 2.0% by weight of the total weight of the composite material.

10. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material has a reinforcing filler component content of no more than about 20.0% by weight of the total weight of the composite material.

11. The composite material or composite material layer according to any one of claims 1 and 2, wherein the silicone-based matrix component comprises a polydimethylsiloxane gum having an average molecular weight between 300,000 and 800,000, or a liquid polydimethylsiloxane polymer having a viscosity between 50 cst and 100,000 cst.

12. The composite material or composite material layer according to any one of claims 1 and 2, wherein the silicone-based matrix component comprises vinyl and Si-hydrogen groups, and the vinyl and Si-hydrogen groups can react with each other in the presence of a platinum catalyst.

13. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material has a silicone-based matrix component content of at least about 30% by weight of the total weight of the composite material.

14. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material has a silicone-based matrix component content of not more than about 60% by weight of the total weight of the composite material.

15. The composite material or composite material layer according to any one of claims 1 and 2, wherein the composite material has a ceramizable filler composition content of at least about 40% by weight of the total weight of the composite material.

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