Filler composition with thermal barrier properties, composite material and composite material layer

Abstract

The invention relates to a filler composition with thermal barrier property, a composite material and a composite material layer. The invention relates to a filler composition. The filler composition may include a ceramized filler component in an amount of at least about 75 wt% and not greater than about 95 wt% based on the total weight of the filler composition, a structure promoter component in an amount of at least about 0.1 wt% and not greater than about 7.0 wt% based on the total weight of the filler composition, a flux component in an amount of at least about 0.1 wt% and not greater than about 7.0 wt% based on the total weight of the filler composition; and a flame retardant component in an amount of at least about 5.0 wt% and not greater than about 20.0 wt% based on the total weight of the filler composition.

Description

Technical Field

[0001] The present disclosure relates to a filler composition, a composite material, and a composite material layer, and particularly to a filler composition, a composite material, and a composite material layer used as a thermal barrier in various applications (e.g., in a battery pack) and methods for forming the same. Background Art

[0002] Filler compositions, composite materials, and composite material layers can be designed for high-temperature protection in various applications, e.g., as a thermal barrier in an electric vehicle battery pack, a thermal barrier covering in high-temperature cable protection, a thermal barrier container for thermal spray containment, etc. However, in these and other applications, due to technological improvements, potential heat growth continues to increase. Thus, 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, the filler composition can include: a ceramifiable filler component in an amount of at least about 75 wt% and no greater than about 95 wt% of the total weight of the filler composition, a structure promoter component in an amount of at least about 0.1 wt% and no greater than about 7.0 wt% of the total weight of the filler composition, a flux component in an amount of at least about 0.1 wt% and no greater than about 7.0 wt% of the total weight of the filler composition, and a flame retardant component in an amount of at least about 5.0 wt% and no greater than about 20.0 wt% of the total weight of the filler composition.

[0004] According to yet another aspect, the composite material can include a polymer-based matrix component and a filler composition distributed within the polymer-based component. The filler composition can include a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0005] According to still another aspect, the composite material layer can include: a polymer-based matrix component and a filler composition distributed within the polymer-based component. The filler composition can include a ceramifiable filler component, a structure promoter component, a flux component, and a flame retardant component. Brief Description of the Drawings

[0006] Embodiments are illustrated by way of example and are not limited to the drawings.

[0007] Figure 1 Diagrams including exemplary composite materials according to certain embodiments described herein.

[0008] 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

[0009] The following discussion will focus on specific embodiments and implementations of the teachings. A detailed description is provided to assist in describing certain embodiments and should not be construed as limiting the scope or applicability of the disclosure or teachings. It should be understood that other embodiments may be utilized based on the disclosure and teachings provided herein.

[0010] The terms "comprising", "including", "having" or any other variant thereof are intended to cover non-exclusive inclusion. For example, a method, article or apparatus that comprises a series of features need not be 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).

[0011] Additionally, the articles "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. The description should be understood to include one, at least one or the singular, and also the plural, or vice versa, unless clearly indicated 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 substituted for the more than one item.

[0012] The embodiments described herein generally relate to a filler composition, a composite material that may comprise the filler composition, or a composite material layer that may comprise the filler composition.

[0013] Referring first to an embodiment of the filler composition, the filler composition may comprise a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0014] According to a specific embodiment, the ceramizable filler component may include specific components. For example, the ceramizable filler component may include components selected from the group consisting of sepiolite, wollastonite, or any combination thereof. According to still other embodiments, the ceramizable filler component may include sepiolite. According to yet other embodiments, the ceramizable filler component may consist of sepiolite. According to still other embodiments, the ceramizable filler component may include wollastonite. According to yet other embodiments, the ceramizable filler component may consist of wollastonite. According to still other embodiments, the ceramizable filler component may include a combination of sepiolite and wollastonite. According to yet other embodiments, the ceramizable filler component may consist of a combination of sepiolite and wollastonite.

[0015] According to still other embodiments, the ceramifiable filler component may be multiple particles. According to still other 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 the multiple particles of the ceramifiable filler component divided by the average diameter of a statistically significant number of the multiple particles of the ceramifiable filler component (L / D). 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 still other 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 values and any of the above maximum values. It should also be understood that the ceramifiable filler component may have an aspect ratio of any value within the range between any of the above minimum values and any of the above maximum values.

[0016] According to still other embodiments, the filler composition may comprise a specific content of the ceramifiable filler component. For example, the filler composition may comprise at least about 75 wt%, such as at least about 76 wt%, or at least about 77 wt%, or at least about 78 wt%, or at least about 79 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% of the ceramifiable filler component content based on the total weight of the filler composition. According to still other embodiments, the filler composition may comprise no greater than about 95 wt%, 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% of the ceramifiable filler component content based on the total weight of the filler composition. It should be understood that the filler composition may comprise a ceramifiable filler component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition may comprise a ceramifiable filler component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0017] According to specific embodiments, the structure promoter component may include specific components. For example, the structure promoter component may include components selected from the group consisting of: crystalline silica, diopside, spodumene, red mica, lithium carbonate, lithium hydroxide, or any combination thereof. According to still other embodiments, the structure promoter component may include crystalline silica. According to yet other embodiments, the structure promoter component may consist of crystalline silica. According to still other embodiments, the structure promoter component may include diopside. According to yet other embodiments, the structure promoter component may consist of diopside. According to still other embodiments, the structure promoter component may include spodumene. According to yet other embodiments, the structure promoter component may consist of spodumene. According to still other embodiments, the structure promoter component may include red mica. According to yet other embodiments, the structure promoter component may consist of red mica. According to still other embodiments, the structure promoter component may include lithium carbonate. According to yet other embodiments, the structure promoter component may consist of lithium carbonate. According to still other embodiments, the structure promoter component may include lithium hydroxide. According to yet other embodiments, the structure promoter component may consist of lithium hydroxide.

[0018] According to still other embodiments, the filler composition may contain a specific content of the structure promoter component. For example, the filler composition may contain a structure promoter component content of at least about 0.1 wt%, 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% based on the total weight of the filler composition. According to still other embodiments, the filler composition may contain a structure promoter component content of not more than about 7.0 wt%, such as not more than about 6.5 wt%, or not more than about 6.0 wt%, or not more than about 5.5 wt%, or not more than about 5.0 wt%, or not more than about 4.5 wt%, or even not more than about 4.0 wt% based on the total weight of the filler composition. It should be understood that the filler composition may contain a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition may contain a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0019] According to specific embodiments, the flux component may include specific components. For example, the flux component may include components selected from the group consisting of: low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth(III) oxide, or any combination thereof. According to still other embodiments, the flux component may include low-T frit. According to yet other embodiments, the flux component may consist of low-T frit. According to still other embodiments, the flux component may include zinc oxide. According to yet other embodiments, the flux component may consist of zinc oxide. According to still other embodiments, the flux component may include zinc borate. According to yet other embodiments, the flux component may consist of zinc borate. According to still other embodiments, the flux component may include antimony(III) oxide. According to yet other embodiments, the flux component may consist of antimony(III) oxide. According to still other embodiments, the flux component may include bismuth(III) oxide. According to yet other embodiments, the flux component may consist of bismuth(III) oxide.

[0020] According to still other embodiments, the filler composition may contain a specific amount of the flux component. For example, the filler composition may contain at least about 0.1 wt%, 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% of the flux component content based on the total weight of the filler composition. According to still other embodiments, the filler composition may contain no greater than about 7.0 wt%, such as no greater than about 6.5 wt%, or no greater than about 6.0 wt%, or no greater than about 5.5 wt%, or no greater than about 5.0 wt%, or no greater than about 4.5 wt%, or even no greater than about 4.0 wt% of the flux component content based on the total weight of the filler composition. It should be understood that the filler composition may contain a flux component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition may contain a flux component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0021] According to specific embodiments, the flame retardant component may include specific components. For example, the flame retardant component may include components selected from the group consisting of: aluminum hydroxide, magnesium hydroxide, or any combination thereof. According to still other embodiments, the flame retardant component may include aluminum hydroxide. According to yet other embodiments, the flame retardant component may consist of aluminum hydroxide. According to still other embodiments, the flame retardant component may include magnesium hydroxide. According to yet other embodiments, the flame retardant component may consist of magnesium hydroxide.

[0022] According to still other embodiments, the filler composition may comprise a specific content of the flame retardant component. For example, the filler composition may comprise at least about 5.0 wt%, 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% of the flame retardant component content based on the total weight of the filler composition. According to still other embodiments, the filler composition may comprise no greater than about 20.0 wt%, such as no greater than about 19.0 wt%, or no greater than about 18.0 wt%, or no greater than about 17.0 wt%, or no greater than about 16.0 wt%, or no greater than about 15.0 wt%, or even no greater than about 14.0 wt% of the flame retardant component content based on the total weight of the filler composition. It should be understood that the filler composition may comprise a flame retardant component content of any value within the range between any one of the above minimum values and any one of the above maximum values. It should also be understood that the filler composition may comprise a flame retardant component content of any value within the range between any one of the above minimum values and any one of the above maximum values.

[0023] According to still other embodiments, the filler composition may further comprise a functional additive. According to yet other embodiments, the functional additive may include specific components. For example, the functional additive may include components selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof. According to still other embodiments, the functional additive component may include iron(III) oxide. According to yet other embodiments, the functional additive component may consist of iron(III) oxide. According to still other embodiments, the functional additive component may include titanium oxide. According to yet other embodiments, the functional additive component may consist of titanium oxide.

[0024] According to still other embodiments, the filler composition may comprise a specific content of the functional additive. For example, the filler composition may comprise a functional additive content of at least about 0.1 wt%, 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% based on the total weight of the filler composition. According to still other embodiments, the filler composition may comprise a functional additive content of not greater than about 7.0 wt%, 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% based on the total weight of the filler composition. It should be understood that the filler composition may comprise a functional additive content of any value within the range between any one of the above minimum values and any one of the above maximum values. It should also be understood that the filler composition may comprise a functional additive content of any value within the range between any one of the above minimum values and any one of the above maximum values.

[0025] Now referring to an embodiment of the composite material, the composite material may comprise a polymer-based matrix component and a filler composition distributed within the polymer-based matrix.

[0026] For illustrative purposes, Figure 1 a composite material 100 according to an embodiment described herein is shown. As Figure 1 shown, the composite material 100 may comprise a polymer-based matrix component 110 and a filler composition 120 distributed within the polymer-based matrix component 110.

[0027] According to a specific embodiment, the polymer-based matrix component 110 of the composite material 100 may comprise a specific material. For example, the polymer-based matrix component 110 may comprise a component selected from the group consisting of silicone resin, polyurethane, epoxy resin, acrylic resin, or any combination thereof. According to still other embodiments, the polymer-based matrix component 110 may comprise a silicone resin. According to yet other embodiments, the polymer-based matrix component 110 may consist of a silicone resin. According to still other embodiments, the polymer-based matrix component 110 may comprise a polyurethane. According to yet other embodiments, the polymer-based matrix component 110 may consist of a polyurethane. According to still other embodiments, the polymer-based matrix component 110 may comprise an epoxy resin. According to yet other embodiments, the polymer-based matrix component 110 may consist of an epoxy resin. According to still other embodiments, the polymer-based matrix component 110 may comprise an acrylic resin. According to yet other embodiments, the polymer-based matrix component 110 may consist of an acrylic resin.

[0028] According to still other embodiments, the composite material 100 may include a specific content of the polymer-based matrix component 110. For example, the composite material 100 may include at least about 30 wt%, 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% of the polymer-based matrix component content based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include no more than about 60 wt%, such as no more than about 58 wt%, or no more than about 55 wt%, or no more than about 53 wt%, or even no more than about 50 wt% of the polymer-based matrix component content based on the total weight of the composite material 100. It should be understood that the composite material 100 may include a polymer-based matrix component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may include a polymer-based matrix component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0029] According to still other embodiments, the composite material 100 may include a specific content of the filler composition 120. For example, the composite material 100 may include at least about 40 wt%, 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% of the filler composition content based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include no more than about 70 wt%, such as no more than about 68 wt%, or no more than about 65 wt%, or no more than about 63 wt%, or even no more than about 60 wt% of the filler composition content based on the total weight of the composite material 100. It should be understood that the composite material 100 may include a filler composition content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may include a filler composition content of any value within the range between any of the above minimum values and any of the above maximum values.

[0030] According to certain embodiments, the filler composition 120 may include a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0031] According to specific embodiments, the ceramizable filler component of the filler composition 120 may include specific components. For example, the ceramizable filler component may include components selected from the group consisting of: sepiolite, wollastonite, or any combination thereof. According to still other embodiments, the ceramizable filler component may include sepiolite. According to yet other embodiments, the ceramizable filler component may consist of sepiolite. According to still other embodiments, the ceramizable filler component may include wollastonite. According to yet other embodiments, the ceramizable filler component may consist of wollastonite. According to still other embodiments, the ceramizable filler component may include a combination of sepiolite and wollastonite. According to yet other embodiments, the ceramizable filler component may consist of a combination of sepiolite and wollastonite.

[0032] According to still other embodiments, the ceramizable filler component of the filler composition 120 may be a plurality of particles. According to still other embodiments, the ceramizable filler component may have a specific aspect ratio. For the purposes of the embodiments described herein, the aspect ratio of the ceramizable filler component may be defined as the average length of a statistically significant number of the plurality of particles of the ceramizable filler component divided by the average diameter of a statistically significant number of the plurality of particles of the ceramizable filler component (L / D). For example, the ceramizable 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 still other embodiments, the ceramizable 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 ceramizable filler component may have an aspect ratio of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the ceramizable filler component may have an aspect ratio of any value within the range between any of the above minimum values and any of the above maximum values.

[0033] According to still other embodiments, the filler composition 120 may comprise a specific content of the ceramizable filler component. For example, the filler composition 120 may comprise at least about 75 wt%, such as at least about 76 wt%, or at least about 77 wt%, or at least about 78 wt%, or at least about 79 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% of the ceramizable filler component content based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may comprise no greater than about 95 wt%, 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% of the ceramizable filler component content based on the total weight of the filler composition 120. It should be understood that the filler composition 120 may comprise a ceramizable filler component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition 120 may comprise a ceramizable filler component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0034] According to still other embodiments, the composite material 100 may comprise a specific content of the ceramizable filler component. For example, the composite material 100 may comprise at least about 50 wt%, such as 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% of the ceramizable filler component content based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may comprise no greater than about 70 wt%, 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% of the ceramizable filler component content based on the total weight of the composite material 100. It should be understood that the composite material 100 may comprise a ceramizable filler component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may comprise a ceramizable filler component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0035] According to specific embodiments, the structure promoter component of the filler composition 120 may include specific components. For example, the structure promoter component may include components selected from the group consisting of: crystalline silica, diopside, spodumene, red mica, lithium carbonate, lithium hydroxide, or any combination thereof. According to still other embodiments, the structure promoter component may include crystalline silica. According to yet other embodiments, the structure promoter component may consist of crystalline silica. According to still other embodiments, the structure promoter component may include diopside. According to yet other embodiments, the structure promoter component may consist of diopside. According to still other embodiments, the structure promoter component may include spodumene. According to yet other embodiments, the structure promoter component may consist of spodumene. According to still other embodiments, the structure promoter component may include red mica. According to yet other embodiments, the structure promoter component may consist of red mica. According to still other embodiments, the structure promoter component may include lithium carbonate. According to yet other embodiments, the structure promoter component may consist of lithium carbonate. According to still other embodiments, the structure promoter component may include lithium hydroxide. According to yet other embodiments, the structure promoter component may consist of lithium hydroxide.

[0036] According to still other embodiments, the filler composition 120 may contain a specific content of the structure promoter component. For example, the filler composition 120 may contain at least about 0.1 wt%, 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% of the structure promoter component content based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may contain no greater than about 7.0 wt%, such as no greater than about 6.5 wt%, or no greater than about 6.0 wt%, or no greater than about 5.5 wt%, or no greater than about 5.0 wt%, or no greater than about 4.5 wt%, or even no greater than about 4.0 wt% of the structure promoter component content based on the total weight of the filler composition 120. It should be understood that the filler composition 120 may contain a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition 120 may contain a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0037] According to still other embodiments, the composite material 100 may include a specific content of the structure promoter component. For example, the composite material 100 may include a structure promoter component content of at least about 0.05 wt%, 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% based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include a structure promoter component content of not more than about 5.0 wt%, such as not more than about 4.5 wt%, or not more than about 4.0 wt%, or not more than about 3.5 wt%, or even not more than about 3.0 wt% based on the total weight of the composite material 100. It should be understood that the composite material 100 may include a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may include a structure promoter component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0038] According to specific embodiments, the flux component of the filler composition 120 may include specific components. For example, the flux component may include components selected from the group consisting of: low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth(III) oxide, or any combination thereof. According to still other embodiments, the flux component may include low-T frit. According to yet other embodiments, the flux component may consist of low-T frit. According to still other embodiments, the flux component may include zinc oxide. According to yet other embodiments, the flux component may consist of zinc oxide. According to still other embodiments, the flux component may include zinc borate. According to yet other embodiments, the flux component may consist of zinc borate. According to still other embodiments, the flux component may include antimony(III) oxide. According to yet other embodiments, the flux component may consist of antimony(III) oxide. According to still other embodiments, the flux component may include bismuth(III) oxide. According to yet other embodiments, the flux component may consist of bismuth(III) oxide.

[0039] According to still other embodiments, the filler composition 120 may comprise a specific content of the flux component. For example, the filler composition 120 may comprise at least about 0.1 wt%, 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% of the flux component content based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may comprise no greater than about 7.0 wt%, such as no greater than about 6.5 wt%, or no greater than about 6.0 wt%, or no greater than about 5.5 wt%, or no greater than about 5.0 wt%, or no greater than about 4.5 wt%, or even no greater than about 4.0 wt% of the flux component content based on the total weight of the filler composition 120. It should be understood that the filler composition 120 may comprise a flux component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition 120 may comprise a flux component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0040] According to still other embodiments, the composite material 100 may comprise a specific content of the flux component. For example, the composite material 100 may comprise at least about 0.01 wt%, 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% of the flux component content based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may comprise no greater than about 5.0 wt%, 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% of the flux component content based on the total weight of the composite material 100. It should be understood that the composite material 100 may comprise a flux component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may comprise a flux component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0041] According to a specific embodiment, the flame retardant component of the filler composition 120 may include specific components. For example, the flame retardant component may include components selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof. According to still other embodiments, the flame retardant component may include aluminum hydroxide. According to yet other embodiments, the flame retardant component may consist of aluminum hydroxide. According to still other embodiments, the flame retardant component may include magnesium hydroxide. According to yet other embodiments, the flame retardant component may consist of magnesium hydroxide.

[0042] According to still other embodiments, the filler composition 120 may comprise a specific content of the flame retardant component. For example, the filler composition 120 may comprise at least about 5.0 wt% of the total weight of the 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% of the flame retardant component content. According to still other embodiments, the filler composition 120 may comprise no greater than about 20.0 wt% of the total weight of the filler composition 120, such as no greater than about 19.0 wt%, or no greater than about 18.0 wt%, or no greater than about 17.0 wt%, or no greater than about 16.0 wt%, or no greater than about 15.0 wt%, or even no greater than about 14.0 wt% of the flame retardant component content. It should be understood that the filler composition 120 may comprise a flame retardant component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition 120 may comprise a flame retardant component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0043] According to still other embodiments, the composite material 100 may comprise a specific content of the flame retardant component. For example, the composite material 100 may comprise 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% of the flame retardant component content. According to still other embodiments, the composite material 100 may comprise no greater than about 10.0 wt% of the total weight of the composite material 100, such as no greater than about 9.5 wt%, or no greater than about 9.0 wt%, or no greater than about 8.5 wt%, or no greater than about 8.0 wt%, or no greater than about 7.5 wt%, or even no greater than about 7.0 wt% of the flame retardant component content. It should be understood that the composite material 100 may comprise a flame retardant component content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may comprise a flame retardant component content of any value within the range between any of the above minimum values and any of the above maximum values.

[0044] According to still other embodiments, the filler composition 120 may further comprise a functional additive. According to yet other embodiments, the functional additive may include specific components. For example, the functional additive may include components selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof. According to still other embodiments, the functional additive component may include iron(III) oxide. According to yet other embodiments, the functional additive component may consist of iron(III) oxide. According to still other embodiments, the functional additive component may include titanium oxide. According to yet other embodiments, the functional additive component may consist of titanium oxide.

[0045] According to still other embodiments, the filler composition 120 may comprise a specific amount of the functional additive. For example, the filler composition 120 may comprise a functional additive content of at least about 0.1 wt%, 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% based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may comprise a functional additive content of no greater than about 7.0 wt%, such as no greater than about 6.5 wt%, or no greater than about 6.0 wt%, or no greater than about 5.5 wt%, or no greater than about 5.0 wt%, or no greater than about 4.5 wt%, or even no greater than about 4.0 wt% based on the total weight of the filler composition 120. It should be understood that the filler composition 120 may comprise a functional additive content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the filler composition 120 may comprise a functional additive content of any value within the range between any of the above minimum values and any of the above maximum values.

[0046] According to still other embodiments, the composite material 100 may comprise a specific content of the functional additive. For example, the composite material 100 may comprise a functional additive content of at least about 0.05 wt%, 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% based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may comprise a functional additive content of no greater than about 5.0 wt%, 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% based on the total weight of the composite material 100. It should be understood that the composite material 100 may comprise a functional additive content of any value within the range between any of the above minimum values and any of the above maximum values. It should also be understood that the composite material 100 may comprise a functional additive content of any value between any of the above minimum values and any of the above maximum values.

[0047] 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.

[0048] According to still other 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 up to 5 minutes. For the purposes of the embodiments described herein, the hot plate test is conducted as follows: A 15 cm × 25 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is placed on top of a hot plate adjusted to the desired temperature, with the composite material side of the specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. 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 still other 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.

[0049] According to further other 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 conducted as follows: A 15 cm × 25 cm specimen of the composite material laminated onto an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is placed on top of a hot plate adjusted to the desired temperature, with the composite material side of the specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. 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 further other 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 a 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.

[0050] According to further other 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 as follows: A 15 cm × 25 cm specimen of the composite material laminated onto an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is placed on top of a hot plate adjusted to the desired temperature, with the composite material side of the specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. According to certain embodiments, the composite material 100 may have a 30-minute HPE cold side temperature that is 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 further other 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 a 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.

[0051] According to still other embodiments, the composite material 100 can have a specific 5-minute torch exposure (TE) cold-side temperature as measured using a torch test conducted at 1300 °C for 5 minutes. For the purposes of the embodiments described herein, the torch test is conducted as follows: A 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is secured to a holder. The torch is placed 7 cm away from the face of the specimen secured to the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the specimen, the external flame reaching a desired temperature as measured using a thermometer at the point where the flame touches the specimen and stabilizing at the desired temperature. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the cold-side surface of the sample (i.e., the side of the specimen opposite the torch) at a specified time. According to certain embodiments, the composite material 100 can have a 5-minute TE cold-side temperature that is 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 still other embodiments, the composite material 100 can 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 can be within a 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 can be any value between any of the above values.

[0052] According to further other 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. For the purposes of the embodiments described herein, the torch test is conducted as follows: A 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is fixed to a holder. The torch is placed 7 cm away from the face of the specimen fixed to the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the specimen, the external flame reaching a desired temperature as measured using a thermometer at the point where the flame touches the specimen and stabilizing at the desired temperature. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the torch) at a specified time. 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 further other 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 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 100 may be any value between any of the above values.

[0053] According to still other 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. For the purposes of the embodiments described herein, the torch test is conducted as follows: A 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is fixed to a holder. The torch is placed 7 cm away from the face of the specimen fixed to the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the specimen, and the external flame reaches the desired temperature as measured using a thermometer at the point where the flame touches the specimen and stabilizes at the desired temperature. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the cold side surface (i.e., the side of the specimen opposite the torch) of the sample at the specified time. 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 still other 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 in 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.

[0054] According to yet 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 in accordance with ASTM D1056. According to certain embodiments, the composite material 100 may have a density of no greater than about 1.7 kg / m 3 , such as no greater than about 1.6 kg / m 3 , or no greater than about 1.5 kg / m 3 , or no greater than about 1.4 kg / m 3 , or no greater than about 1.3 kg / m 3 , or no greater than about 1.2 kg / m 3 , or no greater than about 1.1 kg / m 3 , or no greater than about 1.0 kg / m 3 , or no greater than about 0.9 kg / m 3 , or no greater than about 0.8 kg / m 3 , or no greater than about 0.7 kg / m 3 , or no greater than about 0.6 kg / m3 、 or not greater than about 0.5 kg / m 3 、 or even not greater than about 0.4 kg / m 3 of density. According to still other embodiments, composite material 100 may have a density of at least about 0.001 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 values and any of the above maximum values. It should also be understood that the density of composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0055] According to still 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 0.001 kg / m 2 , such as at least about 0.005 kg / m 2 、 or at least about 0.01 kg / m 2 、 or at least about 0.05 kg / m 2 、 or at least about 0.1 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 of weight. According to still other embodiments, composite material 100 may have a weight not greater than about 2.61 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 values and any of the above maximum values. It should also be understood that the weight of composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0056] According to still 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 61 Shore A, such as at least about 62 Shore A, or at least about 63 Shore A, or at least about 64 Shore A, or even at least about 65 Shore A. According to still 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 values and any of the above maximum values. It should also be understood that the hardness of composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0057] According to yet other embodiments, the composite material 100 may have a specific tensile strength. For the purposes of the embodiments described herein, this 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 2.3 MPa, such as at least about 2.5 MPa, or at least about 5 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 yet other embodiments, the composite material 100 may have a tensile strength of not greater than about 500 MPa. It should be understood that this tensile strength of the composite material 100 may be in the range between any of the above minimum values and any of the above maximum values. It should also be understood that this tensile strength of the composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0058] Now referring to the embodiments of the composite material layer, the composite material described herein may be formed into a material layer. It should be understood that, according to specific embodiments, the composite material layer described herein may include 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 characteristics described herein with reference to the composite material 100.

[0059] According to yet other 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 still other 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 this thickness of the composite material layer may be in the range between any of the above minimum values and any of the above maximum values. It should also be understood that this thickness of the composite material layer may be any value between any of the above minimum values and any of the above maximum values.

[0060] According to certain embodiments, the composite layer may have a specific flammability rating as measured according to ASTM D3801. In particular, the composite layer may have a V-0 flammability rating as measured according to ASTM D3801.

[0061] According to still other embodiments, the composite 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 up to 5 minutes. For the purposes of the embodiments described herein, the hot plate test is conducted as follows: A 15 cm × 25 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is placed on top of a hot plate adjusted to the desired temperature, with the composite side of the specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. According to certain embodiments, the composite 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 still other embodiments, the composite 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 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 layer may be any value between any of the above values.

[0062] According to yet other 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 conducted as follows: Prepare a 15 cm × 25 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm such that the total specimen thickness is 1.5 mm. Place the specimen on top of a hot plate adjusted to the desired temperature, with the composite material side of the specimen facing the hot plate. Use an infrared (IR) thermometer to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. According to certain embodiments, the composite material layer may have a 15-minute HPE cold side temperature that is 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 yet other 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.

[0063] According to yet other 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 conducted as follows: Prepare a 15 cm × 25 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm such that the total specimen thickness is 1.5 mm. Place the specimen on top of a hot plate adjusted to the desired temperature, with the composite material side of the specimen facing the hot plate. Use an infrared (IR) thermometer to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the hot plate) at the specified time. According to certain embodiments, the composite material layer may have a 30-minute HPE cold side temperature that is 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 yet other 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.

[0064] According to still other 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. For the purposes of the embodiments described herein, the torch test is conducted as follows: A 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is secured in a holder. The torch is placed 7 cm away from the face of the specimen secured in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the specimen, the external flame reaching a desired temperature as measured using a thermometer at the point where the flame touches the specimen and stabilizing at the desired temperature. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the torch) at a specified time. 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 still other 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 a 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.

[0065] According to further other 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. For the purposes of the embodiments described herein, the torch test is conducted as follows: Prepare a 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm such that the total specimen thickness is 1.5 mm. Secure the specimen in a holder. Place the torch 7 cm away from the face of the specimen secured in the holder, with the composite material side of the specimen facing the torch. Adjust the torch to produce an external flame that just touches the center point of the composite material side of the specimen, the external flame reaching a desired temperature as measured using a thermometer at the point where the flame touches the specimen and stabilizing at the desired temperature. Use an infrared (IR) thermometer or thermocouple to measure the temperature at the center point of the cold side surface of the sample (i.e., the side of the specimen opposite the torch) at a specified time. 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 further other 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.

[0066] According to yet other 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 conducted as follows: A 15 cm × 15 cm specimen of the composite material laminated to an E-glass fabric layer having a thickness of 0.3 mm is prepared such that the total specimen thickness is 1.5 mm. The specimen is fixed to a holder. The torch is placed 7 cm away from the face of the specimen fixed to the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an external flame that just touches the center point of the composite material side of the specimen, and the external flame reaches and stabilizes at a desired temperature as measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the cold-side surface (i.e., the side of the specimen opposite the torch) of the sample at a specified time. 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 yet other 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.

[0067] According to still other 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 1.7 kg / m 3 , such as no greater than about 1.6 kg / m 3 , or no greater than about 1.5 kg / m 3 , or no greater than about 1.4 kg / m 3 , or no greater than about 1.3 kg / m 3 , or no greater than about 1.2 kg / m 3 , or no greater than about 1.1 kg / m 3 , or no greater than about 1.0 kg / m 3 , or no greater than about 0.9 kg / m 3 , or no greater than about 0.8 kg / m 3 , or no greater than about 0.7 kg / m 3 , or no greater than about 0.6 kg / m 3, or not greater than about 0.5 kg / m 3 , or even not greater than about 0.4 kg / m 3 of density. According to still other embodiments, the composite layer may have a density of at least about 0.001 kg / m 3 . It should be understood that the density of the composite layer may be in the range between any of the above minimum values and any of the above maximum values. It should also be understood that the density of the composite layer may be any value between any of the above minimum values and any of the above maximum values.

[0068] According to still other embodiments, the composite layer may have a specific weight. According to certain embodiments, the composite layer may have a weight of at least about 0.001 kg / m 2 , such as at least about 0.005 kg / m 2 , or at least about 0.01 kg / m 2 , or at least about 0.05 kg / m 2 , or at least about 0.1 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 of weight. According to still other embodiments, the composite layer may have a weight not greater than about 2.61 kg / m 2 . It should be understood that the weight of the composite layer may be in the range between any of the above minimum values and any of the above maximum values. It should also be understood that the weight of the composite layer may be any value between any of the above minimum values and any of the above maximum values.

[0069] According to still other 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 61 Shore A, such as at least about 62 Shore A, or at least about 63 Shore A, or at least about 64 Shore A, or even at least about 65 Shore A. According to still other 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 in the range between any of the above minimum values and any of the above maximum values. It should also be understood that the hardness of the composite layer may be any value between any of the above minimum values and any of the above maximum values.

[0070] According to yet other 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 2.3 MPa, such as at least about 2.5 MPa, or at least about 5 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 yet other embodiments, the composite material layer may have a tensile strength of no 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 one of the above minimum values and any one of the above maximum values. It should also be understood that the tensile strength of the composite material layer may be any value between any one of the above minimum values and any one of the above maximum values.

[0071] According to certain embodiments, the composite material layer described herein may be formed in accordance with any acceptable forming process for a composite material layer.

[0072] Turning now to the additional embodiments described herein, such embodiments generally relate to a thermal barrier composite that may comprise a composite material or composite material layer as described herein. It should be understood that, according to specific embodiments, the thermal barrier composite described herein may comprise any of the components described herein with reference to Composite Material 100. It should also be understood that, according to specific embodiments, the thermal barrier composite described herein may have any of the features described herein with reference to Composite Material 100.

[0073] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, those skilled in the art will understand that those aspects and embodiments are merely exemplary and do not limit the scope of the invention. Embodiments may be in accordance with any one or more of the embodiments listed below.

[0074] Embodiment 1. A filler composition, the filler composition comprising: a ceramizable filler component in an amount of at least about 75 wt% and no greater than about 95 wt% of the total weight of the filler composition, a structure promoter component in an amount of at least about 0.1 wt% and no greater than about 7.0 wt% of the total weight of the filler composition, a flux component in an amount of at least about 0.1 wt% and no greater than about 7.0 wt% of the total weight of the filler composition, and a flame retardant component in an amount of at least about 5.0 wt% and no greater than about 20.0 wt% of the total weight of the filler composition.

[0075] Embodiment 2. A composite material, the composite material comprising: a polymer-based matrix component and a filler composition distributed within the polymer-based component, wherein the filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0076] Embodiment 3. A composite material layer, the composite material layer comprising: a polymer-based matrix component and a filler composition distributed within the polymer-based component, wherein the filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0077] Embodiment 4. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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.

[0078] Embodiment 5. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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.

[0079] Embodiment 6. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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.

[0080] Embodiment 7. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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 during a 5-minute torch test at 1300 °C.

[0081] Embodiment 8. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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 during a 15-minute torch test at 1300 °C.

[0082] Embodiment 9. The composite material or composite material layer according to any one of Embodiments 2 and 3, 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 during a 30-minute torch test at 1300 °C.

[0083] Embodiment 10. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the composite material or composite material layer has a V-0 flammability rating as measured according to ASTM D3801.

[0084] Embodiment 11. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the polymer-based component comprises a component selected from the group consisting of silicone, polyurethane, epoxy resin, acrylic resin, or any combination thereof.

[0085] Embodiment 12. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the composite material comprises a polymer-based component content of at least about 30% by weight of the total weight of the composite material.

[0086] Embodiment 13. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the composite material comprises a polymer-based component content of not more than about 60% by weight of the total weight of the composite material.

[0087] Embodiment 14. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the composite material comprises a filler composition content of at least about 40% by weight of the total weight of the composite material.

[0088] Embodiment 15. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the composite material comprises a filler composition content of not more than about 70% by weight of the total weight of the composite material.

[0089] Embodiment 16. The composite material or composite material layer according to any one of Embodiments 1, 2, and 3, wherein the ceramizable filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof.

[0090] Embodiment 17. The composite material or composite material layer according to Embodiment 16, wherein the ceramizable filler component has an aspect ratio (length / diameter) of not more than about 10.

[0091] Embodiment 18. The composite material or composite material layer according to Embodiment 16, wherein the ceramizable filler component has an aspect ratio (length / diameter) of at least about 2.

[0092] Embodiment 19. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a ceramizable filler component content of at least about 75% by weight of the total weight of the filler composition.

[0093] Embodiment 20. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a ceramizable filler component content of not more than about 95% by weight of the total weight of the filler composition.

[0094] Embodiment 21. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a ceramizable filler component content of at least about 50% by weight of the total weight of the composite material.

[0095] Embodiment 22. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a ceramizable filler component content of not more than about 70% by weight of the total weight of the composite material.

[0096] Embodiment 23. The composite material or composite material layer according to any one of Embodiments 1, 2, and 3, wherein the structure promoter component comprises a component selected from the group consisting of crystalline silica, diopside, spodumene, red mica, lithium carbonate, lithium hydroxide, or any combination thereof.

[0097] Embodiment 24. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a structure promoter component content of at least about 0.1% by weight of the total weight of the filler composition.

[0098] Embodiment 25. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a structure promoter component content of not more than about 7.0% by weight of the total weight of the filler composition.

[0099] Embodiment 26. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a structure promoter component content of at least about 0.05% by weight of the total weight of the composite material.

[0100] Embodiment 27. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a structure promoter component content of not more than about 5% by weight of the total weight of the composite material.

[0101] Embodiment 28. The composite material or composite material layer according to any one of Embodiments 1, 2, and 3, wherein the flux component comprises a component selected from the group consisting of low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth(III) oxide, or any combination thereof.

[0102] Embodiment 29. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flux component content of at least about 0.1% by weight based on the total weight of the filler composition.

[0103] Embodiment 30. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flux component content of not more than about 7.0% by weight based on the total weight of the filler composition.

[0104] Embodiment 31. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flux component content of at least about 0.05% by weight based on the total weight of the composite material.

[0105] Embodiment 32. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flux component content of not more than about 5% by weight based on the total weight of the composite material.

[0106] Embodiment 33. The composite material or composite material layer according to any one of Embodiments 1, 2 and 3, wherein the flame retardant component comprises a component selected from the group consisting of aluminum hydroxide, magnesium hydroxide or any combination thereof.

[0107] Embodiment 34. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flame retardant component content of at least about 5.0% by weight based on the total weight of the filler composition.

[0108] Embodiment 35. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flame retardant component content of not more than about 20.0% by weight based on the total weight of the filler composition.

[0109] Embodiment 36. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flame retardant component content of at least about 2.5% by weight based on the total weight of the composite material.

[0110] Embodiment 37. The composite material or composite material layer according to any one of Embodiments 2 and 3, wherein the filler composition comprises a flame retardant component content of not more than 10% by weight based on the total weight of the composite material.

[0111] Embodiment 38. The composite material or composite material layer according to any one of Embodiments 1, 2 and 3, wherein the filler composition further comprises a functional additive.

[0112] Embodiment 39. The composite material or composite material layer according to Embodiment 38, wherein the functional additive comprises a component selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof.

[0113] Embodiment 40. The composite material or composite material layer according to Embodiment 38, wherein the filler composition comprises a functional additive content of at least about 0.1% by weight of the total weight of the filler composition.

[0114] Embodiment 41. The composite material or composite material layer according to Embodiment 38, wherein the filler composition comprises a functional additive content of not more than about 7.0% by weight of the total weight of the filler composition.

[0115] Embodiment 42. The composite material or composite material layer according to Embodiment 38, wherein the filler composition comprises a functional additive content of at least about 0.05% by weight of the total weight of the composite material.

[0116] Embodiment 43. The composite material or composite material layer according to Embodiment 38, wherein the filler composition comprises a functional additive content of not more than about 5% by weight of the total weight of the composite material.

[0117] Embodiment 44. The composite material layer according to Embodiment 3, wherein the material layer has a thickness of at least about 0.2 mm.

[0118] Embodiment 45. The composite material layer according to Embodiment 3, wherein the material layer has a thickness of not more than about 3.0 mm.

[0119] Embodiment 46. The composite material layer according to Embodiment 2, wherein the composite material has a density of not more than about 1.7 kg / m 3 of.

[0120] Embodiment 47. The composite material layer according to Embodiment 2, wherein the composite material has a density of at least about 0.001 kg / m 3 of.

[0121] Embodiment 48. The composite material layer according to Embodiment 3, wherein the material layer has a density of not more than about 1.7 kg / m 3 of.

[0122] Embodiment 49. The composite material layer according to Embodiment 3, wherein the material layer has a density of at least about 0.001 kg / m 3 of.

[0123] Embodiment 50. The composite material layer according to Embodiment 2, wherein the composite material has a weight of at least about 0.001 kg / m 2 of weight.

[0124] Embodiment 51. The composite material layer according to Embodiment 2, wherein the composite material has a weight of not more than about 2.61 kg / m 2 of weight.

[0125] Embodiment 52. The composite material layer according to Embodiment 3, wherein the material layer has a weight of at least about 0.001 kg / m 2 of weight.

[0126] Embodiment 53. The composite material layer according to Embodiment 3, wherein the material layer has a weight of not more than about 2.61 kg / m 2 of weight.

[0127] Embodiment 54. The composite material layer according to Embodiment 2, wherein the composite material has a hardness of at least about 61 Shore A.

[0128] Embodiment 55. The composite material layer according to Embodiment 2, wherein the composite material has a hardness of not more than about 71 Shore A.

[0129] Embodiment 56. The composite material layer according to Embodiment 3, wherein the material layer has a hardness of at least about 61 Shore A.

[0130] Embodiment 57. The composite material layer according to Embodiment 3, wherein the material layer has a hardness of not more than about 71 Shore A.

[0131] Embodiment 58. The composite material layer according to Embodiment 2, wherein the composite material has a tensile strength of at least about 2.3 MPa.

[0132] Embodiment 59. The composite material layer according to Embodiment 2, wherein the composite material has a tensile strength of not more than about 500 MPa.

[0133] Embodiment 60. The composite material layer according to Embodiment 3, wherein the material layer has a tensile strength of at least about 10 MPa.

[0134] Embodiment 61. The composite material layer according to Embodiment 3, wherein the material layer has a tensile strength of not more than about 500 MPa.

[0135] Embodiment 62. A thermal barrier composite comprising a composite material, wherein the composite material comprises: a polymer-based matrix component and a filler composition distributed within the polymer-based component, and wherein the filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0136] Embodiment 63. A thermal barrier composite comprising a composite material layer, wherein the composite material layer comprises: a polymer-based matrix component and a filler composition distributed within the polymer-based component, and wherein the filler composition comprises: a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component.

[0137] Embodiment 64. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the 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 conducted at 800 °C.

[0138] Embodiment 65. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the 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 conducted at 800 °C.

[0139] Embodiment 66. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the 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 conducted at 800 °C.

[0140] Embodiment 67. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the composite material layer has a 5-minute TE cold-side temperature of no greater than about 800 °C as measured at 5 minutes during a torch test conducted at 1300 °C.

[0141] Embodiment 68. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the composite material layer has a 15-minute TE cold-side temperature of no greater than about 800 °C as measured at 15 minutes during a torch test conducted at 1300 °C.

[0142] Embodiment 69. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or the composite material layer has a 15-minute TE cold-side temperature of no greater than about 800 °C as measured at 15 minutes during a torch test conducted at 1300 °C.

[0143] Embodiment 70. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material or composite material layer has a V-0 flammability rating as measured according to ASTM D3801.

[0144] Embodiment 71. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the polymer-based component comprises a component selected from the group consisting of silicone, polyurethane, epoxy resin, acrylic resin, or any combination thereof.

[0145] Embodiment 72. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material comprises a polymer-based component content of at least about 30% by weight of the total weight of the composite material.

[0146] Embodiment 73. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material comprises a polymer-based component content of not more than about 60% by weight of the total weight of the composite material.

[0147] Embodiment 74. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material comprises a filler composition content of at least about 40% by weight of the total weight of the composite material.

[0148] Embodiment 75. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the composite material comprises a filler composition content of not more than about 70% by weight of the total weight of the composite material.

[0149] Embodiment 76. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the ceramizable filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof.

[0150] Embodiment 77. The thermal barrier composite according to Embodiment 76, wherein the ceramizable filler component has an aspect ratio (length / diameter) of not more than about 10.

[0151] Embodiment 78. The thermal barrier composite according to Embodiment 76, wherein the ceramizable filler component has an aspect ratio (length / diameter) of at least about 2.

[0152] Embodiment 79. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a ceramizable filler component content of at least about 75% by weight of the total weight of the filler composition.

[0153] Embodiment 80. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a ceramizable filler component that is no greater than about 95 wt% of the total weight of the filler composition.

[0154] Embodiment 81. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a ceramizable filler component that is at least about 50 wt% of the total weight of the composite material.

[0155] Embodiment 82. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a ceramizable filler component that is no greater than about 70 wt% of the total weight of the composite material.

[0156] Embodiment 83. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the structural promoter component comprises a component selected from the group consisting of crystalline silica, diopside, spodumene, red mica, lithium carbonate, lithium hydroxide, or any combination thereof.

[0157] Embodiment 84. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a structural promoter component that is at least about 0.1 wt% of the total weight of the filler composition.

[0158] Embodiment 85. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a structural promoter component that is no greater than about 7.0 wt% of the total weight of the filler composition.

[0159] Embodiment 86. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a structural promoter component that is at least about 0.05 wt% of the total weight of the composite material.

[0160] Embodiment 87. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a content of a structural promoter component that is no greater than about 5 wt% of the total weight of the composite material.

[0161] Embodiment 88. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the flux component comprises a component selected from the group consisting of low-T frit, zinc oxide, zinc borate, antimony(III) oxide, bismuth(III) oxide, or any combination thereof.

[0162] Embodiment 89. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flux component content of at least about 0.1% by weight based on the total weight of the filler composition.

[0163] Embodiment 90. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flux component content of not more than about 7.0% by weight based on the total weight of the filler composition.

[0164] Embodiment 91. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flux component content of at least about 0.05% by weight based on the total weight of the composite material.

[0165] Embodiment 92. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flux component content of not more than about 5% by weight based on the total weight of the composite material.

[0166] Embodiment 93. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the flame retardant component comprises a component selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof.

[0167] Embodiment 94. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flame retardant component content of at least about 5.0% by weight based on the total weight of the filler composition.

[0168] Embodiment 95. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flame retardant component content of not more than about 20.0% by weight based on the total weight of the filler composition.

[0169] Embodiment 96. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flame retardant component content of at least about 2.5% by weight based on the total weight of the composite material.

[0170] Embodiment 97. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition comprises a flame retardant component content of not more than 10% by weight based on the total weight of the composite material.

[0171] Embodiment 98. The thermal barrier composite according to any one of Embodiments 62 and 63, wherein the filler composition further comprises a functional additive.

[0172] Embodiment 99. The composite material or composite material layer according to Embodiment 98, wherein the functional additive comprises a component selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof.

[0173] Embodiment 100. The composite material or composite material layer according to Embodiment 98, wherein the filler composition comprises a functional additive content of at least about 0.1 wt% of the total weight of the filler composition.

[0174] Embodiment 101. The composite material or composite material layer according to Embodiment 98, wherein the filler composition comprises a functional additive content of not more than about 7.0 wt% of the total weight of the filler composition.

[0175] Embodiment 102. The composite material or composite material layer according to Embodiment 98, wherein the filler composition comprises a functional additive content of at least about 0.05 wt% of the total weight of the composite material.

[0176] Embodiment 103. The composite material or composite material layer according to Embodiment 98, wherein the filler composition comprises a functional additive content of not more than about 5 wt% of the total weight of the composite material.

[0177] Embodiment 104. The composite material layer according to Embodiment 63, wherein the material layer has a thickness of at least about 0.2 mm.

[0178] Embodiment 105. The composite material layer according to Embodiment 63, wherein the material layer has a thickness of not more than about 3.0 mm.

[0179] Embodiment 106. The composite material layer according to Embodiment 62, wherein the composite material has a density of not more than about 1.7 ± 0.2 kg / m 3 of.

[0180] Embodiment 107. The composite material layer according to Embodiment 62, wherein the composite material has a density of at least about 0.001 kg / m 3 of.

[0181] Embodiment 108. The composite material layer according to Embodiment 63, wherein the material layer has a density of not more than about 1.7 ± 0.2 kg / m 3 of.

[0182] Embodiment 109. The composite material layer according to Embodiment 63, wherein the material layer has a density of at least about 0.001 kg / m 3 of.

[0183] Embodiment 110. The composite material layer according to Embodiment 62, wherein the composite material has a weight of at least about 0.001 kg / m 2 .

[0184] Embodiment 111. The composite material layer according to Embodiment 62, wherein the composite material has a weight of not more than about 2.61 kg / m 2 .

[0185] Embodiment 112. The composite material layer according to Embodiment 63, wherein the material layer has a weight of at least about 0.001 kg / m 2 .

[0186] Embodiment 113. The composite material layer according to Embodiment 63, wherein the material layer has a weight of not more than about 2.61 kg / m 2 .

[0187] Embodiment 114. The composite material layer according to Embodiment 62, wherein the composite material has a hardness of at least about 61 Shore A.

[0188] Embodiment 115. The composite material layer according to Embodiment 62, wherein the composite material has a hardness of not more than about 71 Shore A.

[0189] Embodiment 116. The composite material layer according to Embodiment 63, wherein the material layer has a hardness of at least about 61 Shore A.

[0190] Embodiment 117. The composite material layer according to Embodiment 63, wherein the material layer has a hardness of not more than about 71 Shore A.

[0191] Embodiment 118. The composite material layer according to Embodiment 62, wherein the composite material has a tensile strength of at least about 2.3 MPa.

[0192] Embodiment 119. The composite material layer according to Embodiment 62, wherein the composite material has a tensile strength of not more than about 500 MPa.

[0193] Embodiment 120. The composite material layer according to Embodiment 63, wherein the material layer has a tensile strength of at least about 10 MPa.

[0194] Embodiment 121. The composite material layer according to Embodiment 63, wherein the material layer has a tensile strength of not more than about 500 MPa.

[0195] Note that not all activities described above in the general description or examples are required, some activities that may not be part of a particular activity, and one or more additional activities may be performed in addition to those described. Further, the order in which activities are listed is not necessarily the order in which the activities are performed.

[0196] Benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature that may cause any benefit, advantage, or solution to occur or become more pronounced should not be construed as a critical, required, or essential feature of any or all claims.

[0197] The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and illustrations are not intended to be an exhaustive and comprehensive description of all elements and features of the devices and systems using the structures or methods described herein. Separate embodiments may also be provided combinatorially 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 may be apparent to those skilled in the art only after reading this specification. Other embodiments may be used and derived from this disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of this disclosure. Accordingly, this disclosure should be regarded as illustrative rather than restrictive.

Claims

1. A filler composition, the filler composition comprising: A ceramizable filler component in an amount of at least about 75% by weight and not more than about 95% by weight of the total weight of the filler composition, A structure promoter component in an amount of at least about 0.1% by weight and not more than about 7.0% by weight of the total weight of the filler composition, A flux component in an amount of at least about 0.1% by weight and not more than about 7.0% by weight of the total weight of the filler composition, and A flame retardant component in an amount of at least about 5.0% by weight and not more than about 20.0% by weight of the total weight of the filler composition.

2. A composite material, the composite material comprising: A polymer-based matrix component, and A filler composition distributed within the polymer-based component, wherein the filler composition comprises: A ceramizable filler component, A structure promoter component, A flux component, and A flame retardant component.

3. A composite material layer, the composite material layer comprising: A polymer-based matrix component, and A filler composition distributed within the polymer-based component, wherein the filler composition comprises: A ceramizable filler component, A structure promoter component, A flux component, and A flame retardant component.

4. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 5-minute HPE cold-side temperature of not more than about 800 °C as measured after a 5-minute hot plate test at 800 °C.

5. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 15-minute HPE cold-side temperature of not more than about 800 °C as measured after a 15-minute hot plate test at 800 °C.

6. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 30-minute HPE cold-side temperature of not more than about 800 °C as measured after a 30-minute hot plate test at 800 °C.

7. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 5-minute TE cold-side temperature of not more than about 800 °C as measured at 5 minutes during a torch test at 1300 °C.

8. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 15-minute TE cold-side temperature of not more than about 800 °C as measured at 15 minutes during a torch test at 1300 °C.

9. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a 30-minute TE cold-side temperature of not more than about 800 °C as measured at 30 minutes during a torch test at 1300 °C.

10. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material or composite material layer has a V-0 flammability rating as measured according to ASTM D3801.

11. The composite material or composite material layer according to any one of claims 2 and 3, wherein the polymer-based component comprises a component selected from the group consisting of: silicone resin, polyurethane, epoxy resin, acrylic resin, or any combination thereof.

12. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material comprises a polymer-based component content of at least about 30% by weight based on the total weight of the composite material.

13. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material comprises a polymer-based component content of not more than about 60% by weight based on the total weight of the composite material.

14. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material comprises a filler composition content of at least about 40% by weight based on the total weight of the composite material.

15. The composite material or composite material layer according to any one of claims 2 and 3, wherein the composite material comprises a filler composition content of not more than about 70% by weight based on the total weight of the composite material.

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