Filler compositions, composites, and composite layers with thermal barrier properties

Abstract

The present application relates to a filler composition, a composite material, and a composite material layer having thermal barrier properties. The present disclosure relates to a filler composition, which may include a ceramifying filler component in an amount of at least about 75 wt % and not more than about 95 wt % based on the total weight of the filler composition, a structure-promoting component in an amount of at least about 0.1 wt % and not more 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 more 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 more than about 20.0 wt % based on the total weight of the filler composition.

Description

[Technical Field]

[0001] The present disclosure relates to filler compositions, composite materials, and composite layers, particularly for use in various applications, such as as thermal barriers in battery packs, and methods of forming the same. [Background technology]

[0002] Filler compositions, composites, and composite layers can be designed for high temperature protection in a variety of applications, such as for use as thermal barriers in electric vehicle battery packs, thermal barrier covers in high temperature cable protection, thermal barrier containers for thermal spray containment, etc. However, in these and other applications, the thermal growth potential continues to increase due to improvements in technology. Thus, there is a continuing need for improved barrier designs that protect against such high thermal potentials. Summary of the Invention

[0003] According to a first embodiment, the filler composition may include a ceramifying filler component in an amount of at least about 75 wt % and not more 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 more 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 more 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 more than about 20.0 wt %, based on the total weight of the filler composition.

[0004] According to yet another aspect, a 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 ceramifying filler component, a structure-enhancing component, a flux component, and a flame-retardant component.

[0005] According to yet another aspect, a composite layer can include a polymer-based matrix component and a filler composition distributed within the polymer-based component. The filler composition can include a ceramifying filler component, a structure-enhancing component, a flux component, and a flame-retardant component. [Brief explanation of the drawings]

[0006] Embodiments are illustrated by way of example and not limitation in the accompanying figures. [Figure 1] 1 includes an illustrative diagram of an exemplary composite material according to certain embodiments described herein.

[0007] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. DETAILED DESCRIPTION OF THE INVENTION

[0008] The following discussion focuses on specific implementations and embodiments of the teachings. The detailed description is provided to help explain certain embodiments and should not be construed as a limitation on the scope or applicability of the disclosure or teachings. It will be understood that other embodiments may be used based on the disclosure and teachings provided herein.

[0009] The terms "comprises," "comprising," "includes," "including," "has," "having," or any other variations thereof, are intended to cover non-exclusive inclusions. For example, a method, article, or apparatus that includes a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent in such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive or, not an exclusive or. For example, condition A or B can be satisfied by any one 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).

[0010] Additionally, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be understood as one, at least one, or the singular as including the plural, or vice versa, unless it is clear that this is meant to be otherwise. For example, where a single item is described herein, two or more items may be used in place of the single item. Similarly, where two or more items are described herein, the two or more items may be replaced with a single item.

[0011] Embodiments described herein are generally directed to a filler composition, a composite that may include the filler composition, or a composite layer that may include the filler composition.

[0012] Referring first to embodiments of the filler composition, the filler composition can include a ceramifying filler component, a structure promoter component, a flux component, and a flame retardant component.

[0013] According to certain embodiments, the ceramified filler component may include certain components. For example, the ceramified filler component may include a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. According to still other embodiments, the ceramified filler component may include sepiolite. According to still other embodiments, the ceramified filler component may consist of sepiolite. According to still other embodiments, the ceramified filler component may include wollastonite. According to still other embodiments, the ceramified filler component may consist of wollastonite. According to still other embodiments, the ceramified filler component may include a combination of sepiolite and wollastonite. According to still other embodiments, the ceramified filler component may consist of a combination of sepiolite and wollastonite.

[0014] According to still other embodiments, the ceramified filler component can be a plurality of particles. According to still other embodiments, the ceramified filler component can have a particular aspect ratio. For purposes of the embodiments described herein, the aspect ratio of the ceramified filler component can be defined as the average length of a statistically significant number of particles of the ceramified filler component divided by the average diameter of a statistically significant number of particles of the ceramified filler component (L / D). For example, the ceramified filler component can have an aspect ratio of about 10.0 or less, e.g., about 9.5 or less, or about 9.0 or less, or about 8.5 or less, or about 8.0 or less, or about 7.5 or less, or about 7.0 or less, or about 6.5 or less, or about 6.0 or less, or even about 5.5 or less. According to still other embodiments, the ceramified filler component may have an aspect ratio of at least about 2.0, e.g., 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 will be understood that the ceramified filler component may have an aspect ratio of any value within a range between any of the minimum and maximum values ​​recited above. It will further be understood that the ceramified filler component may have an aspect ratio of any value between any of the minimum and maximum values ​​recited above.

[0015] According to still other embodiments, the filler composition may contain a specific content of the ceramified filler component. For example, the filler composition may contain a content of the ceramified filler component of at least about 75 wt%, e.g., 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%, based on the total weight of the filler composition. According to still other embodiments, the filler composition may contain a content of the ceramified filler component of about 95 wt% or less, e.g., about 94 wt% or less, or about 93 wt% or less, or about 92 wt% or less, or about 91 wt% or less, or about 90 wt% or less, or about 89 wt% or less, or about 88 wt% or less, or even about 87 wt% or less, based on the total weight of the filler composition. It will be understood that the filler composition may include any value of the ceramified filler component content within a range between any of the minimum and maximum values ​​recited above. It will further be understood that the filler composition may include any value of the ceramified filler component content within any of the minimum and maximum values ​​recited above.

[0016] According to certain embodiments, the structure promoter component may include certain components. For example, the structure promoter component may include a component selected from the group consisting of crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof. According to still other embodiments, the structure promoter component may include crystalline silica. According to still 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 still other embodiments, the structure promoter component may consist of diopside. According to still other embodiments, the structure promoter component may include spodumene. According to still other embodiments, the structure promoter component may consist of spodumene. According to still other embodiments, the structure promoter component may include lepidolite. According to still other embodiments, the structure promoter component may consist of lepidolite. According to still other embodiments, the structure promoter component may include lithium carbonate. According to still other embodiments, the structure promoter component may consist of lithium carbonate. According to yet other embodiments, the structure promoter component may include lithium hydroxide. According to yet other embodiments, the structure promoter component may consist of lithium hydroxide.

[0017] According to still other embodiments, the filler composition may include a specific content of the structure-enhancing component. For example, the filler composition may include a content of the structure-enhancing component of at least about 0.1 wt.%, e.g., 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 include a content of the structure-enhancing component of about 7.0 wt.% or less, e.g., about 6.5 wt.% or less, or about 6.0 wt.% or less, or about 5.5 wt.% or less, or about 5.0 wt.% or less, or about 4.5 wt.% or less, or even about 4.0 wt.% or less, based on the total weight of the filler composition. It will be understood that the filler composition may include any value within a range between any of the minimum and maximum values ​​listed above. It will further be appreciated that the filler composition may include any amount of structure-enhancing agent component between any of the minimum and maximum amounts recited above.

[0018] According to certain embodiments, the flux components may include certain components. For example, the flux components may include a component selected from the group consisting of low-T glass frit, zinc oxide, zinc borate, antimony (III) oxide, bismuth (III) oxide, or any combination thereof. According to still other embodiments, the flux components may include low-T glass frit. According to still other embodiments, the flux components may consist of low-T glass frit. According to still other embodiments, the flux components may include zinc oxide. According to still other embodiments, the flux components may consist of zinc oxide. According to still other embodiments, the flux components may include zinc borate. According to still other embodiments, the flux components may consist of zinc borate. According to still other embodiments, the flux components may include antimony (III) oxide. According to still other embodiments, the flux components may consist of antimony (III) oxide. According to still other embodiments, the flux components may include bismuth (III) oxide. According to yet another embodiment, the flux component may consist of bismuth (III) oxide.

[0019] According to still other embodiments, the filler composition may include a specific flux component content. For example, the filler composition may include a flux component content of at least about 0.1 wt %, e.g., 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 include a flux component content of about 7.0 wt % or less, e.g., about 6.5 wt % or less, or about 6.0 wt % or less, or about 5.5 wt % or less, or about 5.0 wt % or less, or about 4.5 wt % or less, or even about 4.0 wt % or less, based on the total weight of the filler composition. It will be understood that the filler composition may include any flux component content within a range between any of the minimum and maximum values ​​listed above. It will further be appreciated that the filler composition may contain any flux component content between any of the minimum and maximum values ​​recited above.

[0020] According to certain embodiments, the flame retardant component may include a particular component. For example, the flame retardant component may include a component 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.

[0021] According to still other embodiments, the filler composition may contain a specific content of the flame retardant component. For example, the filler composition may contain at least about 5.0 wt. %, e.g., 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, based on the total weight of the filler composition. According to still other embodiments, the filler composition may contain no more than about 20.0 wt. %, e.g., no more than about 19.0 wt. %, or no more than about 18.0 wt. %, or no more than about 17.0 wt. %, or no more than about 16.0 wt. %, or no more than about 15.0 wt. %, or even no more than about 14.0 wt. % of the flame retardant component, based on the total weight of the filler composition. It will be understood that the filler composition may contain any value within a range between any of the minimum and maximum values ​​listed above. It will further be understood that the filler composition may contain any amount of flame retardant component between any of the minimum and maximum values ​​recited above.

[0022] According to still other embodiments, the filler composition may further comprise a functional additive. According to still other embodiments, the functional additive may comprise a specific component. For example, the functional additive may comprise a component 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 comprise iron(III) oxide. According to still other embodiments, the functional additive component may consist of iron(III) oxide. According to still other embodiments, the functional additive component may comprise titanium oxide. According to still other embodiments, the functional additive component may consist of titanium oxide.

[0023] According to still other embodiments, the filler composition may contain a specific content of functional additive. For example, the filler composition may contain at least about 0.1 wt. %, e.g., 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 functional additive, based on the total weight of the filler composition. According to still other embodiments, the filler composition may contain no more than about 7.0 wt. %, e.g., no more than about 6.5 wt. %, or no more than about 6.0 wt. %, or no more than about 5.5 wt. %, or no more than about 5.0 wt. %, or no more than about 4.5 wt. %, or even no more than about 4.0 wt. It will be understood that the filler composition may contain any value of functional additive within a range between any of the minimum and maximum values ​​listed above. It will be further understood that the filler composition may include any value of functional additive content between any of the minimum and maximum values ​​recited above.

[0024] Turning now to composite material embodiments, the composite material can include a polymeric matrix component and a filler composition distributed within the polymeric matrix.

[0025] For illustrative purposes, Figure 1 shows a composite material 100 according to embodiments described herein. As shown in Figure 1, composite material 100 can include a polymer-based matrix component 110 and a filler composition 120 distributed within polymer-based matrix component 110.

[0026] According to certain embodiments, the polymer-based matrix component 110 of the composite material 100 may include certain materials. For example, the polymer-based matrix component 110 may include a component selected from the group consisting of silicone, polyurethane, epoxy, acrylic, or any combination thereof. According to still other embodiments, the polymer-based matrix component 110 may include silicone. According to still other embodiments, the polymer-based matrix component 110 may be comprised of silicone. According to still other embodiments, the polymer-based matrix component 110 may include polyurethane. According to still other embodiments, the polymer-based matrix component 110 may be comprised of polyurethane. According to still other embodiments, the polymer-based matrix component 110 may include epoxy. According to still other embodiments, the polymer-based matrix component 110 may be comprised of epoxy. According to still other embodiments, the polymer-based matrix component 110 may include acrylic. According to still other embodiments, the polymer-based matrix component 110 may be comprised of acrylic.

[0027] According to still other embodiments, the composite material 100 can include a particular content of the polymer-based matrix component 110. For example, the composite material 100 can include a polymer-based matrix component content of at least about 30 wt%, e.g., 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%, based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 can include a polymer-based matrix component content of about 60 wt% or less, e.g., about 58 wt% or less, or about 55 wt% or less, or about 53 wt% or less, or even about 50 wt% or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 can include any value of the polymer-based matrix component content within a range between any of the minimum and maximum values ​​noted above. It will be further understood that the composite material 100 may include any value of polymeric matrix component content between any of the minimum and maximum values ​​listed above.

[0028] According to still other embodiments, the composite material 100 can include a particular content of the filler composition 120. For example, the composite material 100 can include a filler composition content of at least about 40 wt%, e.g., 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%, based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 can include a filler composition content of about 70 wt% or less, e.g., about 68 wt% or less, or about 65 wt% or less, or about 63 wt% or less, or even about 60 wt% or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 can include any value of the filler composition content within a range between any of the minimum and maximum values ​​noted above. It will be further understood that the composite material 100 may include any value of filler composition content between any of the minimum and maximum values ​​noted above.

[0029] According to certain embodiments, the filler composition 120 may include a ceramifying filler component, a structure promoter component, a flux component, and a flame retardant component.

[0030] According to certain embodiments, the ceramified filler component of filler composition 120 may include certain components. For example, the ceramified filler component may include a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. According to still other embodiments, the ceramified filler component may include sepiolite. According to still other embodiments, the ceramified filler component may consist of sepiolite. According to still other embodiments, the ceramified filler component may include wollastonite. According to still other embodiments, the ceramified filler component may consist of wollastonite. According to still other embodiments, the ceramified filler component may include a combination of sepiolite and wollastonite. According to still other embodiments, the ceramified filler component may consist of a combination of sepiolite and wollastonite.

[0031] According to still other embodiments, the ceramified filler component of the filler composition 120 can be a plurality of particles. According to still other embodiments, the ceramified filler component can have a particular aspect ratio. For purposes of the embodiments described herein, the aspect ratio of the ceramified filler component can be defined as the average length of a statistically significant number of particles of the ceramified filler component divided by the average diameter of a statistically significant number of particles of the ceramified filler component (L / D). For example, the ceramified filler component can have an aspect ratio of about 10.0 or less, e.g., about 9.5 or less, or about 9.0 or less, or about 8.5 or less, or about 8.0 or less, or about 7.5 or less, or about 7.0 or less, or about 6.5 or less, or about 6.0 or less, or even about 5.5 or less. According to still other embodiments, the ceramified filler component may have an aspect ratio of at least about 2.0, e.g., 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 will be understood that the ceramified filler component may have an aspect ratio of any value within a range between any of the minimum and maximum values ​​recited above. It will further be understood that the ceramified filler component may have an aspect ratio of any value between any of the minimum and maximum values ​​recited above.

[0032] According to still other embodiments, the filler composition 120 may include a particular content of the ceramified filler component. For example, the filler composition 120 may include a ceramified filler component content of at least about 75 wt%, e.g., 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%, based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may comprise a ceramified filler component content of about 95% by weight or less, e.g., about 94% by weight or less, or about 93% by weight or less, or about 92% by weight or less, or about 91% by weight or less, or about 90% by weight or less, or about 89% by weight or less, or about 88% by weight or less, or even about 87% by weight or less, based on the total weight of the filler composition 120. It will be understood that the filler composition 120 may comprise a ceramified filler component content of any value within a range between any of the above minimum and maximum values. It will further be understood that the filler composition 120 may comprise a ceramified filler component content of any value within any of the above minimum and maximum values.

[0033] According to still other embodiments, the composite material 100 can include a particular content of the ceramified filler component. For example, the composite material 100 can include a ceramified filler component content of at least about 50 wt.%, e.g., 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.%, based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include a ceramified filler component content of about 70 wt% or less, e.g., about 69 wt% or less, about 68 wt% or less, or about 67 wt% or less, or about 66 wt% or less, or about 65 wt% or less, or about 64 wt% or less, or about 63 wt% or less, or about 62 wt% or less, or about 61 wt% or less, or even about 60 wt% or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 may include any value of the ceramified filler component content within a range between any of the above minimum and maximum values. It will further be understood that the composite material 100 may include any value of the ceramified filler component content within a range between any of the above minimum and maximum values.

[0034] According to certain embodiments, the structure promoter component of filler composition 120 may include certain ingredients. For example, the structure promoter component may include an ingredient selected from the group consisting of crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof. According to still other embodiments, the structure promoter component may include crystalline silica. According to still 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 still other embodiments, the structure promoter component may consist of diopside. According to still other embodiments, the structure promoter component may include spodumene. According to still other embodiments, the structure promoter component may consist of spodumene. According to still other embodiments, the structure promoter component may include lepidolite. According to still other embodiments, the structure promoter component may consist of lepidolite. According to still other embodiments, the structure promoter component may include lithium carbonate. According to still other embodiments, the structure promoter component may consist of lithium carbonate. According to yet other embodiments, the structure promoter component may include lithium hydroxide. According to yet other embodiments, the structure promoter component may consist of lithium hydroxide.

[0035] According to still other embodiments, the filler composition 120 can include a specific content of the structure-enhancing component. For example, the filler composition 120 can include a content of the structure-enhancing component of at least about 0.1 wt %, e.g., 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 can include a content of the structure-enhancing component of not more than about 7.0 wt %, e.g., 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 120. It will be appreciated that filler composition 120 can include any value of the structure-enhancing component content within a range between any of the minimum and maximum values ​​noted above. It will further be appreciated that filler composition 120 can include any value of the structure-enhancing component content within any of the minimum and maximum values ​​noted above.

[0036] According to still other embodiments, the composite material 100 may include a specific content of the structure-enhancing component. For example, the composite material 100 may include a content of the structure-enhancing component of at least about 0.05 wt %, e.g., 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 content of the structure-enhancing component of not more than about 5.0 wt %, e.g., 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 will be understood that the composite material 100 may include a content of the structure-enhancing component of any value within a range between any of the minimum and maximum values ​​noted above. It will be further understood that the composite material 100 may include any value of the structure-enhancing component content between any of the minimum and maximum values ​​noted above.

[0037] According to certain embodiments, the flux components of filler composition 120 may include certain ingredients. For example, the flux components may include ingredients selected from the group consisting of low-T glass frit, zinc oxide, zinc borate, antimony (III) oxide, bismuth (III) oxide, or any combination thereof. According to still other embodiments, the flux components may include low-T glass frit. According to still other embodiments, the flux components may consist of low-T glass frit. According to still other embodiments, the flux components may include zinc oxide. According to still other embodiments, the flux components may consist of zinc oxide. According to still other embodiments, the flux components may include zinc borate. According to still other embodiments, the flux components may consist of zinc borate. According to still other embodiments, the flux components may include antimony (III) oxide. According to still other embodiments, the flux components may consist of antimony (III) oxide. According to still other embodiments, the flux components may include bismuth (III) oxide. According to yet another embodiment, the flux component may consist of bismuth (III) oxide.

[0038] According to still other embodiments, the filler composition 120 may include a specific content of the flux component. For example, the filler composition 120 may include a flux component content of at least about 0.1 wt %, e.g., 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 include a flux component content of about 7.0 wt % or less, e.g., about 6.5 wt % or less, or about 6.0 wt % or less, or about 5.5 wt % or less, or about 5.0 wt % or less, or about 4.5 wt % or less, or even about 4.0 wt % or less, based on the total weight of the filler composition 120. It will be appreciated that filler composition 120 may include any flux component content within a range between any of the minimum and maximum values ​​noted above. It will further be appreciated that filler composition 120 may include any flux component content within a range between any of the minimum and maximum values ​​noted above.

[0039] According to still other embodiments, the composite material 100 may include a particular content of the flux component. For example, the composite material 100 may include a flux component content of at least about 0.01 wt %, e.g., 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 %, based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include a flux component content of about 5.0 wt % or less, e.g., about 4.5 wt % or less, or about 4.0 wt % or less, or about 3.5 wt % or less, or even about 3.0 wt % or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 may include any value of the flux component content within a range between any of the minimum and maximum values ​​listed above. It will be further understood that the composite material 100 may include any flux component content between any of the minimum and maximum values ​​listed above.

[0040] According to certain embodiments, the flame retardant component of filler composition 120 can include certain ingredients. For example, the flame retardant component can include an ingredient selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof. According to still other embodiments, the flame retardant component can include aluminum hydroxide. According to yet other embodiments, the flame retardant component can consist of aluminum hydroxide. According to still other embodiments, the flame retardant component can include magnesium hydroxide. According to yet other embodiments, the flame retardant component can consist of magnesium hydroxide.

[0041] According to still other embodiments, the filler composition 120 may include a specific content of the flame retardant component. For example, the filler composition 120 may include a content of the flame retardant component of at least about 5.0 wt.%, e.g., 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.%, based on the total weight of the filler composition 120. According to still other embodiments, the filler composition 120 may include a content of the flame retardant component of not more than about 20.0 wt.%, e.g., not more than about 19.0 wt.%, or not more than about 18.0 wt.%, or not more than about 17.0 wt.%, or not more than about 16.0 wt.%, or not more than about 15.0 wt.%, or even not more than about 14.0 wt.%, based on the total weight of the filler composition 120. It will be understood that filler composition 120 can include any value of the flame retardant component content within a range between any of the minimum and maximum values ​​noted above. It will further be understood that filler composition 120 can include any value of the flame retardant component content within any of the minimum and maximum values ​​noted above.

[0042] According to still other embodiments, the composite material 100 may include a specific content of the flame retardant component. For example, the composite material 100 may include a content of the flame retardant component of at least about 2.5 wt.%, e.g., 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.%, based on the total weight of the composite material 100. According to still other embodiments, the composite material 100 may include a content of the flame retardant component of about 10.0 wt.% or less, e.g., about 9.5 wt.% or less, or about 9.0 wt.% or less, or about 8.5 wt.% or less, or about 8.0 wt.% or less, or about 7.5 wt.% or less, or even about 7.0 wt.% or less, based on the total weight of the composite material 100. It will be appreciated that composite material 100 may include any value of the flame retardant component content within a range between any of the minimum and maximum values ​​noted above. It will further be appreciated that composite material 100 may include any value of the flame retardant component content within any of the minimum and maximum values ​​noted above.

[0043] According to still other embodiments, the filler composition 120 may further include a functional additive. According to still other embodiments, the functional additive may include a specific component. For example, the functional additive may include a component 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 still 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 still other embodiments, the functional additive component may consist of titanium oxide.

[0044] According to still other embodiments, the filler composition 120 may include a specific content of functional additives. For example, the filler composition 120 may include a functional additive content of at least about 0.1 wt %, e.g., 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 include a functional additive content of about 7.0 wt % or less, e.g., about 6.5 wt % or less, or about 6.0 wt % or less, or about 5.5 wt % or less, or about 5.0 wt % or less, or about 4.5 wt % or less, or even about 4.0 wt % or less, based on the total weight of the filler composition 120. It will be understood that filler composition 120 can include any value of functional additive content within a range between any of the minimum and maximum values ​​noted above. It will further be understood that filler composition 120 can include any value of functional additive content within any of the minimum and maximum values ​​noted above.

[0045] According to still other embodiments, the composite material 100 may include a specific content of functional additive. For example, the composite material 100 may include a functional additive content of at least about 0.05 wt %, e.g., 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 functional additive content of about 5.0 wt % or less, e.g., about 4.5 wt % or less, or about 4.0 wt % or less, or about 3.5 wt % or less, or even about 3.0 wt % or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 may include any value of functional additive content within a range between any of the minimum and maximum values ​​recited above. It will further be understood that the composite material 100 may include any value of functional additive content within any of the minimum and maximum values ​​recited above.

[0046] According to certain embodiments, the composite material 100 may have a particular flammability rating when measured according to ASTM D3801. In particular, the composite material 100 may have a V-0 flammability rating when measured according to ASTM D3801.

[0047] According to yet another embodiment, the composite material 100 may have a specific 5-minute hot plate exposure (HPE) cold side temperature as measured using a hot plate test conducted at 800°C for 5 minutes. For purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, composite material 100 may have a 5-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, composite material 100 may have a 5-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 5-minute HPE cold-side temperature of composite material 100 can be within a range between any of the above values. It will further be understood that the 5-minute HPE cold-side temperature of composite material 100 can be any value between any of the above values.

[0048] According to yet another embodiment, 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 purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, composite material 100 may have a 15-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, composite material 100 may have a 15-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 15-minute HPE cold-side temperature of composite material 100 can be within a range between any of the above values. It will further be understood that the 15-minute HPE cold-side temperature of composite material 100 can be any value between any of the above values.

[0049] According to yet another embodiment, 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 purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, composite material 100 may have a 30-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, composite material 100 may have a 30-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 30-minute HPE cold-side temperature of composite material 100 can be within a range between any of the above values. It will further be understood that the 30-minute HPE cold-side temperature of composite material 100 can be any value between any of the above values.

[0050] According to yet another embodiment, the composite material 100 may have a specific 5-minute torch exposure (TE) cold-side temperature as measured using a torch test conducted at 1300°C for 5 minutes. For purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, resulting in a total specimen thickness of 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite material 100 may have a 5-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite material 100 may have a 5-minute TE cold-side temperature of at least about 25°C. It will be understood that the 5-minute TE cold-side temperature of the composite material 100 may be within a range between any of the above values. It will further be understood that the 5-minute TE cold-side temperature of the composite material 100 may be any value between any of the above values.

[0051] According to yet another embodiment, 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 purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, resulting in a total specimen thickness of 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite material 100 may have a 15-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite material 100 may have a 15-minute TE cold-side temperature of at least about 25°C. It will be understood that the 15-minute TE cold-side temperature of the composite material 100 can be within a range between any of the above values. It will further be understood that the 15-minute TE cold-side temperature of the composite material 100 can be any value between any of the above values.

[0052] According to yet another embodiment, 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 purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, resulting in a total specimen thickness of 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite material 100 may have a 30-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. 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 will be understood that the 30-minute TE cold-side temperature of the composite material 100 can be within a range between any of the above values. It will further be understood that the 30-minute TE cold-side temperature of the composite material 100 can be any value between any of the above values.

[0053] According to yet other embodiments, the composite material 100 may have a particular density. For purposes of the embodiments described herein, the density of the composite material 100 may be determined according to ASTM D1056. According to one particular embodiment, the composite material 100 has a density of about 1.7 kg / m 3 For example, about 1.6 kg / m 3 or less, or about 1.5 kg / m 3 or less, or about 1.4 kg / m 3 Less than or about 1.3kg / m 3or less, or about 1.2 kg / m 3 or less, or about 1.1 kg / m 3 or less, or about 1.0 kg / m 3 or less, or about 0.9 kg / m 3 or less, or about 0.8 kg / m 3 Less than or about 0.7kg / m 3 or less, or about 0.6 kg / m 3 or less, or about 0.5 kg / m 3 or less, or even about 0.4 kg / m 3 According to yet another embodiment, the composite material 100 may have a density of at least about 0.001 kg / m 3 It will be appreciated that the density of composite material 100 can be within a range between any of the minimum and maximum values ​​noted above. It will be further appreciated that the density of composite material 100 can be any value between any of the minimum and maximum values ​​noted above.

[0054] According to yet other embodiments, the composite material 100 may have a specific weight. According to one particular embodiment, the composite material 100 has a weight of at least about 0.001 kg / m 2 , e.g., 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 According to yet another embodiment, the composite material 100 may have a weight of about 2.61 kg / m 2 It may have the following weight: It will be understood that the weight of the composite material 100 may be within a range between any of the minimum and maximum values ​​noted above. It will further be understood that the weight of the composite material 100 may be any value between any of the minimum and maximum values ​​noted above.

[0055] According to yet other embodiments, the composite material 100 may have a particular hardness. For purposes of the embodiments described herein, the hardness of the composite material 100 may be determined according to ASTM D2240. According to certain embodiments, the composite material 100 may have a hardness of at least about 61 Shore A, e.g., 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 yet other embodiments, the composite material 100 may have a hardness of about 71 Shore A or less, e.g., about 70 Shore A or less, or about 69 Shore A or less, or about 68 Shore A or less, or about 67 Shore A or less, or even about 66 Shore A or less. It will be understood that the hardness of the composite material 100 may be within a range between any of the minimum and maximum values ​​noted above. It will further be understood that the hardness of the composite material 100 may be any value between any of the minimum and maximum values ​​noted above.

[0056] According to yet other embodiments, the composite material 100 may have a particular tensile strength. For purposes of the embodiments described herein, the tensile strength of the composite material 100 may be determined according to ASTM D412. According to certain embodiments, the composite material 100 may have a tensile strength of at least about 2.3 MPa, e.g., 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 about 500 MPa or less. It will be understood that the tensile strength of the composite material 100 may be within a range between any of the minimum and maximum values ​​noted above. It will further be understood that the tensile strength of the composite material 100 may be any value between any of the minimum and maximum values ​​noted above.

[0057] Turning now to embodiments of composite layers, the composite materials described herein may be formed as layers of material. It will be understood that, according to certain embodiments, the composite layers described herein may include any of the components described herein with respect to composite material 100. It will be further understood that, according to certain embodiments, the composite layers described herein may have any of the characteristics described herein with respect to composite material 100.

[0058] According to yet other embodiments, the composite layer can have a specific thickness. For example, the composite layer can have a thickness of at least about 0.2 mm, e.g., 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 layer can have a thickness of about 10 mm or less, e.g., about 9.5 mm or less, or about 9.0 mm or less, or about 8.5 mm or less, or about 8.0 mm or less, or about 7.5 mm or less, or about 7.0 mm or less, or about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the composite layer can be within a range between any of the minimum and maximum values ​​recited above. It will be further understood that the thickness of the composite layer can be any value between any of the minimum and maximum values ​​listed above.

[0059] According to certain embodiments, the composite layer may have a particular flammability rating when measured according to ASTM D3801. In particular, the composite layer may have a V-0 flammability rating when measured according to ASTM D3801.

[0060] According to yet other embodiments, a 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 5 minutes. For purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, the composite layer may have a 5-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 5-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 5-minute HPE cold-side temperature of the composite layer may be within a range between any of the above values. It will further be understood that the 5-minute HPE cold-side temperature of the composite layer may be any value between any of the above values.

[0061] According to yet other embodiments, a composite 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 purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, the composite layer may have a 15-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 15-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 15-minute HPE cold-side temperature of the composite layer can be within a range between any of the above values. It will further be understood that the 15-minute HPE cold-side temperature of the composite layer can be any value between any of the above values.

[0062] According to yet other embodiments, a composite 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 purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm x 25 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is placed on 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 a specified time. According to certain embodiments, the composite layer may have a 30-minute HPE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 30-minute HPE cold-side temperature of at least about 25°C. It will be understood that the 30-minute HPE cold-side temperature of the composite layer can be within a range between any of the above values. It will further be understood that the 30-minute HPE cold-side temperature of the composite layer can be any value between any of the above values.

[0063] According to yet another embodiment, the composite 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 purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of the composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite layer may have a 5-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 5-minute TE cold-side temperature of at least about 25°C. It will be understood that the 5-minute TE cold-side temperature of the composite layer may be within a range between any of the above values. It will further be understood that the 5-minute TE cold-side temperature of the composite layer may be any value between any of the above values.

[0064] According to yet another embodiment, a composite 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 purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite layer may have a 15-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 15-minute TE cold-side temperature of at least about 25°C. It will be understood that the 15-minute TE cold-side temperature of the composite layer may be within a range between any of the above values. It will further be understood that the 15-minute TE cold-side temperature of the composite layer may be any value between any of the above values.

[0065] According to yet another embodiment, a composite 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 purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm x 15 cm specimen of composite laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is secured in a holder. A torch is positioned 7 cm from the face of the specimen secured in the holder, with the composite side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite side of the specimen, and the specimen is allowed to reach and stabilize at the 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 of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to certain embodiments, the composite layer may have a 30-minute TE cold-side temperature of about 800°C or less, e.g., about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to still other embodiments, the composite layer may have a 30-minute TE cold-side temperature of at least about 25°C. It will be understood that the 30-minute TE cold-side temperature of the composite layer can be within a range between any of the above values. It will further be understood that the 30-minute TE cold-side temperature of the composite layer can be any value between any of the above values.

[0066] According to yet other embodiments, the composite layer may have a particular density. For purposes of the embodiments described herein, the density of the composite layer may be determined according to ASTM D1056. According to one particular embodiment, the composite layer may have a density of about 1.7 kg / m 3 For example, about 1.6 kg / m 3 or less, or about 1.5 kg / m 3 or less, or about 1.4 kg / m 3 Less than or about 1.3kg / m 3 or less, or about 1.2 kg / m 3or less, or about 1.1 kg / m 3 or less, or about 1.0 kg / m 3 or less, or about 0.9 kg / m 3 or less, or about 0.8 kg / m 3 Less than or about 0.7kg / m 3 or less, or about 0.6 kg / m 3 or less, or about 0.5 kg / m 3 or less, or even about 0.4 kg / m 3 According to yet another embodiment, the composite layer may have a density of at least about 0.001 kg / m 3 It will be appreciated that the density of the composite layer may be within a range between any of the minimum and maximum values ​​noted above. It will be further appreciated that the density of the composite layer may be any value between any of the minimum and maximum values ​​noted above.

[0067] According to yet other embodiments, the composite layer may have a specific weight. According to one particular embodiment, the composite layer may have a weight of at least about 0.001 kg / m 2 , e.g., 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 According to yet another embodiment, the composite layer may have a weight of about 2.61 kg / m 2 It may have the following weights: It will be understood that the weight of the composite layer may be within a range between any of the minimum and maximum values ​​noted above It will further be understood that the weight of the composite layer may be any value between any of the minimum and maximum values ​​noted above.

[0068] According to yet other embodiments, the composite layer may have a particular hardness. For 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, e.g., 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 yet other embodiments, the composite layer may have a hardness of about 71 Shore A or less, e.g., about 70 Shore A or less, or about 69 Shore A or less, or about 68 Shore A or less, or about 67 Shore A or less, or even about 66 Shore A or less. It will be understood that the hardness of the composite layer may be within a range between any of the minimum and maximum values ​​noted above. It will further be understood that the hardness of the composite layer may be any value between any of the minimum and maximum values ​​noted above.

[0069] According to yet other embodiments, the composite layer may have a specified tensile strength. For purposes of the embodiments described herein, the tensile strength of the composite layer may be determined according to ASTM D412. According to certain embodiments, the composite layer may have a tensile strength of at least about 2.3 MPa, e.g., 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 still other embodiments, the composite layer may have a tensile strength of about 500 MPa or less. It will be understood that the tensile strength of the composite layer may be within a range between any of the minimum and maximum values ​​noted above. It will further be understood that the tensile strength of the composite layer may be any value between any of the minimum and maximum values ​​noted above.

[0070] According to certain embodiments, the composite layers described herein may be formed according to any acceptable forming process for composite layers.

[0071] Turning now to additional embodiments described herein, such embodiments are generally directed to thermal barrier composites, which may include a composite material or composite layer as described herein. It will be understood that, according to certain embodiments, the thermal barrier composites described herein may include any of the components described herein with respect to composite material 100. It will be further understood that, according to certain embodiments, the thermal barrier composites described herein may have any of the characteristics described herein with respect to composite material 100.

[0072] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, those skilled in the art will understand that these aspects and embodiments are merely illustrative and do not limit the scope of the invention. An embodiment may follow any one or more of the embodiments listed below.

[0073] Embodiment 1. A filler composition comprising: a ceramifying filler component in an amount of at least about 75 wt. % and not more 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 more 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 more 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 more than about 20.0 wt. % based on the total weight of the filler composition.

[0074] Embodiment 2. A composite material comprising: a polymer-based matrix component; and a filler composition distributed within the polymer-based component, the filler composition comprising a ceramifying filler component, a structure-promoting component, a flux component, and a flame-retardant component.

[0075] Embodiment 3. A composite layer comprising: a polymer-based matrix component; and a filler composition distributed within the polymer-based component, the filler composition comprising a ceramifying filler component, a structure-enhancing component, a flux component, and a flame-retardant component.

[0076] Embodiment 4. The composite material or composite layer of embodiment 2 or 3, wherein the composite material or composite layer comprises a 5 minute HPE cold side temperature of about 800°C or less when measured 5 minutes after a hot plate test conducted at 800°C.

[0077] Embodiment 5. The composite material or composite layer of embodiment 2 or 3, wherein the composite material or composite layer comprises a 15 minute HPE cold side temperature of about 800°C or less when measured after 15 minutes of a hot plate test conducted at 800°C.

[0078] Embodiment 6. The composite material or composite layer of embodiment 2 or 3, wherein the composite material or composite layer comprises a 30 minute HPE cold side temperature of about 800°C or less when measured 30 minutes after a hot plate test conducted at 800°C.

[0079] Embodiment 7. A composite material or composite layer according to embodiment 2 or 3, wherein the composite material or composite layer comprises a 5 minute TE cold side temperature of about 800°C or less when measured at 5 minutes of a torch test conducted at 1300°C.

[0080] Embodiment 8. A composite material or composite layer according to embodiment 2 or 3, wherein the composite material or composite layer comprises a 15 minute TE cold side temperature of about 800°C or less when measured at 15 minutes of a torch test conducted at 1300°C.

[0081] Embodiment 9. A composite material or composite layer according to embodiment 2 or 3, wherein the composite material or composite layer comprises a 30 minute TE cold side temperature of about 800°C or less when measured at 30 minutes of a torch test conducted at 1300°C.

[0082] Embodiment 10. The composite material or composite layer of embodiment 2 or 3, wherein the composite material or composite layer comprises a V-0 flammability rating when measured according to ASTM D3801.

[0083] Embodiment 11. The composite material or composite layer of embodiment 2 or 3, wherein the polymer-based component comprises a component selected from the group consisting of silicone, polyurethane, epoxy, acrylic resin, or any combination thereof.

[0084] Embodiment 12. A composite material or composite layer according to embodiment 2 or 3, wherein the composite material comprises a polymeric component content of at least about 30 wt. % based on the total weight of the composite material.

[0085] Embodiment 13. A composite material or composite layer according to embodiment 2 or 3, wherein the composite material comprises a polymeric component content of about 60 wt % or less based on the total weight of the composite material.

[0086] Embodiment 14. The composite material or composite layer of embodiment 2 or 3, wherein the composite material comprises a filler composition content of at least about 40 wt. % based on the total weight of the composite material.

[0087] Embodiment 15. The composite material or composite layer of embodiment 2 or 3, wherein the composite material comprises a filler composition content of about 70 wt.% or less, based on the total weight of the composite material.

[0088] Embodiment 16. A composite material or composite layer according to any one of embodiments 1, 2, and 3, wherein the ceramified filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof.

[0089] Embodiment 17. A composite material or composite layer according to embodiment 16, wherein the ceramified filler component has an aspect ratio (length / diameter) of about 10 or less.

[0090] Embodiment 18. A composite material or composite layer according to embodiment 16, wherein the ceramified filler component has an aspect ratio (length / diameter) of at least about 2.

[0091] Embodiment 19. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a ceramified filler component content of at least about 75 wt. % based on the total weight of the filler composition.

[0092] Embodiment 20. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a ceramified filler component content of about 95 wt. % or less, based on the total weight of the filler composition.

[0093] Embodiment 21. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a ceramified filler component content of at least about 50 wt. % based on the total weight of the composite material.

[0094] Embodiment 22. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a ceramified filler component content of about 70 wt.% or less, based on the total weight of the composite material.

[0095] Embodiment 23. The composite material or composite layer of 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, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0096] Embodiment 24. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a content of the structure-enhancing agent component of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0097] Embodiment 25. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a structure-enhancing component content of about 7.0 wt. % or less, based on the total weight of the filler composition.

[0098] Embodiment 26. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a content of the structure-enhancing agent component of at least about 0.05 wt. %, based on the total weight of the composite material.

[0099] Embodiment 27. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a structure-enhancing component content of about 5 wt.% or less, based on the total weight of the composite material.

[0100] Embodiment 28. The composite or composite layer of any one of embodiments 1, 2, and 3, wherein the flux component comprises a component selected from the group consisting of low-T glass frit, zinc oxide, zinc borate, antimony (III) oxide, bismuth (III) oxide, or any combination thereof.

[0101] Embodiment 29. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a flux component content of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0102] Embodiment 30. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a flux component content of about 7.0 wt. % or less, based on the total weight of the filler composition.

[0103] Embodiment 31. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a flux component content of at least about 0.05 wt. % based on the total weight of the composite material.

[0104] Embodiment 32. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a flux component content of about 5 wt.% or less, based on the total weight of the composite material.

[0105] Embodiment 33. The composite or composite layer of 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.

[0106] Embodiment 34. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a flame retardant component content of at least about 5.0 wt. %, based on the total weight of the filler composition.

[0107] Embodiment 35. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a flame retardant component content of about 20.0 wt. % or less, based on the total weight of the filler composition.

[0108] Embodiment 36. The composite material or composite layer of embodiment 2 or 3, wherein the filler composition comprises a flame retardant component content of at least about 2.5 wt. % based on the total weight of the composite material.

[0109] Embodiment 37. A composite material or composite layer according to embodiment 2 or 3, wherein the filler composition comprises a flame retardant component content of 10 wt. % or less, based on the total weight of the composite material.

[0110] Embodiment 38. The composite material or composite layer of any one of embodiments 1, 2, and 3, wherein the filler composition further comprises a functional additive.

[0111] Embodiment 39. The composite material or composite layer of embodiment 38, wherein the functional additive comprises a component selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof.

[0112] Embodiment 40. The composite material or composite layer of embodiment 38, wherein the filler composition comprises a content of the functional additive of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0113] Embodiment 41. The composite material or composite layer of embodiment 38, wherein the filler composition comprises a functional additive content of about 7.0 wt. % or less, based on the total weight of the filler composition.

[0114] Embodiment 42. The composite material or composite layer of embodiment 38, wherein the filler composition comprises a content of the functional additive of at least about 0.05 wt. %, based on the total weight of the composite material.

[0115] Embodiment 43. The composite material or composite layer of embodiment 38, wherein the filler composition comprises a functional additive content of about 5 wt. % or less, based on the total weight of the composite material.

[0116] Embodiment 44. A composite material layer according to embodiment 3, wherein the material layer comprises a thickness of at least about 0.2 mm.

[0117] Embodiment 45. The composite material layer of embodiment 3, wherein the material layer has a thickness of about 3.0 mm or less.

[0118] Embodiment 46. The composite material has a thickness of about 1.7 kg / m 3 3. The composite layer of embodiment 2, comprising the following density:

[0119] Embodiment 47. The composite material has a viscosity of at least about 0.001 kg / m 3 3. The composite layer of embodiment 2, comprising a density of

[0120] Embodiment 48. The material layer has a thickness of about 1.7 kg / m 3 4. The composite layer of embodiment 3, comprising the following density:

[0121] Embodiment 49. The material layer has a thickness of at least about 0.001 kg / m 3 4. The composite layer of embodiment 3, comprising a density of

[0122] Embodiment 50. The composite material has a viscosity of at least about 0.001 kg / m 2 3. The composite layer of embodiment 2, comprising by weight:

[0123] Embodiment 51. The composite material has a hardness of about 2.61 kg / m 2 3. The composite layer of embodiment 2, comprising the following weights:

[0124] Embodiment 52. The material layer has a thickness of at least about 0.001 kg / m 2 4. The composite layer of embodiment 3, comprising by weight:

[0125] Embodiment 53. The material layer has a thickness of about 2.61 kg / m 2 4. The composite layer of embodiment 3, comprising the following weights:

[0126] Embodiment 54. The composite layer of embodiment 2, wherein the composite comprises a hardness of at least about 61 Shore A.

[0127] Embodiment 55. The composite layer of embodiment 2, wherein the composite comprises a hardness of about 71 Shore A or less.

[0128] Embodiment 56. A composite material layer according to embodiment 3, wherein the material layer comprises a hardness of at least about 61 Shore A.

[0129] Embodiment 57. A composite material layer according to embodiment 3, wherein the material layer comprises a hardness of about 71 Shore A or less.

[0130] Embodiment 58. The composite layer of embodiment 2, wherein the composite comprises a tensile strength of at least about 2.3 MPa.

[0131] Embodiment 59. The composite layer of embodiment 2, wherein the composite comprises a tensile strength of about 500 MPa or less.

[0132] Embodiment 60. A composite material layer according to embodiment 3, wherein the material layer comprises a tensile strength of at least about 10 MPa.

[0133] Embodiment 61. A composite material layer according to embodiment 3, wherein the material layer comprises a tensile strength of about 500 MPa or less.

[0134] Embodiment 62. A thermal barrier composite comprising a composite material, the composite material comprising a polymer-based matrix component and a filler composition distributed within the polymer-based component, the filler composition comprising a ceramifying filler component, a structure-promoting component, a flux component, and a flame-retardant component.

[0135] Embodiment 63. A thermal barrier composite comprising a composite layer, wherein the composite layer comprises a polymer-based matrix component and a filler composition distributed within the polymer-based component, and the filler composition comprises a ceramifying filler component, a structure-promoting component, a flux component, and a flame-retardant component.

[0136] Embodiment 64. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite or composite layer comprises a 5 minute HPE cold side temperature of about 800°C or less when measured 5 minutes after a hot plate test conducted at 800°C.

[0137] Embodiment 65. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite or composite layer comprises a 15 minute HPE cold side temperature of about 800°C or less when measured after 15 minutes of a hot plate test conducted at 800°C.

[0138] Embodiment 66. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite or composite layer comprises a 30 minute HPE cold side temperature of about 800°C or less when measured 30 minutes after a hot plate test conducted at 800°C.

[0139] Embodiment 67. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite material or composite layer comprises a 5-minute TE cold side temperature of about 800°C or less when measured at 5 minutes of a torch test conducted at 1300°C.

[0140] Embodiment 68. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite material or composite layer comprises a 15-minute TE cold side temperature of about 800°C or less when measured at 15 minutes of a torch test conducted at 1300°C.

[0141] Embodiment 69. A thermal barrier composite as described in embodiment 62 or 63, wherein the composite material or composite layer comprises a 15-minute TE cold side temperature of about 800°C or less when measured at 15 minutes of a torch test conducted at 1300°C.

[0142] Embodiment 70. A thermal barrier composite according to embodiment 62 or 63, wherein the composite or composite layer comprises a V-0 flammability rating when measured according to ASTM D3801.

[0143] Embodiment 71. A thermal barrier composite according to embodiment 62 or 63, wherein the polymer-based component comprises a component selected from the group consisting of silicone, polyurethane, epoxy, acrylic resin, or any combination thereof.

[0144] Embodiment 72. A thermal barrier composite according to embodiment 62 or 63, wherein the composite comprises a polymeric component content of at least about 30 wt. % based on the total weight of the composite.

[0145] Embodiment 73. A thermal barrier composite according to embodiment 62 or 63, wherein the composite comprises a polymeric component content of about 60 wt % or less, based on the total weight of the composite.

[0146] Embodiment 74. The thermal barrier composite of embodiment 62 or 63, wherein the composite comprises a filler composition content of at least about 40 wt. % based on the total weight of the composite.

[0147] Embodiment 75. The thermal barrier composite of embodiment 62 or 63, wherein the composite comprises a filler composition content of about 70 wt.% or less, based on the total weight of the composite.

[0148] Embodiment 76. The thermal barrier composite of embodiment 62 or 63, wherein the ceramified filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof.

[0149] Embodiment 77. The thermal barrier composite of embodiment 76, wherein the ceramified filler component has an aspect ratio (length / diameter) of about 10 or less.

[0150] Embodiment 78. The thermal barrier composite of embodiment 76, wherein the ceramified filler component has an aspect ratio (length / diameter) of at least about 2.

[0151] Embodiment 79. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a ceramifying filler component content of at least about 75 wt. % based on the total weight of the filler composition.

[0152] Embodiment 80. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a ceramifying filler component content of about 95 wt.% or less, based on the total weight of the filler composition.

[0153] Embodiment 81. A thermal barrier composite according to embodiment 62 or 63, wherein the filler composition comprises a ceramified filler component content of at least about 50 wt. % based on the total weight of the composite.

[0154] Embodiment 82. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a ceramified filler component content of about 70 wt.% or less, based on the total weight of the composite.

[0155] Embodiment 83. The thermal barrier composite of embodiment 62 or 63, wherein the structure promoter component comprises a component selected from the group consisting of crystalline silica, diopside, spodumene, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0156] Embodiment 84. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a content of the structure-enhancing agent component of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0157] Embodiment 85. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a structure-enhancing component content of about 7.0 wt. % or less, based on the total weight of the filler composition.

[0158] Embodiment 86. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a content of the structure-enhancing agent component of at least about 0.05 wt. %, based on the total weight of the composite.

[0159] Embodiment 87. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a structure-enhancing component content of about 5 wt.% or less, based on the total weight of the composite.

[0160] Embodiment 88. The thermal barrier composite of embodiment 62 or 63, wherein the flux component comprises a component selected from the group consisting of low-T glass frit, zinc oxide, zinc borate, antimony (III) oxide, bismuth (III) oxide, or any combination thereof.

[0161] Embodiment 89. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a flux component content of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0162] Embodiment 90. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a flux component content of about 7.0 wt.% or less, based on the total weight of the filler composition.

[0163] Embodiment 91. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a flux component content of at least about 0.05 wt. %, based on the total weight of the composite.

[0164] Embodiment 92. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a flux component content of about 5 wt.% or less, based on the total weight of the composite.

[0165] Embodiment 93. The thermal barrier composite of embodiment 62 or 63, wherein the flame retardant component comprises a component selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof.

[0166] Embodiment 94. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a content of the flame retardant component of at least about 5.0 wt. %, based on the total weight of the filler composition.

[0167] Embodiment 95. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition comprises a flame retardant component content of about 20.0 wt. % or less, based on the total weight of the filler composition.

[0168] Embodiment 96. A thermal barrier composite according to embodiment 62 or 63, wherein the filler composition comprises a content of the flame retardant component of at least about 2.5 wt. %, based on the total weight of the composite.

[0169] Embodiment 97. A thermal barrier composite according to embodiment 62 or 63, wherein the filler composition comprises a flame retardant component content of 10 wt.% or less, based on the total weight of the composite.

[0170] Embodiment 98. The thermal barrier composite of embodiment 62 or 63, wherein the filler composition further comprises a functional additive.

[0171] Embodiment 99. The composite or composite layer of embodiment 98, wherein the functional additive comprises a component selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof.

[0172] Embodiment 100. The composite material or composite layer of embodiment 98, wherein the filler composition comprises a content of the functional additive of at least about 0.1 wt. %, based on the total weight of the filler composition.

[0173] Embodiment 101. The composite material or composite layer of embodiment 98, wherein the filler composition comprises a functional additive content of about 7.0 wt. % or less, based on the total weight of the filler composition.

[0174] Embodiment 102. The composite material or composite layer of embodiment 98, wherein the filler composition comprises a content of the functional additive of at least about 0.05 wt. % based on the total weight of the composite material.

[0175] Embodiment 103. The composite material or composite layer of embodiment 98, wherein the filler composition comprises a content of functional additive of about 5 wt.% or less, based on the total weight of the composite material.

[0176] Embodiment 104. A composite material layer according to embodiment 63, wherein the material layer has a thickness of at least about 0.2 mm.

[0177] Embodiment 105. A composite material layer according to embodiment 63, wherein the material layer has a thickness of about 3.0 mm or less.

[0178] Embodiment 106. The composite material has a hardness of about 1.7±0.2 kg / m 3 63. The composite layer of embodiment 62, comprising the following density:

[0179] Embodiment 107. The composite material has a viscosity of at least about 0.001 kg / m 3 63. The composite layer of embodiment 62, comprising a density of:

[0180] Embodiment 108. The material layer has a thickness of about 1.7±0.2 kg / m 3 64. The composite layer of embodiment 63, comprising the following density:

[0181] Embodiment 109. The material layer has a thickness of at least about 0.001 kg / m 3 64. The composite layer of embodiment 63, comprising a density of:

[0182] Embodiment 110. The composite material has a viscosity of at least about 0.001 kg / m 2 63. The composite layer of embodiment 62, comprising by weight:

[0183] Embodiment 111. The composite material has a thickness of about 2.61 kg / m 2 63. The composite layer of embodiment 62, comprising the following weight:

[0184] Embodiment 112. The material layer has a thickness of at least about 0.001 kg / m 2 64. The composite layer of embodiment 63, comprising by weight:

[0185] Embodiment 113. The material layer has a thickness of about 2.61 kg / m 2 64. The composite layer of embodiment 63, comprising the following weight:

[0186] Embodiment 114. The composite layer of embodiment 62, wherein the composite comprises a hardness of at least about 61 Shore A.

[0187] Embodiment 115. The composite layer of embodiment 62, wherein the composite comprises a hardness of about 71 Shore A or less.

[0188] Embodiment 116. A composite material layer according to embodiment 63, wherein the material layer comprises a hardness of at least about 61 Shore A.

[0189] Embodiment 117. A composite material layer according to embodiment 63, wherein the material layer comprises a hardness of about 71 Shore A or less.

[0190] Embodiment 118. The composite layer of embodiment 62, wherein the composite comprises a tensile strength of at least about 2.3 MPa.

[0191] Embodiment 119. The composite layer of embodiment 62, wherein the composite comprises a tensile strength of about 500 MPa or less.

[0192] Embodiment 120. The composite material layer of embodiment 63, wherein the material layer comprises a tensile strength of at least about 10 MPa.

[0193] Embodiment 121. A composite material layer according to embodiment 63, wherein the material layer comprises a tensile strength of about 500 MPa or less.

[0194] It should be noted that in the general descriptions or examples, not all of the activities described above are required, some of the specific activities may not be required, and one or more additional activities may be performed in addition to the activities described. Still further, the order in which the activities are listed is not necessarily the order in which they are performed.

[0195] Benefits, other advantages, and solutions to problems have been described above with respect to particular embodiments. However, the benefits, advantages, solutions to problems, and any features that may provide or make more pronounced any benefit, advantage, or solution should not be construed as critical, necessary, or essential features of any or all claims.

[0196] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may be provided in combination in a single embodiment, and conversely, various features that are described for brevity in the context of a single embodiment may also be provided separately or in any subcombination. Furthermore, references to values ​​described in ranges include any and all values ​​within that range. Many other embodiments may become apparent to those skilled in the art only after reading this specification. Other embodiments may be utilized and derived from the present disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the present disclosure. Accordingly, the present disclosure should be considered illustrative, not restrictive.

Claims

1. 1. A filler composition comprising: a ceramified filler component in an amount of at least about 75 wt.% and no more than about 95 wt.% based on the total weight of the filler composition; a structure-enhancing component in an amount of at least about 0.1 wt. % and no more 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 more than about 7.0 wt. % based on the total weight of the filler composition; at least about 5.0 wt. % and no more than about 20.0 wt. % of a flame retardant component, based on the total weight of the filler composition.

2. A composite material comprising: a polymeric matrix component; a filler composition distributed within the polymeric component; The filler composition comprises: a ceramified filler component; and a structure promoter component; Flux components; and a flame retardant component.

3. A composite material layer, a polymeric matrix component; a filler composition distributed within the polymeric component; The filler composition comprises: a ceramified filler component; and a structure promoter component; Flux components; a flame retardant component.

4. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 5 minute HPE cold side temperature of about 800°C or less when measured after 5 minutes of a hot plate test conducted at 800°C.

5. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 15 minute HPE cold side temperature of about 800°C or less when measured after 15 minutes of a hot plate test conducted at 800°C.

6. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 30 minute HPE cold side temperature of about 800°C or less when measured after 30 minutes of a hot plate test conducted at 800°C.

7. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 5 minute TE cold side temperature of about 800°C or less as measured at 5 minutes of a torch test conducted at 1300°C.

8. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 15 minute TE cold side temperature of about 800°C or less as measured at 15 minutes of a torch test conducted at 1300°C.

9. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a 30 minute TE cold side temperature of about 800°C or less as measured at 30 minutes of a torch test conducted at 1300°C.

10. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material or composite layer comprises a V-0 flammability rating when measured according to ASTM D3801.

11. 4. The composite material or composite layer of claim 2 or 3, wherein the polymeric component comprises a component selected from the group consisting of silicone, polyurethane, epoxy, acrylic, or any combination thereof.

12. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material comprises a polymeric component content of at least about 30 wt. % based on the total weight of the composite material.

13. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material comprises a polymeric component content of about 60 wt% or less based on the total weight of the composite material.

14. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material comprises a filler composition content of at least about 40 wt. % based on the total weight of the composite material.

15. 4. The composite material or composite layer of claim 2 or 3, wherein the composite material comprises a filler composition content of about 70 wt% or less, based on the total weight of the composite material.

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