Multilayer composite with thermal barrier properties

Abstract

The present disclosure relates to a multi-layer composite that may include a first barrier layer and a first foam layer. The first foam layer may include a polyurethane-based matrix component and a flame-retardant filler component. The multi-layer component may also have an HBF flammability rating as measured according to ASTM D4986.

Description

[Technical Field]

[0001] This disclosure relates to multilayer composites, and more specifically to multilayer composites for various applications, such as use as a thermal barrier in battery packs, and to methods for forming such composites. [Overview of the project] [Problems that the invention aims to solve]

[0002] Multilayer composite films can be designed for high-temperature protection in a variety of applications, such as thermal barriers in electric vehicle battery packs, thermal barrier covers for high-temperature cable protection, and thermal barrier containers for thermal spray containment. However, in these and other applications, potential thermal growth continues to increase due to technological advancements. Therefore, improved barrier designs that protect against such high thermal potential are still needed.

[0003] According to the first embodiment, the multilayer composite may include a first barrier layer and a first foam layer. The first foam layer may include a polyurethane matrix component and a flame-retardant filler component. The multilayer components may also have an HBF flammability rating when measured according to ASTM D4986.

[0004] In yet another embodiment, the multilayer composite may include a first barrier layer and a first foam layer. The first foam layer may include a polyurethane matrix component and a flame-retardant filler component. The first barrier layer may include a material selected from the group consisting of mica, mica-glass fiber composites, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof. The flame-retardant filler component of the first foam layer may include a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0005] In another embodiment, the thermal barrier composite may include a first barrier layer and a first foam layer. The first foam layer may include a polyurethane matrix component and a flame-retardant filler component. The multilayer component may also have an HBF flammability rating when measured according to ASTM D4986.

[0006] In yet another embodiment, the thermal barrier composite may include a first barrier layer and a first foam layer. The first foam layer may include a polyurethane matrix component and a flame-retardant filler component. The first barrier layer may include a material selected from the group consisting of mica, mica-glass fiber composites, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof. The flame-retardant filler component of the first foam layer may include a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic compounds, and any combination thereof. [Brief explanation of the drawing]

[0007] The embodiments are shown as examples and are not limited to the accompanying drawings. [Figure 1] Figure 1 includes an illustrative diagram of an exemplary multilayer complex according to a specific embodiment described herein. [Figure 2] Figure 2 includes an illustrative diagram of an exemplary multilayer complex according to a specific embodiment described herein. [Figure 3] Figure 3 includes an illustrative diagram of an exemplary multilayer composite according to a specific embodiment described herein. [Figure 4] Figure 4 includes an illustrative diagram of an exemplary thermal barrier complex according to a specific embodiment described herein. [Figure 5] Figure 5 includes an illustrative diagram of an exemplary thermal barrier complex according to a specific embodiment described herein. [Figure 6] Figure 6 includes an illustrative diagram of an exemplary thermal barrier complex according to a specific embodiment described herein.

[0008] Those skilled in the art should understand that the elements in the figures are illustrated for the purpose of simplification and clarity, and are not necessarily drawn to scale. [Modes for carrying out the invention]

[0009] The following discussion focuses on specific embodiments and examples of the teachings. The detailed descriptions are provided to aid in illustrating specific embodiments and should not be construed as limitations on the scope or applicability of the disclosure or teachings. It will be understood that other embodiments can be used based on the disclosure and teachings provided herein.

[0010] The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variations thereof are intended to encompass non-exclusive inclusion. For example, a method, article, or apparatus that includes a list of features may include other features not explicitly listed, or other features inherent to such method, article, or apparatus, but is not necessarily limited to those features alone. Furthermore, unless otherwise stated, “or” refers to an inclusive or not an exclusive or. For example, condition A or B is satisfied by one of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0011] Furthermore, the use of "a" or "an" is used to describe elements and components described herein. This is done simply 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 singular including plural, or vice versa, unless it is clear that otherwise. For example, if a single article is described herein, two or more articles may be used instead of a single article. Similarly, if two or more articles are described herein, those two or more articles may be replaced with a single article.

[0012] The embodiments described herein generally relate to multilayer composites that may include a first barrier layer and a first foam layer. According to certain embodiments, the first foam layer may include a polyurethane matrix component and a flame-retardant filler component. According to other embodiments, the multilayer composite may exhibit an improved combination of flame resistance and compression performance.

[0013] For illustrative purposes, Figure 1 shows a multilayer composite 100 according to an embodiment described herein. As shown in Figure 1, the multilayer composite 100 may include a first barrier layer 102 and a first foam layer 104. The first foam layer 104 may include a polyurethane matrix component 110 and a flame-retardant filler component 120.

[0014] According to certain embodiments, the polyurethane matrix component 110 of the first foam layer 104 may include certain materials. For example, the polyurethane matrix component 110 of the first foam layer 104 may include a flexible polyurethane reacted from an isocyanate and a polyol.

[0015] According to certain embodiments, the polyurethane matrix component 110 of the first foam layer 104 may consist of a specific material. For example, the polyurethane matrix component 110 of the first foam layer 104 may consist of a flexible polyurethane reacted from an isocyanate and a polyol.

[0016] According to a particular embodiment, the polyurethane matrix component 110 of the first foam layer 104 may be a layer of a specific material. For example, the polyurethane matrix component 110 of the first foam layer 104 may be a flexible polyurethane layer reacted from an isocyanate and a polyol.

[0017] In further embodiments, the flame-retardant filler component 120 may be selected from a specific group of materials. For example, the flame-retardant filler component 120 may be a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0018] In further embodiments, the flame-retardant filler component 120 may include certain materials. For example, the flame-retardant filler component 120 may include a reactive carbonizing agent. A reactive carbonizing agent can be defined as a compound that reacts with a carbon source, such as a polymer material, at high temperatures to form a carbon layer. In further embodiments, the flame-retardant filler component 120 may include melamine. In further embodiments, the flame-retardant filler component 120 may include an organophosphorus compound. In further embodiments, the flame-retardant filler component 120 may include an inorganic phosphorus compound. In further embodiments, the flame-retardant filler component 120 may include a metal salt. In further embodiments, the flame-retardant filler component 120 may include an inorganic compound. In further embodiments, the flame-retardant filler component 120 may include an endothermic decomposition compound. According to other embodiments, the flame-retardant filler component 120 may include any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0019] In other embodiments, the flame-retardant filler component 120 may consist of specific materials. For example, the flame-retardant filler component 120 may consist of a reactive carbonizing agent. In yet another embodiment, the flame-retardant filler component 120 may consist of melamine. In yet another embodiment, the flame-retardant filler component 120 may consist of an organophosphorus compound. In yet another embodiment, the flame-retardant filler component 120 may consist of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 120 may consist of a metal salt. In yet another embodiment, the flame-retardant filler component 120 may consist of an inorganic compound. In yet another embodiment, the flame-retardant filler component 120 may consist of an endothermic decomposition compound. In yet another embodiment, the flame-retardant filler component 120 may consist of any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0020] In other embodiments, the flame-retardant filler component 120 may be a filler of a specific material. For example, the flame-retardant filler component 120 may be a filler of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 120 may be a filler of melamine. In yet another embodiment, the flame-retardant filler component 120 may be a filler of an organophosphorus compound. In other embodiments, the flame-retardant filler component 120 may be a filler of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 120 may be a filler of a metal salt. In yet another embodiment, the flame-retardant filler component 120 may be a filler of an inorganic compound. In other embodiments, the flame-retardant filler component 120 may be a filler of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 120 may be a filler of any combination of a reactive carbonizing agent, melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, inorganic compounds, or endothermic decomposition compounds.

[0021] In further embodiments, the flame-retardant filler component 120 may include certain organophosphorus compounds or inorganic phosphorus compounds. For example, the flame-retardant filler component 120 may include a phosphate. In yet another embodiment, the flame-retardant filler component 120 may include a phosphonate. In yet another embodiment, the flame-retardant filler component 120 may include a phosphine. In a particular embodiment, the flame-retardant filler component 120 may include any combination of phosphate, phosphonate, or phosphine.

[0022] In further embodiments, the flame-retardant filler component 120 may consist of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 120 may consist of a phosphate. In yet another embodiment, the flame-retardant filler component 120 may consist of a phosphonate. In yet another embodiment, the flame-retardant filler component 120 may consist of a phosphine. In a particular embodiment, the flame-retardant filler component 120 may consist of a phosphate, a phosphonate, or any combination of phosphines.

[0023] In further embodiments, the flame-retardant filler component 120 may be a filler of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 120 may be a phosphate filler. In yet another embodiment, the flame-retardant filler component 120 may be a phosphonate filler. In yet another embodiment, the flame-retardant filler component 120 may be a phosphine filler. In a particular embodiment, the flame-retardant filler component 120 may be a filler of phosphate, phosphonate, or any combination of phosphines.

[0024] In other embodiments, the flame-retardant filler component 120 may include a specific metal salt. For example, the flame-retardant filler component 120 may include aluminum diethyl phosphinate.

[0025] In other embodiments, the flame-retardant filler component 120 may consist of a specific metal salt. For example, the flame-retardant filler component 120 may consist of aluminum diethyl phosphinate.

[0026] In other embodiments, the flame-retardant filler component 120 may be a filler of a specific metal salt. For example, the flame-retardant filler component 120 may be an aluminum diethyl phosphine filler. In other embodiments, the flame-retardant filler component 120 may contain a specific inorganic compound. For example, the flame-retardant filler component 120 may contain expandable graphite.

[0027] In other embodiments, the flame-retardant filler component 120 may consist of a specific inorganic compound. For example, the flame-retardant filler component 120 may consist of expandable graphite.

[0028] In other embodiments, the flame-retardant filler component 120 may be a filler made of a specific inorganic compound. For example, the flame-retardant filler component 120 may be an expandable graphite filler.

[0029] In further embodiments, the flame-retardant filler component 120 may include certain endothermic decomposition compounds. For example, the flame-retardant filler component 120 may include metal hydrates. In further embodiments, the flame-retardant filler component 120 may include metal silicates. In further embodiments, the flame-retardant filler component 120 may include carbonates. In certain embodiments, the flame-retardant filler component 120 may include aluminum trihydrate. In further embodiments, the flame-retardant filler component 120 may include zinc borate. In further embodiments, the flame-retardant filler component 120 may include any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrate, or zinc borate.

[0030] In further embodiments, the flame-retardant filler component 120 may consist of a specific endothermic decomposition compound. For example, the flame-retardant filler component 120 may consist of a metal hydrate. In further embodiments, the flame-retardant filler component 120 may consist of a metal silicate. In further embodiments, the flame-retardant filler component 120 may consist of a carbonate. In a particular embodiment, the flame-retardant filler component 120 may consist of aluminum trihydrate. In further embodiments, the flame-retardant filler component 120 may consist of zinc borate. In further embodiments, the flame-retardant filler component 120 may consist of any combination of metal hydrate, metal silicate, carbonate, aluminum trihydrate, or zinc borate.

[0031] In further embodiments, the flame-retardant filler component 120 may be a filler of a specific endothermic decomposition compound. For example, the flame-retardant filler component 120 may be a metal hydrate filler. In further embodiments, the flame-retardant filler component 120 may be a metal silicate filler. In yet another embodiment, the flame-retardant filler component 120 may be a carbonate filler. In a particular embodiment, the flame-retardant filler component 120 may be an aluminum trihydrate filler. In yet another embodiment, the flame-retardant filler component 120 may be a zinc borate filler. In yet another embodiment, the flame-retardant filler component 120 may be a filler of any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrates, or zinc borate.

[0032] According to one embodiment, the first foam layer 104 may contain a specific amount of polyurethane matrix component 110. For example, the first foam layer 104 may contain a polyurethane matrix component content of at least about 40% by weight, e.g., at least about 45% by weight, or at least about 50% by weight, or at least about 55% by weight, or at least about 60% by weight, or at least about 65% by weight, or even at least about 70% by weight, relative to the total weight of the first foam layer 104. According to yet another embodiment, the first foam layer 104 may contain a polyurethane matrix component content of about 95% by weight or less, e.g., about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or even about 75% by weight, relative to the total weight of the first foam layer 104. It will be understood that the polyurethane matrix component content of the first foam layer 104 may be within a range of any of the above values. It will be further understood that the polyurethane matrix component content of the first foam layer 104 can be any value between the minimum and maximum values ​​mentioned above.

[0033] In other embodiments, the first foam layer 104 may contain a specific amount of flame-retardant filler component 120. For example, the first foam layer 104 may contain a flame-retardant filler component content of at least about 5% by weight, e.g., at least about 10% by weight, or at least about 15% by weight, or at least about 20% by weight, or at least about 25% by weight, or at least about 30% by weight, or even at least about 35% by weight, relative to the total weight of the first foam layer 104. In yet another embodiment, the first foam layer 104 may contain a flame-retardant filler component content of about 60% by weight or less, e.g., about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or even about 40% by weight, relative to the total weight of the first foam layer 104. It will be understood that the flame-retardant filler component content of the first foam layer 104 may be within the range of either the minimum or maximum values ​​described above. It will be further understood that the flame-retardant filler component content of the first foam layer 104 may be any value between the minimum and maximum values ​​mentioned above.

[0034] According to certain embodiments, the first foam layer 104 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HFB flammability rating when measured according to ASTM D4986.

[0035] According to one embodiment, the multilayer composite 100 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HFB flammability rating when measured according to ASTM D4986.

[0036] In other embodiments, the first foam layer 104 may have a specific lower temperature, measured at 5 minutes when a 3 mm thick foam is exposed to a 650°C hot plate test. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the lower surface temperature. In one embodiment, the first foam layer 104 may have a lower temperature of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the first foam layer 104 may have a lower temperature of at least about 25°C. It will be understood that the low-temperature side temperature of the first foam layer 104 may be within the range of any of the above values. It will be further understood that the low-temperature side temperature of the first foam layer 104 may be any value within the range of any of the above values.

[0037] In other embodiments, the multilayer composite 100 may have a specific low-temperature side when a 3 mm thick foam is exposed to a 650°C hot plate test, measured at 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the low-temperature side surface temperature. In one embodiment, the multilayer composite 100 may have a low-temperature side of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the multilayer composite 100 may have a low-temperature side of at least about 25°C. It will be understood that the low-temperature side temperature of the multilayer composite 100 may be within the range of any of the above values. It will be further understood that the low-temperature side of the multilayer composite 100 can be any value between any of the above values.

[0038] In further embodiments, the first foam layer 104 may have a specific thickness. For example, the first foam layer 104 may have a thickness of at least about 0.5 mm, for example, 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. In other embodiments, the first foam layer 104 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the first foam layer 104 may be within the range of any of the above minimum and maximum values. It will be further understood that the thickness of the first foam layer 104 can be any value between the minimum and maximum values ​​mentioned above.

[0039] In further embodiments, the multilayer composite 100 may have a specific thickness. For example, the multilayer composite 100 may have a thickness of at least about 0.5 mm, for example, 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. In addition, in further embodiments, the multilayer composite 100 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the multilayer composite 100 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the multilayer composite 100 may be any value between any of the above minimum and maximum values.

[0040] In further embodiments, the first foam layer 104 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain and is determined by measuring the force-to-compression and compression-force-deflection of the sample at 25% strain. Force-to-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at a desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0041] According to one embodiment, the first foam layer 104 may have a 25% strain compression rating of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the first foam layer 104 may have a 25% strain compression rating of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the first foam layer 104 may be within the range between any of the above minimum and maximum values. It will be further understood that the 25% strain compression evaluation of the first foam layer 104 may be any value between any of the above minimum and maximum values.

[0042] In further embodiments, the multilayer composite 100 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain and is determined by measuring the force-compression and compression-force-deflection of the sample at 25% strain. Force-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at the desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0043] According to one embodiment, the multilayer composite 100 may have a 25% strain compression evaluation of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the multilayer composite 100 may have a 25% strain compression evaluation of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the multilayer composite 100 can be within the range between any of the above minimum and maximum values. It will be further understood that the 25% strain compression evaluation of the multilayer composite 100 can be any value between any of the above minimum and maximum values.

[0044] According to yet another embodiment, the first foam layer 104 may have a specific density. For the purposes of the embodiments described herein, the density of the first foam layer 104 can be determined in accordance with ASTM D1056. According to one embodiment, the first foam layer 104 has a density of about 600 kg / m 3 or less, for example, about 575 kg / m 3 or less, or about 550 kg / m 3 or less, or about 525 kg / m 3 or less, or about 500 kg / m 3 or less, or about 450 kg / m 3 or less, or about 400 kg / m 3 or less, or about 350 kg / m 3 or less, or even about 300 kg / m 3 or less. According to yet another embodiment, the first foam layer 104 has a density of at least about 50 kg / m 3 , for example, at least about 60 kg / m 3 , or at least about 80 kg / m 3 , or at least about 100 kg / m3 , or at least about 120 kg / m 3 , or at least about 140 kg / m 3 , or at least about 160 kg / m 3 , or at least about 180 kg / m 3 , or at least about 200 kg / m 3 , or at least about 220 kg / m³ 3 , or even more, at least approximately 240 kg / m³ 3 It may have a density of . It will be understood that the density of the first foam layer 104 may be within the range between any of the above minimum and maximum values. It will be further understood that the density of the first foam layer 104 may be any value between any of the above minimum and maximum values.

[0045] In further embodiments, the multilayer composite 100 may have a specific density. For the purposes of the embodiments described herein, the density of the multilayer composite 100 may be determined according to ASTM D1056. According to one embodiment, the multilayer composite 100 has a density of approximately 600 kg / m³. 3 For example, approximately 575 kg / m³ 3 The following, or approximately 550 kg / m³ 3 The following, or approximately 525 kg / m³ 3 The following, or approximately 500 kg / m 3 The following, or approximately 450 kg / m³ 3 The following, or approximately 400 kg / m³ 3 The following, or approximately 350 kg / m 3 The following, or even more, approximately 300 kg / m 3 It may have the following densities. For example, the multilayer composite 100 may have at least about 50 kg / m³ 3 For example, at least about 60 kg / m³ 3 , or at least about 80 kg / m 3 , or at least about 100 kg / m 3 , or at least about 120 kg / m 3 , or at least about 140 kg / m 3 , or at least about 160 kg / m 3 , or at least about 180 kg / m 3 , or at least about 200 kg / m3 , or at least about 220 kg / m³ 3 , or even more, at least approximately 240 kg / m³ 3 It may have a density of . It will be understood that the density of the multilayer composite 100 may be within the range between any of the above minimum and maximum values. It will be further understood that the density of the multilayer composite 100 may be any value between any of the above minimum and maximum values.

[0046] In other embodiments, the first foam layer 104 may have a specific thermal conductivity when measured according to ASTM C518. For example, the first foam layer 104 may have a thermal conductivity of at least about 0.01 W / mK, for example, at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. In other embodiments, the first foam layer 104 may have a thermal conductivity of about 0.15 W / mK or less, for example, about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be understood that the thermal conductivity of the first foam layer 104 may be within the range between any of the above minimum and maximum values. It will be further understood that the thermal conductivity of the first foam layer 104 may be any value between any of the above minimum and maximum values.

[0047] In further embodiments, the multilayer composite 100 may have a specific thermal conductivity when measured according to ASTM C518. For example, the multilayer composite 100 may have a thermal conductivity of at least about 0.01 W / mK, for example, at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. In other embodiments, the multilayer composite 100 may have a thermal conductivity of about 0.15 W / mK or less, for example, about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be understood that the thermal conductivity of the multilayer composite 100 may be within the range between any of the above minimum and maximum values. It will be further understood that the thermal conductivity of the multilayer composite 100 may be any value between any of the above minimum and maximum values.

[0048] In other embodiments, the first barrier layer 102 may be made of a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0049] In other embodiments, the first barrier layer 102 may include certain materials. For example, the first barrier layer 102 may include mica. In other embodiments, the first barrier layer 102 may include a mica-glass fiber composite. In yet another embodiment, the first barrier layer 102 may include glass cloth. In other embodiments, the first barrier layer 102 may include silica cloth. In other embodiments, the first barrier layer 102 may include basalt cloth. In yet another embodiment, the first barrier layer 102 may include vermiculite-coated glass cloth. In other embodiments, the first barrier layer 102 may include aerogel. In yet another embodiment, the first barrier layer 102 may include nonwoven glass cloth. In other embodiments, the first barrier layer 102 may include any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In further embodiments, the first barrier layer 102 may include any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0050] In other embodiments, the first barrier layer 102 may be made of a specific material. For example, the first barrier layer 102 may be made of mica. In other embodiments, the first barrier layer 102 may be made of a mica-fiber glass composite. In yet another embodiment, the first barrier layer 102 may be made of glass cloth. In other embodiments, the first barrier layer 102 may be made of silica cloth. In other embodiments, the first barrier layer 102 may be made of basalt cloth. In yet another embodiment, the first barrier layer 102 may be made of vermiculite-coated glass cloth. In other embodiments, the first barrier layer 102 may be made of aerogel. In yet another embodiment, the first barrier layer 102 may be made of nonwoven glass cloth. In other embodiments, the first barrier layer 102 may consist of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the first barrier layer 102 may consist of any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0051] In other embodiments, the first barrier layer 102 may be a specific material layer. For example, the first barrier layer 102 may be a mica layer. In other embodiments, the first barrier layer 102 may be a mica-glass fiber composite layer. In yet another embodiment, the first barrier layer 102 may be a glass fiber layer. In another embodiment, the first barrier layer 102 may be a silica fiber layer. In another embodiment, the first barrier layer 102 may be a basalt cloth layer. In yet another embodiment, the first barrier layer 102 may be a vermiculite-coated glass fiber layer. In another embodiment, the first barrier layer 102 may be an aerogel layer. In yet another embodiment, the first barrier layer 102 may be a nonwoven glass cloth layer. In other embodiments, the first barrier layer 102 may be a layer of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the first barrier layer 102 may be a layer of any laminate of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0052] In further embodiments, the first barrier layer 102 may have a specific thickness. For example, the first barrier layer 102 may have a thickness of at least about 0.05 mm, for example, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or at least about 0.5 mm, or at least about 0.6 mm, or at least about 0.7 mm, or at least about 0.8 mm, or at least about 0.9 mm, or at least about 1.0 mm, or at least about 1.1 mm, or at least about 1.2 mm, or at least about 1.3 mm, or even at least about 1.4 mm. In addition, according to other embodiments, the first barrier layer 102 may have a thickness of about 7 mm or less, for example, about 6.5 mm or less, or about 6.0 mm or less, or about 5.5 mm or less, or about 5.0 mm or less, or about 4.5 mm or less, or about 4.0 mm or less, or about 3.5 mm or less, or about 3.0 mm or less, or about 2.9 mm or less, or about 2.8 mm or less, or about 2.7 mm or less, or about 2.6 mm or less, or about 2.5 mm or less, or about 2.4 mm or less, or about 2.3 mm or less, or even about 2.2 mm or less. It will be understood that the thickness of the first barrier layer 102 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the first barrier layer 102 may be any value between any of the above minimum and maximum values.

[0053] Figure 2 shows another multilayer composite 200 according to an embodiment described herein. As shown in Figure 2, the multilayer composite 200 may include a first barrier layer 202, a first foam layer 204, and a second barrier layer 206. The first foam layer 204 may include a polyurethane matrix component 210 and a flame-retardant filler component 220.

[0054] It will be understood that the multilayer composite 200, and all components described with respect to the multilayer composite 200 as shown in Figure 2, may have any of the properties described herein in relation to the corresponding components in Figure 1. In particular, the properties of the multilayer composite 200, the first barrier layer 202, the first foam layer 204, the polyurethane matrix component 210, and the flame-retardant filler component 220 shown in Figure 2 may each have any of the corresponding properties described herein with respect to the multilayer composite 100, the first barrier layer 102, the first foam layer 104, the polyurethane matrix component 110, and the flame-retardant filler component 120 shown in Figure 1.

[0055] In other embodiments, the second barrier layer 206 may be made of a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0056] In other embodiments, the second barrier layer 206 may include certain materials. For example, the second barrier layer 206 may include mica. In other embodiments, the second barrier layer 206 may include a mica-glass fiber composite. In yet another embodiment, the second barrier layer 206 may include glass cloth. In other embodiments, the second barrier layer 206 may include silica cloth. In other embodiments, the second barrier layer 206 may include basalt cloth. In yet another embodiment, the second barrier layer 206 may include vermiculite-coated glass cloth. In other embodiments, the second barrier layer 206 may include aerogel. In yet another embodiment, the second barrier layer 206 may include nonwoven glass cloth. In other embodiments, the second barrier layer 206 may include any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In further embodiments, the second barrier layer 206 may include any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0057] In other embodiments, the second barrier layer 206 may be made of a specific material. For example, the second barrier layer 206 may be made of mica. In other embodiments, the second barrier layer 206 may be made of a mica-fiber glass composite. In yet another embodiment, the second barrier layer 206 may be made of glass cloth. In other embodiments, the second barrier layer 206 may be made of silica cloth. In other embodiments, the second barrier layer 206 may be made of basalt cloth. In yet another embodiment, the second barrier layer 206 may be made of vermiculite-coated glass cloth. In other embodiments, the second barrier layer 206 may be made of aerogel. In yet another embodiment, the second barrier layer 206 may be made of nonwoven glass cloth. In other embodiments, the second barrier layer 206 may consist of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the second barrier layer 206 may consist of any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0058] In other embodiments, the second barrier layer 206 may be a specific material layer. For example, the second barrier layer 206 may be a mica layer. In other embodiments, the second barrier layer 206 may be a mica-glass fiber composite layer. In yet another embodiment, the second barrier layer 206 may be a glass fiber layer. In another embodiment, the second barrier layer 206 may be a silica fiber layer. In another embodiment, the second barrier layer 206 may be a basalt cloth layer. In yet another embodiment, the second barrier layer 206 may be a vermiculite-coated glass fiber layer. In another embodiment, the second barrier layer 206 may be an aerogel layer. In yet another embodiment, the second barrier layer 206 may be a nonwoven glass cloth layer. In other embodiments, the second barrier layer 206 may be a layer of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the second barrier layer 206 may be a layer of any laminate of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0059] In further embodiments, the second barrier layer 206 may have a specific thickness. For example, the second barrier layer 206 may have a thickness of at least about 0.05 mm, for example, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or at least about 0.5 mm, or at least about 0.6 mm, or at least about 0.7 mm, or at least about 0.8 mm, or at least about 0.9 mm, or at least about 1.0 mm, or at least about 1.1 mm, or at least about 1.2 mm, or at least about 1.3 mm, or even at least about 1.4 mm. In addition, according to other embodiments, the second barrier layer 206 may have a thickness of about 7 mm or less, for example, about 6.5 mm or less, or about 6.0 mm or less, or about 5.5 mm or less, or about 5.0 mm or less, or about 4.5 mm or less, or about 4.0 mm or less, or about 3.5 mm or less, or about 3.0 mm or less, or about 2.9 mm or less, or about 2.8 mm or less, or about 2.7 mm or less, or about 2.6 mm or less, or about 2.5 mm or less, or about 2.4 mm or less, or about 2.3 mm or less, or even about 2.2 mm or less. It will be understood that the thickness of the second barrier layer 206 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the second barrier layer 206 may be any value between any of the above minimum and maximum values.

[0060] Figure 3 shows another multilayer composite 300 according to an embodiment described herein. As shown in Figure 3, the multilayer composite 300 may include a first barrier layer 302, a first foam layer 304, a second foam layer 308, and a second barrier layer 306. The first foam layer 304 may include a polyurethane matrix component 310 and a flame-retardant filler component 320. The second foam layer 308 may include a polyurethane matrix component 340 and a flame-retardant filler component 350. As shown in Figure 3, both the first foam layer 304 and the second foam layer 308 are located between the first barrier layer 302 and the second barrier layer 306.

[0061] It will be understood that all components described with respect to the multilayer composite 300 and the multilayer composite 200 as shown in Figure 2 may have any of the properties described herein in relation to the corresponding components in Figure 1 and / or Figure 2. In particular, the properties of the multilayer composite 300, the first barrier layer 302, the first foam layer 304, the second barrier layer 306, the polyurethane matrix component 310, and the flame-retardant filler component 320 shown in Figure 3 may each have any of the corresponding properties described herein in relation to the multilayer composite 100 (200), the first barrier layer 102 (202), the first foam layer 104 (204), the polyurethane matrix component 110 (210), and the flame-retardant filler component 120 (220) shown in Figure 1 (Figure 2).

[0062] According to certain embodiments, the polyurethane matrix component 340 of the second foam layer 308 may include certain materials. For example, the polyurethane matrix component 340 of the second foam layer 308 may include a flexible polyurethane reacted from an isocyanate and a polyol.

[0063] According to certain embodiments, the polyurethane matrix component 340 of the second foam layer 308 may consist of a specific material. For example, the polyurethane matrix component 340 of the second foam layer 308 may consist of a flexible polyurethane reacted from an isocyanate and a polyol.

[0064] According to certain embodiments, the polyurethane matrix component 340 of the second foam layer 308 may be a layer of a specific material. For example, the polyurethane matrix component 340 of the second foam layer 308 may be a flexible polyurethane layer reacted from an isocyanate and a polyol.

[0065] In further embodiments, the flame-retardant filler component 350 may be selected from a specific group of materials. For example, the flame-retardant filler component 350 may be a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0066] In further embodiments, the flame-retardant filler component 350 may include certain materials. For example, the flame-retardant filler component 350 may include a reactive carbonizing agent. Here, the reactive carbonizing agent can be understood as a compound that can react with a carbon source, such as a polymer material, at high temperatures to form a carbon layer. In further embodiments, the flame-retardant filler component 350 may include melamine. In further embodiments, the flame-retardant filler component 350 may include an organophosphorus compound. In further embodiments, the flame-retardant filler component 350 may include an inorganic phosphorus compound. In further embodiments, the flame-retardant filler component 350 may include a metal salt. In further embodiments, the flame-retardant filler component 350 may include an inorganic compound. In further embodiments, the flame-retardant filler component 350 may include an endothermic decomposition compound. According to other embodiments, the flame-retardant filler component 350 may include any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0067] In other embodiments, the flame-retardant filler component 350 may consist of specific materials. For example, the flame-retardant filler component 350 may consist of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 350 may consist of melamine. In yet another embodiment, the flame-retardant filler component 350 may consist of melamine. In other embodiments, the flame-retardant filler component 350 may consist of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 350 may consist of a metal salt. In yet another embodiment, the flame-retardant filler component 350 may consist of an inorganic compound. In other embodiments, the flame-retardant filler component 350 may consist of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 350 may consist of any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0068] In other embodiments, the flame-retardant filler component 350 may be a filler of a specific material. For example, the flame-retardant filler component 350 may be a filler of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 350 may be a filler of melamine. In yet another embodiment, the flame-retardant filler component 350 may be a filler of an organophosphorus compound. In other embodiments, the flame-retardant filler component 350 may be a filler of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 350 may be a filler of a metal salt. In yet another embodiment, the flame-retardant filler component 350 may be a filler of an inorganic compound. In other embodiments, the flame-retardant filler component 350 may be a filler of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 350 may be a filler of any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0069] In further embodiments, the flame-retardant filler component 350 may include certain organophosphorus compounds or inorganic phosphorus compounds. For example, the flame-retardant filler component 350 may include a phosphate. In yet another embodiment, the flame-retardant filler component 350 may include a phosphonate. In yet another embodiment, the flame-retardant filler component 350 may include a phosphine. In a particular embodiment, the flame-retardant filler component 350 may include any combination of phosphate, phosphonate, or phosphine.

[0070] In further embodiments, the flame-retardant filler component 350 may consist of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 350 may consist of a phosphate. In yet another embodiment, the flame-retardant filler component 350 may consist of a phosphonate. In yet another embodiment, the flame-retardant filler component 350 may consist of a phosphine. In a particular embodiment, the flame-retardant filler component 350 may consist of a phosphate, a phosphonate, or any combination of phosphines.

[0071] In further embodiments, the flame-retardant filler component 350 may be a filler of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 350 may be a phosphate filler. In yet another embodiment, the flame-retardant filler component 350 may be a phosphonate filler. In yet another embodiment, the flame-retardant filler component 350 may be a phosphine filler. In a particular embodiment, the flame-retardant filler component 350 may be a filler of phosphate, phosphonate, or any combination of phosphines.

[0072] In other embodiments, the flame-retardant filler component 350 may include a specific metal salt. For example, the flame-retardant filler component 350 may include aluminum diethyl phosphinate.

[0073] In other embodiments, the flame-retardant filler component 350 may consist of a specific metal salt. For example, the flame-retardant filler component 350 may consist of aluminum diethyl phosphinate.

[0074] In other embodiments, the flame-retardant filler component 350 may be a filler of a specific metal salt. For example, the flame-retardant filler component 350 may be an aluminum diethyl phosphinate filler. In other embodiments, the flame-retardant filler component 350 may contain a specific inorganic compound. For example, the flame-retardant filler component 350 may contain expandable graphite.

[0075] In other embodiments, the flame-retardant filler component 350 may consist of a specific inorganic compound. For example, the flame-retardant filler component 350 may consist of expandable graphite.

[0076] In other embodiments, the flame-retardant filler component 350 may be a filler made of a specific inorganic compound. For example, the flame-retardant filler component 350 may be an expandable graphite filler.

[0077] In further embodiments, the flame-retardant filler component 350 may include certain endothermic decomposition compounds. For example, the flame-retardant filler component 350 may include metal hydrates. In further embodiments, the flame-retardant filler component 350 may include metal silicates. In further embodiments, the flame-retardant filler component 350 may include carbonates. In certain embodiments, the flame-retardant filler component 350 may include aluminum trihydrate. In further embodiments, the flame-retardant filler component 350 may include zinc borate. In further embodiments, the flame-retardant filler component 350 may include any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrate, or zinc borate.

[0078] In further embodiments, the flame-retardant filler component 350 may consist of a specific endothermic decomposition compound. For example, the flame-retardant filler component 350 may consist of a metal hydrate. In further embodiments, the flame-retardant filler component 350 may consist of a metal silicate. In further embodiments, the flame-retardant filler component 350 may consist of a carbonate. In a particular embodiment, the flame-retardant filler component 350 may consist of aluminum trihydrate. In further embodiments, the flame-retardant filler component 350 may consist of zinc borate. In further embodiments, the flame-retardant filler component 350 may consist of any combination of metal hydrate, metal silicate, carbonate, aluminum trihydrate, or zinc borate.

[0079] In further embodiments, the flame-retardant filler component 350 may be a filler of a specific endothermic decomposition compound. For example, the flame-retardant filler component 350 may be a metal hydrate filler. In further embodiments, the flame-retardant filler component 350 may be a metal silicate filler. In yet another embodiment, the flame-retardant filler component 350 may be a carbonate filler. In a particular embodiment, the flame-retardant filler component 350 may be an aluminum trihydrate filler. In yet another embodiment, the flame-retardant filler component 350 may be a zinc borate filler. In yet another embodiment, the flame-retardant filler component 350 may be a filler of any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrates, or zinc borate.

[0080] According to one embodiment, the second foam layer 308 may contain a specific amount of polyurethane matrix component 340. For example, the second foam layer 308 may contain a polyurethane matrix component content of at least about 40% by weight, e.g., at least about 45% by weight, or at least about 50% by weight, or at least about 55% by weight, or at least about 60% by weight, or at least about 65% by weight, or even at least about 70% by weight, relative to the total weight of the second foam layer 308. According to yet another embodiment, the second foam layer 308 may contain a polyurethane matrix component content of about 95% by weight or less, e.g., about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or even about 75% by weight, relative to the total weight of the second foam layer 308. It will be understood that the polyurethane matrix component content of the second foam layer 308 may be within a range of any of the above values. It will be further understood that the polyurethane matrix component content of the second foam layer 308 can be any value between the minimum and maximum values ​​mentioned above.

[0081] In other embodiments, the second foam layer 308 may contain a specific amount of flame-retardant filler component 350. For example, the second foam layer 308 may contain a flame-retardant filler component content of at least about 5% by weight, e.g., at least about 10% by weight, or at least about 15% by weight, or at least about 20% by weight, or at least about 25% by weight, or at least about 30% by weight, or even at least about 35% by weight, relative to the total weight of the second foam layer 308. In yet another embodiment, the second foam layer 308 may contain a flame-retardant filler component content of about 60% by weight or less, e.g., about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or even about 40% by weight, relative to the total weight of the second foam layer 308. It will be understood that the flame-retardant filler component content of the second foam layer 308 may be within a range of any of the above values. It will be further understood that the flame-retardant filler component content of the second foam layer 308 may be any value between the minimum and maximum values ​​mentioned above.

[0082] According to certain embodiments, the second foam layer 308 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HBF flammability rating when measured according to ASTM D4986.

[0083] According to certain embodiments, the second foam layer 308 may have a specific flammability rating when measured according to ASTM D3801. In particular, the foam layer may have a V-0 flammability rating when measured according to ASTM D3801.

[0084] In other embodiments, the second foam layer 308 may have a specific lower temperature, measured at 5 minutes when a 3 mm thick foam is exposed to a 650°C hot plate test. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the lower surface temperature. In one embodiment, the second foam layer 308 may have a lower temperature of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the second foam layer 308 may have a lower temperature of at least about 25°C. It will be understood that the low-temperature side temperature of the second foam layer 308 may be within the range of any of the above values. It will be further understood that the low-temperature side temperature of the second foam layer 308 may be any value within the range of any of the above values.

[0085] In further embodiments, the second foam layer 308 may have a specific thickness. For example, the second foam layer 308 may have a thickness of at least about 0.5 mm, for example, 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. In addition, in further embodiments, the second foam layer 308 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the second foam layer 308 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the second foam layer 308 can be any value between the minimum and maximum values ​​mentioned above.

[0086] In further embodiments, a second foam layer 308 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain, and is determined by measuring the force-compression and compression-force-deflection of the sample at 25% strain. Force-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at the desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0087] According to one embodiment, the second foam layer 308 may have a 25% strain compression rating of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the second foam layer 308 may have a 25% strain compression rating of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the second foam layer 308 may be within the range of either the minimum or maximum value mentioned above. It will be further understood that the 50% strain compression evaluation of the second foam layer 308 may be any value within the range of either the minimum or maximum value mentioned above.

[0088] In further embodiments, the second foam layer 308 may have a specific density. For the purposes of the embodiments described herein, the density of the second foam layer 308 may be determined according to ASTM D1056. In one embodiment, the second foam layer 308 has a density of approximately 600 kg / m³. 3 For example, approximately 575 kg / m³ 3 The following, or approximately 550 kg / m³ 3 The following, or approximately 525 kg / m³ 3 The following, or approximately 500 kg / m 3 The following, or approximately 450 kg / m³ 3 The following, or approximately 400 kg / m³ 3 The following, or approximately 350 kg / m 3 The following, or approximately 300 kg / m³ 3 It may have the following densities. Furthermore, according to other embodiments, the second foam layer 308 has at least about 50 kg / m³ 3 For example, at least about 60 kg / m³ 3 , or at least about 80 kg / m 3, or at least about 100 kg / m 3 , or at least about 120 kg / m 3 , or at least about 140 kg / m 3 , or at least about 160 kg / m 3 , or at least about 180 kg / m 3 , or at least about 200 kg / m 3 , or at least about 220 kg / m³ 3 , or even more, at least approximately 240 kg / m³ 3 It may have a density of . It will be understood that the density of the second foam layer 308 may be within the range between any of the above minimum and maximum values. It will be further understood that the density of the second foam layer 308 may be any value between any of the above minimum and maximum values.

[0089] In other embodiments, the second foam layer 308 may have a specific thermal conductivity when measured according to ASTM C518. For example, the second foam layer 308 may have a thermal conductivity of at least about 0.01 W / mK, for example, at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. In other embodiments, the second foam layer 308 may have a thermal conductivity of about 0.15 W / mK or less, for example, about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be understood that the thermal conductivity of the second foam layer 308 may be within the range between any of the above minimum and maximum values. It will be further understood that the thermal conductivity of the second foam layer 308 may be any value between any of the above minimum and maximum values.

[0090] According to one embodiment, the foam layer described herein may be formed according to any acceptable forming process for the foam material or the foam layer.

[0091] Turning to additional embodiments described herein, such embodiments generally relate to thermal barrier composites that may include a first barrier layer and a first foam layer. According to certain embodiments, the first foam layer may include a polyurethane matrix component and a flame-retardant filler component. According to yet other embodiments, the thermal barrier composite may exhibit an improved combination of flame resistance and compression performance.

[0092] For illustrative purposes, Figure 4 shows a thermal barrier composite 400 according to an embodiment described herein. As shown in Figure 4, the thermal barrier composite 400 may include a first barrier layer 402 and a first foam layer 404. The first foam layer 404 may include a polyurethane matrix component 410 and a flame-retardant filler component 420.

[0093] According to certain embodiments, the polyurethane matrix component 410 of the first foam layer 404 may include certain materials. For example, the polyurethane matrix component 410 of the first foam layer 404 may include a flexible polyurethane reacted from an isocyanate and a polyol.

[0094] According to certain embodiments, the polyurethane matrix component 410 of the first foam layer 404 may consist of a specific material. For example, the polyurethane matrix component 410 of the first foam layer 404 may consist of a flexible polyurethane reacted from an isocyanate and a polyol.

[0095] According to certain embodiments, the polyurethane matrix component 410 of the first foam layer 404 may be a layer of a specific material. For example, the polyurethane matrix component 410 of the first foam layer 404 may be a flexible polyurethane layer reacted from an isocyanate and a polyol.

[0096] In further embodiments, the flame-retardant filler component 420 may be selected from a specific group of materials. For example, the flame-retardant filler component 420 may be a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0097] In further embodiments, the flame-retardant filler component 420 may include certain materials. For example, the flame-retardant filler component 420 may include a reactive carbonizing agent. Here, a reactive carbonizing agent can be defined as a compound that reacts with a carbon source, such as a polymer material, at high temperatures to form a carbon layer. In further embodiments, the flame-retardant filler component 420 may include melamine. In further embodiments, the flame-retardant filler component 420 may include an organophosphorus compound. In further embodiments, the flame-retardant filler component 420 may include an inorganic phosphorus compound. In further embodiments, the flame-retardant filler component 420 may include a metal salt. In further embodiments, the flame-retardant filler component 420 may include an inorganic compound. In further embodiments, the flame-retardant filler component 420 may include an endothermic decomposition compound. According to other embodiments, the flame-retardant filler component 420 may include any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0098] In other embodiments, the flame-retardant filler component 420 may consist of specific materials. For example, the flame-retardant filler component 420 may consist of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 420 may consist of melamine. In yet another embodiment, the flame-retardant filler component 420 may consist of an organophosphorus compound. In other embodiments, the flame-retardant filler component 420 may consist of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 420 may consist of a metal salt. In yet another embodiment, the flame-retardant filler component 420 may consist of an inorganic compound. In other embodiments, the flame-retardant filler component 420 may consist of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 420 may consist of any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0099] In other embodiments, the flame-retardant filler component 420 may be a filler of a specific material. For example, the flame-retardant filler component 420 may be a filler of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 420 may be a filler of melamine. In yet another embodiment, the flame-retardant filler component 420 may be a filler of an organophosphorus compound. In other embodiments, the flame-retardant filler component 420 may be a filler of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 420 may be a filler of a metal salt. In yet another embodiment, the flame-retardant filler component 420 may be a filler of an inorganic compound. In other embodiments, the flame-retardant filler component 420 may be a filler of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 420 may be a filler of any combination of a reactive carbonizing agent, melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, inorganic compounds, or endothermic decomposition compounds.

[0100] In further embodiments, the flame-retardant filler component 420 may include certain organophosphorus compounds or inorganic phosphorus compounds. For example, the flame-retardant filler component 420 may include a phosphate. In yet another embodiment, the flame-retardant filler component 420 may include a phosphonate. In yet another embodiment, the flame-retardant filler component 420 may include a phosphine. In a particular embodiment, the flame-retardant filler component 420 may include any combination of phosphate, phosphonate, or phosphine.

[0101] In further embodiments, the flame-retardant filler component 420 may consist of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 420 may consist of a phosphate. In yet another embodiment, the flame-retardant filler component 420 may consist of a phosphonate. In yet another embodiment, the flame-retardant filler component 420 may consist of a phosphine. In a particular embodiment, the flame-retardant filler component 420 may consist of a phosphate, a phosphonate, or any combination of phosphines.

[0102] In further embodiments, the flame-retardant filler component 420 may be a filler of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 420 may be a phosphate filler. In yet another embodiment, the flame-retardant filler component 420 may be a phosphonate filler. In yet another embodiment, the flame-retardant filler component 420 may be a phosphine filler. In a particular embodiment, the flame-retardant filler component 420 may be a filler of phosphate, phosphonate, or any combination of phosphines.

[0103] In other embodiments, the flame-retardant filler component 420 may include a specific metal salt. For example, the flame-retardant filler component 420 may include aluminum diethyl phosphinate.

[0104] In other embodiments, the flame-retardant filler component 420 may consist of a specific metal salt. For example, the flame-retardant filler component 420 may consist of aluminum diethyl phosphinate.

[0105] In other embodiments, the flame-retardant filler component 420 may be a filler of a specific metal salt. For example, the flame-retardant filler component 420 may be an aluminum diethyl phosphinate filler. In other embodiments, the flame-retardant filler component 420 may contain a specific inorganic compound. For example, the flame-retardant filler component 420 may contain expandable graphite.

[0106] In other embodiments, the flame-retardant filler component 420 may consist of a specific inorganic compound. For example, the flame-retardant filler component 420 may consist of expandable graphite.

[0107] In other embodiments, the flame-retardant filler component 420 may be a filler made of a specific inorganic compound. For example, the flame-retardant filler component 420 may be an expandable graphite filler.

[0108] In further embodiments, the flame-retardant filler component 420 may include certain endothermic decomposition compounds. For example, the flame-retardant filler component 420 may include metal hydrates. In further embodiments, the flame-retardant filler component 420 may include metal silicates. In further embodiments, the flame-retardant filler component 420 may include carbonates. In certain embodiments, the flame-retardant filler component 420 may include aluminum trihydrate. In further embodiments, the flame-retardant filler component 420 may include zinc borate. In further embodiments, the flame-retardant filler component 420 may include any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrate, or zinc borate.

[0109] In further embodiments, the flame-retardant filler component 420 may consist of a specific endothermic decomposition compound. For example, the flame-retardant filler component 420 may consist of a metal hydrate. In further embodiments, the flame-retardant filler component 420 may consist of a metal silicate. In further embodiments, the flame-retardant filler component 420 may consist of a carbonate. In a particular embodiment, the flame-retardant filler component 420 may consist of aluminum trihydrate. In further embodiments, the flame-retardant filler component 420 may consist of zinc borate. In further embodiments, the flame-retardant filler component 420 may consist of any combination of metal hydrate, metal silicate, carbonate, aluminum trihydrate, or zinc borate.

[0110] In further embodiments, the flame-retardant filler component 420 may be a filler of a specific endothermic decomposition compound. For example, the flame-retardant filler component 420 may be a metal hydrate filler. In further embodiments, the flame-retardant filler component 420 may be a metal silicate filler. In further embodiments, the flame-retardant filler component 420 may be a carbonate filler. In particular embodiments, the flame-retardant filler component 420 may be an aluminum trihydrate filler. In further embodiments, the flame-retardant filler component 420 may be a zinc borate filler. In further embodiments, the flame-retardant filler component 420 may be a filler of any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrates, or zinc borate.

[0111] According to one embodiment, the first foam layer 404 may contain a specific amount of polyurethane matrix component 410. For example, the first foam layer 404 may contain a polyurethane matrix component content of at least about 40% by weight, e.g., at least about 45% by weight, or at least about 50% by weight, or at least about 55% by weight, or at least about 60% by weight, or at least about 65% by weight, or even at least about 70% by weight, relative to the total weight of the first foam layer 404. According to yet another embodiment, the first foam layer 404 may contain a polyurethane matrix component content of about 95% by weight or less, e.g., about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or even about 75% by weight, relative to the total weight of the first foam layer 404. It will be understood that the polyurethane matrix component content of the first foam layer 404 may be within a range of any of the above values. It will be further understood that the polyurethane matrix component content of the first foam layer 404 can be any value between the minimum and maximum values ​​mentioned above.

[0112] In other embodiments, the first foam layer 404 may contain a specific amount of flame-retardant filler component 420. For example, the first foam layer 404 may contain a flame-retardant filler component content of at least about 5% by weight, e.g., at least about 10% by weight, or at least about 15% by weight, or at least about 20% by weight, or at least about 25% by weight, or at least about 30% by weight, or even at least about 35% by weight, relative to the total weight of the first foam layer 404. In yet another embodiment, the first foam layer 404 may contain a flame-retardant filler component content of about 60% by weight or less, e.g., about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or even about 40% by weight, relative to the total weight of the first foam layer 404. It will be understood that the flame-retardant filler component content of the first foam layer 404 may be within the range of either the minimum or maximum values ​​described above. It will be further understood that the flame-retardant filler component content of the first foam layer 404 may be any value between the minimum and maximum values ​​mentioned above.

[0113] According to certain embodiments, the first foam layer 404 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HFB flammability rating when measured according to ASTM D4986.

[0114] According to one embodiment, the multilayer composite 400 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HFB flammability rating when measured according to ASTM D4986.

[0115] In other embodiments, the first foam layer 404 may have a specific lower temperature measured at 5 minutes when a 3 mm thick foam is exposed to a 650°C hot plate test. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the lower surface temperature. In one embodiment, the first foam layer 404 may have a lower temperature of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the first foam layer 404 may have a lower temperature of at least about 25°C. It will be understood that the low-temperature side temperature of the first foam layer 404 may be within the range of any of the above values. It will be further understood that the low-temperature side temperature of the first foam layer 404 may be any value within the range of any of the above values.

[0116] In other embodiments, the thermal barrier composite 400 may have a specific low-temperature side when a 3 mm thick foam is exposed to a 650°C hot plate test, measured at 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the low-temperature side surface temperature. In one embodiment, the thermal barrier composite 400 may have a low-temperature side of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the thermal barrier composite 400 may have a low-temperature side of at least about 25°C. It will be understood that the low-temperature side temperature of the thermal barrier composite 400 may be within the range of any of the above values. It will be further understood that the low-temperature side temperature of the thermal barrier composite 400 can be any value between any of the above values.

[0117] In other embodiments, the first foam layer 404 may have a specific thickness. For example, the first foam layer 404 may have a thickness of at least about 0.5 mm, for example, 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. In other embodiments, the first foam layer 404 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the first foam layer 404 may be within the range of any of the above minimum and maximum values. It will be further understood that the thickness of the first foam layer 404 can be any value between the minimum and maximum values ​​mentioned above.

[0118] In further embodiments, the thermal barrier composite 400 may have a specific thickness. For example, the thermal barrier composite 400 may have a thickness of at least about 0.5 mm, for example, 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. In other embodiments, the thermal barrier composite 400 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the thermal barrier composite 400 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the thermal barrier composite 400 can be any value between the minimum and maximum values ​​mentioned above.

[0119] In further embodiments, the first foam layer 404 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain and is determined by measuring the force-compression and compression-force-deflection of the sample at 25% strain. Force-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at the desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0120] According to one embodiment, the first foam layer 404 may have a 25% strain compression rating of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the first foam layer 404 may have a 25% strain compression rating of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the first foam layer 404 may be within the range between any of the above minimum and maximum values. It will be further understood that the 25% strain compression evaluation of the first foam layer 404 may be any value between any of the above minimum and maximum values.

[0121] In further embodiments, the thermal barrier composite 400 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain and is determined by measuring the force-compression and compression-force-deflection of the sample at 25% strain. Force-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at the desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0122] According to one embodiment, the thermal barrier composite 400 may have a 25% strain compression rating of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the thermal barrier composite 400 may have a 25% strain compression rating of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the thermal barrier composite 400 may be within the range of either the minimum or maximum value mentioned above. It will be further understood that the 25% strain compression evaluation of the thermal barrier composite 400 may be any value within the range of either the minimum or maximum value mentioned above.

[0123] In further embodiments, the first foam layer 404 may have a specific density. For the purposes of the embodiments described herein, the density of the first foam layer 404 may be determined according to ASTM D1056. In one embodiment, the first foam layer 404 has a density of approximately 600 kg / m³. 3 For example, approximately 575 kg / m³ 3 The following, or approximately 550 kg / m³ 3 The following, or approximately 525 kg / m³ 3 The following, or approximately 500 kg / m 3 The following, or approximately 450 kg / m³ 3 The following, or approximately 400 kg / m³ 3 The following, or approximately 350 kg / m 3 The following, or even more, approximately 300 kg / m 3 It may have the following densities. Furthermore, according to other embodiments, the first foam layer 404 has at least about 50 kg / m³ 3 For example, at least about 60 kg / m³ 3 Or at least about 80 kg / m 3or at least about 100 kg / m 3 or at least about 120 kg / m 3 or at least about 140 kg / m 3 or at least about 160 kg / m 3 or at least about 180 kg / m 3 or at least about 200 kg / m 3 or at least about 220 kg / m 3 or even at least about 240 kg / m 3 and may have a density of. It will be understood that the density of the first foam layer 404 can be within the range between any of the above minimum and maximum values. It will be further understood that the density of the first foam layer 404 can be any value between any of the above minimum and maximum values.

[0124] According to yet another embodiment, the thermal barrier composite 400 can have a specific density. For the purposes of the embodiments described herein, the density of the thermal barrier composite 400 can be determined in accordance with ASTM D1056. According to one embodiment, the thermal barrier composite 400 is about 600 kg / m 3 or less, for example, about 575 kg / m 3 or less, or about 550 kg / m 3 or less, or about 525 kg / m 3 or less, or about 500 kg / m 3 or less, or about 450 kg / m 3 or less, or about 4OO kg / m 3 or less, or about 350 kg / m 3 or less, or even about 300 kg / m 3 and may have a density of. According to yet another embodiment, the thermal barrier composite 400 is at least about 50 kg / m 3 , for example, at least about 60 kg / m 3 , or at least about 80 kg / m 3 , or at least about 100 kg / m 3 , or at least about 120 kg / m 3 , or at least about 140 kg / m 3 , or at least about 160 kg / m 3 , or at least about 180 kg / m3 or at least about 200 kg / m 3 or at least about 220 kg / m 3 or even at least about 240 kg / m 3 and may have a density. It will be appreciated that the density of the thermal barrier composite 400 can be within a range between any of the above minimum and maximum values. It will be further appreciated that the density of the thermal barrier composite 400 can be any value between any of the above minimum and maximum values.

[0125] According to yet other embodiments, the first foam layer 404 may have a specific thermal conductivity when measured in accordance with ASTM C518. For example, the first foam layer 404 may have a thermal conductivity of at least about 0.01 W / mK, such as at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. According to still other embodiments, the first foam layer 404 may have a thermal conductivity of about 0.15 W / mK or less, such as about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be appreciated that the thermal conductivity of the first foam layer 404 can be within a range between any of the above minimum and maximum values. It will be further appreciated that the thermal conductivity of the first foam layer 404 can be any value between any of the above minimum and maximum values.

[0126] In other embodiments, the thermal barrier composite 400 may have a specific thermal conductivity when measured according to ASTM C518. For example, the thermal barrier composite 400 may have a thermal conductivity of at least about 0.01 W / mK, for example, at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. In other embodiments, the thermal barrier composite 400 may have a thermal conductivity of about 0.15 W / mK or less, for example, about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be understood that the thermal conductivity of the thermal barrier composite 400 may be within the range between any of the above minimum and maximum values. It will be further understood that the thermal conductivity of the thermal barrier composite 400 may be any value between any of the above minimum and maximum values.

[0127] In other embodiments, the first barrier layer 402 may be made of a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0128] In other embodiments, the first barrier layer 402 may include certain materials. For example, the first barrier layer 402 may include mica. In other embodiments, the first barrier layer 402 may include a mica-glass fiber composite. In yet another embodiment, the first barrier layer 402 may include glass cloth. In other embodiments, the first barrier layer 402 may include silica cloth. In other embodiments, the first barrier layer 402 may include basalt cloth. In yet another embodiment, the first barrier layer 402 may include vermiculite-coated glass cloth. In other embodiments, the first barrier layer 402 may include aerogel. In yet another embodiment, the first barrier layer 402 may include nonwoven glass cloth. In other embodiments, the first barrier layer 402 may include any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In further embodiments, the first barrier layer 402 may include any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0129] In other embodiments, the first barrier layer 402 may be made of a specific material. For example, the first barrier layer 402 may be made of mica. In other embodiments, the first barrier layer 402 may be made of a mica-fiber glass composite. In yet another embodiment, the first barrier layer 402 may be made of glass cloth. In other embodiments, the first barrier layer 402 may be made of silica cloth. In other embodiments, the first barrier layer 402 may be made of basalt cloth. In yet another embodiment, the first barrier layer 402 may be made of vermiculite-coated glass cloth. In other embodiments, the first barrier layer 402 may be made of aerogel. In yet another embodiment, the first barrier layer 402 may be made of nonwoven glass cloth. In other embodiments, the first barrier layer 402 may consist of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. Furthermore, in yet another embodiment, the first barrier layer 402 may consist of any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0130] In other embodiments, the first barrier layer 402 may be a specific material layer. For example, the first barrier layer 402 may be a mica layer. In other embodiments, the first barrier layer 402 may be a mica-glass fiber composite layer. In yet another embodiment, the first barrier layer 402 may be a glass fiber layer. In other embodiments, the first barrier layer 402 may be a silica fiber layer. In other embodiments, the first barrier layer 402 may be a basalt cloth layer. In yet another embodiment, the first barrier layer 402 may be a vermiculite-coated glass fiber layer. In other embodiments, the first barrier layer 402 may be an aerogel layer. In yet another embodiment, the first barrier layer 402 may be a nonwoven glass cloth layer. In other embodiments, the first barrier layer 402 may be a layer of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the first barrier layer 402 may be a layer of any laminate of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0131] In further embodiments, the first barrier layer 402 may have a specific thickness. For example, the first barrier layer 402 may have a thickness of at least about 0.05 mm, for example, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or at least about 0.5 mm, or at least about 0.6 mm, or at least about 0.7 mm, or at least about 0.8 mm, or at least about 0.9 mm, or at least about 1.0 mm, or at least about 1.1 mm, or at least about 1.2 mm, or at least about 1.3 mm, or even at least about 1.4 mm. In addition, according to other embodiments, the first barrier layer 402 may have a thickness of about 7 mm or less, for example, about 6.5 mm or less, or about 6.0 mm or less, or about 5.5 mm or less, or about 5.0 mm or less, or about 4.5 mm or less, or about 4.0 mm or less, or about 3.5 mm or less, or about 3.0 mm or less, or about 2.9 mm or less, or about 2.8 mm or less, or about 2.7 mm or less, or about 2.6 mm or less, or about 2.5 mm or less, or about 2.4 mm or less, or about 2.3 mm or less, or even about 2.2 mm or less. It will be understood that the thickness of the first barrier layer 402 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the first barrier layer 402 may be any value between any of the above minimum and maximum values.

[0132] Figure 5 shows another thermal barrier composite 500 according to an embodiment described herein. As shown in Figure 5, the thermal barrier composite 500 may include a first barrier layer 502, a first foam layer 504, and a second barrier layer 506. The first foam layer 504 may include a polyurethane matrix component 510 and a flame-retardant filler component 520.

[0133] It will be understood that the thermal barrier composite 500, and all components described with respect to the thermal barrier composite 500 as shown in Figure 5, may have any of the properties described herein in relation to the corresponding components in Figure 4. In particular, the properties of the thermal barrier composite 500, the first barrier layer 502, the first foam layer 504, the polyurethane matrix component 510, and the flame retardant filler component 520 shown in Figure 5 may each have any of the corresponding properties described herein with respect to the thermal barrier composite 400, the first barrier layer 402, the first foam layer 404, the polyurethane matrix component 410, and the flame retardant filler component 420 shown in Figure 4.

[0134] In other embodiments, the second barrier layer 506 may be made of a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0135] In other embodiments, the second barrier layer 506 may include certain materials. For example, the second barrier layer 506 may include mica. In other embodiments, the second barrier layer 506 may include a mica-glass fiber composite. In yet another embodiment, the second barrier layer 506 may include glass cloth. In other embodiments, the second barrier layer 506 may include silica cloth. In other embodiments, the second barrier layer 506 may include basalt cloth. In yet another embodiment, the second barrier layer 506 may include vermiculite-coated glass cloth. In other embodiments, the second barrier layer 506 may include aerogel. In yet another embodiment, the second barrier layer 506 may include nonwoven glass cloth. In other embodiments, the second barrier layer 506 may include any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In further embodiments, the second barrier layer 506 may include any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0136] In other embodiments, the second barrier layer 506 may be made of a specific material. For example, the second barrier layer 506 may be made of mica. In other embodiments, the second barrier layer 506 may be made of a mica-fiber glass composite. In yet another embodiment, the second barrier layer 506 may be made of glass cloth. In other embodiments, the second barrier layer 506 may be made of silica cloth. In other embodiments, the second barrier layer 506 may be made of basalt cloth. In yet another embodiment, the second barrier layer 506 may be made of vermiculite-coated glass cloth. In other embodiments, the second barrier layer 506 may be made of aerogel. In yet another embodiment, the second barrier layer 506 may be made of nonwoven glass cloth. In other embodiments, the second barrier layer 506 may consist of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. Furthermore, in yet another embodiment, the second barrier layer 506 may consist of any lamination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0137] In other embodiments, the second barrier layer 506 may be a specific material layer. For example, the second barrier layer 506 may be a mica layer. In other embodiments, the second barrier layer 506 may be a mica-glass fiber composite layer. In yet another embodiment, the second barrier layer 506 may be a glass fiber layer. In another embodiment, the second barrier layer 506 may be a silica fiber layer. In another embodiment, the second barrier layer 506 may be a basalt cloth layer. In yet another embodiment, the second barrier layer 506 may be a vermiculite-coated glass fiber layer. In another embodiment, the second barrier layer 506 may be an aerogel layer. In yet another embodiment, the second barrier layer 506 may be a nonwoven glass cloth layer. In other embodiments, the second barrier layer 506 may be a layer of any combination of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth. In yet another embodiment, the second barrier layer 506 may be a layer of any laminate of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, or nonwoven glass cloth.

[0138] In further embodiments, the second barrier layer 506 may have a specific thickness. For example, the second barrier layer 506 may have a thickness of at least about 0.05 mm, for example, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or at least about 0.5 mm, or at least about 0.6 mm, or at least about 0.7 mm, or at least about 0.8 mm, or at least about 0.9 mm, or at least about 1.0 mm, or at least about 1.1 mm, or at least about 1.2 mm, or at least about 1.3 mm, or even at least about 1.4 mm. In addition, according to other embodiments, the second barrier layer 506 may have a thickness of about 7 mm or less, for example, about 6.5 mm or less, or about 6.0 mm or less, or about 5.5 mm or less, or about 5.0 mm or less, or about 4.5 mm or less, or about 4.0 mm or less, or about 3.5 mm or less, or about 3.0 mm or less, or about 2.9 mm or less, or about 2.8 mm or less, or about 2.7 mm or less, or about 2.6 mm or less, or about 2.5 mm or less, or about 2.4 mm or less, or about 2.3 mm or less, or even about 2.2 mm or less. It will be understood that the thickness of the second barrier layer 506 may be within the range between any of the above minimum and maximum values. It will be further understood that the thickness of the second barrier layer 506 may be any value between any of the above minimum and maximum values.

[0139] Figure 6 shows another thermal barrier composite 600 according to an embodiment described herein. As shown in Figure 6, the thermal barrier composite 600 may include a first barrier layer 602, a first foam layer 604, a second foam layer 608, and a second barrier layer 606. The first foam layer 604 may include a polyurethane matrix component 610 and a flame-retardant filler component 620. The second foam layer 608 may include a polyurethane matrix component 640 and a flame-retardant filler component 650. As shown in Figure 6, both the first foam layer 604 and the second foam layer 608 are located between the first barrier layer 602 and the second barrier layer 606.

[0140] It will be understood that the thermal barrier composite 600, and all components described in relation to the thermal barrier composite 600 as shown in Figure 6, may have any of the properties described herein in relation to the corresponding components in Figure 4 and / or Figure 5. In particular, the properties of the thermal barrier composite 600, the first barrier layer 602, the first foam layer 604, the second barrier layer 606, the polyurethane matrix component 610, and the flame-retardant filler component 620 shown in Figure 6 may each have any of the corresponding properties described herein in relation to the thermal barrier composite 400 (500), the first barrier layer 402 (502), the first foam layer 404 (504), the polyurethane matrix component 410 (510), and the flame-retardant filler component 420 (520) shown in Figure 4 (Figure 5).

[0141] According to certain embodiments, the polyurethane matrix component 640 of the second foam layer 608 may include certain materials. For example, the polyurethane matrix component 640 of the second foam layer 608 may include a flexible polyurethane reacted from an isocyanate and a polyol.

[0142] According to certain embodiments, the polyurethane matrix component 640 of the second foam layer 608 may consist of a specific material. For example, the polyurethane matrix component 640 of the second foam layer 608 may consist of a flexible polyurethane reacted from an isocyanate and a polyol.

[0143] According to certain embodiments, the polyurethane matrix component 640 of the second foam layer 608 may be a layer of a specific material. For example, the polyurethane matrix component 640 of the second foam layer 608 may be a flexible polyurethane layer reacted from an isocyanate and a polyol.

[0144] In further embodiments, the flame-retardant filler component 650 may be selected from a specific group of materials. For example, the flame-retardant filler component 650 may be a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0145] In further embodiments, the flame-retardant filler component 650 may include certain materials. For example, the flame-retardant filler component 650 may include a reactive carbonizing agent. Here, the reactive carbonizing agent can be defined as a compound that reacts with a carbon source, such as a polymer material, at high temperatures to form a carbon layer. In further embodiments, the flame-retardant filler component 650 may include melamine. In further embodiments, the flame-retardant filler component 650 may include an organophosphorus compound. In further embodiments, the flame-retardant filler component 650 may include an inorganic phosphorus compound. In further embodiments, the flame-retardant filler component 650 may include a metal salt. In further embodiments, the flame-retardant filler component 650 may include an inorganic compound. In further embodiments, the flame-retardant filler component 650 may include an endothermic decomposition compound. According to other embodiments, the flame-retardant filler component 650 may include any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0146] In other embodiments, the flame-retardant filler component 650 may consist of specific materials. For example, the flame-retardant filler component 650 may consist of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 650 may consist of melamine. In yet another embodiment, the flame-retardant filler component 650 may consist of an organophosphorus compound. In other embodiments, the flame-retardant filler component 650 may consist of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 650 may consist of a metal salt. In yet another embodiment, the flame-retardant filler component 650 may consist of an inorganic compound. In other embodiments, the flame-retardant filler component 650 may consist of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 650 may consist of any combination of a reactive carbonizing agent, melamine, an organophosphorus compound, an inorganic phosphorus compound, a metal salt, an inorganic compound, or an endothermic decomposition compound.

[0147] In other embodiments, the flame-retardant filler component 650 may be a filler of a specific material. For example, the flame-retardant filler component 650 may be a filler of a reactive carbonizing agent. In other embodiments, the flame-retardant filler component 650 may be a filler of melamine. In yet another embodiment, the flame-retardant filler component 650 may be a filler of an organophosphorus compound. In other embodiments, the flame-retardant filler component 650 may be a filler of an inorganic phosphorus compound. In yet another embodiment, the flame-retardant filler component 650 may be a filler of a metal salt. In yet another embodiment, the flame-retardant filler component 650 may be a filler of an inorganic compound. In other embodiments, the flame-retardant filler component 650 may be a filler of an endothermic decomposition compound. In other embodiments, the flame-retardant filler component 650 may be a filler of any combination of a reactive carbonizing agent, melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, inorganic compounds, or endothermic decomposition compounds.

[0148] In further embodiments, the flame-retardant filler component 650 may include certain organophosphorus compounds or inorganic phosphorus compounds. For example, the flame-retardant filler component 650 may include a phosphate. In yet another embodiment, the flame-retardant filler component 650 may include a phosphonate. In yet another embodiment, the flame-retardant filler component 650 may include a phosphine. In a particular embodiment, the flame-retardant filler component 650 may include any combination of phosphate, phosphonate, or phosphine.

[0149] In further embodiments, the flame-retardant filler component 650 may consist of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 650 may consist of a phosphate. In yet another embodiment, the flame-retardant filler component 650 may consist of a phosphonate. In yet another embodiment, the flame-retardant filler component 650 may consist of a phosphine. In a particular embodiment, the flame-retardant filler component 650 may consist of a phosphate, a phosphonate, or any combination of phosphines.

[0150] In further embodiments, the flame-retardant filler component 650 may be a filler of a specific organophosphorus compound or an inorganic phosphorus compound. For example, the flame-retardant filler component 650 may be a phosphate filler. In yet another embodiment, the flame-retardant filler component 650 may be a phosphonate filler. In yet another embodiment, the flame-retardant filler component 650 may be a phosphine filler. In a particular embodiment, the flame-retardant filler component 650 may be a filler of phosphate, phosphonate, or any combination of phosphines.

[0151] In other embodiments, the flame-retardant filler component 650 may include a specific metal salt. For example, the flame-retardant filler component 650 may include aluminum diethyl phosphinate.

[0152] In other embodiments, the flame-retardant filler component 650 may consist of a specific metal salt. For example, the flame-retardant filler component 650 may consist of aluminum diethyl phosphinate.

[0153] In other embodiments, the flame-retardant filler component 650 may be a filler of a specific metal salt. For example, the flame-retardant filler component 650 may be an aluminum diethyl phosphinate filler. In other embodiments, the flame-retardant filler component 650 may contain a specific inorganic compound. For example, the flame-retardant filler component 650 may contain expandable graphite.

[0154] In other embodiments, the flame-retardant filler component 650 may consist of a specific inorganic compound. For example, the flame-retardant filler component 650 may consist of expandable graphite.

[0155] In other embodiments, the flame-retardant filler component 650 may be a filler made of a specific inorganic compound. For example, the flame-retardant filler component 650 may be an expandable graphite filler.

[0156] In further embodiments, the flame-retardant filler component 650 may include certain endothermic decomposition compounds. For example, the flame-retardant filler component 650 may include metal hydrates. In further embodiments, the flame-retardant filler component 650 may include metal silicates. In further embodiments, the flame-retardant filler component 650 may include carbonates. In certain embodiments, the flame-retardant filler component 650 may include aluminum trihydrate. In further embodiments, the flame-retardant filler component 650 may include zinc borate. In further embodiments, the flame-retardant filler component 650 may include any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrate, or zinc borate.

[0157] In further embodiments, the flame-retardant filler component 650 may consist of a specific endothermic decomposition compound. For example, the flame-retardant filler component 650 may consist of a metal hydrate. In further embodiments, the flame-retardant filler component 650 may consist of a metal silicate. In further embodiments, the flame-retardant filler component 650 may consist of a carbonate. In a particular embodiment, the flame-retardant filler component 650 may consist of aluminum trihydrate. In further embodiments, the flame-retardant filler component 650 may consist of zinc borate. In further embodiments, the flame-retardant filler component 650 may consist of any combination of metal hydrate, metal silicate, carbonate, aluminum trihydrate, or zinc borate.

[0158] In further embodiments, the flame-retardant filler component 650 may be a filler of a specific endothermic decomposition compound. For example, the flame-retardant filler component 650 may be a metal hydrate filler. In further embodiments, the flame-retardant filler component 650 may be a metal silicate filler. In yet another embodiment, the flame-retardant filler component 650 may be a carbonate filler. In a particular embodiment, the flame-retardant filler component 650 may be an aluminum trihydrate filler. In further embodiments, the flame-retardant filler component 650 may be a zinc borate filler. In yet another embodiment, the flame-retardant filler component 650 may be a filler of any combination of metal hydrates, metal silicates, carbonates, aluminum trihydrates, or zinc borate.

[0159] According to one embodiment, the second foam layer 608 may contain a specific amount of polyurethane matrix component 640. For example, the second foam layer 608 may contain a polyurethane matrix component content of at least about 40% by weight, e.g., at least about 45% by weight, or at least about 50% by weight, or at least about 55% by weight, or at least about 60% by weight, or at least about 65% by weight, or even at least about 70% by weight, relative to the total weight of the second foam layer 608. According to yet another embodiment, the second foam layer 608 may contain a polyurethane matrix component content of about 95% by weight or less, e.g., about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or even about 75% by weight, relative to the total weight of the second foam layer 608. It will be understood that the polyurethane matrix component content of the second foam layer 608 may be within a range of any of the above values. It will be further understood that the polyurethane matrix component content of the second foam layer 608 can be any value between the minimum and maximum values ​​mentioned above.

[0160] In other embodiments, the second foam layer 608 may contain a specific amount of flame-retardant filler component 650. For example, the second foam layer 608 may contain a flame-retardant filler component content of at least about 5% by weight, e.g., at least about 10% by weight, or at least about 15% by weight, or at least about 20% by weight, or at least about 25% by weight, or at least about 30% by weight, or even at least about 35% by weight, relative to the total weight of the second foam layer 608. In yet another embodiment, the second foam layer 608 may contain a flame-retardant filler component content of about 60% by weight or less, e.g., about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or even about 40% by weight, relative to the total weight of the second foam layer 608. It will be understood that the flame-retardant filler component content of the second foam layer 608 may be within a range of any of the above values. It will be further understood that the flame-retardant filler component content of the second foam layer 608 may be any value between the minimum and maximum values ​​mentioned above.

[0161] According to certain embodiments, the second foam layer 608 may have a specific flammability rating when measured according to ASTM D4986. In particular, the foam layer may have an HBF flammability rating when measured according to ASTM D4986.

[0162] According to certain embodiments, the second foam layer 608 may have a specific flammability rating when measured according to ASTM D3801. In particular, the foam layer may have a V-0 flammability rating when measured according to ASTM D3801.

[0163] In other embodiments, the second foam layer 608 may have a specific lower temperature, measured at 5 minutes when a 3 mm thick foam is exposed to a 650°C hot plate test. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 1-inch x 1-inch test specimen of the material and placing it on a hot plate. A thermocouple is then fixed to a steel weight (1 inch in diameter, 2 inches in height) placed on the test specimen to measure the lower surface temperature. In one embodiment, the second foam layer 608 may have a lower temperature of about 300°C or less, for example, about 275°C or less, or about 250°C or less, or about 225°C or less, or about 200°C or less, or about 175°C or less, or even about 150°C or less. In other embodiments, the second foam layer 608 may have a lower temperature of at least about 25°C. It will be understood that the low-temperature side temperature of the second foam layer 608 may be within the range of any of the above values. It will be further understood that the low-temperature side temperature of the second foam layer 608 may be any value within the range of any of the above values.

[0164] In other embodiments, the second foam layer 608 may have a specific thickness. For example, the second foam layer 608 may have a thickness of at least about 0.5 mm, for example, 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. In other embodiments, the second foam layer 608 may have a thickness of about 10 mm or less, for example, about 9.5 mm or less, about 9.0 mm or less, about 8.5 mm or less, about 8.0 mm or less, about 7.5 mm or less, about 7.0 mm or less, about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the second foam layer 608 may be within the range of any of the above minimum and maximum values. It will be further understood that the thickness of the second foam layer 608 can be any value between the minimum and maximum values ​​mentioned above.

[0165] In further embodiments, a second foam layer 608 may have a specific 25% strain compression evaluation. For the purposes of the embodiments described herein, the 25% strain compression evaluation is defined as the compression evaluation of a sample measurement at 25% strain and is determined by measuring the force-compression and compression-force-deflection of the sample at 25% strain. Force-compression (FTC) is defined as the peak force (or stress) that compresses the sample to a given strain, and compression-force-deflection (CFD) is defined as the plateau or relaxation force (or stress) that the sample is held at when held at the desired strain (i.e., 25%). The measurement is performed using a texture analyzer that finds and records both FTC and CFD values ​​after a holding time of 60 seconds, a compression rate of 0.16 mm / second, and a trigger force of 10 grams.

[0166] According to one embodiment, the second foam layer 608 may have a 25% strain compression rating of about 500 kPa or less, for example, about 475 kPa or less, or about 450 kPa or less, or about 425 kPa or less, or about 400 kPa or less, or about 375 kPa or less, or about 350 kPa or less, or about 325 kPa or less, or about 300 kPa or less, or about 275 kPa or less, or about 250 kPa or less, or about 225 kPa or less, or about 200 kPa or less, or about 175 kPa or less, or about 150 kPa or less, or about 125 kPa or less, or about 100 kPa or less. According to another embodiment, the second foam layer 608 may have a 25% strain compression rating of at least about 5 kPa, for example, at least about 10 kPa, or at least about 15 kPa, or at least about 20 kPa, or at least about 25 kPa. It will be understood that the 25% strain compression evaluation of the second foam layer 608 may be within the range of either the minimum or maximum value mentioned above. It will also be understood that the 50% strain compression evaluation of the second foam layer 608 may be any value within the range of either the minimum or maximum value mentioned above.

[0167] In further embodiments, the second foam layer 608 may have a specific density. For the purposes of the embodiments described herein, the density of the second foam layer 608 may be determined according to ASTM D1056. In one embodiment, the second foam layer 608 has a density of approximately 600 kg / m³. 3 For example, approximately 575 kg / m³ 3 The following, or approximately 550 kg / m³ 3 The following, or approximately 525 kg / m³ 3 The following, or approximately 500 kg / m 3 The following, or approximately 450 kg / m³ 3 The following, or approximately 400 kg / m³ 3 The following, or approximately 350 kg / m 3 The following, or approximately 300 kg / m³ 3 It may have the following densities. Furthermore, according to other embodiments, the second foam layer 608 has at least about 50 kg / m³ 3 For example, at least about 60 kg / m³ 3 , or at least about 80 kg / m 3, or at least about 100 kg / m 3 , or at least about 120 kg / m 3 , or at least about 140 kg / m 3 , or at least about 160 kg / m 3 , or at least about 180 kg / m 3 , or at least about 200 kg / m 3 , or at least about 220 kg / m³ 3 , or even more, at least approximately 240 kg / m³ 3 It may have a density of . It will be understood that the density of the second foam layer 608 may be within the range between any of the above minimum and maximum values. It will be further understood that the density of the second foam layer 608 may be any value between any of the above minimum and maximum values.

[0168] In other embodiments, the second foam layer 608 may have a specific thermal conductivity when measured according to ASTM C518. For example, the second foam layer 608 may have a thermal conductivity of at least about 0.01 W / mK, for example, at least about 0.02 W / mK, or at least about 0.03 W / mK, or at least about 0.04 W / mK, or even at least about 0.05 W / mK. In other embodiments, the second foam layer 608 may have a thermal conductivity of about 0.15 W / mK or less, for example, about 0.14 W / mK or less, or about 0.13 W / mK or less, or about 0.12 W / mK or less, or about 0.11 W / mK or less, or about 0.10 W / mK or less, or about 0.09 W / mK or less, or about 0.08 W / mK or less, or even about 0.07 W / mK or less. It will be understood that the thermal conductivity of the second foam layer 608 may be within the range between any of the above minimum and maximum values. It will be further understood that the thermal conductivity of the second foam layer 608 may be any value between any of the above minimum and maximum values.

[0169] According to one embodiment, the thermal barrier composite described herein may be formed according to any acceptable forming process for thermal barrier composites. According to a particular embodiment, the thermal barrier composite may be formed using a lamination process in which a porous foam and a barrier layer are laminated using a transfer adhesive such as a silicone adhesive, rubber adhesive, acrylic adhesive, phenolic adhesive, polyurethane adhesive, or any combination thereof. According to yet another embodiment, the thermal barrier composite may be formed using a lamination process using a porous foam and a coating barrier layer, the coating on the barrier layer being an adhesive such as a silicone adhesive, rubber adhesive, acrylic adhesive, phenolic adhesive, polyurethane adhesive, or any combination thereof. According to yet another embodiment, the thermal barrier composite may be formed using a direct cast forming process in which the foam is directly cast onto or between barrier films.

[0170] 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 illustrative only and do not limit the scope of the invention. Embodiments may follow one or more of the embodiments listed below.

[0171] Embodiment 1. A multilayer composite comprising a first barrier layer and a first foam layer containing a polyurethane matrix component and a flame-retardant filler component, comprising an HBF flammability evaluation when measured according to ASTM D4986.

[0172] Embodiment 2. A multilayer composite comprising a first barrier layer and a first foam layer containing a polyurethane matrix component and a flame-retardant filler component, wherein the first barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof, and the flame-retardant filler component comprises a filler selected from the group consisting of reactive carbonizers, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0173] Embodiment 3. A multilayer composite according to any one of Embodiments 1 and 2, wherein the polyurethane matrix component of the first foam layer includes a flexible polyurethane obtained by reacting an isocyanate and a polyol.

[0174] Embodiment 4. A multilayer composite according to any one of Embodiments 1 and 2, wherein the reactive carbonizing agent is selected from the group consisting of melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, such as phosphates, phosphonates, phosphinates, aluminum diethylphosphinate, and any combination thereof, and / or the inorganic compound is selected from the group consisting of expandable graphite, and / or the endothermic decomposition compound is selected from the group consisting of metal hydrates, metal silicates, aluminum trihydrates, and carbonates such as zinc borate, and any combination thereof.

[0175] Embodiment 5. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer contains at least about 40% by weight of a polyurethane matrix component relative to the total weight of the first foam layer.

[0176] Embodiment 6. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer contains a polyurethane matrix component in an amount of approximately 95% by weight or less relative to the total weight of the first foam layer.

[0177] Embodiment 7. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer contains at least about 5% by weight of a flame-retardant filler component relative to the total weight of the first foam layer.

[0178] Embodiment 8. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer contains a flame-retardant filler component in an amount of about 60% by weight or less relative to the total weight of the first foam layer.

[0179] Embodiment 9. A multilayer composite according to any one of Embodiments 1 and 2, comprising an HBF flammability evaluation when the first foam layer is measured according to ASTM D4986.

[0180] Embodiment 10. A multilayer composite according to any one of Embodiments 1 and 2, comprising an HBF flammability assessment when the multilayer composite is measured according to ASTM D4986.

[0181] Embodiment 11. A multilayer composite according to any one of Embodiments 1 and 2, wherein when the multilayer composite is exposed to a hot plate test at 650°C, the temperature measured at 5 minutes includes a low-temperature side of approximately 300°C or less.

[0182] Embodiment 12. A multilayer composite according to any one of Embodiments 1 and 2, wherein when the multilayer composite is exposed to a hot plate test at 650°C, the temperature measured at 5 minutes includes at least about 25°C on the lower end.

[0183] Embodiment 13. A multilayer composite according to any one of Embodiments 1 or 2, wherein the first foam layer includes a thickness of at least about 0.5 mm.

[0184] Embodiment 14. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer includes a thickness of approximately 10 mm or less.

[0185] Embodiment 15. A multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite includes a thickness of at least about 0.5 mm.

[0186] Embodiment 16. A multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite includes a thickness of approximately 10 mm or less.

[0187] Embodiment 17. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer includes a 25% strain compression evaluation at at least about 5 kPa.

[0188] Embodiment 18. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer includes a 25% strain compression evaluation of approximately 500 kPa or less.

[0189] Embodiment 19. A multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite includes a 25% strain compression evaluation at at least about 5 kPa.

[0190] Embodiment 20. A multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite includes a 25% strain compression evaluation of approximately 500 kPa or less.

[0191] Embodiment 21. The first foam layer is approximately 600 kg / m³ 3 A multilayer composite according to any one of Embodiments 1 and 2, comprising the following densities.

[0192] Embodiment 22. The first foam layer has a density of at least about 50 kg / m³ 3 A multilayer composite according to any one of Embodiments 1 and 2, including the density of the following:

[0193] Embodiment 23. The multilayer composite layer has a density of approximately 600 kg / m². 3 A multilayer composite according to any one of Embodiments 1 and 2, comprising the following densities.

[0194] Embodiment 24. The multilayer composite has a load of at least about 50 kg / m³ 3 A multilayer composite according to any one of Embodiments 1 and 2, including the density of the following:

[0195] Embodiment 25. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer has a thermal conductivity of at least about 0.01 W / mK.

[0196] Embodiment 26. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first foam layer has a thermal conductivity of about 0.15 W / mK or less.

[0197] Embodiment 27. A multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite has a thermal conductivity of at least about 0.01 W / mK.

[0198] Embodiment 28. A multilayer composite according to either Embodiment 1 or 2, wherein the multilayer composite has a thermal conductivity of about 0.15 W / mK or less.

[0199] Embodiment 29. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0200] Embodiment 30. A multilayer composite according to any one of Embodiments 1 or 2, wherein the first barrier layer has a thickness of at least about 0.05 mm.

[0201] Embodiment 31. A multilayer composite according to any one of Embodiments 1 and 2, wherein the first barrier layer has a thickness of approximately 7 mm or less.

[0202] Embodiment 32. The multilayer composite according to any one of Embodiments 1 and 2, wherein the multilayer composite further comprises a second barrier layer, and the first foam layer is located between the first barrier layer and the second barrier layer.

[0203] Embodiment 33. The multilayer composite according to Embodiment 32, wherein the second barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0204] Embodiment 34. The multilayer composite according to Embodiment 32, wherein the second barrier layer has a thickness of at least about 0.05 mm.

[0205] Embodiment 35. The multilayer composite according to Embodiment 32, wherein the second barrier layer has a thickness of approximately 7 mm or less.

[0206] Embodiment 36. The multilayer composite according to any one of Embodiments 1 and 2, further comprising a second foam layer and a second barrier layer, wherein the second layer comprises a polyurethane matrix component and a flame-retardant filler component, and both the first foam layer and the second foam layer are located between the first barrier layer and the second barrier layer.

[0207] Embodiment 37. The multilayer composite according to Embodiment 36, wherein the second barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0208] Embodiment 38. The multilayer composite according to Embodiment 36, wherein the second barrier layer has a thickness of at least about 0.05 mm.

[0209] Embodiment 39. The multilayer composite according to Embodiment 36, wherein the second barrier layer has a thickness of approximately 7 mm or less.

[0210] Embodiment 40. The multilayer composite according to Embodiment 36, wherein the polyurethane matrix component of the second foam layer includes a flexible polyurethane reacted from an isocyanate and a polyol.

[0211] Embodiment 41. The multilayer composite according to Embodiment 36, wherein the flame-retardant filler component of the second foam layer comprises a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0212] Embodiment 42. The multilayer composite according to Embodiment 36, wherein the second foam layer contains at least about 40% by weight of a polyurethane matrix component relative to the total weight of the second foam layer.

[0213] Embodiment 43. The multilayer composite according to Embodiment 36, wherein the second foam layer contains a polyurethane matrix component content of approximately 95% by weight or less relative to the total weight of the second foam layer.

[0214] Embodiment 44. The multilayer composite according to Embodiment 36, wherein the second foam layer contains at least about 5% by weight of a flame-retardant filler component relative to the total weight of the second foam layer.

[0215] Embodiment 45. The multilayer composite according to Embodiment 36, wherein the second foam layer contains a flame-retardant filler component in an amount of about 60% by weight or less relative to the total weight of the second foam layer.

[0216] Embodiment 46. The multilayer composite according to Embodiment 36, comprising an HBF flammability evaluation when the second foam layer is measured according to ASTM D4986.

[0217] Embodiment 47. The multilayer composite according to Embodiment 36, wherein the second foam layer, when exposed to a hot plate test at 650°C, measures at 5 minutes and includes a low-temperature side of approximately 300°C or less.

[0218] Embodiment 48. The multilayer composite according to Embodiment 36, wherein the second foam layer, when exposed to a hot plate test at 650°C, includes a lower temperature of at least about 25°C as measured at 5 minutes.

[0219] Embodiment 49. The multilayer composite according to Embodiment 36, wherein the second foam layer includes a thickness of at least about 0.5 mm.

[0220] Embodiment 50. The multilayer composite according to Embodiment 36, wherein the second foam layer includes a thickness of approximately 10 mm or less.

[0221] Embodiment 51. The multilayer composite according to Embodiment 36, wherein the second foam layer includes a 25% strain compression evaluation at at least about 5 kPa.

[0222] Embodiment 52. The multilayer composite according to Embodiment 36, wherein the second foam layer includes a 25% strain compression evaluation of approximately 500 kPa or less.

[0223] Embodiment 53. The second foam layer is approximately 600 kg / m³ 3 A multilayer composite according to embodiment 36, comprising the following densities.

[0224] Embodiment 54. The second foam layer has a density of at least about 50 kg / m³ 3 A multilayer composite according to embodiment 36, comprising a foam layer having a density of [value missing].

[0225] Embodiment 55. The multilayer composite according to Embodiment 36, wherein the second foam layer has a thermal conductivity of at least about 0.01 W / mK.

[0226] Embodiment 56. The multilayer composite according to Embodiment 36, wherein the second foam layer has a thermal conductivity of about 0.15 W / mK or less.

[0227] Embodiment 57. A thermal barrier comprising a first barrier layer and a first foam layer containing a polyurethane matrix component and a flame-retardant filler component, wherein the thermal barrier includes an HBF flammability evaluation when measured according to ASTM D4986.

[0228] Embodiment 58. A thermal barrier comprising a first barrier layer and a first foam layer comprising a polyurethane matrix component and a flame-retardant filler component, wherein the first barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof, and the flame-retardant filler component comprises a filler selected from the group consisting of reactive carbides, inorganic compounds, endothermic decomposition compounds, and any combination thereof.

[0229] Embodiment 59. The thermal barrier according to any one of Embodiments 57 and 58, wherein the polyurethane matrix component of the first foam layer includes a flexible polyurethane reacted from an isocyanate and a polyol.

[0230] Embodiment 60. A thermal barrier according to any one of Embodiments 57 and 58, wherein the reactive carbonizing agent is selected from the group consisting of melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, such as phosphates, phosphonates, phosphinates, aluminum diethylphosphinate, and any combination thereof, and / or the inorganic compound is selected from the group consisting of expandable graphite, and / or the endothermic decomposition compound is selected from the group consisting of metal hydrates, metal silicates, aluminum trihydrates, and carbonates such as zinc borate, and any combination thereof.

[0231] Embodiment 61. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer contains at least about 40% by weight of a polyurethane matrix component relative to the total weight of the first foam layer.

[0232] Embodiment 62. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer contains a polyurethane matrix component in an amount of about 95% by weight or less relative to the total weight of the first foam layer.

[0233] Embodiment 63. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer contains at least about 5% by weight of a flame-retardant filler component relative to the total weight of the first foam layer.

[0234] Embodiment 64. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer contains a flame-retardant filler component in an amount of about 60% by weight or less relative to the total weight of the first foam layer.

[0235] Embodiment 65. A thermal barrier according to any one of Embodiments 57 and 58, including an HBF flammability assessment when the first foam layer is measured according to ASTM D4986.

[0236] Embodiment 66. A thermal barrier according to any one of Embodiments 57 and 58, including an HBF flammability assessment when the thermal barrier is measured in accordance with ASTM D4986.

[0237] Embodiment 67. The thermal barrier according to any one of Embodiments 57 and 58, wherein when the thermal barrier is exposed to a hot plate test at 650°C, it measures at 5 minutes and includes a low-temperature side of approximately 300°C or less.

[0238] Embodiment 68. The thermal barrier according to any one of Embodiments 57 and 58, wherein when the thermal barrier is exposed to a hot plate test at 650°C, the temperature measured at 5 minutes includes at least about 25°C on the lower end.

[0239] Embodiment 69. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a thickness of at least about 0.5 mm.

[0240] Embodiment 70. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a thickness of about 10 mm or less.

[0241] Embodiment 71. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier has a thickness of at least about 0.5 mm.

[0242] Embodiment 72. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier includes a thickness of about 10 mm or less.

[0243] Embodiment 73. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a 25% strain compression evaluation of at least about 5 kPa.

[0244] Embodiment 74. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a 25% strain compression evaluation of about 500 kPa or less.

[0245] Embodiment 75. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier includes a 25% strain compression evaluation of at least about 5 kPa.

[0246] Embodiment 76. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier includes a 25% strain compression evaluation of about 500 kPa or less.

[0247] Embodiment 77. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a density of about 600 kg / m 3 as follows.

[0248] Embodiment 78. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer includes a density of at least about 50 kg / m 3 as follows.

[0249] Embodiment 79. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier includes a density of about 600 kg / m 3 as follows.

[0250] Embodiment 80. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier includes a density of at least about 50 kg / m 3 as follows.

[0251] Embodiment 81. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer has a thermal conductivity of at least about 0.01 W / mK.

[0252] Embodiment 82. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first foam layer has a thermal conductivity of about 0.15 W / mK or less.

[0253] Embodiment 83. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier has a thermal conductivity of at least about 0.01 W / mK.

[0254] Embodiment 84. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier has a thermal conductivity of about 0.15 W / mK or less.

[0255] Embodiment 85. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0256] Embodiment 86. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first barrier layer has a thickness of at least about 0.05 mm.

[0257] Embodiment 87. The thermal barrier according to any one of Embodiments 57 and 58, wherein the first barrier layer has a thickness of about 7 mm or less.

[0258] Embodiment 88. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier further comprises a second barrier layer, and the first foam layer is located between the first barrier layer and the second barrier layer.

[0259] Embodiment 89. The thermal barrier according to Embodiment 88, wherein the second barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0260] Embodiment 90. The thermal barrier according to Embodiment 88, wherein the second barrier layer has a thickness of at least about 0.05 mm.

[0261] Embodiment 91. The thermal barrier according to Embodiment 88, wherein the second barrier layer has a thickness of approximately 7 mm or less.

[0262] Embodiment 92. The thermal barrier according to any one of Embodiments 57 and 58, wherein the thermal barrier further comprises a second foam layer and a second barrier layer, the second layer comprising a polyurethane matrix component and a flame-retardant filler component, and both the first foam layer and the second foam layer are located between the first barrier layer and the second barrier layer.

[0263] Embodiment 93. The thermal barrier according to Embodiment 92, wherein the second barrier layer comprises a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof.

[0264] Embodiment 94. The thermal barrier according to Embodiment 92, wherein the second barrier layer has a thickness of at least about 0.05 mm.

[0265] Embodiment 95. The thermal barrier according to Embodiment 92, wherein the second barrier layer has a thickness of approximately 7 mm or less.

[0266] Embodiment 96. The thermal barrier according to Embodiment 92, wherein the polyurethane matrix component of the second foam layer includes a flexible polyurethane reacted from an isocyanate and a polyol.

[0267] Embodiment 97. The heat barrier according to Embodiment 92, wherein the flame retardant filler component of the second foam layer includes a filler selected from the group consisting of a reactive charring agent, an inorganic compound, an exothermic decomposition compound, and any combination thereof.

[0268] Embodiment 98. The heat barrier according to Embodiment 92, wherein the second foam layer includes a polyurethane-based matrix component content of at least about 40% by weight based on the total weight of the second foam layer.

[0269] Embodiment 99. The heat barrier according to Embodiment 92, wherein the second foam layer includes a polyurethane-based matrix component content of about 95% by weight or less based on the total weight of the second foam layer.

[0270] Embodiment 100. The heat barrier according to Embodiment 92, wherein the second foam layer includes a flame retardant filler component content of at least about 5% by weight based on the total weight of the second foam layer.

[0271] Embodiment 101. The heat barrier according to Embodiment 92, wherein the second foam layer includes a flame retardant filler component of about 60% by weight or less based on the total weight of the second foam layer.

[0272] Embodiment 102. The heat barrier according to Embodiment 92, wherein the second foam layer includes an HBF flammability evaluation when measured according to ASTM D4986.

[0273] Embodiment 103. The heat barrier according to Embodiment 92, wherein when the second foam layer is exposed to a hot plate test at 650 °C, the low-temperature side temperature measured in 5 minutes is about 300 °C or less.

[0274] Embodiment 104. The heat barrier according to Embodiment 92, wherein when the second foam layer is exposed to a hot plate test at 650 °C, the low-temperature side temperature measured in 5 minutes includes at least about 25 °C.

[0275] Embodiment 105. The heat barrier according to Embodiment 92, wherein the second foam layer includes a thickness of at least about 0.5 mm.

[0276] Embodiment 106. The thermal barrier according to Embodiment 92, wherein the second foam layer includes a thickness of approximately 10 mm or less.

[0277] Embodiment 107. The thermal barrier according to Embodiment 92, wherein the second foam layer includes a 25% strain compression evaluation at at least about 5 kPa.

[0278] Embodiment 108. The thermal barrier according to Embodiment 92, wherein the second foam layer includes a 25% strain compression evaluation of approximately 500 kPa or less.

[0279] Embodiment 109. The second foam layer is approximately 600 kg / m³ 3 A thermal barrier according to Embodiment 92, comprising the following densities.

[0280] Embodiment 110. The second foam layer has a density of at least about 50 kg / m³ 3 A thermal barrier according to embodiment 92, including the density of the thermal barrier.

[0281] Embodiment 111. The thermal barrier according to Embodiment 92, wherein the second foam layer has a thermal conductivity of at least about 0.01 W / mK.

[0282] Embodiment 112. The thermal barrier according to Embodiment 92, wherein the second foam layer has a thermal conductivity of about 0.15 W / mK or less. [Examples]

[0283] The concepts described herein will be further illustrated in the following examples, but will not limit the scope of the present invention as defined in the claims.

[0284] Example 1 Three sample multilayer composites S1, S2, and S3 were formed according to the embodiments described herein. For comparison with sample multilayer composites S1-S3, three comparative sample multilayer composites CS1, CS2, CS3, CS4, and CS5 were formed. The composition and structure of each multilayer composite S1-S3 and comparative sample multilayer composites CS1-CS5 are summarized in Table 1 below.

[0285] [Table 1]

[0286] The performance evaluations (i.e., flame retardancy evaluation, autoignition time, melt-off time, and low-temperature side) of sample multilayer composites S1-S6 and comparative sample multilayer composite CS1 are summarized in Table 2 below. It should be understood that the flame retardancy evaluation is based on the performance of the samples in the UL94 V0 test, the autoignition time is measured in a 650°C hot plate test as described herein, the melt-off time is measured in a 1000°C torch test as described herein, and the low-temperature side is measured in a 650°C hot plate test as described herein.

[0287] [Table 2]

[0288] In general descriptions or examples, not all of the activities described above are required, some of the activities may be omitted, and one or more additional activities may be performed in addition to those described. Furthermore, the order in which the activities are listed does not necessarily indicate the order in which they are performed.

[0289] Benefits, other advantages, and solutions to problems are described above in relation to specific embodiments. However, benefits, advantages, solutions to problems, and any features that may result in or enhance any benefit, advantage, or solution should not be construed as essential, necessary, or essential features of any or all of the claims.

[0290] The description and illustrative drawings of the embodiments described herein are intended to provide a general understanding of the structures of various embodiments. The description and illustrative drawings are not intended to serve as a comprehensive and exhaustive description of all elements and features of apparatuses and systems using the structures or methods described herein. Different embodiments may be combined within a single embodiment, and conversely, various features described in the context of a single embodiment for brevity may be provided separately or in any partial combination. Furthermore, references to values ​​within a range include all of each value within that range. Many other embodiments may become apparent to those skilled in the art only after reading this specification. Other embodiments may be used and derived from this disclosure so that structural substitutions, logical substitutions, or other modifications can be made without departing from the scope of this disclosure. Therefore, this disclosure should be considered illustrative, not restrictive.

Claims

1. It is a heat barrier, The first barrier layer, A first foam layer comprising a polyurethane matrix component and a flame-retardant filler component, When the thermal barrier is measured according to ASTM D4986, including an HBF flammability evaluation, The first barrier layer is a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof. The first foam layer contains a flame-retardant filler component content of at least 10% by weight and 60% by weight or less, relative to the total weight of the first foam layer. A thermal barrier comprising a thickness of at least 1.0 mm and 10 mm or less.

2. It is a heat barrier, The first barrier layer, A first foam layer comprising a polyurethane matrix component and a flame-retardant filler component, The first barrier layer is a material selected from the group consisting of mica, mica-glass fiber composite, glass cloth, silica cloth, basalt cloth, vermiculite-coated glass cloth, aerogel, nonwoven glass cloth, any combination thereof, and any laminate thereof. The flame-retardant filler component comprises a filler selected from the group consisting of a reactive carbonizing agent, an inorganic compound, an endothermic decomposition compound, and any combination thereof. The first foam layer contains a flame-retardant filler component content of at least 10% by weight and 60% by weight or less, relative to the total weight of the first foam layer. A thermal barrier comprising a thickness of at least 1.0 mm and 10 mm or less.

3. The thermal barrier according to any one of claims 1 and 2, wherein the polyurethane matrix component of the first foam layer includes a flexible polyurethane reacted from an isocyanate and a polyol.

4. The reactive carbonizing agent is selected from the group consisting of melamine, organophosphorus compounds, inorganic phosphorus compounds, metal salts, and any combination thereof, and / or The inorganic compound is selected from the group consisting of expansive graphite, and / or The thermal barrier according to claim 2, wherein the endothermic decomposition compound is selected from the group consisting of metal hydrates, metal silicates, carbonates, and any combination thereof.

5. The thermal barrier according to any one of claims 1 and 2, wherein the first foam layer contains polyurethane matrix components in amounts of at least 40% by weight and 90% by weight or less, relative to the total weight of the first foam layer.

6. The thermal barrier according to any one of claims 1 and 2, wherein the first foam layer is measured according to ASTM D4986, and the HBF flammability evaluation is performed.

7. The thermal barrier according to any one of claims 1 and 2, wherein when the thermal barrier is exposed to a hot plate test at 650°C, it measures at 5 minutes and includes a low-temperature side of 300°C or less.

8. The thermal barrier according to any one of claims 1 and 2, wherein the first foam layer includes thicknesses of at least 0.5 mm and 9.5 mm or less.

9. The thermal barrier according to any one of claims 1 and 2, wherein the first barrier layer has a thickness of at least 0.05 mm and 7 mm or less.

10. The thermal barrier according to any one of claims 1 and 2, wherein the thermal barrier further comprises a second barrier layer, and the first foam layer is located between the first barrier layer and the second barrier layer.

11. The thermal barrier according to any one of claims 1 and 2, wherein the thermal barrier further comprises a second foam layer and a second barrier layer, the second foam layer comprising a polyurethane matrix component and a flame-retardant filler component, and both the first foam layer and the second foam layer are located between the first barrier layer and the second barrier layer.

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