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

Abstract

The present application relates to a filler composition, a composite material, and a composite material layer having thermal barrier properties. The present disclosure relates to a filler composition, which may include a ceramifying filler component in an amount of at least about 75 wt % and not more than about 95 wt % based on the total weight of the filler composition, a structure-promoting component in an amount of at least about 0.1 wt % and not more than about 7.0 wt % based on the total weight of the filler composition, a flux component in an amount of at least about 0.1 wt % and not more than about 7.0 wt % based on the total weight of the filler composition, and a flame-retardant component in an amount of at least about 5.0 wt % and not more than about 20.0 wt % based on the total weight of the filler composition.

Description

[Technical Field]

[0001] This disclosure relates to filler compositions, composite materials, and composite material layers, in particular to filler compositions, composite materials, and composite material layers for use in various applications, such as thermal barriers in battery packs, and to methods for forming them. [Background technology]

[0002] Filler compositions, composite materials, and composite material layers can be designed for high-temperature protection in various 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. [Overview of the project]

[0003] According to the first embodiment, the filler composition may include a ceramic filler component in an amount of at least about 75% by weight and about 95% by weight or less based on the total weight of the filler composition; a structure accelerator component in an amount of at least about 0.1% by weight and about 7.0% by weight or less based on the total weight of the filler composition; a flux component in an amount of at least about 0.1% by weight and about 7.0% by weight or less based on the total weight of the filler composition; and a flame retardant component in an amount of at least about 5.0% by weight and about 20.0% by weight or less based on the total weight of the filler composition.

[0004] In yet another embodiment, the composite material may include a polymer matrix component and a filler composition distributed within the polymer component. The filler composition may include a ceramic filler component, a structure promoter component, a flux component, and a flame retardant component.

[0005] According to yet another aspect, the composite material layer may comprise a polymer-based matrix component and a filler composition distributed within the polymer-based component. The filler composition may comprise a ceramizable filler component, a structure promoter component, a flux component, and a flame retardant component. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Embodiments are illustrated by way of example and are not limited to the accompanying drawings. [Figure 1] Includes an illustrative diagram of an exemplary composite material according to certain specific embodiments described herein.

[0007] Those skilled in the art will understand that elements in the drawings are illustrated for the purposes of simplification and clarity, and are not necessarily drawn to scale. DETAILED DESCRIPTION OF THE INVENTION

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

[0009] 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 that are not explicitly listed or that are inherent to such method, article, or apparatus, but are 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).

[0010] 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, where a single article is described herein, two or more articles may be used instead of a single article. Similarly, where two or more articles are described herein, those two or more articles may be replaced with a single article.

[0011] The embodiments described herein generally relate to filler compositions, composite materials that may contain filler compositions, or composite material layers that may contain filler compositions.

[0012] First, referring to embodiments of the filler composition, the filler composition may include a ceramic filler component, a structure accelerator component, a flux component, and a flame retardant component.

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

[0014] In other embodiments, the ceramic filler component may consist of multiple particles. In other embodiments, the ceramic filler component may have a specific aspect ratio. For the purposes of the embodiments described herein, the aspect ratio of the ceramic filler component may be defined as the ratio (L / D) of the average length of a statistically significant number of particles of the ceramic filler component divided by the average diameter of a statistically significant number of particles of the ceramic filler component. For example, the ceramic filler component may have an aspect ratio of about 10.0 or less, for example, about 9.5 or less, or about 9.0 or less, or about 8.5 or less, or about 8.0 or less, or about 7.5 or less, or about 7.0 or less, or about 6.5 or less, or about 6.0 or less, or even about 5.5 or less. Furthermore, according to other embodiments, the ceramic filler component may have an aspect ratio of at least about 2.0, for example, at least about 2.5, or at least about 3.0, or at least about 3.5, or at least about 4.0, or even at least about 4.5. It will be understood that the ceramic filler component may have an aspect ratio of any value within the range between any of the above minimum and maximum values. It will be further understood that the ceramic filler component may have an aspect ratio of any value within the range between any of the above minimum and maximum values.

[0015] In other embodiments, the filler composition may contain a specific amount of ceramic filler components. For example, the filler composition may contain a ceramic filler component in an amount of at least about 75% by weight, for example, at least about 76% by weight, or at least about 77% by weight, or at least about 78% by weight, or at least about 79% by weight, or at least about 80% by weight, or at least about 81% by weight, or at least about 82% by weight, or at least about 83% by weight, or at least about 84% by weight, or even at least about 85% by weight, based on the total weight of the filler composition. In other embodiments, the filler composition may contain a ceramic filler component in an amount of about 95% by weight or less, for example, about 94% by weight or less, or about 93% by weight or less, or about 92% by weight or less, or about 91% by weight or less, or about 90% by weight or less, or about 89% by weight or less, or about 88% by weight or less, or about 88% by weight or even about 87% by weight or less, based on the total weight of the filler composition. It will be understood that the filler composition may contain any value of the ceramic filler component within the range between the minimum and maximum values ​​mentioned above. It will be further understood that the filler composition may contain any value of the ceramic filler component within the range between the minimum and maximum values ​​mentioned above.

[0016] According to a particular embodiment, the structure-promoting component may include a specific component. For example, the structure-promoting component may include a component selected from the group consisting of crystalline silica, diopside, sialite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof. According to another embodiment, the structure-promoting component may include crystalline silica. According to yet another embodiment, the structure-promoting component may consist of crystalline silica. According to yet another embodiment, the structure-promoting component may include diopside. According to yet another embodiment, the structure-promoting component may consist of diopside. According to yet another embodiment, the structure-promoting component may include sialite. According to yet another embodiment, the structure-promoting component may consist of sialite. According to yet another embodiment, the structure-promoting component may include lepidolite. According to yet another embodiment, the structure-promoting component may consist of lepidolite. According to yet another embodiment, the structure-promoting component may include lithium carbonate. According to yet another embodiment, the structure-promoting component may consist of lithium carbonate. In other embodiments, the structure-promoting component may include lithium hydroxide. In yet another embodiment, the structure-promoting component may consist of lithium hydroxide.

[0017] In other embodiments, the filler composition may contain a specific amount of structure-promoting component. For example, the filler composition may contain a structure-promoting component in an amount of at least about 0.1% by weight, e.g., at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition. In other embodiments, the filler composition may contain a structure-promoting component in an amount of about 7.0% by weight or less, e.g., about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition. It will be understood that the filler composition may contain a structure-promoting component in any value within the range between any of the above minimum and maximum values. It will be further understood that the filler composition may contain a content of structure-promoting components in any value between the minimum and maximum values ​​described above.

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

[0019] In other embodiments, the filler composition may contain flux components in specific amounts. For example, the filler composition may contain flux components in an amount of at least about 0.1% by weight, e.g., at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition. In other embodiments, the filler composition may contain flux components in an amount of about 7.0% by weight or less, e.g., about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition. It will be understood that the filler composition may contain flux components in any value within the range between any of the above minimum and maximum values. It will be further understood that the filler composition may contain flux components in any value between the minimum and maximum values ​​described above.

[0020] According to certain embodiments, the flame retardant component may include certain components. For example, the flame retardant component may include components selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof. According to yet another embodiment, the flame retardant component may include aluminum hydroxide. According to yet another embodiment, the flame retardant component may consist of aluminum hydroxide. According to yet another embodiment, the flame retardant component may include magnesium hydroxide. According to yet another embodiment, the flame retardant component may consist of magnesium hydroxide.

[0021] In other embodiments, the filler composition may contain a specific amount of flame retardant component. For example, the filler composition may contain a flame retardant component in an amount of at least about 5.0% by weight, e.g., at least about 6.0% by weight, or at least about 7.0% by weight, or at least about 8.0% by weight, or at least about 9.0% by weight, or at least about 10.0% by weight, or at least about 11.0% by weight, or even at least about 12.0% by weight, relative to the total weight of the filler composition. In other embodiments, the filler composition may contain a flame retardant component in an amount of about 20.0% by weight or less, e.g., about 19.0% by weight or less, or about 18.0% by weight or less, or about 17.0% by weight or less, or about 16.0% by weight or less, or about 15.0% by weight or less, or even about 14.0% by weight or less, relative to the total weight of the filler composition. It will be understood that the filler composition may contain a flame retardant component in any value within the range between any of the above minimum and maximum values. It will be further understood that the filler composition may contain a flame retardant component in any value between the minimum and maximum values ​​mentioned above.

[0022] In other embodiments, the filler composition may further include a functional additive. In yet another embodiment, the functional additive may include a specific component. For example, the functional additive may include a component selected from the group consisting of iron(III) oxide, titanium oxide, or any combination thereof. In yet another embodiment, the functional additive component may include iron(III) oxide. In yet another embodiment, the functional additive component may consist of iron(III) oxide. In yet another embodiment, the functional additive component may include titanium oxide. In yet another embodiment, the functional additive component may consist of titanium oxide.

[0023] In other embodiments, the filler composition may contain functional additives in specific amounts. For example, the filler composition may contain functional additives in an amount of at least about 0.1% by weight, e.g., at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition. In other embodiments, the filler composition may contain functional additives in an amount of about 7.0% by weight or less, e.g., about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition. It will be understood that the filler composition may contain functional additives in any value within the range between any of the above minimum and maximum values. It will be further understood that the filler composition may contain a functional additive in any value between the minimum and maximum values ​​mentioned above.

[0024] Referring here to embodiments of composite materials, a composite material may include a polymer matrix component and a filler composition distributed within the polymer matrix.

[0025] For illustrative purposes, Figure 1 shows a composite material 100 according to an embodiment described herein. As shown in Figure 1, the composite material 100 may comprise a polymer matrix component 110 and a filler composition 120 distributed within the polymer matrix component 110.

[0026] According to certain embodiments, the polymer matrix component 110 of the composite material 100 may include certain materials. For example, the polymer matrix component 110 may include components selected from the group consisting of silicone, polyurethane, epoxy, acrylic resin, or any combination thereof. According to yet another embodiment, the polymer matrix component 110 may include silicone. According to yet another embodiment, the polymer matrix component 110 may consist of silicone. According to yet another embodiment, the polymer matrix component 110 may include polyurethane. According to yet another embodiment, the polymer matrix component 110 may consist of polyurethane. According to yet another embodiment, the polymer matrix component 110 may include epoxy. According to yet another embodiment, the polymer matrix component 110 may consist of epoxy. According to yet another embodiment, the polymer matrix component 110 may include acrylic resin. According to yet another embodiment, the polymer matrix component 110 may consist of acrylic resin.

[0027] In other embodiments, the composite material 100 may contain polymer matrix components 110 in specific amounts. For example, the composite material 100 may contain polymer matrix components in an amount of at least about 30% by weight, e.g., at least about 33% by weight, or at least about 35% by weight, or at least about 38% by weight, or at least about 40% by weight, or at least about 43% by weight, or at least about 45% by weight, or even at least about 48% by weight, relative to the total weight of the composite material 100. In other embodiments, the composite material 100 may contain polymer matrix components in an amount of about 60% by weight or less, e.g., about 58% by weight or less, or about 55% by weight or less, or about 53% by weight or even about 50% by weight or less, relative to the total weight of the composite material 100. It will be understood that the composite material 100 may contain polymer matrix components in any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain a polymer matrix component in any value between the minimum and maximum values ​​mentioned above.

[0028] In other embodiments, the composite material 100 may contain a filler composition 120 in a specific amount. For example, the composite material 100 may contain a filler composition in an amount of at least about 40% by weight, e.g., at least about 43% by weight, or at least about 45% by weight, or at least about 48% by weight, or at least about 50% by weight, or at least about 53% by weight, or at least about 55% by weight, or even at least about 58% by weight, relative to the total weight of the composite material 100. In other embodiments, the composite material 100 may contain a filler composition in an amount of about 70% by weight or less, e.g., about 68% by weight or less, or about 65% by weight or less, or about 63% by weight or less, or even about 60% by weight or less, relative to the total weight of the composite material 100. It will be understood that the composite material 100 may contain a filler composition in any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain a filler composition in any value between the minimum and maximum values ​​described above.

[0029] According to a particular embodiment, the filler composition 120 may include a ceramic filler component, a structure accelerator component, a flux component, and a flame retardant component.

[0030] According to a particular embodiment, the ceramic filler component of the filler composition 120 may include a specific component. For example, the ceramic filler component may include a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. According to another embodiment, the ceramic filler component may include sepiolite. According to yet another embodiment, the ceramic filler component may consist of sepiolite. According to yet another embodiment, the ceramic filler component may include wollastonite. According to yet another embodiment, the ceramic filler component may consist of wollastonite. According to yet another embodiment, the ceramic filler component may include a combination of sepiolite and wollastonite. According to yet another embodiment, the ceramic filler component may consist of a combination of sepiolite and wollastonite.

[0031] In other embodiments, the ceramic filler component of the filler composition 120 may consist of multiple particles. In other embodiments, the ceramic filler component may have a specific aspect ratio. For the purposes of the embodiments described herein, the aspect ratio of the ceramic filler component may be defined as the ratio (L / D) of the average length of a statistically significant number of particles of the ceramic filler component divided by the average diameter of a statistically significant number of particles of the ceramic filler component. For example, the ceramic filler component may have an aspect ratio of about 10.0 or less, for example, about 9.5 or less, or about 9.0 or less, or about 8.5 or less, or about 8.0 or less, or about 7.5 or less, or about 7.0 or less, or about 6.5 or less, or about 6.0 or less, or even about 5.5 or less. Furthermore, according to other embodiments, the ceramic filler component may have an aspect ratio of at least about 2.0, for example, at least about 2.5, or at least about 3.0, or at least about 3.5, or at least about 4.0, or even at least about 4.5. It will be understood that the ceramic filler component may have an aspect ratio of any value within the range between any of the above minimum and maximum values. It will be further understood that the ceramic filler component may have an aspect ratio of any value within the range between any of the above minimum and maximum values.

[0032] In other embodiments, the filler composition 120 may contain a specific amount of ceramic filler components. For example, the filler composition 120 may contain a ceramic filler component in an amount of at least about 75% by weight, for example, at least about 76% by weight, or at least about 77% by weight, or at least about 78% by weight, or at least about 79% by weight, or at least about 80% by weight, or at least about 81% by weight, or at least about 82% by weight, or at least about 83% by weight, or at least about 84% by weight, or even at least about 85% by weight, based on the total weight of the filler composition 120. Furthermore, according to other embodiments, the filler composition 120 may contain a ceramic filler component in an amount of about 95% by weight or less, for example, about 94% by weight or less, or about 93% by weight or less, or about 92% by weight or less, or about 91% by weight or less, or about 90% by weight or less, or about 89% by weight or less, or about 88% by weight or less, or about 88% by weight or less, or even about 87% by weight or less, based on the total weight of the filler composition 120. It will be understood that the filler composition 120 may contain a ceramic filler component in any value within the range between any of the above minimum and maximum values. It will be further understood that the filler composition 120 may contain a ceramic filler component in any value between any of the above minimum and maximum values.

[0033] In other embodiments, the composite material 100 may contain a specific content of ceramic filler components. For example, the composite material 100 may contain a ceramic filler component in an amount of at least about 50% by weight, for example, at least about 51% by weight, or at least about 52% by weight, or at least about 53% by weight, or at least about 54% by weight, or at least about 55% by weight, or at least about 56% by weight, or at least about 57% by weight, or at least about 58% by weight, or at least about 59% by weight, or even at least about 60% by weight, relative to the total weight of the composite material 100. Furthermore, according to other embodiments, the composite material 100 may contain a ceramic filler component content of about 70% by weight or less, for example, about 69% by weight or less, about 68% by weight or less, or about 67% by weight or less, or about 66% by weight or less, or about 65% by weight or less, or about 64% by weight or less, or about 63% by weight or less, or about 62% by weight or less, or about 61% by weight or less, or even about 60% by weight or less, based on the total weight of the composite material 100. It will be understood that the composite material 100 may contain a ceramic filler component content of any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain a ceramic filler component content of any value within the range between any of the above minimum and maximum values.

[0034] According to a particular embodiment, the structure-promoting component of the filler composition 120 may include a specific component. For example, the structure-promoting component may include a component selected from the group consisting of crystalline silica, diopside, sciaenopsis, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof. According to another embodiment, the structure-promoting component may include crystalline silica. According to yet another embodiment, the structure-promoting component may consist of crystalline silica. According to another embodiment, the structure-promoting component may include diopside. According to yet another embodiment, the structure-promoting component may consist of diopside. According to another embodiment, the structure-promoting component may include sciaenopsis. According to yet another embodiment, the structure-promoting component may consist of sciaenopsis. According to another embodiment, the structure-promoting component may include lepidolite. According to yet another embodiment, the structure-promoting component may consist of lepidolite. According to another embodiment, the structure-promoting component may include lithium carbonate. According to yet another embodiment, the structure-promoting component may consist of lithium carbonate. In other embodiments, the structure-promoting component may include lithium hydroxide. In yet another embodiment, the structure-promoting component may consist of lithium hydroxide.

[0035] In other embodiments, the filler composition 120 may contain a structure-promoting component in a specific amount. For example, the filler composition 120 may contain a structure-promoting component in an amount of at least about 0.1% by weight, for example, at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition 120. In other embodiments, the filler composition 120 may contain a structure-promoting component in an amount of about 7.0% by weight or less, for example, about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition 120. It will be understood that the filler composition 120 may contain any value of the structure-promoting component within the range between the minimum and maximum values ​​mentioned above. It will be further understood that the filler composition 120 may contain any value of the structure-promoting component within the range between the minimum and maximum values ​​mentioned above.

[0036] In other embodiments, the composite material 100 may contain a specific amount of structure-promoting agent components. For example, the composite material 100 may contain a structure-promoting agent component in an amount of at least about 0.05% by weight, for example, at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or even at least about 2.5% by weight, relative to the total weight of the composite material 100. In other embodiments, the composite material 100 may contain a structure-promoting agent component in an amount of about 5.0% by weight or less, for example, about 4.5% by weight or less, or about 4.0% by weight or less, or about 3.5% by weight or even about 3.0% by weight or less, relative to the total weight of the composite material 100. It will be understood that the composite material 100 may contain a structure-promoting agent component in any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain a content of a structure-promoting agent component in any value between the minimum and maximum values ​​mentioned above.

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

[0038] In other embodiments, the filler composition 120 may contain flux components in specific amounts. For example, the filler composition 120 may contain flux components in an amount of at least about 0.1% by weight, for example, at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition 120. In other embodiments, the filler composition 120 may contain flux components in an amount of about 7.0% by weight or less, for example, about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition 120. It will be understood that the filler composition 120 may contain a flux component content of any value within the range between the minimum and maximum values ​​described above. It will be further understood that the filler composition 120 may contain a flux component content of any value within the range between the minimum and maximum values ​​described above.

[0039] Furthermore, according to other embodiments, the composite material 100 may contain flux components in specific amounts. For example, the composite material 100 may contain flux components in an amount of at least about 0.01% by weight, e.g., at least about 0.05% by weight, or at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or even at least about 2.5% by weight, relative to the total weight of the composite material 100. Furthermore, according to other embodiments, the composite material 100 may contain flux components in an amount of about 5.0% by weight or less, e.g., about 4.5% by weight or less, or about 4.0% by weight or less, or about 3.5% by weight or even about 3.0% by weight or less, relative to the total weight of the composite material 100. It will be understood that the composite material 100 may contain flux components in any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain flux component content of any value between the minimum and maximum values ​​mentioned above.

[0040] According to certain embodiments, the flame retardant component of the filler composition 120 may include certain components. For example, the flame retardant component may include components selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof. According to yet another embodiment, the flame retardant component may include aluminum hydroxide. According to yet another embodiment, the flame retardant component may consist of aluminum hydroxide. According to yet another embodiment, the flame retardant component may include magnesium hydroxide. According to yet another embodiment, the flame retardant component may consist of magnesium hydroxide.

[0041] In other embodiments, the filler composition 120 may contain a specific amount of flame retardant components. For example, the filler composition 120 may contain a flame retardant component in an amount of at least about 5.0% by weight, for example, at least about 6.0% by weight, or at least about 7.0% by weight, or at least about 8.0% by weight, or at least about 9.0% by weight, or at least about 10.0% by weight, or at least about 11.0% by weight, or even at least about 12.0% by weight, relative to the total weight of the filler composition 120. In other embodiments, the filler composition 120 may contain a flame retardant component in an amount of about 20.0% by weight or less, for example, about 19.0% by weight or less, or about 18.0% by weight or less, or about 17.0% by weight or less, or about 16.0% by weight or less, or about 15.0% by weight or less, or even about 14.0% by weight or less, relative to the total weight of the filler composition 120. It will be understood that the filler composition 120 may contain any value of the flame retardant component within the range between the minimum and maximum values ​​mentioned above. It will be further understood that the filler composition 120 may contain any value of the flame retardant component within the range between the minimum and maximum values ​​mentioned above.

[0042] In other embodiments, the composite material 100 may contain a specific amount of flame retardant components. For example, the composite material 100 may contain a flame retardant component in an amount of at least about 2.5% by weight, for example, at least about 3.0% by weight, or at least about 3.5% by weight, or at least about 4.0% by weight, or at least about 4.5% by weight, or at least about 5.0% by weight, or at least about 5.5% by weight, or even at least about 6.0% by weight, relative to the total weight of the composite material 100. In other embodiments, the composite material 100 may contain a flame retardant component in an amount of about 10.0% by weight or less, for example, about 9.5% by weight or less, or about 9.0% by weight or less, or about 8.5% by weight or less, or about 8.0% by weight or less, or about 7.5% by weight or even about 7.0% by weight or less, relative to the total weight of the composite material 100. It will be understood that composite material 100 may contain any value of flame retardant component within the range between the minimum and maximum values ​​mentioned above. It will be further understood that composite material 100 may contain any value of flame retardant component within the range between the minimum and maximum values ​​mentioned above.

[0043] In other embodiments, the filler composition 120 may further include a functional additive. In yet another embodiment, the functional additive may include a specific component. For example, the functional additive may include a component selected from the group consisting of iron(III) oxide, titanium dioxide, or any combination thereof. In yet another embodiment, the functional additive component may include iron(III) oxide. In yet another embodiment, the functional additive component may consist of iron(III) oxide. In yet another embodiment, the functional additive component may include titanium dioxide. In yet another embodiment, the functional additive component may consist of titanium dioxide.

[0044] In other embodiments, the filler composition 120 may contain functional additives in specific amounts. For example, the filler composition 120 may contain functional additives in an amount of at least about 0.1% by weight, for example, at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or at least about 2.5% by weight, or at least about 3.0% by weight, or even at least about 3.5% by weight, relative to the total weight of the filler composition 120. In other embodiments, the filler composition 120 may contain functional additives in an amount of about 7.0% by weight or less, for example, about 6.5% by weight or less, or about 6.0% by weight or less, or about 5.5% by weight or less, or about 5.0% by weight or less, or about 4.5% by weight or even about 4.0% by weight or less, relative to the total weight of the filler composition 120. It will be understood that the filler composition 120 may contain any value of the functional additive within the range between the minimum and maximum values ​​mentioned above. It will be further understood that the filler composition 120 may contain any value of the functional additive within the range between the minimum and maximum values ​​mentioned above.

[0045] Furthermore, according to other embodiments, the composite material 100 may contain functional additives in specific amounts. For example, the composite material 100 may contain functional additives in an amount of at least about 0.05% by weight, for example, at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1.0% by weight, or at least about 1.5% by weight, or at least about 2.0% by weight, or even at least about 2.5% by weight, relative to the total weight of the composite material 100. Furthermore, according to other embodiments, the composite material 100 may contain functional additives in an amount of about 5.0% by weight or less, for example, about 4.5% by weight or less, or about 4.0% by weight or less, or about 3.5% by weight or even about 3.0% by weight or less, relative to the total weight of the composite material 100. It will be understood that the composite material 100 may contain functional additives in any value within the range between any of the above minimum and maximum values. It will be further understood that the composite material 100 may contain functional additives in any value within the range between any of the above minimum and maximum values.

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

[0047] In other embodiments, the composite material 100 may have a specific 5-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at a specified time. According to a particular embodiment, the composite material 100 may have a 5-minute HPE low-temperature side temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material 100 may have a 5-minute HPE low-temperature side temperature of at least about 25°C. It will be understood that the 5-minute HPE low-temperature side temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 5-minute HPE low-temperature side temperature of the composite material 100 may be any value within any of the above values.

[0048] In other embodiments, the composite material 100 may have a specific 15-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 15 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at a specified time. According to a particular embodiment, the composite material 100 may have an HPE low-temperature side temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less for 15 minutes. According to another embodiment, the composite material 100 may have an HPE low-temperature side temperature of at least about 25°C for 15 minutes. It will be understood that the 15-minute HPE low-temperature side temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 15-minute HPE low-temperature side temperature of the composite material 100 may be any value within any of the above values.

[0049] In other embodiments, the composite material 100 may have a specific 30-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 30 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at a specified time. According to a particular embodiment, the composite material 100 may have an HPE low-temperature side temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less for 30 minutes. According to another embodiment, the composite material 100 may have an HPE low-temperature side temperature of at least about 25°C for 30 minutes. It will be understood that the 30-minute HPE low-temperature side temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 30-minute HPE low-temperature side temperature of the composite material 100 may be any value within any of the above values.

[0050] In other embodiments, the composite material 100 may have a specific 5-minute torch exposure (TE) low-side temperature when measured using a torch test performed at 1300°C for 5 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material 100 may have a 5-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material 100 may have a 5-minute TE lower temperature of at least about 25°C. It will be understood that the 5-minute TE lower temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 5-minute TE lower temperature of the composite material 100 may be any value within any of the above values.

[0051] In other embodiments, the composite material 100 may have a specific 15-minute torch exposure (TE) low-temperature side temperature when measured using a torch test performed at 1300°C for 15 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-temperature side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material 100 may have a 15-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material 100 may have a 15-minute TE lower temperature of at least about 25°C. It will be understood that the 15-minute TE lower temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 15-minute TE lower temperature of the composite material 100 may be any value within any of the above values.

[0052] In other embodiments, the composite material 100 may have a specific 30-minute torch exposure (TE) low-temperature side temperature when measured using a torch test performed at 1300°C for 30 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-temperature side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material 100 may have a 30-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material 100 may have a 30-minute TE lower temperature of at least about 25°C. It will be understood that the 30-minute TE lower temperature of the composite material 100 may be within the range of any of the above values. It will be further understood that the 30-minute TE lower temperature of the composite material 100 may be any value within any of the above values.

[0053] In further embodiments, the composite material 100 may have a specific density. For the purposes of the embodiments described herein, the density of the composite material 100 may be determined according to ASTM D1056. According to a particular embodiment, the composite material 100 has a density of about 1.7 kg / m³. 3 For example, approximately 1.6 kg / m 3 The following, or approximately 1.5 kg / m 3 The following, or approximately 1.4 kg / m 3 Less than or about 1.3kg / m 3or less, or about 1.2 kg / m 3 or less, or about 1.1 kg / m 3 or less, or about 1.0 kg / m 3 or less, or about 0.9 kg / m 3 or less, or about 0.8 kg / m 3 or less, or about 0.7 kg / m 3 or less, or about 0.6 kg / m 3 or less, or about 0.5 kg / m 3 or less, or even about 0.4 kg / m 3 may have a density equal to or lower than the above values. According to still another embodiment, the composite material 100 has a density of at least about 0.001 kg / m 3 It will be understood that the density of the composite material 100 may be within a range between any of the above minimum values and any of the above maximum values. It will be further understood that the density of the composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0054] According to still another embodiment, the composite material 100 may have a specific weight. According to a certain specific embodiment, the composite material 100 has a weight of at least about 0.001 kg / m 2 , for example, at least about 0.005 kg / m 2 , or at least about 0.01 kg / m 2 , or at least about 0.05 kg / m 2 , or at least about 0.1 kg / m 2 , or at least about 0.5 kg / m 2 , or at least about 1.0 kg / m 2 , or even at least about 1.5 kg / m 2 According to still another embodiment, the composite material 100 may have a weight of about 2.61 kg / m 2 or less. It will be understood that the weight of the composite material 100 may be within a range between any of the above minimum values and any of the above maximum values. It will be further understood that the weight of the composite material 100 may be any value between any of the above minimum values and any of the above maximum values.

[0055] In further embodiments, the composite material 100 may have a specific hardness. For the purposes of the embodiments described herein, the hardness of the composite material 100 may be determined according to ASTM D2240. In certain embodiments, the composite material 100 may have a hardness of at least about 61 Shore A, for example, at least about 62 Shore A, or at least about 63 Shore A, or at least about 64 Shore A, or even at least about 65 Shore A. In further embodiments, the composite material 100 may have a hardness of about 71 Shore A or less, for example, about 70 Shore A or less, or about 69 Shore A or less, or about 68 Shore A or less, or about 67 Shore A or even about 66 Shore A or less. It will be understood that the hardness of the composite material 100 may be within the range between any of the above minimum and maximum values. It will be further understood that the hardness of the composite material 100 may be any value between any of the above minimum and maximum values.

[0056] In further embodiments, the composite material 100 may have a specific tensile strength. For the purposes of the embodiments described herein, the tensile strength of the composite material 100 may be determined in accordance with ASTM D412. In certain embodiments, the composite material 100 may have a tensile strength of at least about 2.3 MPa, for example, at least about 2.5 MPa, or at least about 5 MPa, or at least about 10 MPa, or at least about 20 MPa, or at least about 30 MPa, or at least about 40 MPa, or at least about 50 MPa, or at least about 100 MPa, or even at least about 150 MPa. In further embodiments, the composite material 100 may have a tensile strength of about 500 MPa or less. It will be understood that the tensile strength of the composite material 100 may be within the range between any of the above minimum and maximum values. It will be further understood that the tensile strength of the composite material 100 may be any value between any of the above minimum and maximum values.

[0057] Referring here to embodiments of composite material layers, the composite materials described herein may be formed as layers of material. According to certain embodiments, it will be understood that the composite material layer described herein may contain any of the components described herein with respect to the composite material 100. According to certain embodiments, it will be further understood that the composite material layer described herein may have any of the features described herein with respect to the composite material 100.

[0058] In further embodiments, the composite material layer may have a specific thickness. For example, the composite material layer may have a thickness of at least about 0.2 mm, e.g., at least about 0.5 mm, or at least about 1.0 mm, or at least about 1.5 mm, or at least about 2.0 mm, or at least about 2.5 mm, or at least about 3.0 mm, or at least about 3.5 mm, or at least about 4.0 mm, or at least about 4.5 mm, or even at least about 5.0 mm. In yet another embodiment, the composite material layer may have a thickness of about 10 mm or less, e.g., about 9.5 mm or less, or about 9.0 mm or less, or about 8.5 mm or less, or about 8.0 mm or less, or about 7.5 mm or less, or about 7.0 mm or less, or about 6.5 mm or less, or even about 6.0 mm or less. It will be understood that the thickness of the composite material layer may be within the range of any of the above minimum and maximum values. It will be further understood that the thickness of the composite material layer can be any value between the minimum and maximum values ​​mentioned above.

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

[0060] In other embodiments, the composite material layer may have a specific 5-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 5 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at a specified time. According to a particular embodiment, the composite material layer may have a 5-minute HPE low-temperature side temperature of approximately 800°C or less, for example, approximately 775°C or less, or approximately 750°C or less, or approximately 725°C or less, or approximately 700°C or less, or approximately 675°C or less, or approximately 650°C or less, or approximately 625°C or less, or even approximately 600°C or less. According to another embodiment, the composite material layer may have a 5-minute HPE low-temperature side temperature of at least approximately 25°C. It will be understood that the 5-minute HPE low-temperature side temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 5-minute HPE low-temperature side temperature of the composite material layer may be any value within the range of any of the above values.

[0061] In other embodiments, the composite material layer may have a specific 15-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 15 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at a specified time. According to a particular embodiment, the composite material layer may have an HPE low-temperature side temperature of approximately 800°C or less, for example, approximately 775°C or less, or approximately 750°C or less, or approximately 725°C or less, or approximately 700°C or less, or approximately 675°C or less, or approximately 650°C or less, or approximately 625°C or less, or even approximately 600°C or less for 15 minutes. According to another embodiment, the composite material layer may have an HPE low-temperature side temperature of at least approximately 25°C for 15 minutes. It will be understood that the 15-minute HPE low-temperature side temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 15-minute HPE low-temperature side temperature of the composite material layer may be any value within any of the above values.

[0062] In other embodiments, the composite material layer may have a specific 30-minute hot plate exposure (HPE) low-side temperature when measured using a hot plate test performed at 800°C for 30 minutes. For the purposes of the embodiments described herein, the hot plate test is performed by preparing a 15 cm × 25 cm test specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the test specimen is 1.5 mm. The test specimen is placed on a hot plate adjusted to the desired temperature, with the composite material side of the test specimen facing the hot plate. An infrared (IR) thermometer is used to measure the temperature at the center point of the low-side surface of the sample (i.e., the side of the test specimen opposite the hot plate) at the specified time. According to a particular embodiment, the composite material layer may have an HPE low-temperature side temperature of approximately 800°C or less, for example, approximately 775°C or less, or approximately 750°C or less, or approximately 725°C or less, or approximately 700°C or less, or approximately 675°C or less, or approximately 650°C or less, or approximately 625°C or less, or even approximately 600°C or less for 30 minutes. According to another embodiment, the composite material layer may have an HPE low-temperature side temperature of at least approximately 25°C for 30 minutes. It will be understood that the 30-minute HPE low-temperature side temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 30-minute HPE low-temperature side temperature of the composite material layer may be any value within any of the above values.

[0063] In other embodiments, the composite material layer may have a specific 5-minute torch exposure (TE) low-temperature side temperature when measured using a torch test performed at 1300°C for 5 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-temperature side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material layer may have a 5-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material layer may have a 5-minute TE lower temperature of at least about 25°C. It will be understood that the 5-minute TE lower temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 5-minute TE lower temperature of the composite material layer may be any value within any of the above values.

[0064] In other embodiments, the composite material layer may have a specific 15-minute torch exposure (TE) low-temperature side temperature when measured using a torch test performed at 1300°C for 15 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-temperature side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material layer may have a 15-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material layer may have a 15-minute TE lower temperature of at least about 25°C. It will be understood that the 15-minute TE lower temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 15-minute TE lower temperature of the composite material layer may be any value within the range of any of the above values.

[0065] In other embodiments, the composite material layer may have a specific 30-minute torch exposure (TE) low-temperature side temperature when measured using a torch test performed at 1300°C for 30 minutes. For the purposes of the embodiments described herein, the torch test is performed by preparing a 15 cm × 15 cm specimen of the composite material laminated on a layer of alkali-free glass cloth having a thickness of 0.3 mm, such that the total thickness of the specimen is 1.5 mm. The specimen is fixed in a holder. The torch is positioned 7 cm away from the surface of the specimen fixed in the holder, with the composite material side of the specimen facing the torch. The torch is adjusted to produce an outer flame that just touches the center point of the composite material side of the specimen, and the specimen is allowed to reach and stabilize at the desired temperature, when measured using a thermometer at the point where the flame touches the specimen. An infrared (IR) thermometer or thermocouple is used to measure the temperature at the center point of the low-temperature side surface of the sample (i.e., the side of the specimen opposite the torch) at the specified time. According to a particular embodiment, the composite material layer may have a 30-minute TE lower temperature of about 800°C or less, for example, about 775°C or less, or about 750°C or less, or about 725°C or less, or about 700°C or less, or about 675°C or less, or about 650°C or less, or about 625°C or less, or even about 600°C or less. According to another embodiment, the composite material layer may have a 30-minute TE lower temperature of at least about 25°C. It will be understood that the 30-minute TE lower temperature of the composite material layer may be within the range of any of the above values. It will be further understood that the 30-minute TE lower temperature of the composite material layer may be any value within any of the above values.

[0066] In further embodiments, the composite material layer may have a specific density. For the purposes of the embodiments described herein, the density of the composite material layer may be determined according to ASTM D1056. According to a particular embodiment, the composite material layer has a density of approximately 1.7 kg / m³. 3 For example, approximately 1.6 kg / m 3 The following, or approximately 1.5 kg / m 3 The following, or approximately 1.4 kg / m 3 Less than or about 1.3kg / m 3 The following, or approximately 1.2 kg / m 3The following, or approximately 1.1 kg / m 3 The following, or approximately 1.0 kg / m 3 The following, or approximately 0.9 kg / m 3 The following, or approximately 0.8 kg / m 3 Less than or about 0.7kg / m 3 The following, or approximately 0.6 kg / m 3 The following, or approximately 0.5 kg / m 3 The following, or even further, approximately 0.4 kg / m 3 The following densities may be present. Furthermore, according to other embodiments, the composite material layer may have at least about 0.001 kg / m³ 3 It may have a density of . It will be understood that the density of the composite material layer may be within the range between any of the above minimum and maximum values. It will be further understood that the density of the composite material layer may be any value between any of the above minimum and maximum values.

[0067] According to further embodiments, the composite material layer may have a specific weight. According to a particular embodiment, the composite material layer has a weight of at least about 0.001 kg / m 2 For example, at least about 0.005 kg / m 2 , or at least about 0.01 kg / m 2 , or at least about 0.05 kg / m 2 , or at least about 0.1 kg / m 2 , or at least about 0.5 kg / m 2 , or at least about 1.0 kg / m 2 , or even more precisely, at least about 1.5 kg / m 2 It may have a weight of approximately 2.61 kg / m³. In further embodiments, the composite material layer may have a weight of approximately 2.61 kg / m³. 2 The weight may be as follows. It will be understood that the weight of the composite material layer may be within the range between any of the above minimum and maximum values. It will be further understood that the weight of the composite material layer may be any value between any of the above minimum and maximum values.

[0068] In further embodiments, the composite material layer may have a specific hardness. For the purposes of the embodiments described herein, the hardness of the composite material layer may be determined according to ASTM D2240. In certain embodiments, the composite material layer may have a hardness of at least about 61 Shore A, for example, at least about 62 Shore A, or at least about 63 Shore A, or at least about 64 Shore A, or even at least about 65 Shore A. In further embodiments, the composite material layer may have a hardness of about 71 Shore A or less, for example, about 70 Shore A or less, or about 69 Shore A or less, or about 68 Shore A or less, or about 67 Shore A or less, or even about 66 Shore A or less. It will be understood that the hardness of the composite material layer may be within the range between any of the above minimum and maximum values. It will be further understood that the hardness of the composite material layer may be any value between any of the above minimum and maximum values.

[0069] In further embodiments, the composite material layer may have a specific tensile strength. For the purposes of the embodiments described herein, the tensile strength of the composite material layer may be determined according to ASTM D412. In certain embodiments, the composite material layer may have a tensile strength of at least about 2.3 MPa, for example, at least about 2.5 MPa, or at least about 5 MPa, or at least about 10 MPa, or at least about 20 MPa, or at least about 30 MPa, or at least about 40 MPa, or at least about 50 MPa, or at least about 100 MPa, or even at least about 150 MPa. In further embodiments, the composite material layer may have a tensile strength of about 500 MPa or less. It will be understood that the tensile strength of the composite material layer may be within the range between any of the above minimum and maximum values. It will be further understood that the tensile strength of the composite material layer may be any value between any of the above minimum and maximum values.

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

[0071] Turning to additional embodiments described herein, such embodiments generally relate to thermal barrier composites that may include composite materials or composite material layers as described herein. According to certain embodiments, it will be understood that the thermal barrier composite described herein may include any of the components described herein with respect to the composite material 100. According to certain embodiments, it will be further understood that the thermal barrier composite described herein may have any of the features described herein with respect to the composite material 100.

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

[0073] Embodiment 1. A filler composition comprising: a ceramic filler component in an amount of at least about 75% by weight and about 95% by weight or less based on the total weight of the filler composition; a structure accelerator component in an amount of at least about 0.1% by weight and about 7.0% by weight or less based on the total weight of the filler composition; a flux component in an amount of at least about 0.1% by weight and about 7.0% by weight or less based on the total weight of the filler composition; and a flame retardant component in an amount of at least about 5.0% by weight and about 20.0% by weight or less based on the total weight of the filler composition.

[0074] Embodiment 2. A composite material comprising a polymer matrix component and a filler composition distributed within the polymer matrix component, wherein the filler composition comprises a ceramic filler component, a structure accelerator component, a flux component, and a flame retardant component.

[0075] Embodiment 3. A composite material layer comprising a polymer matrix component and a filler composition distributed within the polymer component, wherein the filler composition comprises a ceramic filler component, a structure accelerator component, a flux component, and a flame retardant component.

[0076] Embodiment 4. The composite material or composite material layer according to Embodiment 2 or 3, wherein when the composite material or composite material layer is measured 5 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 5 minutes.

[0077] Embodiment 5. The composite material or composite material layer according to Embodiment 2 or 3, wherein when the composite material or composite material layer is measured 15 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 15 minutes.

[0078] Embodiment 6. The composite material or composite material layer according to Embodiment 2 or 3, wherein, when the composite material or composite material layer is measured 30 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 30 minutes.

[0079] Embodiment 7. The composite material or composite material layer according to Embodiment 2 or 3, wherein when the composite material or composite material layer is measured over 5 minutes in a torch test performed at 1300°C, the TE low-temperature side temperature is approximately 800°C or lower for 5 minutes.

[0080] Embodiment 8. When the composite material or composite material layer is measured over 15 minutes of a torch test performed at 1300°C, the composite material or composite material layer according to Embodiment 2 or 3, including a TE low-temperature side temperature of approximately 800°C or lower for 15 minutes.

[0081] Embodiment 9. When the composite material or composite material layer is measured over 30 minutes in a torch test performed at 1300°C, the composite material or composite material layer according to Embodiment 2 or 3 includes a TE low-temperature side temperature of approximately 800°C or lower for 30 minutes.

[0082] Embodiment 10. The composite material or composite material layer according to Embodiment 2 or 3, including a V-0 flammability evaluation when the composite material or composite material layer is measured according to ASTM D3801.

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

[0084] Embodiment 12. The composite material or composite material layer according to Embodiment 2 or 3, wherein the composite material contains at least about 30% by weight of polymer components relative to the total weight of the composite material.

[0085] Embodiment 13. The composite material or composite material layer according to Embodiment 2 or 3, wherein the composite material contains polymer components in an amount of about 60% by weight or less relative to the total weight of the composite material.

[0086] Embodiment 14. The composite material or composite material layer according to Embodiment 2 or 3, wherein the composite material contains at least about 40% by weight of the filler composition relative to the total weight of the composite material.

[0087] Embodiment 15. The composite material or composite material layer according to Embodiment 2 or 3, wherein the composite material contains a filler composition in an amount of about 70% by weight or less relative to the total weight of the composite material.

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

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

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

[0091] Embodiment 19. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 75% by weight of a ceramic filler component relative to the total weight of the filler composition.

[0092] Embodiment 20. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a ceramic filler component in an amount of about 95% by weight or less relative to the total weight of the filler composition.

[0093] Embodiment 21. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 50% by weight of a ceramic filler component relative to the total weight of the composite material.

[0094] Embodiment 22. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a ceramic filler component in an amount of about 70% by weight or less relative to the total weight of the composite material.

[0095] Embodiment 23. A composite material or composite material layer according to any one of Embodiments 1, 2, and 3, wherein the structure-promoting component comprises a component selected from the group consisting of crystalline silica, diopside, siecite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0096] Embodiment 24. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 0.1% by weight of a structure-promoting component relative to the total weight of the filler composition.

[0097] Embodiment 25. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a structure-promoting agent component in an amount of about 7.0% by weight or less relative to the total weight of the filler composition.

[0098] Embodiment 26. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 0.05% by weight of a structure-promoting component relative to the total weight of the composite material.

[0099] Embodiment 27. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a structure-promoting agent component in an amount of about 5% by weight or less relative to the total weight of the composite material.

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

[0101] Embodiment 29. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 0.1% by weight of a flux component relative to the total weight of the filler composition.

[0102] Embodiment 30. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a flux component content of about 7.0% by weight or less relative to the total weight of the filler composition.

[0103] Embodiment 31. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 0.05% by weight of a flux component relative to the total weight of the composite material.

[0104] Embodiment 32. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a flux component in an amount of about 5% by weight or less relative to the total weight of the composite material.

[0105] Embodiment 33. A composite material or composite material layer according to any one of Embodiments 1, 2, and 3, wherein the flame retardant component comprises a component selected from the group consisting of aluminum hydroxide, magnesium hydroxide, or any combination thereof.

[0106] Embodiment 34. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 5.0% by weight of a flame retardant component relative to the total weight of the filler composition.

[0107] Embodiment 35. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a flame retardant component in an amount of about 20.0% by weight or less relative to the total weight of the filler composition.

[0108] Embodiment 36. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains at least about 2.5% by weight of a flame retardant component relative to the total weight of the composite material.

[0109] Embodiment 37. The composite material or composite material layer according to Embodiment 2 or 3, wherein the filler composition contains a flame retardant component in an amount of 10% by weight or less relative to the total weight of the composite material.

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

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

[0112] Embodiment 40. The composite material or composite material layer according to Embodiment 38, wherein the filler composition contains at least about 0.1% by weight of a functional additive relative to the total weight of the filler composition.

[0113] Embodiment 41. The composite material or composite material layer according to Embodiment 38, wherein the filler composition contains a functional additive in an amount of about 7.0% by weight or less relative to the total weight of the filler composition.

[0114] Embodiment 42. The composite material or composite material layer according to Embodiment 38, wherein the filler composition contains at least about 0.05% by weight of a functional additive relative to the total weight of the composite material.

[0115] Embodiment 43. The composite material or composite material layer according to Embodiment 38, wherein the filler composition contains a functional additive in an amount of about 5% by weight or less relative to the total weight of the composite material.

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

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

[0118] Embodiment 46. The composite material is approximately 1.7 kg / m 3 A composite material layer according to Embodiment 2, comprising the following densities.

[0119] Embodiment 47. The composite material has a density of at least about 0.001 kg / m³ 3 A composite material layer according to Embodiment 2, including the density of [the specified density].

[0120] Embodiment 48. The material layer is approximately 1.7 kg / m 3 A composite material layer according to Embodiment 3, comprising the following densities.

[0121] Embodiment 49. The material layer has a density of at least about 0.001 kg / m 3 A composite material layer according to Embodiment 3, including the density of [the specified density].

[0122] Embodiment 50. The composite material has a density of at least about 0.001 kg / m³ 2 The composite material layer according to Embodiment 2, including the weight of the composite material.

[0123] Embodiment 51. The composite material has a density of approximately 2.61 kg / m³. 2 The composite material layer according to Embodiment 2, comprising the following weights.

[0124] Embodiment 52. The material layer has a density of at least about 0.001 kg / m 2 A composite material layer according to Embodiment 3, including the weight of the composite material.

[0125] Embodiment 53. The material layer is approximately 2.61 kg / m 2 The composite material layer according to Embodiment 3, comprising the following weights.

[0126] Embodiment 54. The composite material layer according to Embodiment 2, wherein the composite material has a hardness of at least about 61 Shore A.

[0127] Embodiment 55. The composite material layer according to Embodiment 2, wherein the composite material has a hardness of about 71 Shore A or less.

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

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

[0130] Embodiment 58. The composite material layer according to Embodiment 2, wherein the composite material has a tensile strength of at least about 2.3 MPa.

[0131] Embodiment 59. The composite material layer according to Embodiment 2, wherein the composite material has a tensile strength of approximately 500 MPa or less.

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

[0133] Embodiment 61. The composite material layer according to Embodiment 3, wherein the material layer has a tensile strength of approximately 500 MPa or less.

[0134] Embodiment 62. A thermal barrier composite material comprising a composite material, wherein the composite material comprises a polymer matrix component and a filler composition distributed within the polymer component, and the filler composition comprises a ceramic filler component, a structure accelerator component, a flux component, and a flame retardant component.

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

[0136] Embodiment 64. A thermal barrier composite according to Embodiment 62 or 63, wherein, when the composite material or composite material layer is measured 5 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 5 minutes.

[0137] Embodiment 65. A thermal barrier composite according to Embodiment 62 or 63, wherein, when the composite material or composite material layer is measured 15 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 15 minutes.

[0138] Embodiment 66. A thermal barrier composite according to Embodiment 62 or 63, wherein, when the composite material or composite material layer is measured 30 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is approximately 800°C or lower for 30 minutes.

[0139] Embodiment 67. A thermal barrier composite according to Embodiment 62 or 63, wherein when the composite material or composite material layer is measured over 5 minutes in a torch test performed at 1300°C, the TE low-temperature side temperature is approximately 800°C or lower for 5 minutes.

[0140] Embodiment 68. A thermal barrier composite according to Embodiment 62 or 63, wherein when the composite material or composite material layer is measured over 15 minutes in a torch test performed at 1300°C, the TE low-temperature side temperature is approximately 800°C or lower for 15 minutes.

[0141] Embodiment 69. A thermal barrier composite according to Embodiment 62 or 63, wherein when the composite material or composite material layer is measured over 15 minutes in a torch test performed at 1300°C, the TE low-temperature side temperature is approximately 800°C or lower for 15 minutes.

[0142] Embodiment 70. A thermal barrier composite according to Embodiment 62 or 63, including a V-0 flammability evaluation when the composite material or composite material layer is measured according to ASTM D3801.

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

[0144] Embodiment 72. The thermal barrier composite material according to Embodiment 62 or 63, wherein the composite material contains at least about 30% by weight of polymer components relative to the total weight of the composite material.

[0145] Embodiment 73. A thermal barrier composite material according to Embodiment 62 or 63, wherein the composite material contains polymer components in an amount of about 60% by weight or less relative to the total weight of the composite material.

[0146] Embodiment 74. The thermal barrier composite material according to Embodiment 62 or 63, wherein the composite material contains at least about 40% by weight of a filler composition relative to the total weight of the composite material.

[0147] Embodiment 75. A thermal barrier composite material according to Embodiment 62 or 63, wherein the composite material contains a filler composition in an amount of about 70% by weight or less relative to the total weight of the composite material.

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

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

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

[0151] Embodiment 79. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 75% by weight of a ceramic filler component relative to the total weight of the filler composition.

[0152] Embodiment 80. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a ceramic filler component in an amount of about 95% by weight or less relative to the total weight of the filler composition.

[0153] Embodiment 81. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 50% by weight of a ceramic filler component relative to the total weight of the composite material.

[0154] Embodiment 82. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a ceramic filler component in an amount of about 70% by weight or less relative to the total weight of the composite material.

[0155] Embodiment 83. The thermal barrier composite material according to Embodiment 62 or 63, wherein the structure-promoting component comprises a component selected from the group consisting of crystalline silica, diopside, sielite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

[0156] Embodiment 84. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 0.1% by weight of a structure-promoting component relative to the total weight of the filler composition.

[0157] Embodiment 85. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a structure-promoting agent component in an amount of about 7.0% by weight or less relative to the total weight of the filler composition.

[0158] Embodiment 86. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 0.05% by weight of a structure-promoting component relative to the total weight of the composite material.

[0159] Embodiment 87. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a structure-promoting agent component in an amount of about 5% by weight or less relative to the total weight of the composite material.

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

[0161] Embodiment 89. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 0.1% by weight of a flux component relative to the total weight of the filler composition.

[0162] Embodiment 90. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a flux component content of about 7.0% by weight or less relative to the total weight of the filler composition.

[0163] Embodiment 91. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 0.05% by weight of a flux component relative to the total weight of the composite material.

[0164] Embodiment 92. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a flux component in an amount of about 5% by weight or less relative to the total weight of the composite material.

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

[0166] Embodiment 94. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 5.0% by weight of a flame retardant component relative to the total weight of the filler composition.

[0167] Embodiment 95. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a flame retardant component in an amount of about 20.0% by weight or less relative to the total weight of the filler composition.

[0168] Embodiment 96. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains at least about 2.5% by weight of a flame retardant component relative to the total weight of the composite material.

[0169] Embodiment 97. The thermal barrier composite material according to Embodiment 62 or 63, wherein the filler composition contains a flame retardant component in an amount of 10% by weight or less relative to the total weight of the composite material.

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

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

[0172] Embodiment 100. The composite material or composite material layer according to Embodiment 98, wherein the filler composition contains at least about 0.1% by weight of a functional additive relative to the total weight of the filler composition.

[0173] Embodiment 101. The composite material or composite material layer according to Embodiment 98, wherein the filler composition contains a functional additive in an amount of about 7.0% by weight or less relative to the total weight of the filler composition.

[0174] Embodiment 102. The composite material or composite material layer according to Embodiment 98, wherein the filler composition contains at least about 0.05% by weight of a functional additive relative to the total weight of the composite material.

[0175] Embodiment 103. The composite material or composite material layer according to Embodiment 98, wherein the filler composition contains a functional additive in an amount of about 5% by weight or less relative to the total weight of the composite material.

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

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

[0178] Embodiment 106. The composite material has a density of approximately 1.7 ± 0.2 kg / m². 3 A composite material layer according to Embodiment 62, comprising the following densities.

[0179] Embodiment 107. The composite material has a density of at least about 0.001 kg / m³ 3 A composite material layer according to Embodiment 62, including the density of the composite material.

[0180] Embodiment 108. The material layer is approximately 1.7 ± 0.2 kg / m 3 A composite material layer according to Embodiment 63, comprising the following densities.

[0181] Embodiment 109. The material layer has a density of at least about 0.001 kg / m 3 A composite material layer according to Embodiment 63, including the density of the composite material.

[0182] Embodiment 110. The composite material has a density of at least about 0.001 kg / m³ 2 A composite material layer according to embodiment 62, including the weight of the composite material layer.

[0183] Embodiment 111. The composite material has a density of approximately 2.61 kg / m³. 2 The composite material layer according to Embodiment 62, comprising the following weights.

[0184] Embodiment 112. The material layer has a density of at least about 0.001 kg / m 2 A composite material layer according to embodiment 63, including the weight of the composite material layer.

[0185] Embodiment 113. The material layer is approximately 2.61 kg / m 2 The composite material layer according to Embodiment 63, comprising the following weights.

[0186] Embodiment 114. The composite material layer according to Embodiment 62, wherein the composite material has a hardness of at least about 61 Shore A.

[0187] Embodiment 115. The composite material layer according to Embodiment 62, wherein the composite material has a hardness of about 71 Shore A or less.

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

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

[0190] Embodiment 118. The composite material layer according to Embodiment 62, wherein the composite material has a tensile strength of at least about 2.3 MPa.

[0191] Embodiment 119. The composite material layer according to Embodiment 62, wherein the composite material has a tensile strength of approximately 500 MPa or less.

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

[0193] Embodiment 121. The composite material layer according to Embodiment 63, wherein the material layer has a tensile strength of approximately 500 MPa or less.

[0194] In general explanations or examples, not all of the activities described above are required, and some parts of certain activities may not be necessary. It should also be noted that one or more additional activities may be performed in addition to those listed. Furthermore, the order in which the activities are listed does not necessarily reflect the order in which they are performed.

[0195] 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.

[0196] 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 also be provided separately or in any partial combination. Furthermore, references to values ​​within a range include all values ​​within that range. Many other embodiments may become apparent to those skilled in the art only after reading this specification. Other embodiments may be 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. A filler composition, A ceramic filler component in an amount of at least 75% by weight and 94% by weight or less relative to the total weight of the filler composition, A structure-promoting component contained in an amount of at least 0.1% by weight and 7.0% by weight or less relative to the total weight of the filler composition, The filler composition comprises a flux component in an amount of at least 0.1% by weight and 7.0% by weight or less relative to the total weight of the filler composition, The filler composition comprises at least 5.0% by weight and 20.0% by weight or less of a flame retardant component relative to the total weight of the filler composition, The ceramic filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. The aforementioned structure-promoting component comprises a filler composition selected from the group consisting of crystalline silica, diopside, sielite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

2. It is a composite material, Polymer matrix components, The filler composition distributed within the polymer matrix component comprises, The aforementioned filler composition Ceramic filler components, Structure accelerator components, Flux components and, It contains flame retardant components, The ceramic filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. The aforementioned structure-promoting component comprises a composite material selected from the group consisting of crystalline silica, diopside, sielite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

3. A composite material layer, Polymer matrix components, The filler composition distributed within the polymer matrix component comprises, The aforementioned filler composition Ceramic filler components, Structure accelerator components, Flux components and, It contains flame retardant components, The ceramic filler component comprises a component selected from the group consisting of sepiolite, wollastonite, or any combination thereof. The composite material layer comprises a structure-promoting component selected from the group consisting of crystalline silica, diopside, sielite, lepidolite, lithium carbonate, lithium hydroxide, or any combination thereof.

4. The composite material or composite material layer according to claim 2 or 3, wherein, when the composite material or composite material layer is measured 5 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is 800°C or lower for 5 minutes.

5. The composite material or composite material layer according to claim 2 or 3, wherein, when the composite material or composite material layer is measured 15 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is 800°C or lower for 15 minutes.

6. The composite material or composite material layer according to claim 2 or 3, wherein, when the composite material or composite material layer is measured 30 minutes after a hot plate test performed at 800°C, the HPE low-temperature side temperature is 800°C or lower for 30 minutes.

7. The composite material or composite material layer according to claim 2 or 3, wherein when the composite material or composite material layer is measured over 5 minutes of a torch test performed at 1300°C, the TE low-temperature side temperature is 800°C or lower for 5 minutes.

8. The composite material or composite material layer according to claim 2 or 3, wherein when the composite material or composite material layer is measured over 15 minutes of a torch test performed at 1300°C, the TE low-temperature side temperature is 800°C or lower for 15 minutes.

9. The composite material or composite material layer according to claim 2 or 3, wherein when the composite material or composite material layer is measured in a torch test performed at 1300°C for 30 minutes, the TE low-temperature side temperature is 800°C or lower for 30 minutes.

10. The composite material or composite material layer according to claim 2 or 3, wherein the composite material or composite material layer is measured according to ASTM D3801, and includes a V-0 flammability evaluation.

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

12. The composite material or composite material layer according to claim 2 or 3, wherein the composite material contains at least 30% by weight of polymer-based components relative to the total weight of the composite material.

13. The composite material or composite material layer according to claim 2 or 3, wherein the composite material contains a polymer-based component in an amount of 60% by weight or less relative to the total weight of the composite material.

14. The composite material or composite material layer according to claim 2 or 3, wherein the composite material contains at least 40% by weight of a filler composition relative to the total weight of the composite material.

15. The composite material or composite material layer according to claim 2 or 3, wherein the composite material contains a filler composition in an amount of 70% by weight or less relative to the total weight of the composite material.

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