WO2026050504A1 - Fire-resistant cables using high temperature insulative composites - Google Patents

Abstract

Fire-resistant cables using high temperature insulative composites are provided. A cable assembly includes a thermally insulative composite layer to be wrapped around a core. The thermally insulative composite layer includes a thermally insulative composite including 50 wt% or less of a fibrillated polymer matrix, 40 wt% or more of insulative particles, and more than 10 wt% of a combined total of additional particulate components. In some instances, an inorganic protection layer is wrapped around the thermally insulative composite layer.

Description

FIRE-RESISTANT CABLES USING HIGH TEMPERATURE INSULATIVE COMPOSITES CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of Provisional Application No. 63/689,302, filed August 30, 2024, which is incorporated herein by reference in its entirety for all purposes. FIELD [0002] The present disclosure relates generally to apparatuses, systems, and methods for providing composites operable to be fire resistant. More specifically, the disclosure relates to fire-resistant cables that include high temperature insulative composites. BACKGROUND [0003] Aircrafts (e.g., typical aircraft using fuel propulsion, or new electric aircraft such as electric vertical take-off and landing aircrafts) have requirements for certain areas of the wiring systems to withstand extreme temperatures or harsh environment. Commercial fire-resistant cables are available for power connection and have a gauge size generally greater than American Wire Gauge (AWG) size 22 (i.e., a conductor diameter of approximately 0.64 mm). SUMMARY [0004] There is a need to provide fire-resistant protective layer(s) for cables (e.g., electrical power and data cables) that can withstand an extreme temperature (e.g., 900 ^o C or higher) for at least a short duration (e.g., 30 seconds or longer). In some embodiments, the fire-resistant protective layer(s) can enable internal electrical power and data cable components to provide emergency electrical connectivity during and after exposure to the extreme temperature. In some embodiments, cables for power and data connections can include the fire-resistant protective layer(s) and have a gauge size smaller than American Wire Gauge (AWG) size 22 (i.e., a diameter of approximately 0.64 mm or less). According to some embodiments, high temperature insulative composites can be used in the fire-resistant protective layer(s) of cables which can maintain electrical integrity for at least 5 minutes after an exposure to a flame with a DMS_US.373301541.1 - 8/28/20252:28:06 PM 1 temperature of at least 900 degrees °C for a minimum of 30 seconds. According to other embodiments, high temperature insulative composites can be used in the fire- resistant protective layer(s) of cables which can maintain electrical integrity for at least 5 minutes after an exposure to a flame with a temperature of at least 900 degrees °C of from about 60 seconds to about 600 seconds. [0005] According to one embodiment (“Embodiment 1”), a cable assembly includes a core member, and a thermally insulative composite layer configured to surround the core member. The thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface. The inner surface faces the core member. The thermally insulative composite layer includes 50 wt% or less of a fibrillated polymer matrix, 40 wt% or more of aerogel particles, and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof. The weight percent is based on the total weight of the thermally insulative composite. The aerogel particles are durably enmeshed within the fibrillated polymer matrix. [0006] According to another embodiment (“Embodiment 2”), further to Embodiment 1, the cable assembly further includes an inorganic protection layer to be wrapped around the outer surface of the thermally insulative composite layer. [0007] According to another embodiment (“Embodiment 3”), further to Embodiment 2, the inorganic protection layer includes a non-flammable inorganic material having a melting point not less than 1000 ^oC. [0008] According to another embodiment (“Embodiment 4”), further to Embodiment 3, the non-flammable inorganic material is selected from silica, alumina, mica, basalt, borosilicate, and a combination thereof. [0009] According to another embodiment (“Embodiment 5”) further to any one of Embodiments 1-4, the aerogel particles include silica aerogel particles. [00010] According to another embodiment (“Embodiment 6”) further to any one of Embodiments 1-5, the thermally insulative composite layer further includes insulative particles including one or more particles selected from fumed silica, amorphous silica, colloidal silica, precipitated silica, fused silica, silica gel, silica xerogel, silicates, fumed metal oxides, and combinations thereof. [00011] According to another embodiment (“Embodiment 7”) further to any one of Embodiments 1-6, the fibrillated polymer matrix includes a polyolefin, an ultrahigh DMS_US.373301541.1 - 8/28/20252:28:06 PM 2 molecular weight polyethylene (UHMWPE), a fluoropolymer, polytetrafluoroethylene, expanded polytetrafluoroethylene (ePTFE), a polyurethane, a polyester, a polyamide, or any combination thereof. [00012] According to another embodiment (“Embodiment 8”) further to any one of Embodiments 1-7, the fibrillated polymer matrix includes an expanded polytetrafluorethylene (ePTFE), an expanded ultra-high molecular weight polyethylene (eUHMWPE) or a combination thereof. [00013] According to another embodiment (“Embodiment 9”) further to any one of Embodiments 1-8, the fibrillated polymer matrix includes a gel processed polymer selected from polyethylene, polypropylene, ethylene-propylene copolymers, polyoxymethylene, polyethylene oxide, polyamides, polyethyleneterephtalate, polyacrylonitrile, polyvinylalcohol, and polyvinylidenefluoride. [00014] According to another embodiment (“Embodiment 10”) further to Embodiment 9, the fibrillated polymer matrix includes a gel processed ultra-high molecular weight polyethylene (UHMWPE). [00015] According to another embodiment (“Embodiment 11”) further to any one of Embodiments 1-10, the thermally insulative composite layer has at least one of properties including a thickness in a range from 0.5 mm to 6.0 mm, a density in a range from 200 kg/m³ to 600 kg/m³, or a thermal conductivity not greater than 0.025 W/m·K at room temperature and atmospheric pressure. [00016] According to another embodiment (“Embodiment 12”) further to any one of Embodiments 1-11, the thermally insulative composite layer is in the form of a tube having an outer diameter in a range from 2.5 mm to 25 mm, and an inner diameter in a range from 1.5 mm to 13 mm. [00017] According to another embodiment (“Embodiment 13”) further to any one of Embodiments 1-12, the cable assembly is in the form a tube to receive the core member, the tube having an outer diameter in a range from 2.86 mm to 25.5 mm, and an inner diameter in a range from 1.5 mm to 13 mm. [00018] According to another embodiment (“Embodiment 14”) further to any one of Embodiments 2-13, the cable assembly further includes an abrasion resistant layer to wrap around the inorganic protection layer. [00019] According to another embodiment (“Embodiment 15”) further to any one of Embodiments 1-14, the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 °C and a duration of at DMS_US.373301541.1 - 8/28/20252:28:06 PM 3 least 30 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame. [00020] According to another embodiment (“Embodiment 16”) further to any one of Embodiments 1-14, the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 °C and a duration of from about 60 seconds to about 600 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame. [00021] According to another embodiment (“Embodiment 17”), a method of using a thermally insulative composite layer for a cable assembly including a core member includes providing a thermally insulative composite layer to surround the core member. The thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface, the inner surface faces the core member. The thermally insulative composite layer includes 50 wt% or less of a fibrillated polymer matrix, 40 wt% or more of aerogel particles, and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof. The weight percent is based on the total weight of the thermally insulative composite, and the aerogel particles are durably enmeshed within the fibrillated polymer matrix. [00022] According to another embodiment (“Embodiment 18”) further to Embodiment 17, the method further includes wrapping an inorganic protection layer around the outer surface of the thermally insulative composite layer. [00023] According to another embodiment (“Embodiment 19”) further to Embodiment 18, the method further includes wrapping an abrasion resistant layer around the inorganic protection layer. [00024] According to another embodiment (“Embodiment 20”) further to any one of Embodiments 17-19, the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 degrees °C and a duration of at least 30 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame. [00025] According to another embodiment (“Embodiment 21”) further to any one of Embodiments 17-19, the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 degrees °C and a duration of from about 60 seconds to 600 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame. DMS_US.373301541.1 - 8/28/20252:28:06 PM 4 [00026] According to another embodiment (“Embodiment 22”), a fire-resistant cable assembly includes one or more core conductors for signal or power transmission, a thermally insulative composite layer configured to surround the one or more core member, and an inorganic protection layer to wrap around the thermally insulative composite layer. The thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface. The inner surface faces the one or more core members. The thermally insulative composite layer includes 50 wt% or less of a fibrillated polymer matrix including an expanded polytetrafluorethylene (ePTFE), an expanded ultra-high molecular weight polyethylene (eUHMWPE) or a combination thereof, 40 wt% or more of aerogel particles, and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof. The weight percent is based on the total weight of the thermally insulative composite, and the aerogel particles are durably enmeshed within the fibrillated polymer matrix. [00027] According to another embodiment (“Embodiment 23”) further to Embodiment 22, the fire-resistant cable assembly further includes one or more inner layers, each of the inner layers being disposed between one of the core conductors and the thermally insulative composite layer to wrap around the one of the core conductors. [00028] According to another embodiment (“Embodiment 24”) further to Embodiment 23, each of the inner layers includes a low-dielectric constant material selected from polytetrafluoroethylene (PTFE), ePTFE, and eUHMWPE. [00029] According to another embodiment (“Embodiment 25”) further to Embodiment 23, each of the inner layers includes a low-dielectric constant dense material selected from PTFE, a perfluoroalkoxy polymer (PFA), and a fluorinated ethylene propylene (FEP). [00030] According to another embodiment (“Embodiment 26”) further to Embodiment 23, each of the inner layers includes a fluoropolymer, a polyimide, polyamide, or ultra-high molecular weight polyethylene (UHMWPE). [00031] The foregoing embodiments are just that and should not be read to limit or otherwise narrow the scope of any of the inventive concepts otherwise provided by the instant disclosure. While multiple examples are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative examples. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature rather than restrictive in nature. DMS_US.373301541.1 - 8/28/20252:28:06 PM 5 BRIEF DESCRIPTION OF THE DRAWINGS [00032] The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description serve to explain the principles of the disclosure. [00033] FIG.1 is a cross-sectional view of a cable assembly, in accordance with some embodiments; [00034] FIG.2A is a schematic cross-section of a high temperature insulative composite having therein varying particulate components through a thickness thereof in accordance with some embodiments; [00035] FIG.2B is a schematic cross-section of a multi-layer high temperature insulative composite having therein differing particulate size distributions in different layers in accordance with some embodiments; and [00036] FIG.3 is a cross-sectional view of a cable assembly with a twisted shielded pair core, in accordance with some embodiments. DETAILED DESCRIPTION Definitions and Terminology [00037] This disclosure is not meant to be read in a restrictive manner. For example, the terminology used in the application should be read broadly in the context of the meaning those in the field would attribute such terminology. [00038] With respect to terminology of inexactitude, the terms “about” and “approximately” may be used, interchangeably, to refer to a measurement that includes the stated measurement and that also includes any measurements that are reasonably close to the stated measurement. Measurements that are reasonably close to the stated measurement deviate from the stated measurement by a reasonably small amount as understood and readily ascertained by individuals having ordinary skill in the relevant arts. Such deviations may be attributable to measurement error, differences in measurement and/or manufacturing equipment calibration, human error in reading and/or setting measurements, minor adjustments made to optimize performance and/or structural parameters in view of differences in measurements associated with other components, particular implementation scenarios, imprecise adjustment and/or manipulation of objects by a person or machine, and/or the like, for example. In the DMS_US.373301541.1 - 8/28/20252:28:06 PM 6 event it is determined that individuals having ordinary skill in the relevant arts would not readily ascertain values for such reasonably small differences, the terms “about” and “approximately” can be understood to mean plus or minus 10% of the stated value. [00039] As used herein, the terms “fibrillating” and “fibrillatable” refer to the ability of a polymer to form a node and fibril microstructure or a microstructure substantially comprised of only fibrils when exposed to sufficient shear. In some embodiments, the fibrillated polymer may be mixed, such as, for example, by wet mixing, by dispersion, or by coagulation. Time and temperatures at which the shearing and/or mixing occurs varies with particle size, material used, and the amount of particles being mixed and is easily determined by those of skill in the art. [00040] As used herein, the term “durably enmeshed” is meant to describe the particulate components of the high temperature insulative composite (e.g., aerogel, expandable microspheres, reinforcement fibers, opacifier(s), and additional particulate components) as being non-covalently immobilized within the fibrillated microstructure of the polymer membrane. No separate binder is present to fix or otherwise bind the particulate components within the fibrillated membrane. Additionally, it is to be appreciated that in some embodiments, the particulate components are located throughout the thickness of the fibrillated polymer membrane of the high temperature insulative composite. [00041] As used herein, “ultra-high molecular weight” refers to a polymer having a number average molecular weight of at least 500,000 g/mol, preferably at least 1,000,000 g/mol. In one aspect, ultra-high molecular weight refers to a polymer having a number average molecular weight in the range of 500,000 g/mol to 12,000,000 g/mol, or from 1,000,000 g/mol to 12,000,000 g/mol, or from 1,000,000 g/mol to 10,000,000 g/mol. In some embodiments, the number average molecular weight of the polymer may be from 3,000,000 g/mol to 10,000,000 g/mol or from 5,000,000 g/mol to 10,000,000 g/mol. [00042] Unless specifically noted, the term “weight percent” or “wt %” as used herein is meant to denote the weight percent of that component based on the total weight percent of the final insulative composite (i.e., after lubricant is removed). “Wt %” may be defined as the mass of the component divided by the total mass of the insulative component (after lubricant is removed) multiplied by 100. DMS_US.373301541.1 - 8/28/20252:28:06 PM 7 [00043] As used herein, the term “gel processed polymer matrix” refers to a polymer having been formed by a gel process and specifically excludes any polymer formed by paste processing. [00044] As used herein, the term “gel processed polyethylene” refers to an ultra- high molecular weight polyethylene (UHMWPE) formed by a gel process, and which has a number average molecular weight of at least about 200,000 g/mol, at least about 500,000 g/mol, at least about 1,000,000 g/mol, at least about 5,000,000 g/mol, at least about 7,000,000 g/mol, or at least about 10,000,000 g/mol. [00045] Persons skilled in the art will readily appreciate that various aspects of the present disclosure can be realized by any number of methods and apparatuses configured to perform the intended functions. It should also be noted that the accompanying drawing figures referred to herein are not necessarily drawn to scale, but may be exaggerated to illustrate various aspects of the present disclosure, and in that regard, the drawing figures should not be construed as limiting. [00046] Cables, cable assemblies, and relevant components shown in FIGS.1-3 are provided as examples of the various features of apparatuses, systems, and methods that include high temperature insulative composites that may be used in fire- resistant cables. Although the combination of those illustrated features is clearly within the scope of this disclosure, the examples and their illustrations are not meant to suggest that the inventive concepts provided herein are limited from fewer features, additional features, or alternative features to one or more of those features shown in FIGS.1-3. [00047] Referring to FIG.1, a thermally insulative composite layer 104 is provided to a cable assembly 100. The thermally insulative composite layer 104 surrounds a core member 102 to provide thermal insulation when the cable assembly 100 is exposed to an extreme temperature (e.g., 900 ^o C or higher for 30 seconds or longer). The thermally insulative composite layer 104 has an inner surface 104a and an outer surface 104b opposing the inner surface 104a. The inner surface 104a faces the core member 102. [00048] In some embodiments, the thermally insulative composite layer 104 can be in direct contact with the core member 102 to provide insulation. In some embodiments, no intermediate layers are provided between the thermally insulative composite layer 104 and the core member 102 such that the inner surface 104 of the thermally insulative composite layer 104 is in direct contact with an outer surface of the DMS_US.373301541.1 - 8/28/20252:28:06 PM 8 core member 102. Without limiting the embodiments described herein, the core member 102 may be for signal or power transmission. [00049] In some embodiments, the thermally insulative composite layer 104 can have a thickness in a range, for example, from 0.2 mm to 10.0 mm, from 0.5 mm to 8.0 mm, from 0.5 mm to 6.0 mm, or from 0.5 mm to 5.0 mm, or any have a thickness of any value encompassed by the foregoing ranges. [00050] In some embodiments, the thermally insulative composite layer 104 can have a density in a range, for example, from 100 kg/m³ to 800 kg/m³, from 100 kg/m³ to 600 kg/m³, or from 200 kg/m³ to 600 kg/m³, or any have a density of any value encompassed by the foregoing ranges. [00051] In some embodiments, the thermally insulative composite layer 104 can have a thermal conductivity not greater than 40 mW/m·K, not greater than 30 mW/m·K, not greater than 25 mW/m·K, or not greater than 20 mW/m·K at room temperature and atmospheric pressure (298.15 K and 101.3 kPa), or for examples, from 5 mW/m·K to 40 mW/m·K, from 5 mW/m·K to 30 mW/m·K, from 5 mW/m·K to 25 mW/m·K, from 5 mW/m·K to 20 mW/m·K, or any have a thermal conductivity of any value encompassed by the foregoing ranges. [00052] As shown in FIG.1, the thermally insulative composite layer 104 is assembled in the form of a tube wrapped around the core member 102. In some embodiments, the tube formed by the thermally insulative composite layer 104 can have an outer diameter in a range, for example, from 2.5 mm to 25 mm, and have an inner diameter in a range, for example, from 1.5 mm to 13 mm. The tube has a generally round cross-sectional shape such as an oval shape or a circular shape. It is to be appreciated that the thermally insulative composite layer 104 can be assembled in the form of other regular or irregular cross-sectional shapes. [00053] As shown in FIG.1, the cable assembly 100 is assembled in the form a tube to receive the core member 102. In some embodiments, the tube of the cable assembly 100 can have an outer diameter in a range, for example, from 2.0 mm to 30.0 mm, from 2.5 mm to 28 mm, or from 2.86 mm to 25.5 mm, and have an inner diameter in a range, for example, from 1.0 mm to 20 mm, from 1.5 mm to 20 mm, or from 1.5 mm to 13 mm, or any have a diameter of any value encompassed by the foregoing ranges. [00054] In some embodiments, the thermally insulative composite layer 104 is configured to protect the core member 102 from a high temperature event such as, for example, an exposure to a flame with a temperature of at least 900 °C and a duration of DMS_US.373301541.1 - 8/28/20252:28:06 PM 9 at least 30 seconds. The thermally insulative composite layer 104 wrapped around the core member 102 can maintain an electrical integrity of the core member 102 for at least 5 minutes after such an exposure to the flame. [00055] In some embodiments, the thermally insulative composite layer 104 is configured to protect the core member 102 from a high temperature event such as, for example, an exposure to a flame with a temperature of at least 900 °C and a duration of from about 60 seconds to about 600 seconds, i.e., about 60 seconds, about 80 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds, about 600 seconds, or within any range encompassed by any toe of the foregoing values as endpoints. For example, the flame exposure may be from about 60 seconds to about 580 seconds, from about 80 seconds to about 520 seconds, from about 100 seconds to about 600 seconds, from about 200 seconds to about 400 seconds, from about 300 seconds to about 550 seconds, from about 440 seconds to about 540 seconds, or from 180 seconds to about 460 seconds. The thermally insulative composite layer 104 wrapped around the core member 102 can maintain an electrical integrity of the core member 102 for at least 5 minutes after such an exposure to the flame. [00056] The thermally insulative composite layer 104 is formed of one or more thermally insulative or insulating composites. In some embodiments, a thermally insulative composite of the thermally insulative composite layer 104 includes 50 wt% or less of a fibrillated polymer matrix, and 40 wt% or more of insulative particles. In some embodiments, the weight ratio between the fibrillated polymer matrix and the insulative particles may be, for example, 5:4 or less, 1:1 or less, 1:1.5 or less, 1:2 or less, 1:3 or less, 1:4 or less, or 1:3 or less. In some embodiments, a thermally insulative composite of the thermally insulative composite layer 104 includes 5 wt% to 50 wt%, 10 wt% to 50 wt%, or 20 wt% to 50 wt% of a fibrillated polymer matrix, or any have a weight percentage of any value encompassed by the foregoing ranges. In some embodiments, a thermally insulative composite of the thermally insulative composite layer 104 includes, for example, 40 wt% to 85 wt%, 40 wt% to 80 wt%, 40 wt% to 70 wt% of DMS_US.373301541.1 - 8/28/20252:28:06 PM 10 insulative particles, or any have a weight percentage of any value encompassed by the foregoing ranges. The weight percent is based on the total weight of the thermally insulative composite. The insulative particles are durably enmeshed within the fibrillated polymer matrix. As used herein, the phrase “durably enmeshed” is meant to describe the particulate components (e.g., insulative particles, and additional particulate components) of the high temperature insulative composite as being non-covalently immobilized within the fibrillated polymer matrix such as, for example, a fibrillated microstructure of a polymer membrane. [00057] In some embodiments, the thermally insulative composite of the thermally insulative composite layer 104 provides a thermal conductivity of less than or equal to 25 milliwatts per meter Kelvin (mW/m K) at atmospheric conditions (298.15 K and 101.3 kPa) prior to exposure to a high temperature event. In one aspect, the “high temperature” may refer to a temperature that is sufficient to volatilize the fibrillated polymer partially or completely within the thermally insulative composite. In one aspect, an example high temperature event may refer to an exposure to a flame with a temperature of at least 900 °C and a duration of at least 30 seconds. In another aspect, an example high temperature event may refer to an exposure to a flame with a temperature of at least 900 °C and a duration of from about 60 seconds to about 600 seconds. The thermally insulative composite of the thermally insulative composite layer 104 functions as a protective heat propagation barrier when subjected to a high temperature event. High Temperature Insulative Composites [00058] High temperature insulative composites of the present disclosure include a fibrillated polymer matrix, high temperature insulative particles, one or more opacifier, and optionally, reinforcement fibers and/or expandable microspheres and/or additional particulate components. [00059] According to some embodiment, the high temperature high temperature insulative composite includes 50 wt% or less of a fibrillated polymer matrix, more than 40 wt% insulative particles, and more than 10 wt% of an opacifier(s), and/or reinforcement fibers, and/or expandable microspheres. As set forth above, the term weight percent (wt%) is the percent of the total weight of the high temperature insulative composite. [00060] In some embodiments, the high temperature insulative composite DMS_US.373301541.1 - 8/28/20252:28:06 PM 11 includes less than 50 wt% of a fibrillated polymer matrix, less than 80 wt% of insulative particles, greater than 10 wt% of at least one opacifier, up to 25 wt% reinforcement fibers, and less than 20 wt% expandable microspheres. The weight percent is based on the total weight of the high temperature insulative composite article in a final state, and the insulative particles (e.g., aerogel particles) and the additional particulate components are durably enmeshed within the fibrillated polymer matrix. [00061] The aerogel particles, the one or more opacifier, the reinforcement fibers and/or expandable microspheres, and/or additional particulate components are durably enmeshed within the fibrillated polymer matrix, and the thermal conductivity of the high temperature insulative composite is not more than 25 milliwatts per meter Kelvin (mW/m K), 23 mW/m K, 21 mW/m K, 19 mW/m K or 17 mW/m K at atmospheric conditions (298.15 K and 101.3 kPa). [00062] The high temperature insulative composite may be formed into thin, flexible, compressible, and conformable shapes at least due to the strength of the fibrillated polymer matrix, thereby facilitating the ability to fabricate shaped materials suitable for the target application, e.g., thermally insulative composite layer(s) for fire- resistant cable(s). [00063] In at least one embodiment, the high temperature insulative composites have a thickness of about 6 mm or less, about 4 mm or less, about 3 mm or less, about 2 mm or less, or about 1 mm or less. In some embodiments, the high temperature insulative composite has a thickness from about 0.5 mm to about 6 mm, from about 1 mm to about 4 mm, from about 1 mm to about 3 mm, from about 1 mm to about 2 mm, from about 0.01 mm to about 5 mm, from about 0.01 mm to about 4 mm, from about 0.1 mm to about 3 mm, from about 0.1 mm to about 2.5 mm, from about 0.1 mm to about 2 mm, from about 0.1 mm to about 1.5 mm, or from about 0.1 mm to about 1 mm, or any have a thickness of any value encompassed by the foregoing ranges. [00064] In some embodiments, the insulative particles and additional components of the high temperature insulative composite may be located through the thickness of the gel processed polymer matrix. As illustrated in FIG.2A, the particulate components 230 are located fairly equally throughout the microstructure of the gel processed polymer matrix (membrane) of the high temperature insulative composite 200. The high temperature insulative composite 200 has a challenge side 210, a protected side 220, a height (H) and a length (L). It is to be appreciated that, in some embodiments (not illustrated), the insulative particles and additional materials may be located on a surface DMS_US.373301541.1 - 8/28/20252:28:06 PM 12 of the insulative composite. For example, the insulative particles and additional materials may be located on or proximate the outer surface 104b of the thermally insulative composite layer 104 in FIG.1. [00065] The insulative composite may be formed of a composite (e.g., one layer) as generally depicted in FIG.2A or optionally as a multi-layer stack high temperature insulative composite (e.g., multiple, individual layers) as generally depicted in FIG.2B. In a multi-layer stack high temperature insulative composite, each layer may have therein a particulate that has a different chemical composition, a different particle size, a different particle size distribution, or a different particle distribution. In one embodiment, opacifiers having differing properties such as composition, size, and/or shape may be distributed in various layers throughout the thickness of the high temperature insulative composite. [00066] In the multi-layer stack high temperature insulative composite illustrated in FIG.2B, for ease of illustration, of the particulate components present in the multi-layer stack high temperature insulative composite, only the opacifiers are depicted. FIG.2B is a schematic cross-section of one embodiment of a multi-layer stack high temperature insulative composite having multiple layers. As shown, the multi-layer stack high temperature insulative composite 240 has a height (H) and a length (L). The multi-layer stack high temperature insulative composite 240 contains a challenge side 250 and a protected side 260. [00067] In the embodiment depicted in FIG.2B, the height (H) is divided into three layers, namely Layer A 270, Layer B 280, and Layer C 290. In some embodiments, Layer A 270, Layer B 280, and Layer C 290 may contain the same type of opacifier but with different size distributions. In other embodiments, Layer A 270, Layer B 280, and Layer C 290 may contain different types of opacifier with different size distributions. As shown in FIG.2B, Layer A 270 has a first opacifier 205 with a first size distribution, Layer B 280 has a first opacifier 205 with a second size distribution, and Layer C 290 has a second opacifier 206 with the first size distribution. The first opacifier 205 may silicon carbide and the second opacifier 206 may be carbon black, although this is exemplary in nature and is not meant to restrict the purview of this disclosure. In some embodiments, the particulate components themselves may be different in each layer, or only in certain layers. In other embodiments, the particulate components are the same in each layer, but each layer has a different size distribution. Thus, each layer in a multi- layer stack high temperature insulative composite may include one or more particulate DMS_US.373301541.1 - 8/28/20252:28:06 PM 13 components(s) that have a different chemical composition, a different particle size, and/or a different particle size distribution within each layer (or only within certain layers). [00068] In forming a multi-layer stack high temperature insulative composite, each layer is separately formed as described below and then layered or stacked upon each other in a manner to obtain a desired orientation of the layers in the multi-layer stack high temperature insulative composite. The layers may be bound to each other in any conventional manner such as laminating, adhering, or other bonding techniques to form a multi-layer high temperature insulative composite. Fibrillated Polymer Matrix [00069] The use of a fibrillatable polymer to create the high temperature insulative composites enables the formation of thin and flexible form factors (e.g., films, sheets, tubes, and the like). The thermally insulative particles (e.g., aerogel particles) and other particulate filler components can be durably bound (e.g., non-covalently bound; have little or no dusting) and distributed within the fibrillated polymer matrix. It is to be appreciated that there may be no imbibing step to introduce the insulative particles and other particulate filler components into the fibrillated polymer matrix. Thus, the thermally insulative particles (e.g., aerogel particles) and particulate components within the high temperature insulative composite are durably enmeshed within the fibrillated polymer matrix. Thin and flexible form factors are important to many applications where a high temperature event may occur, such as, for example, the cable assembly 100 of FIG.1 and the cable assembly 300 of FIG.3. It is to be understood that upon partial or complete volatilization of the fibrillated polymer matrix within the high temperature insulative composite, the remaining components can provide a separate matrix that provides a protective effect. This may be due at least to the particulate filler components being more thermally stable relative to the fibrillated polymer matrix. [00070] In some embodiments, the fibrillated polymer matrix includes a polyolefin, an ultrahigh molecular weight polyethylene (UHMWPE), a fluoropolymer, polytetrafluoroethylene, expanded polytetrafluoroethylene (ePTFE), a polyurethane, a polyester, a polyamide, or any combination thereof. [00071] In some embodiments, the fibrillated polymer matrix includes an expanded polytetrafluorethylene (ePTFE), an expanded ultra-high molecular weight polyethylene (eUHMWPE) or a combination thereof. DMS_US.373301541.1 - 8/28/20252:28:06 PM 14 [00072] A variety of fibrillatable polymers may be used to obtain the present high temperature insulative composites. The use of fibrillatable polymers as a binder for the high temperature insulative composite provides both strength (and the ability to form thin materials), conformability, and compressibility while durably enmeshing the particulate components into a cohesive shape. It is to be noted that components such as the aerogels, the expandable microspheres, the opacifier, and the reinforcement fibers, and additional components are considered as “particulate components” herein. Blending the fibrillatable polymer particles and other particulate components in the high temperature insulative composite (e.g., aerogels, opacifiers, reinforcement fibers, expandable microspheres, etc.) with sufficient shear during the blending/forming process results in a fibrillated polymeric matrix (nodes interconnected by fibrils or a microstructure of substantially only fibrils) having the particulate materials durably enmeshed therein. [00073] The decomposition temperature of the fibrillated polymer matrix varies according to the nature of the polymer. In one aspect, the fibrillated polymer matrix is prepared from a fibrillatable polymer particle of a polyolefin, a fluoropolymer, a polyurethane, a polyester, a polyamide, polylactic acid, or any combination thereof. Non-limiting examples of fibrillatable polymers include, but are not limited to, polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), ultrahigh molecular weight polyethylene (UHMWPE), polylactic acid, copolymers of vinylidene fluoride with tetrafluoroethylene or trifluoroethylene (e.g. VDF-co-(TFE or TrFE) polymers), poly (ethylene tetrafluoroethylene) (ETFE), polyparaxylxylene (PPX), and polytetrafluoroethylene (PTFE). In one embodiment, the fibrillated polymer is fibrillated PTFE made from PTFE fine powder particles that are non-melt processible (i.e., the melt flow viscosity is too high for melt extrusion and requires high shear blending and/or paste processing for form the fibrillated polymer matrix) (see, e.g. Expanded PTFE Applications Handbook – Technology, Manufacturing and Applications, Ebnesajjad, Sina, (1997), Elsevier, Cambridge, MA). [00074] As used herein, the term “PTFE” includes homopolymer PTFE and modified PTFE resins (e.g., having up to 5 wt%, up to 4 wt%, up to 3 wt% up to 2 wt%, or up to 1 wt% of one or more ethylenic comonomers including, but not limited to perfluoroalkyl ethylene (e.g. perfluorobutyl ethylene; U.S. Patent No.7,083,225 to Baille), hexafluoropropylene, perfluoroalkyl vinyl ether (C1-C8 alkyl; such as perfluoro methyl vinyl ether, perfluoro ethyl vinyl ether, perfluoro propyl vinyl ether, perfluoro octyl DMS_US.373301541.1 - 8/28/20252:28:06 PM 15 vinyl ether, etc.). PTFE is also meant to include, expanded modified PTFE and expanded copolymers of PTFE, such as, for example, those described in U.S. Patent No.5,708,044 to Branca, U.S. Patent No.6,541,589 to Baillie, U.S. Patent No. 7,531,611 to Sabol et al., U.S. Patent No.8,637,144 to Ford, and U.S. Patent No. 9,139,669 to Xu et al. [00075] Suitable fibrillated fluoropolymers may also include fibrillatable copolymers and terpolymers of tetrafluoroethylene (TFE) with comonomers such as vinylidene fluoride (VDF), vinylidene difluoride, hexafluoroisobutylene (HFIB), trifluoroethylene (TrFE), chlorotrifluoroethylene (CTFE), hexafluoropropylene (HFP), fluorodioxole or fluorodioxalane (e.g., U.S. Patent No.9,040,646 to Ford), and ethylene (e.g. ethylene tetrafluoroethylene (ETFE; US Patent No.9,932,429; supra). All of the above-identified polymers will at least partially or fully volatilize (degrade) when exposed to a high temperature event having a temperature of at least 800 ^oC. [00076] In some embodiments, the fibrillated polymer matrix is a polytetrafluoroethylene (PTFE) matrix or an expanded polytetrafluoroethylene (ePTFE) matrix having a node and fibril microstructure or a microstructure containing substantially only fibrils. The fibrils of the PTFE particles interconnect with other PTFE fibrils and/or to nodes to form a net within and around the particulate components, effectively immobilizing them within the polymer matrix. [00077] The amount of fibrillated polymer present in the high temperature insulative composite is about 60 wt% or less, about 50 wt% or less, about 40 wt% or less, about 30 wt% or less, about 20 wt% or less, or about 10 wt% or less. The fibrillated polymer may be present in the high temperature insulative composite in an amount from about 1 wt% to about 60 wt%, from about 1 wt% to about 50 wt%, from about 1 wt % to about 40 wt%, from about 1 wt% to about 30 wt%, from about 1 wt% to about 25 wt%, from about 1 wt% to about 20%, from about 1 wt% to about 15 wt%, from about 1 wt% to about 15 wt%, or from about 1 wt% to about 10 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In other embodiments, the amount of fibrillated polymer ranges from about 5 wt% to about 30 wt%, from about 10 wt% to about 25 wt%, from about 1 wt% to about 20 wt%, from about 1 wt% to about 15 wt%, from about 1 wt% to about 10 wt%, or from about 1 wt% to about 5 wt% or any have a weight percentage of any value encompassed by the foregoing ranges. DMS_US.373301541.1 - 8/28/20252:28:06 PM 16 [00078] In some embodiments, the porous fibrillated polymer matrix may be formed by dry mixing the fibrillatable polymer particles with the other particulate components in a manner such as is generally taught in U.S. Publication No. 2010/0119699 to Zhong, et al., U.S. Patent No.7,118,801 to Ristic-Lehmann et al., U.S. Patent No.5,849,235 to Sassa, et al., U.S. Patent No.6,218,000 to Rudolf, et al., or U.S. Patent No.4,985,296 to Mortimer, Jr. [00079] In one embodiment, a coagulum may be prepared using the general methodology described in U.S. Patent No.7,118,801 to Ristic-Lehmann et al. The general method of preparing the coagulum includes mixing an aqueous dispersion of particulate component particles (aerogel particles, opacifiers, reinforcement fibers and/or additional particulate components) with a fibrillatable polymer particle dispersion and then coagulating the mixture by agitation or by the addition of coagulating agents. The resulting co-coagulation of the polymer particles in the presence of the other particulate components creates an intimate blend of the fibrillatable polymer particles and the other particulate component particles (i.e., insulative material). The insulative material is drained and dried in a convection oven at about 433 K. Depending on the type of wetting agent used, the dried insulative material may be in the form of loosely bound powder or in the form of soft cakes that may then be chilled and ground to obtain the insulative material in the form of a powder. The powdered insulative material may then be blended with a suitable hydrocarbon lubricant (for example, an isoparaffinic lubricant (e.g., ISOPAR K^®, available from Exxon Mobil Corp., Houston, Texas)) for subsequent mechanical processing steps to induce fibrillation and the formation of a cohesive matrix into a desired form factor, such as a tape, sheet or putty. The mechanical processing steps may include one or more steps of high shear mixing, pressing, calendaring, and combinations thereof to form the high temperature insulative composite having a fibrillated polymer matrix. At least one drying step is included to remove the hydrocarbon lubricant. [00080] The high temperature insulative composite can be formed into relative thin form factors (e.g., films or sheets). In one embodiment, the high temperature insulative composite is formed into a shaped tube, tape or sheet having an average thickness (or tube wall thickness in the instance of a tube) of less than about 6 mm, less than about 5 mm, about 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less, or from 0.5 mm to 6.0 mm. In some embodiments, the insulative composite can be in DMS_US.373301541.1 - 8/28/20252:28:06 PM 17 the form of an extruded profile, extruded article, injection molded shape, or injection molded article. Gel Processed Polymer Matrix [00081] In some embodiments, the fibrillated polymer matrix includes a gel processed polymer selected from polyethylene, polypropylene, ethylene-propylene copolymers, polyoxymethylene, polyethylene oxide, polyamides, polyethyleneterephtalate, polyacrylonitrile, polyvinylalcohol, and polyvinylidenefluoride. [00082] In some embodiments, the fibrillated polymer matrix includes a gel processed ultra-high molecular weight polyethylene (UHMWPE) having a molecular weight from about 200,000 g/mol to about 3,000,000 g/mol, from about 500,000 g/mol to about 2,500,000 g/mol, or from about 1,000,00 g/mol to about 2,000,000 g/mol. [00083] The use of a gel processed polymer matrix to create the high temperature insulative composites enables the formation of thin, strong, and flexible form factors (e.g., films, sheets, and tubes) having the insulative particles and other components distributed within the gel processed polymer matrix. The gel processed polymer matrix may be any polymer that can be processed by a gel process, such as, but not limited to, extrusion, injection molding, compression molding, and calendering. It is to be appreciated that there is no imbibing step to introduce the aerogel particle(s), reinforcement fiber(s), and/or other additional components into the gel processed polymer matrix. As discussed above, thin and flexible form factors are important in lithium-ion battery cells and modules. [00084] In some embodiments, the high temperature gel processed insulative composites may have a thickness up to about 250 mm. The gel processed insulative composite may have a thickness from about 0.1 mm to about 2 mm, from about 0.5 mm to about 2 mm, from about 0.75 mm to about 2 mm, from about 1 mm to about 2 mm, from about 1.25 mm to about 2 mm, from about 1.5 mm to about 2 mm, from about 1.75 mm to about 2 mm, from about 0.1 mm to about 1 mm, from about 0.25 mm to about 1 mm, from about 0.5 mm to about 1mm, or from about 0.75 mm to about 1 mm. In some embodiments, the high temperature gel processed insulative composite has a thickness from about 2 mm to about 4 mm, from about 2.25 mm to about 4 mm, from about 2.5 mm to about 4 mm, from about 2.75 mm to about 4 mm, from about 3 mm to about 4 mm, from about 3.25 to about 4 mm, from about 3.5 mm to about 4 mm. In some embodiments, the insulative composite has a thickness from about 4 mm to about 10 DMS_US.373301541.1 - 8/28/20252:28:06 PM 18 mm, from about 5 mm to about 10 mm, from about 6 mm to about 10 mm, from about 7 mm to about 10 mm, from about 8 mm to about 10 mm, or from about 9 mm to about 10 mm. In some embodiments, the gel processed insulative composite has a thickness from about 10 mm to about 50 mm, from about 15 mm to about 50 mm, from about 20 mm to about 25 mm to about 50 mm, from about 30 mm to about 50 mm, from about 35 mm to about 50 mm, from about 40 mm to about 50 mm, or from about 45 mm to about 50 mm. In some embodiments, the gel processed insulative composite has a thickness from 50 mm to 100 mm, from about 55 mm to about 100 mm, from about 60 mm to about 100 mm, from about 65 mm to about 100 mm, from about 70 mm to about 100 mm, from about 75 mm to about 100 mm, from about 80 mm to about 100 mm, from about 85 mm to about 100 mm, from about 90 mm to about 100 mm, or from about 95 mm to about 100 mm. In some embodiments, the gel processed insulative composite has a thickness from about 100 mm to about 250 mm, from about 125 mm to about 250 mm, from about 150 mm to about 200 mm, or from about 175 mm to about 250 mm. In some embodiments, the thickness of the high temperature insulative composite is greater than or equal to about 0.1 mm, greater than or equal to about 0.5 mm, less than or equal to about 1 mm, less than or equal to about 1.5 mm, less than or equal to 2 mm, less than or equal to 4 mm, less than or equal to 10 mm, less than or equal to 50 mm, less than or equal to 75, less than or equal to 100, less than or equal to 125, less than or equal to 150 mm, less than or equal to 175 mm, less than or equal to 200 mm, less than or equal to 225 mm, or less than or equal to 250 mm. [00085] The gel processed polymer matrix may be prepared from any conventional gel processing. Non-limiting examples of gel processed polymers include polyethylene, polypropylene, ethylene-propylene copolymers, polyoxymethylene, polyethylene oxide, polyamides, polyethyleneterephtalate, polyacrylonitrile, polyvinylalcohol, and polyvinylidenefluoride. [00086] In some embodiments, the gel processed polymer matrix is a gel processed polyethylene matrix having a number average molecular weight greater than about 200,000 g/mol, 500,000 g/mol, greater than about 1,000,000 g/mol, greater than about 1,500,000 g/mol, greater than about 2,000,000 g/mol, greater than about 2,500,000 g/mol, or greater than about 3,000,000 g/mol, or even higher. The gel processed polymer matrix may have molecular weight in the range, for example, from about 200,000 g/mol to about 3,000,000 g/mol, from about 500,000 g/mol to about 2,500,000 g/mol, or from about 1,000,00 g/mol to about 2,000,000 g/mol, or any have a DMS_US.373301541.1 - 8/28/20252:28:06 PM 19 molecular weight of any value encompassed by the foregoing ranges. In some embodiments, the gel processed polymer may include a blend of various number average molecular weights of the gel processed polymer within the gel processed polymer matrix. In some embodiments, the blend includes being both high molecular weight (e.g., 3,000,000 g/mol) and low molecular weight (e.g., 200,000 g/mol) gel processed polyethylene. It is to be appreciated that any blend of number average molecular weight gel processed polyethylene matrix is within the purview of this disclosure. [00087] The amount of gel processed polymer matrix present in the high temperature insulative composite is about 35 wt% or less, about 30 wt% or less, about 25 wt% or less, about 20 wt% or less, about 15 wt% or less, about 10 wt% or less, about 7 wt% or less, about 5 wt% or less, or about 4 wt% or less. The gel processed polymer matrix may be present in the high temperature insulative composite in an amount range from about 1 wt% to about 35 wt%, from about 1 wt% to about 30 wt%, from about 1 wt % to about 25 wt%, from about 1 wt% to about 20 wt%, from about 1 wt% to about 15 wt%, from about 1 wt% to about 10%, from about 1 wt% to about 5 wt%, or from about 1 wt% to about 4 wt%. In other embodiments, the amount of gel processed polymer matrix ranges from about 0.5 wt% to about 20 wt%, from about 0.5 wt% to about 15 wt%, from about 0.5 wt% to about 10 wt%, from about 0.5 wt% to about 5 wt%, or from about 0.5 wt% to about 4 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. Insulative particles [00088] In some embodiments, the insulative particles of the insulative composite include aerogel particles. In some embodiments, the aerogel particles include silica aerogel particles. [00089] The terms "aerogel", “aerogels”, and "aerogel particles" are used interchangeably herein. Aerogels are thermal insulators which significantly reduce convection and conductive heat transfer. Silica aerogel particles are particularly good conductive insulators. Aerogel particles are solid, rigid, dry materials, and may be commercially obtained in a powdered form. One non-limiting example of a commercially available aerogel material is a silica aerogel that is formed by a relatively low-cost process as described by Smith et al. in U.S. Patent No.6,172,120. Additionally, the size of the aerogel particles can be reduced to a desired dimension or grade by jet-milling or DMS_US.373301541.1 - 8/28/20252:28:06 PM 20 other known size reduction techniques. Aerogel particles suitable for use in the high temperature insulative composite may have a size from about 1 µm to about 1 mm, from about 1 µm to about 500 µm, from about 1 µm to about 250 µm, from about 1 µm to about 200 µm, from about 1 µm to about 150 µm, from about 1 µm to about 100 µm, form about 1 µm to about 75 µm, from about 1 to about 50 µm, from about 1 µm to about 25 µm, from about 1 µm to about 10 µm, or from about 1 µm to about 5 µm. Further suitable aerogel particles have a size from about 0.1 µm to about 1 µm, from about 0.2 µm to about 1 µm, from about 0.3 µm to about 1 µm, from about 0.4 µm to about 1 µm, from about 0.5 µm to about 1 µm, from about 0.6 µm to about 1 µm, from about 0.7 µm to about 1 µm, from about 0.8 µm to about 1 µm, or from about 0.9 µm to about 1 µm, or any have a size of any value encompassed by the foregoing ranges. Aerogel(s) having smaller particle sizes such as less or equal to 200 nm, less than or equal to 150 nm, less than or equal to 100 nm, or less than or equal to 50 nm may also or alternatively be utilized in the high temperature insulative composite. [00090] The amount of aerogel particles present within the insulative composite may be more than 35 wt%, more than 40 wt%, more than 50 wt%, more than 60 wt%, more than 70 wt%, or more than 80 wt%. In some embodiments, the amount of aerogel particles present in the insulative composite ranges from about 10 wt% to about 80 wt%, from about 15 wt% to about 80 wt%, from about 20 wt% to about 80 wt%, from about 25 wt% to about 80 wt%, from about 30 wt% to about 80 wt%, from about 35 wt% to about 70 wt%, from about 40 wt% from about 80%, from about 40 wt% to about 70 wt%, from about 40 wt% to about 65 wt%, from about 40 wt% to about 60 wt%, from about 45 wt% to about 60 wt%, or from about 45 wt% to about 55 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In other embodiments, the aerogel particles may be present in the high temperature insulative composite in an amount from about 45 wt% to about 75 wt%, from about 50 wt% to 70 wt%, or from about 45 wt% to about 60 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. [00091] In some embodiments, the bulk density of the aerogel particles can be less than about 100 kg/m³, less than about 75 kg/m³, less than about 50 kg/m³, less than about 25 kg/m³ or less than about 10 kg/m³. In at least one embodiment, the aerogel particles have a bulk density from about 30 kg/m³ to about 50 kg/m³. [00092] Aerogels suitable for use in the high temperature insulative composite include inorganic aerogels, organic aerogels, and mixtures thereof. Non-limiting DMS_US.373301541.1 - 8/28/20252:28:06 PM 21 examples of suitable inorganic aerogels include those formed from an inorganic oxide of silicon (silicon dioxide), an inorganic oxide of aluminum, an inorganic oxide of titanium, an inorganic oxide of zirconium, an inorganic oxide of hafnium, an inorganic oxide of yttrium, an inorganic oxide of vanadium, and combinations thereof. In at least one embodiment, the high temperature insulative composite contains an inorganic aerogel such as a silica aerogel. Another example of a high temperature insulative particle suitable for the high temperature insulative composite is fumed silica. [00093] The aerogels used in the high temperature insulative composite may be hydrophilic or hydrophobic. In some embodiments, the aerogels are hydrophobic to partially hydrophobic and have a thermal conductivity of less than about 15 mW/m K. It is to be appreciated that particle size reduction techniques, such as milling, may affect some of the external surface groups of hydrophobic aerogel particles, which, in turn, may result in partial surface hydrophilicity (e.g., hydrophobic properties are retained within the aerogel particle). Partially hydrophobic aerogels may exhibit enhanced bonding to other compounds and may be utilized in applications where such bonding is desired. [00094] In some embodiments, the insulative particles of the insulative composite include one or more particles selected from fumed silica, amorphous silica, colloidal silica, precipitated silica, fused silica, silica gel, silica xerogel, silicates, fumed metal oxides, and combinations thereof. [00095] In some embodiments, the insulative particles can further include silica- based insulative particles that include at least one of: fumed silica, amorphous silica, colloidal silica, precipitated silica, fused silica, silica gel (excluding any silica aerogel), silica xerogel, silicates (such as calcium silicate), fumed metal oxides (such as fumed alumina, fumed titania, fumed blends of silica/alumina/titania, and combinations thereof. In one embodiment, the thermally insulative particles may be modified to contain functional groups to alter the relative hydrophilicity/hydrophobicity of the particles (e.g., fumed hydrophobic silica). In another embodiment, the “insulative particles” may consist of fumed silica particles, amorphous silica particles, hydrophobic silica particles, precipitated silica particles, fused silica particles, silica gel particles (excluding silica aerogel), silicate particles (such as calcium silicate particles), and any combination thereof. In a further embodiment, the “insulative particles” may consist solely of fumed silica particles. DMS_US.373301541.1 - 8/28/20252:28:06 PM 22 [00096] The amount of silica-based insulative particles present within the insulative composite may be at least 1 wt% (based on the total weight of insulative particles), at least 2 wt%, at least 3 wt%, at least 4 wt%, at least 5 wt%, at least 6 wt%, at least 7 wt%, at least 8 wt%, at least 9 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, at least 90 wt%, at least 95 wt%, or at least 99 wt%. In some embodiments, the silica-based insulative particles are present within the insulative composite in an amount from about 1 wt% to about 100 wt%, from about 5 wt% to about 100 wt%, from about 10 wt% to about 100 wt%, from about 20 wt% to about 100 wt%, from about 30 wt% to about 100 wt%, from about 40 wt% to about 100 wt%, from about 50 wt% to about 100 wt%, from about 60 wt% to about 100 wt%, from about 70 wt% to about 100 wt%, from about 80 wt% to about 100 wt%, or from about 90 wt% to about 100 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In other embodiments, the silica-based insulative particles may be present in the insulative composite in an amount from about 40 wt% to about 100 wt%, from about 40 wt% to about 99 wt%, from about 40 wt% to about 95 wt%, from about 50 wt% to about 95 wt%, from about 60 wt% to about 95 wt%, from about 70 wt% to about 95 wt%, from about 80 wt% to about 95 wt%, or from about 90 wt% to about 95 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In further embodiments, the insulative particles may be present in the insulative composite in an amount from about 1 wt% to about 80 wt%, from about 2 wt% to about 80 wt%, from about 3 wt% to about 80 wt%, from about 4 wt% to about 80 wt%, from about 5 wt% to about 80 wt%, from about 6 wt% to about 80 wt%, from about 7 wt% to about 80 wt%, from about 8 wt% to about 80 wt%, from about 9 wt% to about 80 wt%, from about 10 wt% to about 80 wt%, from about 20 wt% to about 80 wt%, from about 30 wt% to about 80 wt%, from about 40 wt% to about 80 wt%, from about 50 wt% to about 80 wt%, from about 60 wt% to about 80 wt%, or from about 70 wt% to about 80 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In some embodiments, the silica-based insulative particles may be solely present in the insulative particles. The silica-based insulative particles may be or include fumed silica. In other embodiments, aerogel particles may be present within the insulative particles, but may not form the total particles present in the insulative particles. [00097] In another aspect, the insulative particles may contain at least a portion of which includes one or more types of aerogel particles (such as silica aerogel DMS_US.373301541.1 - 8/28/20252:28:06 PM 23 particles), with the proviso that the insulative particles used in the present composites contain less than 100 wt% aerogel particles based on the total weight of the insulative particles incorporated in the insulative composite. [00098] In another embodiment, the aerogel-based insulative particles (e.g., aerogel particles) include less than 100 wt% (based on the total weight of insulative particles), less than 99 wt%, less than 98 wt%, less than 97 wt%, less than 96 wt%, less than 95 wt%, less than 94 wt%, less than 93 wt%, less than 92 wt%, less than 91 wt%, less than 90 wt%, less than 85 wt%, less than 80 wt%, less than 75 wt%, less than 70 wt%, less than 65 wt%, less than 60 wt%, less than 55 wt%, less than 50 wt%, less than 45 wt%, less than 40 wt%, less than 35 wt%, less than 30 wt%, less than 25 wt%, less than 20 wt%, less than 15 wt%, less than 10 wt%, less than 5 wt%, less than 4 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt% or 0 wt% of aerogel particles, or any have a weight percentage of any value encompassed by the foregoing ranges. The aerogel-based insulative particles present in the insulative composite may be from about 1 wt% to about 60 wt%, from about 1 wt% to about 55 wt%, from about 1 wt% to about 50 wt%, from about 1 wt% to about 45 wt%, from about 1 wt% to about 40 wt%, from about 1 wt% to about 35 wt%, from about 1 wt% to about 30 wt%, from about 1 wt% to about 25 wt%, from about 20 wt%, from about 1 wt% to about 15 wt%, from about 1 wt% to about 10 wt%, or from about 1 wt% to about 5 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In at least one embodiment, the aerogel particle is a silica aerogel. Additional particulate components [00099] In some embodiments, the insulative composite further includes 10 wt% or more of a combined total of additional particulate components selected from one or more opacifiers, one or more reinforcement fibers, one or more expandable microspheres, and any combination thereof. [000100] In some embodiments, the insulative composite may include one or more additional components in an amount less than about 35 wt%. In some embodiments, the additional components are present in the insulative composite in an amount less than about 30 wt%, less than about 25 wt%, less than about 20 wt%, less than about 15 wt%, less than about 10 wt%, or less than about 5 wt%. In some embodiments, the additional components may be present in an amount from about 5 wt% to about 35 wt%, from about 5 wt% to about 30 wt%, from about 10 wt% to about 25 wt%, from DMS_US.373301541.1 - 8/28/20252:28:06 PM 24 about 10 wt% to about 20 wt%, from about 5 wt% to about 20 wt%, or from about 5 wt% to about 15 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. Non-limiting additional components include, but not limited to, flame retardant materials, additional polymers, opacifier(s) (as discussed below), reinforcement fiber(s) (as discussed below) antioxidant(s), intumescent material(s), oxygen scavenger(s), dyes, plasticizers, and thickeners. [000101] In some embodiments, the insulative composite includes at least one opacifier. Opacifiers reduce radiative heat transfer and improve thermal performance. Non-limiting examples of suitable opacifiers for use in the insulative composite include, but are not limited to, carbon black, titanium dioxide, aluminum oxide, zirconium dioxide, iron oxides, silicon carbide, molybdenum silicide, manganese oxide, a polydialkylsiloxane where the alkyl groups contain 1 to 7 carbon atoms, or any combination thereof. In some embodiments, the opacifier may be used in the form of a finely dispersed powder. In at least one embodiment, the amount of opacifier present in the high temperature insulative composite (based on the total weight of the insulative composite) is up to about 35 wt%, up to about 30 wt%, up to about 25 wt%, up to about 20 wt%, up to about 15 wt%, up to about 10 wt%, or up to about 5 wt%. In some embodiments, the opacifier(s) is present in the insulative composite (based on the total weight of the insulative composite) in an amount less than equal to 20 wt%. In some embodiments, the amount of opacifier(s) present in the high temperature gel processed insulative composite (based on the total weight of the gel processed insulative composite) may be from about 5 wt% to about 35 wt%, from about 5 wt% to about 30 wt%, from about 5 wt% to about 25 wt%, from about 5 wt% to about 20 wt%, from about 5 wt% to about 15 wt%, or from about 5 wt% to about 10 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. [000102] In some embodiments, the high temperature insulative composite also includes at least one reinforcement fiber. In one embodiment, the reinforcement fiber may be chopped fibers having a size from about 0.1 mm to about 25 mm, from about 0.1 to about 19 mm, from about 0.1 mm to about 15 mm, from about 0.1 mm to about 13 mm, from about 0.1 mm to about 10 mm, from about 0.1 mm to about 7 mm, or from about 0.1 mm to about 5 mm, or any have a size of any value encompassed by the foregoing ranges. A variety of reinforcement fibers may be used and may include fibers such as, but not limited to, carbon fibers, glass fibers, aluminoborosilicate fibers, or combinations thereof. In some embodiments, the reinforcement fibers are chopped DMS_US.373301541.1 - 8/28/20252:28:06 PM 25 glass fibers. The amount of reinforcement fibers present in the high temperature insulative composite may be up to about 25 wt%. In some embodiments, the reinforcement fiber is present in an amount from about 1 wt% to about 25 wt%, from about 2 wt% to about 20 wt%, from about 3 wt% to about 20 wt%, from about 5 wt% to about 15 wt%, from about 8 wt% to about 15 wt%, from about 9 wt% to about 15 wt%, or from about 10 wt% to about 15 wt%. In some embodiments, the reinforcement fiber is present in an amount from about 1 wt% to about 10 wt%, from about 2 wt% to about 10 wt%, from about 3 wt% to about 10 wt%, from about 4 wt% to about 10 wt%, from about 5 wt% to about 10 wt%, from about 6 wt% to about 10 wt%, from about 7 wt% to about 10 wt%, or from about 8 wt% to about 10 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. In some embodiments, the reinforcement fiber(s) may be present in the insulative composite in an amount from about 2 wt% to 10 wt%, from about 3 wt% to about 10 wt%, from about 4 wt% to about 10 wt%, from about 5 wt% to about 9 wt%, or from about 6 wt% to about 9 wt%, or any have a weight percentage of any value encompassed by the foregoing ranges. Inorganic protection layer [000103] Referring again to FIG.1, an inorganic protection layer 106 is wrapped around the outer surface 104b of the thermally insulative composite layer 104. The inorganic protection layer 106 can protect the inner, thermally insulative composite layer 104 from a direct flame exposure. The layers 104 and 106 may be bound to each other in any conventional manner such as laminating, adhering, or other bonding techniques to form a layered structure. [000104] In some embodiments, the inorganic protection layer 106 has a first thickness, and the thermally insulative composite layer 104 has a second thickness of the inorganic protection layer 106. The second thickness of the thermally insulative composite layer 104 is generally greater than the first thickness, for example, at least 1.5 times greater, at least 2 times greater, at least 3 times greater, at least 4 times greater, or at least 5 times greater. [000105] In some embodiments, the inorganic protection layer 106 includes a non- flammable inorganic material which can survive from a direct flame exposure at a temperature of 900 ^oC or higher. The non-flammable inorganic material can have a melting point, for example, not less than 900 ^oC, not less than 1000 ^oC, or not less than 1050 ^oC. In some embodiments, the non-flammable inorganic material has a thermal DMS_US.373301541.1 - 8/28/20252:28:06 PM 26 conductivity, for example, not greater than 5.0 W/m K, not greater than 4.0 W/m K, or not greater than 3.0 W/m K. In some embodiments, the non-flammable inorganic material has a density, for example, in the range from 1,000 kg/m³ to 20,000 kg/m³. In general, the non-flammable inorganic material of the inorganic protection layer 106 has a greater thermal conductivity and a greater density than the insulative composites of the thermally insulative composite layer 104. [000106] In some embodiments, the non-flammable inorganic material is selected from silica, alumina, mica, basalt, borosilicate, or a combination thereof. It is to be understood that the non-flammable inorganic material may include other inorganic materials (e.g., oxides, nitrides, carbides, and the like) that have high thermal resistance and stability upon the exposure to a direct flame at a temperature of 1000 ^oC or higher. In some embodiments, examples of inorganic materials include, but not limited to, silica, alumina, mica, titanium oxide, zirconia, magnesium oxide, calcium carbonate, boron nitride, graphite, kaolinite, talc, spinel, barium sulfate, zinc oxide, silicon carbide, yttria, chromia, magnesite, hafnia, feldspar, perovskite, and the like. [000107] In some embodiments, an inorganic protection layer can be wrapped helically around the outer surface of a thermally insulative composite layer. In some embodiments, an inorganic protection layer can be pre-formed in a tube shape, which can be then wrapped longitudinally, braided, or served onto the thermally insulative composite layer. [000108] As shown in FIG.1, an optional abrasion resistant layer 108 is wrapped around the inorganic protection layer 106. The abrasion resistant layer 108 has a tubular shape or sheet and can be wrapped on the cable assembly 100 as the outer most layer. The abrasion resistant layer 108 can be formed of a jacket material such as, for example, engineered fluoropolymer. It is to be appreciated that any suitable jacket materials with desired properties such as abrasion resistance, heat resistance, and flexibility can be used. Example jacket materials can be formed from fluoropolymers, polyamides, polyesters, ultra-high molecular weight polyethylene (UHMWPE), meta- aramids, para-aramids, or combinations and mixtures thereof. These materials may be applied over the cable assembly 100 in a variety of ways, including by extrusion, tape wrap, insertion within pre-formed tubes, shrink wrap, etc. [000109] Referring to FIG.3, a thermally insulative composite layer 304 surrounds a core 302 including a pair of conductors 302a and 302b to provide thermal insulation when the cable assembly 300 is exposed to an extreme temperature (e.g., 900 ^oC or DMS_US.373301541.1 - 8/28/20252:28:06 PM 27 higher for 30 seconds or longer). The thermally insulative composite layer 304 can be formed of the same thermally insulative composite as the thermally insulative composite layer 104 of FIG.1. [000110] An inorganic protection layer 306 is wrapped around the thermally insulative composite layer 304 to protect the thermally insulative composite layer 304 from a direct flame exposure. The inorganic protection layer 306 can be formed of the same non-flammable inorganic material as the inorganic protection layer 106 of FIG.1. [000111] As shown in FIG.3, the thermally insulative composite layer 304 and the inorganic protection layer 306 are assembled as a layered structure in the form of a tube to be wrapped around the core 302. In some embodiments, the tube formed by the layered structure of the thermally insulative composite layer 304 and inorganic protection layer 306 can have a cross-sectional oval shape or round shape. The tube can have an outer diameter in a range, for example, from 2.5 mm to 25 mm, and an inner diameter in a range, for example, from 1.5 mm to 13 mm. [000112] An optional abrasion resistant layer 308 is wrapped on the cable assembly 100 as the outer most layer to provide abrasion resistance. The abrasion resistant layer 308 can be formed of the same jacket material as the abrasion resistant layer 108 of FIG.1. [000113] As shown in FIG.3, the core 302 includes multiple conductors 302a and 302b being wrapped in the respective composite dielectric 301a and 301b. In some embodiments, the conductors can be, for example, silver plated copper conductors having a size, for example, 28 AWG. The composite dielectric can be formed of, for example, polytetrafluoroethylene (PTFE), expanded polytetrafluorethylene (ePTFE), and the like. It is to be understood that the core 302 may include any numbers of conductors in various formats (e.g., stranded, braided, and the like). [000114] In some embodiments, the inner layers 301a and 301b can be formed of a low-dielectric constant material selected from PTFE, an expanded polytetrafluorethylene (ePTFE), and an expanded ultra-high molecular weight polyethylene (eUHMWPE). In some embodiments, the inner layers 301a and 301b can be formed of a low-dielectric constant dense material selected from PTFE, a perfluoroalkoxy polymer (PFA), and a fluorinated ethylene propylene (FEP). In some embodiments, the inner layers 301a and 301b can further include a high temperature polymer such as, for example, a fluoropolymer, a polyimide, polyamide, or UHMWPE, to prevent the internal dielectric from melting or vaporizing. DMS_US.373301541.1 - 8/28/20252:28:06 PM 28 TEST METHODS [000115] It should be understood that although certain methods and equipment are described below, other methods or equipment determined suitable by one of ordinary skill in the art may be alternatively utilized. Test Methods for Insulated Electric Wire – Flammability Method 801 [000116] Fire withstand capability of the proposed up-jacket was evaluated by using post-exposure dielectric withstand testing. The fire exposure was utilizing the International Society of Automotive Engineers (SAE) test method AS4373 flammability method 801 (Test Methods for Insulated Electric Wire; SAE International, Warrendale, PA). Following the exposure of the flame per AS4373 method 801 for varying durations (30 seconds was the focus of the effort to this point), the tested parts were evaluated for dry dielectric withstand voltage, typically between the center conductors and the braided shield. This should be the weakest point of the part since the interface between primary and shield is closer to the flame exposure when compared to the distance between the two primaries. The pass/fail criteria was set at 750 Vdc (volts direct current) holding for 30 seconds. If the part was able to hold voltage withstand at 750 Vdc for 30 seconds, it was considered a passing specimen for this low voltage application. Diameter constraint for initial work based on application was a maximum outer diameter (OD) of 0.200 inches (about 0.51 cm). [000117] Extended exposure fire withstand capability of the proposed up-jacket encompassing continuous flame exposure time from 60 seconds to 600 seconds was evaluated by using a modified version of International Society of Automotive Engineers (SAE) test method AS4373 flammability method 801 (Test Methods for Insulated Electric Wire; SAE International, Warrendale, PA). The modifications involved applying continuous 750 VDC voltage to the cable while applying the continuous flame condition outlined by AS4373 Method 801 until dry dielectric breakdown occurred, typically occurring between the center conductors and the braided shield. This should be the weakest point of the part since the interface between primary and shield is closer to the flame exposure when compared to the distance between the two primaries. The pass/fail criteria was set at 750 Vdc (volts direct current) and holding until voltage breakdown occurred. Diameter constraint for initial work based on application was a maximum outer diameter (OD) of 0.65 inches (about 0.51 cm). DMS_US.373301541.1 - 8/28/20252:28:06 PM 29 EXAMPLES Example 1 – Cable Assembly Core Without High Temperature Insulation [000118] An impedance matched shielded twisted pair cable assembly (Part number DXN2604, W.L. Gore & Associates Inc., Newark, DE) was constructed of 2 silver plated copper conductors (size 28awg, stranded) wrapped in a composite dielectric of polytetrafluoroethylene (PTFE) and expanded polytetrafluorethylene (ePTFE), twisted and braided (with 40awg silver plated copper braid material) to form a core (thereafter the “Core”, e.g., the core 302 in FIG.3). The “Core” was jacketed with Gore^® abrasion resistant engineered fluoropolymer from W. L. Gore & Associates, Inc. See the layer 308 in FIG.3. The cable assembly of Example 1 was prepared having an outer diameter (OD) of 0.070” – 0.080”. The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 1 failed the fire withstand assay (Table 1). Example 2 – Cable Assembly Core with Thermal Insulation Layer [000119] The “Core” described in Example 1 was helically wrapped with a 0.035" wall thickness of thermal insulation composite tape described in U.S. Patent No. 7,226,969 to Ristic-Lehmann et al. including 40 wt% PTFE and 60 wt% aerogel particles. The tape can be the layer 304 in FIG.3. An additional layer of abrasion resistant engineered fluoropolymer (e.g., the layer 308 in FIG.3), was helically wrapped around the thermal insulation material to create the final cable assembly having an outer diameter of 0.150" (consisting of the “Core”, the thermal insulation material, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 2 failed the fire withstand assay (Table 1). Example 3 – Cable Assembly Core with Thermal Insulation Layer with an Additional Layer of Glass Fiber Layer [000120] The “Core” described in Example 1 was helically wrapped with a 0.035" wall thickness of thermal insulation composite tape described in U.S. Patent No. 7,226,969 to Ristic-Lehmann et al. comprising 40 wt% PTFE and wt% 60 wt% aerogel DMS_US.373301541.1 - 8/28/20252:28:06 PM 30 particles. The tape can be the layer 304 in FIG.3. An additional layer (layer 306 in FIG. 3) of 0.020" of Nextel 312 alumina-borosilicate glass fibers, 1/2 yarn 1800 denier, was served onto the thermal insulation material. A final layer of abrasion resistant engineered fluoropolymer (e.g., the layer 308 in FIG.3) was helically wrapped around the Nextel 312 fibers to create a cable assembly, having an outer diameter of 0.190" (consisting of the “Core”, the thermal insulation material, the Nextel 312 fibers, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 3 failed the fire withstand assay (Table 1). Example 4 – Cable Assembly Core with High Temperature Insulation Layer [000121] The “Core” described in Example 1 was helically wrapped with 0.040" of high temperature insulation composite tape as described in U.S. Pat. Appl. Publ. No. 2024-02586132874 to Fillery et al. and WIPO PCT Publ. No. WO2024/124091 to Bielewicz et al. including 12 wt% PTFE, 30 wt% silicon carbide (opacifier), 50 wt% silica aerogel particles, and 8 wt% glass reinforcement fibers. The tape can be the layer 304 in FIG.3. A final layer of abrasion resistant engineered fluoropolymer (e.g., the layer 308 in FIG.3) was helically wrapped around the high temperature insulation composite to form a cable assembly having an outer diameter of 0.165" (consisting of the “Core”, the high temperature insulation composite, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 4 failed the fire withstand assay (Table 1). Example 5 – Cable Assembly Core with High Temperature Insulation Layer and an Additional Layer of Mica Tape [000122] The “Core” described in Example 1 was helically wrapped with 0.040" of high temperature insulation, 304, composite tape as described in U.S. Pat. Appl. Publ. No. 2024-02586132874 to Fillery et al. and WIPO PCT Publ. No. WO2024/124091 to Bielewicz et al. including 12 wt% PTFE, 30 wt% silicon carbide (opacifier), 50 wt% silica aerogel particles, and 8 wt% glass reinforcement fibers. The tape can be the layer 304 in FIG.3. An additional layer of 0.005" of inorganic mica material (Mica tape, Axim Mica, e.g., the layer 306 in FIG.3) was helically wrapped around the high temperature DMS_US.373301541.1 - 8/28/20252:28:06 PM 31 insulation composite. The additional layer can be the layer 306 in FIG.3. A final layer (e.g., the layer 308 in FIG.3) of abrasion resistant engineered fluoropolymer was helically wrapped around the inorganic mica material to form a cable assembly (e.g., the cable assembly in FIG.300), having an outer diameter of 0.175" (consisting of the “Core”, the high temperature insulation composite, the inorganic material, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 5 passed the fire withstand assay (Table 1) and was subjected to extended fire exposure testing and dry dielectric voltage withstand during flame exposure, failing at a time less than 60 seconds. Example 6 – Cable Assembly Core with Double Layer of High Temperature Insulation Layer and an Additional Layer of Mica Tape [000123] The “Core” described in Example 1 was helically wrapped with 0.080" of high temperature insulation, 304, composite tape as described in U.S. Pat. Appl. Publ. No. 2024-02586132874 to Fillery et al. and WIPO PCT Publ. No. WO2024/124091 to Bielewicz et al. including 12 wt% PTFE, 30 wt% silicon carbide (opacifier), 50 wt% silica aerogel particles, and 8 wt% glass reinforcement fibers. The tape can be the layer 304 in FIG.3. An additional layer of 0.005" of inorganic mica material (Mica tape, Axim Mica, e.g., the layer 306 in FIG.3) was helically wrapped around the high temperature insulation composite. The additional layer can be the layer 306 in FIG.3. A final layer (e.g., the layer 308 in FIG.3) of abrasion resistant engineered fluoropolymer was helically wrapped around the inorganic mica material to form a cable assembly (e.g., the cable assembly in FIG.300), having an outer diameter of 0.280" (consisting of the “Core”, the high temperature insulation composite, the inorganic material, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 6 passed the fire withstand assay (Table 1) and was subjected to extended fire exposure testing and dry dielectric voltage withstand during flame exposure, with cable integrity remaining for at least 60 seconds, at which point the test was ended. Example 7 – Cable Assembly Core, Followed by Multiple Sequential Layers of High Temperature Insulation and Mica Tape DMS_US.373301541.1 - 8/28/20252:28:06 PM 32 [000124] The “Core” described in Example 1 was helically wrapped with 0.040" of high temperature insulation, 304, composite tape as described in U.S. Pat. Appl. Publ. No. 2024-02586132874 to Fillery et al. and WIPO PCT Publ. No. WO2024/124091 to Bielewicz et al. including 12 wt% PTFE, 30 wt% silicon carbide (opacifier), 50 wt% silica aerogel particles, and 8 wt% glass reinforcement fibers. The tape can be the layer 304 in FIG.3. An additional layer of 0.005" of inorganic mica material (Mica tape, Axim Mica, e.g., the layer 306 in FIG.3) was helically wrapped around the high temperature insulation composite. The additional layer can be the layer 306 in FIG.3. A final layer (e.g., the layer 308 in FIG.3) of abrasion resistant engineered fluoropolymer was helically wrapped around the inorganic mica material to form a cable assembly (e.g., the cable assembly in FIG.300). This core was subject to five sequential applications of the process described above, which resulted in five total applications of the high temperature insulation, mica tape, and fluoropolymer jacket solution. This resulted in a total outer diameter of .600” (consisting of the “Core” and five layers of the high temperature insulation composite, the inorganic material, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 7 passed the fire withstand assay (Table 1) and was subjected to extended fire exposure testing and dry dielectric voltage withstand during flame exposure with cable integrity remaining for at least 400 seconds, at which point the test was ended. Example 8 – Cable Assembly Core with High Temperature Insulation Layer and an Additional Layer of Mica Tape [000125] The “Core”, described as a high voltage shielded twisted pair (Part number GSC-04-86550-00, W.L. Gore & Associates Inc., Newark, DE) was constructed of 2 nickel plated copper conductors (size 8awg, stranded) with a dielectric composed of a composite fluoropolymer and engineered fluoropolymer, twisted and braided (with 40awg nickel plated copper braid material) to form a core. The core assembly of Example 8, having an outer diameter (OD) of 0.430” – 0.454”, was helically wrapped with 0.040" of high temperature insulation, 304, composite tape as described in U.S. Pat. Appl. Publ. No. 2024-02586132874 to Fillery et al. and WIPO PCT Publ. No. WO2024/124091 to Bielewicz et al. including 12 wt% PTFE, 30 wt% silicon carbide (opacifier), 50 wt% silica aerogel particles, and 8 wt% glass reinforcement fibers. The DMS_US.373301541.1 - 8/28/20252:28:06 PM 33 tape can be the layer 304 in FIG.3. An additional layer of 0.005" of inorganic mica material (Mica tape, Axim Mica, e.g., the layer 306 in FIG.3) was helically wrapped around the high temperature insulation composite. The additional layer can be the layer 306 in FIG.3. A final layer (e.g., the layer 308 in FIG.3) of abrasion resistant engineered fluoropolymer was helically wrapped around the inorganic mica material to form a cable assembly (e.g., the cable assembly in FIG.300), having an outer diameter of 0.580" (consisting of the “Core”, the high temperature insulation composite, the inorganic material, and the abrasion resistant layer). The cable assembly was tested according to the fire withstand assay as described above (Test Methods for Insulated Electric Wire – Flammability Method 801). The cable assembly of Example 5 passed the fire withstand assay (Table 1) and was subjected to extended fire exposure testing and dry dielectric voltage breakdown during flame exposure, with cable integrity remaining for at least 600 seconds, at which point the test was ended. Table 1 Insulative Composite Layer Example # PTFE Aerogel Wt% other inorganic Core OD Final Fire Extended nd 0 d e) DMS_US.373301541.1 - 8/28/20252:28:06 PM 34 6 12 50 38 Inorganic 0.080 0.280 Pass Pass mica (0.203 (0.711 (60 layer cm) cm) seconds) s) s) [000126] The invention of this application has been described above both generically and with regard to specific embodiments. It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments without departing from the scope of the disclosure. Thus, it is intended that the embodiments cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. DMS_US.373301541.1 - 8/28/20252:28:06 PM 35

Claims

WHAT IS CLAIMED IS: 1. A cable assembly comprising: a core member; and a thermally insulative composite layer configured to surround the core member, wherein the thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface, the inner surface faces the core member, and wherein the thermally insulative composite layer comprises: 50 wt% or less of a fibrillated polymer matrix; 40 wt% or more of aerogel particles; and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof; wherein the weight percent is based on the total weight of the thermally insulative composite, and wherein the aerogel particles are durably enmeshed within the fibrillated polymer matrix.

2. The cable assembly of claim 1, further comprising an inorganic protection layer to be wrapped around the outer surface of the thermally insulative composite layer.

3. The cable assembly of claim 2, wherein the inorganic protection layer comprises a non-flammable inorganic material having a melting point not less than 1000 ^oC.

4. The cable assembly of claim 3, wherein the non-flammable inorganic material is selected from silica, alumina, mica, basalt, borosilicate, and a combination thereof.

5. The cable assembly of any one of claims 1-4, wherein the aerogel particles include silica aerogel particles.

6. The cable assembly of any one of claims 1-5, wherein the thermally insulative composite layer further comprises insulative particles including one or more particles selected from fumed silica, amorphous silica, colloidal silica, precipitated silica, fused silica, silica gel, silica xerogel, silicates, fumed metal oxides, and combinations thereof. DMS_US.373301541.1 - 8/28/20252:28:06 PM 36

7. The cable assembly of any one of claims 1-6, wherein the fibrillated polymer matrix comprises a polyolefin, an ultrahigh molecular weight polyethylene (UHMWPE), a fluoropolymer, polytetrafluoroethylene, expanded polytetrafluoroethylene (ePTFE), a polyurethane, a polyester, a polyamide, or any combination thereof.

8. The cable assembly of any one of claims 1-7, wherein the fibrillated polymer matrix comprises an expanded polytetrafluorethylene (ePTFE), an expanded ultra-high molecular weight polyethylene (eUHMWPE) or a combination thereof.

9. The cable assembly of any one of claims 1-8, wherein the fibrillated polymer matrix comprises a gel processed polymer selected from polyethylene, polypropylene, ethylene-propylene copolymers, polyoxymethylene, polyethylene oxide, polyamides, polyethyleneterephtalate, polyacrylonitrile, polyvinylalcohol, polylactic acid (PLA), polyhydroxyalkanoates (PHAs), polyvinylidenefluoride, and combinations thereof.

10. The cable assembly of claim 9, wherein the fibrillated polymer matrix comprises a gel processed ultra-high molecular weight polyethylene (UHMWPE).

11. The cable assembly of any one of claims 1-10, wherein the thermally insulative composite layer has at least one of properties including: a thickness in a range from 0.5 mm to 6.0 mm, a density in a range from 200 kg/m³ to 600 kg/m³, or a thermal conductivity not greater than 0.025 W/m·K at room temperature and atmospheric pressure.

12. The cable assembly of any one of claims 1-11, wherein the thermally insulative composite layer is in the form of a tube having an outer diameter in a range from 2.5 mm to 25 mm, and an inner diameter in a range from 1.5 mm to 13 mm.

13. The cable assembly of any one of claims 1-12, which is in the form a tube to receive the core member, the tube having an outer diameter in a range from 2.86 mm to 25.5 mm, and an inner diameter in a range from 1.5 mm to 13 mm. DMS_US.373301541.1 - 8/28/20252:28:06 PM 37

14. The cable assembly of any one of claims 2-13, further comprising an abrasion resistant layer to wrap around the inorganic protection layer.

15. The cable assembly of any one of claims 1-14, wherein the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 °C and a duration of at least 30 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame.

16. The cable assembly of any one of claims 1-14, wherein the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 °C and a duration of from about 60 seconds to about 600 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame.

17. A method of using a thermally insulative composite layer for a cable assembly comprising a core member, the method comprising: providing a thermally insulative composite layer to surround the core member, wherein the thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface, the inner surface faces the core member, and wherein the thermally insulative composite layer comprises: 50 wt% or less of a fibrillated polymer matrix; 40 wt% or more of aerogel particles; and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof; wherein the weight percent is based on the total weight of the thermally insulative composite, and wherein the aerogel particles are durably enmeshed within the fibrillated polymer matrix.

18. The method of claim 17, further comprising wrapping an inorganic protection layer around the outer surface of the thermally insulative composite layer. DMS_US.373301541.1 - 8/28/20252:28:06 PM 38

19. The method of claim 18, further comprising wrapping an abrasion resistant layer around the inorganic protection layer.

20. The method of any one of claims 17-19, wherein the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 degrees °C and a duration of at least 30 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame.

21. The method of any one of claims 17-19, wherein the thermally insulative composite layer is configured to protect the core member from a flame with a temperature of at least 900 degrees °C and a duration of from about 60 seconds to about 600 seconds and maintain an electrical integrity of the core member for at least 5 minutes after an exposure to the flame.

22. A fire-resistant cable assembly comprising: one or more core conductors for signal or power transmission; a thermally insulative composite layer configured to surround the one or more core member; and an inorganic protection layer to wrap around the thermally insulative composite layer, wherein the thermally insulative composite layer has an inner surface and an outer surface opposing the inner surface, the inner surface faces the one or more core members, and wherein the thermally insulative composite layer comprises: 50 wt% or less of a fibrillated polymer matrix comprising an expanded polytetrafluorethylene (ePTFE), an expanded ultra-high molecular weight polyethylene (eUHMWPE) or a combination thereof; 40 wt% or more of aerogel particles; and more than 10 wt% of a combined total of additional particulate components selected from one or more opacifier, one or more reinforcement fiber, one or more expandable microsphere, and any combination thereof; wherein the weight percent is based on the total weight of the thermally insulative composite, and DMS_US.373301541.1 - 8/28/20252:28:06 PM 39 wherein the aerogel particles are durably enmeshed within the fibrillated polymer matrix.

23. The fire-resistant cable assembly of claim 22, further comprising one or more inner layers, each of the inner layers being disposed between one of the core conductors and the thermally insulative composite layer to wrap around the one of the core conductors.

24. The fire-resistant cable assembly of claim 23, wherein each of the inner layers comprises a low-dielectric constant material selected from polytetrafluoroethylene (PTFE), ePTFE, and eUHMWPE.

25. The fire-resistant cable assembly of claim 23, wherein each of the inner layers comprises a low-dielectric constant dense material selected from PTFE, a perfluoroalkoxy polymer (PFA), and a fluorinated ethylene propylene (FEP).

26. The fire-resistant cable assembly of claim 23, wherein each of the inner layers comprises a fluoropolymer, a polyimide, polyamide, or ultra-high molecular weight polyethylene (UHMWPE). DMS_US.373301541.1 - 8/28/20252:28:06 PM 40