Fireproof composite as fire-activated thermal barrier or fire barrier in battery packs

Abstract

Disclosed are thermoplastic composites or organic sheets comprising a polymer composition embedded in a fibrous material having excellent flame retardancy and fire barrier properties. The polymer composition can contain one or more thermoplastic polymers. The polymer composition can contain recycled or virgin polycarbonate content. Methods of making such organic sheets are disclosed. Structures made from the disclosed organic sheets are disclosed.

Description

Cross-referencing

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 562,925, filed March 8, 2024, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0002] Disclosed are thermoplastic composite materials or organic sheets comprising polymer compositions embedded in fibrous materials, exhibiting excellent flame retardant and fire-resistant properties. The polymer composition may contain one or more thermoplastic polymers. The polymer composition may contain recycled or virgin polycarbonate contents. A method for preparing such organic sheets is disclosed. Structures prepared from the disclosed organic sheets are disclosed. Background Technology

[0003] Thermoplastic composites or organic sheets comprise continuous and / or discontinuous fibrous materials embedded in a polymer composition and are used as alternatives to metals due to their excellent mechanical properties, low density, recyclability, excellent corrosion resistance, and unlimited shelf life. A polymer composition consisting of thermoplastic polymers is used as a resin to impregnate / embed continuous and / or discontinuous fibrous materials to form a polymer composite matrix, which forms the organic sheet. This polymer composition forms at room temperature and melts and expands upon exposure to high temperatures. Composites based on thermoplastic polymers and fibrous materials can be formed into various structures through thermoforming, net-shape stretching, deep drawing, etc. These organic sheets can be used for a variety of applications, including automotive parts, electronic devices, medical devices, etc. The flame retardancy and thermal insulation properties of organic sheets are important safety considerations, especially when organic sheets are exposed to increased fire exposure risks. The market demands organic sheets with excellent flame retardant and fire-resistant properties. In some applications, organic sheets containing specially formulated polymer compositions of polycarbonate or its copolymers need to pass flame retardancy tests, such as UL94 V-0, see US 2016 / 25794A1 and WO2019 / 115506 A1. However, the limited glass transition temperature of most organic sheets causes the composite to lose its formal integrity and mechanical strength during combustion. Furthermore, most organic sheets, regardless of their thermosetting or thermoplastic type, do not sufficiently reduce heat transfer through the organic sheet, necessitating the use of additional fire-resistant materials.

[0004] What is needed is an improved organic sheet containing a polymer composition having a thermoplastic polymer that ridges at room temperature and melts and expands when exposed to high temperatures, the polymer composition being embedded within a fibrous material layer with excellent flame retardant and fire-resistant properties. What is needed is an organic sheet with excellent flame retardant and fire-resistant properties, which can be used as a fire-resistant layer. What is needed is a molded composition prepared from such an organic sheet that exhibits excellent flame retardant and fire-resistant properties. What is also needed is an organic sheet prepared from such a composition that exhibits improved flame retardant and fire-resistant properties. Summary of the Invention

[0005] The disclosed composition comprises a) one or more layers of fibrous material consisting of one or more layers of one or more fibrous materials, at least one fibrous material layer being a nonwoven fibrous material, and the fibers of the nonwoven fibrous material having a diameter of about 0.1 μm to about 18 μm; b) one or more polymer compositions; c) a fiber content of about 30% to about 80% by weight; wherein the one or more polymer compositions are embedded within the fibrous material layers to form an organic sheet. The composition may contain about 30% to about 50% by weight of the polymer composition. The one or more polymer compositions may contain one or more thermoplastic polymers. The one or more polymer compositions may contain one or more thermoplastic polymers that are rigid at room temperature and melt and expand when exposed to high temperatures. When exposed to temperatures of about 300°C to about 500°C, the one or more thermoplastic polymers may melt and expand. One or more thermoplastic polymers may consist of one or more styrene-acrylonitrile (SAN), one or more poly(methyl methacrylate) (PMMA), one or more polyolefins, one or more polyarylsulfones (PSU), one or more polypropylenes (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonates (PC), or any combination thereof. One or more polymer compositions may contain at least one or more polyarylsulfones. One or more polymer compositions may contain at least one or more polycarbonates. The one or more polycarbonates may be virgin polycarbonate, recycled polycarbonate, or a mixture of both.

[0006] One or more fiber materials may have continuous or discontinuous fibers. One or more fiber materials may consist of one or more fiber types. One or more fiber materials may have nonwoven or woven fibers. One or more fiber types may consist of: one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, one or more polyacrylonitrile fibers, one or more pre-oxidized polyacrylonitrile fibers, one or more recycled carbon fibers, one or more polyaramid fibers, one or more natural cellulose fibers, one or more mineral fibers, or any combination of one or more fiber types. Two or more different fibers may be combined to form co-knitted fibers. Layers of one or more fiber materials may have a thickness of about 20 μm to about 500 μm.

[0007] Nonwoven fiber materials can be made from nonwoven fibers. Nonwoven fiber materials can have discontinuous fibers. One or more fiber materials of a nonwoven fiber material can have co-knitted fibers. The fibers of a nonwoven fiber material can be randomly knitted. The fibers of a nonwoven fiber material can have a diameter of about 0.1 μm to about 18 μm. The fibers of a nonwoven fiber material can have a diameter of about 1 μm to about 10 μm. The nonwoven fibers of a nonwoven fiber material can be made from nonwoven glass fibers, nonwoven carbon fibers, nonwoven ceramic fibers, polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, or any combination thereof. Nonwoven glass fibers can have a diameter of about 6 μm to about 18 μm. Nonwoven glass fibers can have a diameter of about 6 μm to about 10 μm. Nonwoven carbon fibers can have a diameter of about 1 μm to about 18 μm. Nonwoven carbon fibers can have a diameter of about 4 μm to about 6 μm.

[0008] The polymer composition may contain one or more halogen-free flame retardants. The one or more halogen-free flame retardants may be one or more phosphorus-containing flame retardants. The one or more phosphorus-containing flame retardants may contain phosphate esters, phosphazenes, or mixtures thereof. The one or more phosphorus-containing flame retardants may be bisphenol A bis(diphenyl phosphate), hexaphenoxycyclophosphamide, or a mixture of bisphenol A bis(diphenyl phosphate) and hexaphenoxycyclophosphamide. The polymer composition may contain about 0% to about 25% by weight of one or more halogen-free flame retardants. The polymer composition may contain one or more antioxidants, one or more release agents, one or more carbide salts, or any combination thereof. The polymer composition may contain about 0.1% to about 0.3% by weight of one or more antioxidants. The polymer composition may contain about 0.1% to about 0.7% by weight of one or more release agents. The polymer composition may contain about 75% to about 90% by weight of one or more thermoplastic polymers.

[0009] Prior to embedding the fibrous material layer, the polymer composition may be one or more polymer composition layers. The one or more polymer composition layers may have a thickness of about 0.05 mm to about 0.15 mm.

[0010] The disclosed composition may comprise two or more layers of fibrous material. Each fibrous material layer may comprise at least one nonwoven fibrous material layer and at least one woven fibrous material layer. Each fibrous material layer may comprise nonwoven fibrous material. One or more polymer composition layers may be disposed between the fibrous material layers. A fibrous material layer may be disposed between two polymer composition layers.

[0011] The organic sheet can have a thickness of about 0.1 mm to about 10 mm. The organic sheet can be combined with a polycarbonate composition to form a reinforced organic sheet and / or a molded organic sheet. The organic sheet can be combined with a fiber-filled polycarbonate composition to form a reinforced organic sheet and / or a molded organic sheet. The fiber-filled polycarbonate composition can be a glass fiber-filled polycarbonate composition.

[0012] Articles prepared from the compositions disclosed herein are disclosed.

[0013] A method for preparing the compositions disclosed herein is disclosed, comprising: forming a layered stack of one or more layers of fibrous material and one or more layers of one or more polymer compositions, wherein at least one fibrous material layer is a nonwoven fibrous material and the fibers of the nonwoven fibrous material have a diameter of about 0.1 μm to about 18 μm; stacking alternating layers of one or more fibrous material layers and one or more polymer composition layers; pressing and heating the layered stack to embed one or more fibrous material layers with one or more polymer compositions to form one or more organic sheets having a fiber content of about 30% to about 80% by weight and a top and bottom surface. The outer layer of the stack may be a layer of one or more polymer compositions. The pressing and heating of the layered stack can be performed using batch lamination by pressing or continuous lamination by two belts. The method may include molding one or more organic sheets into a desired form. The method may include molding one or more organic sheets into a battery pack or part of a battery pack.

[0014] The disclosed methods may include adding a polycarbonate composition to one or more organic sheets to form a reinforced organic sheet and / or an overmolded organic sheet. The disclosed methods may include heating one or more organic sheets; placing one or more organic sheets into a compression mold; extruding a polycarbonate composition onto the heated one or more organic sheets; and compression molding the heated one or more organic sheets and polycarbonate; and forming a reinforced organic sheet and / or an overmolded organic sheet. The disclosed methods may include heating a second organic sheet; placing the second heated organic sheet on top of the extruded polycarbonate composition prior to compression molding; and compression molding; and forming a reinforced organic sheet. The disclosed methods may include molding a polycarbonate composition onto one or more organic sheets to form an overmolded organic sheet. The disclosed methods may include inserting a polycarbonate composition into a molded organic sheet to form a reinforced organic sheet and / or an overmolded organic sheet. The disclosed methods may include injection molding organic sheets with a polycarbonate composition to form reinforced organic sheets and / or overmolded organic sheets.

[0015] The disclosed composition and articles prepared from the disclosed composition exhibit excellent flame retardant and fire-resistant properties. When exposed to fire, the composition expands and reduces heat transfer through the composition. The expansion rate of the composition when exposed to fire can be about 3% or more, or about 4% or more. The composition reduces heat transfer from one side of the organic sheet formed from the composition to the other. When exposed to fire, the polymer composition retains its mechanical properties, and the nonwoven fiber material layer insulates against heat transfer through the organic sheet.

[0016] An organic sheet of about 0.1 mm to about 10 mm thickness (having at least one layer of nonwoven fibrous material and a fiber content of about 30% by weight or more, about 50% by weight or more, about 70% by weight or more, and about 80% by weight or less) may have a temperature on its top side of about 370°C or less, about 330°C or less, about 300°C or less, about 270°C or less, or about 250°C or less after the bottom side of the organic sheet has been exposed to fire for 10 minutes. An organic sheet of about 1.0 mm to about 3.0 mm thickness (having a fiber content of about 45% by weight or more, about 50% by weight or more, about 70% by weight or more, and about 75% by weight or less, and at least one nonwoven glass fiber layer consisting of nonwoven glass fibers with a diameter of about 18 μm or less, about 10 μm or less, or about 8 μm or less) may have a temperature on its top side of about 370°C or less, about 350°C or less, or about 330°C or less after the bottom side of the organic sheet has been exposed to fire for 10 minutes, and may have an expansion rate of about 3% or more, or about 4% or more. An organic sheet of about 1.0 mm to about 3.0 mm thickness (having a fiber content of about 45% by weight or more, about 50% by weight or more, about 70% by weight or more, and about 75% by weight or less, and at least one nonwoven glass fiber layer consisting of nonwoven glass fibers with a glass fiber diameter between about 6 μm and about 10 μm) may have a temperature of about 350°C or less, or about 330°C or less on its top side after the bottom side of the organic sheet has been exposed to fire for 10 minutes. An organic sheet of about 1.0 mm to about 3.0 mm thickness (having a fiber content of about 45% by weight or more, about 50% by weight or more, about 60% by weight or more, and about 65% by weight or less, and at least one layer of nonwoven fiber material composed of nonwoven carbon fibers) may have a temperature on its top side of about 300°C or less, about 280°C or less, about 260°C or less, or about 250°C or less after the bottom side of the organic sheet has been exposed to fire for 10 minutes.

[0017] An organic sheet approximately 2.0 mm thick (having a fiber content of approximately 70% by weight and at least one nonwoven layer composed of nonwoven glass fibers with a diameter of approximately 18 μm) has a top temperature of approximately 370°C, an expansion coefficient of approximately 3% or greater, a flexural modulus of approximately 15 GPa or greater, and a flexural strength of approximately 500 MPa or greater. An organic sheet approximately 2.0 mm thick (having a fiber content of approximately 70% by weight and a nonwoven glass fiber layer comprising glass fibers with a diameter of approximately 18 μm) may have a top temperature of approximately 370°C or lower, an expansion coefficient of approximately 3% or greater, a flexural modulus of approximately 15 GPa or greater, and a flexural strength of approximately 230 MPa or greater. Organic sheets approximately 1.5 mm thick (containing approximately 50% by weight fiber content and a nonwoven glass fiber layer with glass fibers having diameters between approximately 6 μm and 10 μm) can have a top temperature of approximately 330°C or lower, an expansion coefficient of approximately 4% or greater, a flexural modulus of approximately 12 GPa or greater, and a flexural strength of approximately 150 MPa or greater. Organic sheets approximately 1.3 mm thick (containing approximately 50% by weight fiber content and a nonwoven carbon fiber layer) can have a top temperature of approximately 260°C or lower, an expansion coefficient of approximately 4% or greater, a flexural modulus of approximately 29 GPa or greater, and a flexural strength of approximately 300 MPa or greater. Organic sheets approximately 2.0 mm thick (containing approximately 50% by weight fiber content and a nonwoven carbon fiber layer) can have a top temperature of approximately 250°C or lower, an expansion coefficient of approximately 4% or greater, a flexural modulus of approximately 19 GPa or greater, and a flexural strength of approximately 370 MPa or greater. The product can be used in battery packs. Attached Figure Description

[0018] Figure 1 It is a layered stacking design with one fiber material layer and two layers before the polymer composition is embedded with the fiber material layer.

[0019] Figure 2 It is a layered stacking design of fiber material layers with the same fiber material before the polymer composition is embedded with the fiber material layer.

[0020] Figure 3 It is a layered stacking design of fiber material layers with two different fiber materials before the polymer composition is embedded with fiber material layers, at least one of which has nonwoven fiber material.

[0021] Figure 4 It is a layered stacking design of fiber material layers with two different fiber materials before the polymer composition is embedded with fiber material layers, and at least two fiber material layers have the same nonwoven fiber material.

[0022] Figure 5This is done before the polymer composition embeds the fiber material layer. Figure 6 The layered stacking design of the composition.

[0023] Figure 6 This is a scanning electron microscope image magnified to x 65 of the cross-section of the composition after the polymer composition has been embedded with a layer of fibrous material.

[0024] Figure 7 This is a scanning electron microscope image magnified to x1.00K of the cross-section of the composition after the polymer composition has been embedded with a layer of fibrous material.

[0025] Figure 8 The lamination process that can be used to produce organic sheets is shown. Detailed Implementation

[0026] While this disclosure has been described in conjunction with certain embodiments, it should be understood that this disclosure is not limited to the disclosed embodiments and is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, the scope of which is to be interpreted in the broadest possible sense to cover all such modifications and equivalent structures permitted by law.

[0027] As used herein, "one or more" means that at least one or more of the listed components may be used as disclosed. Unless otherwise stated, weight % or parts by weight as used herein refers to or is based on the weight of the disclosed composition or laminate. Unless otherwise stated, such parts by weight are based on 100 parts.

[0028] A composition is disclosed comprising one or more fibrous material layers, the fibrous material layers being composed of one or more layers of one or more fibrous materials, wherein at least one fibrous material layer is a nonwoven fibrous material; and one or more polymer compositions embedded within the fibrous material layers to form an organic sheet having a fiber content of about 30% to about 80% by weight based on the composition. The composition may contain about 30% to about 50% by weight based on the composition. The one or more polymer compositions may contain one or more thermoplastic polymers that are rigid at room temperature and melt and expand when exposed to high temperatures.

[0029] The composition may contain a certain fiber concentration, which provides enhanced flame retardancy and reduced heat transfer through fiber-containing structures. The composition may have a fiber content of up to 80% by weight, about 75% by weight or less, or about 65% by weight or less, based on the weight of the composition. The composition may contain a fiber content of about 30% by weight or more, about 35% by weight or more, about 50% by weight or more, or about 55% by weight or more, based on the weight of the composition. The composition may have a fiber content of about 30% by weight to about 80% by weight, about 35% by weight to about 75% by weight, about 50% by weight to about 65% by weight, or about 55% by weight to about 65% by weight.

[0030] The composition may contain a certain concentration of polymer composition that provides enhanced flame retardancy and reduced heat transfer through structures containing fibers and polymer composition. The composition may contain up to about 70% by weight of polymer composition, about 50% by weight or less, or about 45% by weight or less of polymer composition based on the weight of the composition. The composition may contain about 20% by weight or more of polymer composition, about 25% by weight or more, or about 30% by weight or more of polymer composition based on the weight of the composition. The composition may contain about 20% by weight to about 70% by weight, about 30% by weight to about 50% by weight, or about 30% by weight to about 45% by weight of polymer composition.

[0031] The fiber material layer may consist of one or more layers of one or more fiber materials, two or more layers of one or more fiber materials, or three or more layers of one or more fiber materials. The fiber material layer may consist of 40 or fewer layers of one or more fiber materials, 10 or fewer layers of one or more fiber materials, or 5 or fewer layers of one or more fiber materials. The fiber material layer may include a nonwoven fiber material layer, a woven fiber material layer, or a combination of woven and nonwoven fiber material layers. One or more fiber materials may be composed of continuous or discontinuous fibers. One or more fiber materials may be composed of discontinuous fibers.

[0032] The layer of one or more fibrous materials may have a thickness of about 500 μm or less, or about 250 μm or less. The layer of one or more fibrous materials may have a thickness of about 20 μm or more, about 50 μm or more, or about 250 μm. The layer of one or more fibrous materials may have a thickness of about 20 μm to about 500 μm, about 50 μm to about 500 μm, about 50 μm to about 250 μm, or about 250 μm to about 500 μm.

[0033] One or more fibrous materials can be composed of woven or nonwoven fibers. Nonwoven fibers can produce fibrous materials as nonwoven fiber materials. Woven fibers can produce fibrous materials as woven fiber materials. One or more layers of nonwoven fiber material form a nonwoven fiber material layer. One or more layers of woven fiber material form a woven fiber material layer.

[0034] The disclosed composition may consist of multiple layers of fibrous material sufficient to provide excellent flame retardant and fire-resistant properties. The disclosed composition may consist of at least one layer of nonwoven fibrous material. The disclosed composition may consist of one or more, two or more, or three or more layers of fibrous material. Two or more layers of fibrous material or three or more layers of fibrous material may consist of at least one layer of nonwoven fibrous material and at least one layer of woven fibrous material. The composition may consist of a nonwoven fibrous material layer.

[0035] One or more fiber materials can be nonwoven materials, felts, or mats that can be made from one or more fibers. The fibers of one or more fiber materials can include one or more fiber types that impart desired properties. One or more fiber types can consist of: one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, one or more polyacrylonitrile fibers, one or more pre-oxidized polyacrylonitrile fibers, one or more recycled carbon fibers, one or more polyaramid fibers, one or more natural cellulose fibers, one or more mineral fibers, or any combination of one or more fiber types. One or more metal fibers can consist of: one or more nickel fibers, one or more aluminum fibers, one or more steel fibers, one or more carbon steel fibers, one or more stainless steel fibers, one or more copper fibers, one or more brass fibers, one or more silver fibers, one or more nickel-silver fibers, one or more nickel-iron alloy fibers, one or more magnesium fibers, or a mixture of any one or more metal fibers. One or more metal-coated fibers can consist of: one or more aluminum-coated fibers, one or more aluminum-coated glass fibers, one or more aluminum-coated basalt fibers, one or more nickel-coated fibers, one or more nickel-coated carbon fibers, one or more nickel-coated glass fibers, one or more silver-coated fibers, or a mixture of any one or more metal-coated fibers. One or more metal-coated fibers may be one or more aluminum-coated basalt fibers. Mineral fibers may be wollastonite fibers or basalt fibers. Cellulose fibers may be flax fibers. Two or more different fibers may be combined to form co-knitted fibers. One or more polymer fibers may contain one or more polymers selected from polycarbonate, aramid, polyester, polyolefin, polyethyleneamine, etc. Fibers may be formed into substructures, such as braided structures, tapes, etc.

[0036] The composition may contain fibers of a certain diameter, which provide enhanced flame retardancy and reduced heat transfer through the fiber-containing structure. The fibers of the fiber material may have a diameter of about 20 μm or less, about 10 μm or less, or about 6 μm or less. The fibers of the fiber material may have a diameter of about 0.1 μm or greater, about 1 μm or greater, about 4 μm or greater, or about 8 μm or greater. The fibers of the fiber material may have a diameter of about 0.1 μm to about 20 μm, about 1 μm to about 18 μm, about 1 μm to about 10 μm, about 4 μm to about 10 μm, about 6 μm to about 10 μm, or about 4 μm to about 6 μm.

[0037] The fiber diameter used in this article can be determined using a KEYENCE digital microscope VHX-500F, which is equipped with real-time observation, recording, and measurement of the diameter on a monitor screen. The composition can be polished using a Struers Tagramin-25 polisher, and the fiber diameter can be observed and measured under the digital microscope.

[0038] The fibers of the nonwoven fiber material have a diameter that allows the composition to expand during exposure to combustion and reduces heat transfer through the composition. The fibers of the nonwoven fiber material may have a diameter of about 18 μm or less, about 10 μm or less, or about 6 μm or less. The fibers of the nonwoven fiber material may have a diameter of about 0.1 μm or greater, about 1 μm or greater, about 4 μm or greater, or about 8 μm or greater. The fibers of the nonwoven fiber material may have a diameter of about 0.1 μm to about 18 μm, about 1 μm to about 10 μm, about 4 μm to about 10 μm, about 6 μm to about 10 μm, or about 4 μm to about 6 μm.

[0039] The nonwoven fiber material layer may consist of multiple layers of nonwoven fiber material sufficient to provide the desired properties to the composition. The nonwoven fiber material layer may consist of one or more layers of nonwoven fiber material. The nonwoven fiber layer may have discontinuous fibers. The nonwoven fiber material may be made of nonwoven fibers. The nonwoven fiber may be any fiber type disclosed herein. The nonwoven fiber material may be made of glass fiber, carbon fiber, ceramic fiber, polymer-spun fiber, metal fiber, metal-coated fiber, or any combination thereof. The metal fiber of the nonwoven fiber material may be stainless steel fiber. The metal-coated fiber of the nonwoven fiber material may be aluminum-coated basalt fiber. The fibers of the nonwoven fiber material may be randomly knitted. The nonwoven fiber material may contain co-knitted fibers. The co-knitted fibers may contain one or more glass fibers, one or more carbon fibers, one or more polymer-spun fibers, or any combination thereof. The co-knitted fibers may be a mixture of glass fiber and carbon fiber. The co-knitted fibers may be polymer-spun fibers co-knitted into carbon fibers. The ratio of polymer-spun fibers to carbon fibers may be 10-90% by weight to 90-10% by weight. Polymer spun fibers may comprise spun fibers of polymer compositions as disclosed herein. Nonwoven fiber materials may consist of mixtures of knitted fibers, glass fibers, or carbon fiber blends.

[0040] The glass fibers in the nonwoven glass fiber material have a diameter that allows the composition to expand during exposure to combustion and reduces heat transfer through the composition. The glass fibers in the nonwoven glass fiber material can have a diameter of about 0.1 μm or greater, or about 6 μm or greater. The glass fibers in the nonwoven glass fiber material can have a diameter of about 18 μm or less, about 10 μm or less, or about 8 μm or less. The glass fibers in the nonwoven glass fiber material can have a diameter of about 8 μm. The glass fibers in the nonwoven glass fiber material can have a diameter of about 0.1 μm to about 18 μm, about 6 μm to about 10 μm, or about 6 μm to about 8 μm.

[0041] The carbon fibers in nonwoven carbon fiber materials have a diameter that allows the composition to expand during exposure to combustion and reduces heat transfer through the composition. The carbon fibers in nonwoven carbon fiber materials can have a diameter of about 18 μm or less, about 10 μm or less, about 8 μm or less, or about 6 μm or less. The carbon fibers in nonwoven carbon fiber materials can have a diameter of about 1 μm or greater, or about 4 μm or greater. The carbon fibers in nonwoven carbon fiber materials can have a diameter of about 1 μm to about 18 μm, about 1 μm to about 10 μm, about 4 μm to about 8 μm, or about 4 μm to about 6 μm.

[0042] The woven fiber material layer may consist of one or more layers of woven fiber material. The woven fiber material may be composed of fibers of one or more fiber types as described herein. The fibers of the woven fiber material may be woven carbon fiber, glass fiber, ceramic fiber, polymer fiber, metal fiber, or metal-coated fiber. The metal fibers of the woven fiber material may be stainless steel fibers. The metal-coated fibers of the woven fiber material may be aluminum-coated basalt fibers. The fibers of the woven fiber material are woven fibers. The woven fibers may have any weave that contributes to achieving the desired properties. The woven fibers may have a plain weave, a unidirectional weave, a wrinkle-free weave, or a twill weave.

[0043] Before embedding one or more fibrous material layers, the polymer composition can be one or more polymer composition layers. The polymer composition layers can be formed from powder, flakes, or granules of the polymer composition. The polymer composition layers can be formed from powder, flakes, or granules of the polymer composition that have already been melted and extruded in an extruder. One or more polymer composition layers can have a thickness sufficient to embed a portion of the polymer composition layer within one or more fibrous material layers. The polymer composition layers can have a thickness sufficient to partially or completely embed the polymer composition layer within one or more fibrous material layers. When a fibrous material layer is between two polymer composition layers, the polymer composition layer can have a thickness sufficient to embed a portion of the polymer composition layer within one or more fibrous material layers. The polymer composition layer can have a thickness sufficient to adhere adjacent fibrous layers together. The polymer composition layer can have a thickness sufficient to form an outer polymer composition layer on each side of one or more fibrous layers. When the layer is exposed to heat and pressure, the polymer composition layer can have a thickness sufficient to embed the polymer composition between the fibers of one or more fibrous material layers. One or more polymer composition layers can have a thickness of about 0.05 mm to about 0.15 mm. One or more polymer composition layers can be disposed between fibrous material layers. A fibrous material layer may be disposed between two polymer composition layers. One or more polymer composition layers may be disposed on one or both outer layers of the fibrous layer.

[0044] One or more polymer compositions may comprise: one or more thermoplastic polymers; one or more halogen-free flame retardants; one or more additives commonly used in this type of composition; one or more impact modifiers; and / or a second polymer. One or more polymer compositions may comprise: one or more thermoplastic polymers; one or more halogen-free flame retardants; one or more additives commonly used in this type of composition. One or more polymer compositions may comprise: one or more thermoplastic polymers; one or more halogen-free flame retardants; one or more antioxidants; one or more mold release agents; one or more carbide salts; or any combination thereof.

[0045] The polymer composition may comprise: about 75% to about 100% by weight of one or more thermoplastic polymers; about 0% to about 25% by weight of one or more halogen-free flame retardants; about 0.2% to about 2% by weight of one or more additives commonly used in compositions of this type; about 0% to about 5% by weight of one or more impact modifiers; and / or about 0% to about 30% by weight of a second polymer. The weight percentages provided for the polymer composition are based on the weight of the polymer composition.

[0046] The polymer composition may comprise one or more thermoplastic polymers in amounts of about 75% by weight or more, about 80% by weight or more, or about 85% by weight or more, based on the total weight of the polymer composition. The polymer composition may comprise one or more thermoplastic polymers in amounts of about 100% by weight or less, about 95% by weight or less, or about 85% by weight or less, based on the total weight of the polymer composition. The polycarbonate composition may comprise one or more thermoplastic polymers in amounts of about 75% by weight to about 100% by weight, about 80% by weight to about 95% by weight, or about 80% by weight to about 85% by weight.

[0047] The polymer composition may contain one or more thermoplastic polymers that are rigid at room temperature and melt and expand when exposed to high temperatures. The polymer composition may contain one or more thermoplastic polymers that melt and expand when exposed to temperatures between about 300°C and about 500°C. One or more thermoplastic polymers may be composed of one or more styrene-acrylonitrile (SAN), one or more poly(methyl methacrylate) (PMMA), one or more polyolefins, one or more polyarylsulfones (PSU), one or more polypropylenes (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonate (PC), or any combination thereof. One or more thermoplastic polymers may contain one or more polycarbonates. One or more thermoplastic polymers may be composed of at least one or more polycarbonate polymers. One or more thermoplastic polymers may be composed of at least one polyarylsulfone polymer. One or more thermoplastic polymers may be composed of at least one or more polycarbonate polymers.

[0048] Polymer compositions may contain one or more flame retardants commonly used in thermoplastic compositions. Polymer compositions may contain one or more non-halogenated flame retardants commonly used in thermoplastic compositions. Polymer compositions containing polycarbonate may contain one or more flame retardants commonly used in polycarbonate compositions. Polymer compositions containing polycarbonate may contain one or more non-halogenated flame retardants commonly used in polycarbonate compositions. Non-halogenated means that the flame retardant does not contain halogen atoms. Using a non-halogenated flame retardant means that the composition containing the non-halogenated flame retardant will not release halogens during combustion. The flame retardant can be any flame retardant known for use in thermoplastic compositions that provides flame retardant properties and does not negatively affect the impact, heat resistance, flexural modulus, flexural strength, haze, and transparency of the composition. The amount of flame retardant used is sufficient to meet the flame retardant requirements of the end use and is used in an amount that will not harmfully affect the properties of the article made from the composition. One or more halogen-free flame retardants may be one or more phosphorus-containing flame retardants. One or more phosphorus-containing flame retardants may contain phosphate esters, phosphazenes, or mixtures thereof. Exemplary phosphorus flame retardants include phosphorus-containing compounds, such as phosphate esters, such as oligophosphate esters, poly(block-phosphonate-esters), and / or poly(block-phosphonate-carbonates), see USP 7,645,850, the entire contents of which are incorporated herein by reference. Exemplary oligophosphate esters include bisphenol A bis(diphenyl phosphate) (BAPP). Exemplary additional flame retardants include 1,3-phenyltetra(2,6-dimethylphenyl) ester (Daihachi PX-200).

[0049] One or more non-halogenated flame retardants may be one or more phosphazenes. Any one or more phosphazenes that enhance flame retardancy can be used. Phosphazenes may contain more than one phosphazene unit. Phosphazenes are organic compounds having a –P=N- structure. Phosphazenes can be a linear structure containing one or more phosphazene units, or a cyclic structure containing one or more phosphazene units. The phosphorus atom on the phosphazene structure may be bonded to one or more alkyloxy groups. The alkyloxy group may be an alkoxy, aryloxy, alkyl-substituted aryloxy, alkoxy-substituted aryloxy, or halogen-substituted aryloxy. The alkyloxy group may be an aryloxy or an alkyl-substituted aryloxy. The alkyl group may be C... 1-10 Alkyl, C 1-3Alkyl, methyl, or ethyl compounds. Cyclic phosphazene compounds may contain one or more phosphazene units, or three or more phosphazene units. Cyclic phosphazene compounds may contain 25 or fewer phosphazene units, 10 or fewer phosphazene units, or five or fewer phosphazene units. Linear phosphazene compounds may contain one or more phosphazene units, three or more phosphazene units, five or more phosphazene units, or six or more phosphazene units. Linear phosphazene compounds may contain 10,000 or fewer phosphazene units, 1,000 or fewer phosphazene units, 100 or fewer phosphazene units, or 25 or fewer phosphazene units. Exemplary cyclic phosphazenes include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, hexaphenoxycyclophosphazene, and decaphenoxycyclopentaphosphazene. Phosphazene compounds may be cross-linked. Phosphazene compounds can be crosslinked with bisphenol compounds, such as 4,4'-diphenylene groups, including 4,4'-sulfonyldiphenylene (bisphenol S residue), 2,2-(4,4'-diphenylene), isopropylidene groups, 4,4'-oxodiphenylene groups, and 4,4'-thiodiphenylene groups. The phenylene content of crosslinked phenoxyphosphazene compounds is typically 50-99.9% by weight or 70-90% by weight. The crosslinked phenoxyphosphazene compound molecule may not contain any free hydroxyl groups.

[0050] One or more halogen-free flame retardants may be present in amounts of about 0% by weight or more, about 3% by weight or more, about 5% by weight or more, about 8% by weight or more, or about 12% by weight or more, based on the weight of the polymer composition. One or more halogen-free flame retardants may be present in amounts of about 25% by weight or less, about 15% by weight or less, or about 13% by weight or less, based on the weight of the polymer composition. One or more halogen-free flame retardants may be present in amounts of about 0% by weight to about 25% by weight, based on the weight of the polymer composition.

[0051] The polymer composition may contain one or more phosphate ester flame retardants and one or more phosphazene flame retardants.

[0052] One or more phosphazene flame retardants may be present in amounts of about 0% by weight or more, about 3% by weight or more, about 5% by weight or more, or about 8% by weight or more, based on the weight of the polymer composition. One or more phosphazene flame retardants may be present in amounts of about 25% by weight or less, about 15% by weight or less, or about 13% by weight or less, based on the weight of the polymer composition. One or more phosphazene flame retardants may be present in amounts of about 0% to about 25% by weight, about 5% to about 15% by weight, or about 8% to about 13% by weight, based on the weight of the polymer composition.

[0053] One or more phosphate-containing flame retardants based on the polymer composition may be present in amounts of about 0% by weight or more, about 3% by weight or more, about 5% by weight or more, or about 8% by weight or more. One or more phosphate-containing flame retardants based on the polymer composition may be present in amounts of about 25% by weight or less, about 15% by weight or less, or about 13% by weight or less. One or more phosphate-containing flame retardants based on the polymer composition may be present in amounts of about 0% to about 25% by weight, about 5% to about 15% by weight, or about 8% to about 13% by weight.

[0054] The polymer composition may contain one or more additives commonly used in this type of composition. Exemplary additives include: zinc salts, colorants, reinforcing fibers, stabilizers, antistatic agents, silicone oils, flow enhancers, release agents, carbide salts, UV absorbers, etc. Exemplary flame-retardant additives may also include antimony oxide and metal salts of aromatic sulfur, or mixtures thereof may be used. Compounds may be used to stabilize rubber-modified vinylidene-substituted aromatic copolymer compositions to prevent degradation caused by, but not limited to, heat, light, and oxygen, or mixtures thereof. Some of these additives may adsorb volatile organic compounds, such as, for example, zeolites, activated carbon, bamboo charcoal, etc. One or more additives may be one or more antioxidants, one or more release agents, one or more carbide salts, one or more UV absorbers, or any combination thereof.

[0055] The polymer composition of the disclosed composition may contain one of a variety of antioxidants. The antioxidant may be introduced into the composition from the components used (e.g., impact modifiers or post-consumer recycled polymers). The antioxidant may be added to the composition alone. The antioxidant may be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonate, aromatic hydroxybenzyl compounds, triazine compounds, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or amino antioxidants. The antioxidant may be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonate, aromatic hydroxybenzyl compounds, triazine compounds, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or amino antioxidants without sulfur-containing groups.

[0056] Phenol-based antioxidants include 2,6-di-tert-butyl-4-methylphenol; 2,6-diphenyl-4-methoxyphenol; 2,2'-methylenebis(6-tert-butyl-4-methylphenol); 2,2'-methylenebis(6-tert-butyl-4-methylphenol); 2,2'-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol]; 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2'-methylenebis(4-methyl-6-cyclohexylphenol); 2,2'-methylenebis(4-methyl-6-nonylphenol); 1,1, 3-Tris(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)-4-n-dodecyl mercaptobutane; ethylene glycol bis[3,3-bis(3-tert-butyl-4-hydroxyphenyl)butyrate]; 1,1-bis(3,5-dimethyl-2-hydroxyphenyl)-3-(n-dodecylthio)butane; 4,4'-thiobis(6-tert-butyl-3-methylphenol); 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene; 2,2-bis(3,5-di-tert-butyl) -4-hydroxybenzyl)malonide dioctadecyl ester; n-octadecyl-3-(4-hydroxy-3,5-di-tert-butylphenyl)propionate; tetra[methylene(3,5-di-tert-butyl-4-hydroxycinnamate)]methane; and pentaerythritol tetra(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate. Hydroquinone-based and alkylated hydroquinone antioxidants include 2,6-di-tert-butyl-4-methoxyphenol, 2,5-di-tert-butylhydroquinone, 2,5-di-tert-pentylhydroquinone, 2,6-diphenyl-4-octadecyloxyphenol, and 2,6-di-tert-butyl-4-methoxyphenol. Diphenols, 2,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyphenyl stearate, and bis(3,5-di-tert-butyl-4-hydroxyphenyl) adipate. Tocopherol-based antioxidants include α-tocopherol, β-tocopherol, γ-tocopherol, δ-tocopherol, and mixtures thereof (vitamin E). Antioxidants based on O- and N-benzyl compounds include, for example, 3,5,3′,5′-tetra-tert-butyl-4,4′-dihydroxydibenzyl ether and tris(3,5-di-tert-butyl-4-hydroxybenzyl)amine.Antioxidants based on alkylene bisphenols include 2,2'-methylenebis(6-tert-butyl-4-methylphenol), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), 2,2'-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol], 2,2'-methylenebis(4-methyl-6-cyclohexylphenol), 2,2'-methylenebis(6-nonyl-4-methylphenol), 2 2'-Methylenebis(4,6-di-tert-butylphenol), 2,2'-Ethylenebis(4,6-di-tert-butylphenol), 2,2'-Ethylenebis(6-tert-butyl-4-isobutylphenol), 2,2'-Methylenebis[6-(α-methylbenzyl)-4-nonylphenol], 2,2'-Methylenebis[6-(α,α-dimethylbenzyl)-4-nonylphenol], 4,4'-Methylenebis(2, 6-Di-tert-butylphenol), 4,4′-methylenebis(6-tert-butyl-2-methylphenol), 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, 2,6-bis(3-tert-butyl-5-methyl-2-hydroxybenzyl)-4-methylphenol, 1,1,3-tris(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, ethylene glycol bis[3,3-bis(3′-tert-butyl- Antioxidants based on hydroxybenzyl malonates include bis[2-(3′-tert-butyl-2′-hydroxy-5′-methylbenzyl)-6-tert-butyl-4-methylphenyl] terephthalate, 1,1-bis-(3,5-dimethyl-2-hydroxyphenyl)butane, 2,2-bis(3,5-di-tert-butyl-4-hydroxyphenyl)propane, and 1,1,5,5-tetra(5-tert-butyl-4-hydroxy-2-methylphenyl)pentane. Antioxidants based on aromatic hydroxybenzyl groups include 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, 1,4-bis(3,5-di-tert-butyl-4-hydroxybenzyl)-2,3,5,6-tetramethylbenzene, and 2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)phenol.Antioxidants based on triazine compounds include 2,4-bis(octylmercapto)-6-(3,5-di-tert-butyl-4-hydroxyaniline)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyaniline)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyphenoxy)-1,3,5-triazine, and 2,4,6-tri-(3,5-di-tert-butyl- 4-Hydroxyphenoxy)-1,2,3-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)isocyanurate, 2,4,6-tris(3,5-di-tert-butyl-4-hydroxyphenylethyl)-1,3,5-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)-hexahydro-1,3,5-triazine and 1,3,5-tris(3,5-dicyclohexyl-4-hydroxybenzyl)isocyanurate. Antioxidants based on benzylphosphonates include dimethyl-2,5-di-tert-butyl-4-hydroxybenzylphosphonate, diethyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-5-tert-butyl-4-hydroxy-3-methylbenzylphosphonate, and calcium salts of monoethyl 3,5-di-tert-butyl-4-hydroxybenzylphosphonate. Antioxidants based on acylaminophenols include, for example, 4-hydroxylauroyl aniline, 4-hydroxystearoyl aniline, and octyl N-(3,5-di-tert-butyl-4-hydroxyphenyl)carbamate. Exemplary antioxidants include esters of D-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctanol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tri(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxalamide, 3-thioundecanool, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctanol, stearyl alcohol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)isocyanurate, etc. 3-Thioundecanool, 3-Thiopentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane; 3,9-bis[2-{3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5.5]-undecane.Exemplary antioxidants include esters of β-(3,5-dicyclohexyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols, such as methanol, ethanol, octanol, octadecyl alcohol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol, tri(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxalamide, 3-thiadecanool, 3-thiapentadecanool, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of 3,5-di-tert-butyl-4-hydroxyphenylacetic acid with monohydric or polyhydric alcohols, such as methanol, ethanol, octanol, octadecyl alcohol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol, tri(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxalamide, 3-thiadecanool, 3-thiapentadecanol, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid, such as N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hexamethylenediamide, N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)trimethylenediamide, N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazide, and N,N'-bis[2-(3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionyloxy)ethyl]oxalamide (Naugard® XL-1, supplied by Uniroyal). An exemplary antioxidant is ascorbic acid (vitamin C).Amine antioxidants include N,N'-di-isopropyl-p-phenylenediamine, N,N'-di-sec-butyl-p-phenylenediamine, N,N'-bis(1,4-dimethylpentyl)-p-phenylenediamine, N,N'-bis(1-ethyl-3-methylpentyl)-p-phenylenediamine, N,N'-bis(1-methylheptyl)-p-phenylenediamine, N,N'-dicyclohexyl-p-phenylenediamine, N,N'-diphenyl-p-phenylenediamine, N,N'-bis(2-naphthyl)-p-phenylenediamine, N-isopropyl-N'-phenyl-p-phenylenediamine, N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, N... -(1-Methylheptyl)-N'-phenyl-p-phenylenediamine, N-cyclohexyl-N'-phenyl-p-phenylenediamine, N,N'-dimethyl-N,N'-di-sec-butyl-p-phenylenediamine, diphenylamine, N-allyl diphenylamine, 4-isopropoxydiphenylamine, N-phenyl-1-naphthylamine, N-(4-tert-octylphenyl)-1-naphthylamine, N-phenyl-2-naphthylamine, octylated diphenylamine, p,p'-di-tert-octyl diphenylamine, 4-n-butylaminophenol, 4-butyrylaminophenol, 4-nonanoylaminophenol, 4-dodecylaminophenol, 4-octadecylaminophenol, bis(4- Methoxyphenyl)amine, 2,6-di-tert-butyl-4-dimethylaminomethylphenol, 2,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, N,N,N',N'-tetramethyl-4,4'-diaminodiphenylethane, 1,2-bis[(2-methylphenyl)amino]ethane, 1,2-bis(phenylamino)propane, (o-tolyl)biguanidine, bis[4-(1',3'-dimethylbutyl)phenyl]amine, tert-octylated N-phenyl-1-naphthylamine, mixtures of monoalkylated and dialkylated tert-butyl / tert-octyldiphenylamine, monoalkylated and dialkylated Mixtures of nonyldiphenylamine, mixtures of monoalkylated and dialkylated dodecyldiphenylamine, mixtures of monoalkylated and dialkylated isopropyl / isohexyldiphenylamine, mixtures of monoalkylated and dialkylated tert-butyldiphenylamine, N,N,N',N'-tetraphenyl-1,4-diaminobut-2-ene, N,N-bis(2,2,6,6-tetramethylpiperidin-4-yl-hexamethylenediamine), bis(2,2,6,6-tetramethylpiperidin-4-yl) sebacate, 2,2,6,6-tetramethylpiperidin-4-one, 2,2,6,6-tetramethylpiperidin-4-ol.Phosphorus antioxidants include tetrakis(2,4-di-tert-butylphenyl)-4,4-biphenylphosphite, tris(2,4-di-tert-butylphenyl) phosphite, 2,2'-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, di(nonylphenyl)pentaerythritol diphosphite, phenyl-bisphenol A-pentaerythritol diphosphite, distearate pentaerythritol diphosphite, dioctyl pentaerythritol diphosphite, and dilauryl pentaerythritol diphosphite. Phosphate esters, including diphenyl pentaerythritol diphosphite, dicyclohexyl pentaerythritol diphosphite, bis(2,4,6-tri-tert-butylphenyl) pentaerythritol diphosphite, 2,2'-ethylidene bis(4,6-di-tert-butylphenyl) fluorophosphite, heptanediol phosphite, tridodecyl phosphite, phenyl isooctyl phosphite, phenyl undecyl phosphite, phenyl dodecyl phosphite, diphenyl isooctyl phosphite, diphenyl isodecyl phosphite, diphenyl isodecyl phosphite, diphenyl dodecyl phosphite, triphenyl phosphite, tri(mononophenyl) phosphite, and tri(dinonylphenyl) phosphite. The antioxidant may be octadecyl 3,5-di(tert-butyl-4-hydroxyhydrogenated cinnamate, which is commercially available from BASF as IRGANOX 1076.

[0057] Exemplary antioxidant additives include, for example, organic phosphites such as tris(nonylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite (e.g., “IRGAFOS 168” or “I-168”), bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, distearate pentaerythritol diphosphite, etc.; alkylated monophenols or polyphenols; alkylation products of polyphenols with dienes, such as tetra[methylene(3,5-di-tert-butyl-4-hydroxycinnamate)methane, etc.; butylation products of p-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with mono- or polyols. Esters; esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with mono- or polyols; esters of thioalkyl or thioaryl compounds, such as distearate thiopropionate, dilaurate thiopropionate, ditridecyl thiodipropionate, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythritol propionate tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) ester, etc.; amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid, etc., or combinations comprising at least one of the aforementioned antioxidants.

[0058] The antioxidant may be one or more of phenol and / or phosphorus-based antioxidants. The antioxidant may be at least one of tris(2,4-di-tert-butylphenyl) phosphite and octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate. The antioxidant may be octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, which is commercially available as IRGANOX B900.

[0059] Antioxidants may be present in the polymer composition and the structure formed therefrom in any amount that delays polymer oxidation. Based on the weight of the disclosed polymer composition, the antioxidant may be present in amounts of about 100 or more (0.01 wt%), about 200 or more (0.02 wt%), about 300 or more (0.03 wt%), about 500 or more (0.05 wt%), or about 1000 or more (0.1 wt%). The antioxidant may be present in amounts of about 10,000 or less (1.0 wt%), about 8,000 or less (0.8 wt%), about 6,000 or less (0.6 wt%), about 5,000 or less (0.5 wt%), or about 3,000 or less (0.3 wt%), or about 2,000 or less (0.2 wt%) based on the weight of the disclosed polymer composition.

[0060] The polymer composition may contain one or more release agents. Exemplary release agents include any release agents and combinations thereof known in the art. The release agent may be an internal release agent. The release agent may include one or more compatibilizers, such as those taught in the now-expired U.S. Patent 5,212,209A, which is incorporated herein by reference in its entirety for all purposes. Example classes of release agents include aliphatic carboxylic acids; esters of aliphatic carboxylic acids and alcohols; aliphatic hydrocarbon compounds with a number average molecular weight of 200 to 15,000; and polysiloxane-alkyl silicone oils. Examples of aliphatic carboxylic acids include saturated or unsaturated aliphatic monovalent, divalent, or trivalent carboxylic acids. Aliphatic carboxylic acids also include alicyclic carboxylic acids. Aliphatic carboxylic acids may be C 6-36 Monovalent or divalent carboxylic acids. Aliphatic carboxylic acids can be C10 or C20. 6-36Aliphatic saturated monovalent carboxylic acids. Specific examples of such aliphatic carboxylic acids include palmitic acid, stearic acid, hexanoic acid, decanoic acid, lauric acid, arachidic acid, behenic acid, tetracosanoic acid, ceric acid, beeswax acid, tritetracosanoic acid, linalic acid, adipic acid, and azelaic acid. Examples of aliphatic carboxylic acids in esters of aliphatic carboxylic acids and alcohols include the same aliphatic carboxylic acids as described above. Examples of alcohols include saturated or unsaturated, monohydric or polyhydric alcohols that may have substituents, such as fluorine or aryl groups. Alcohols can be monohydric or polyhydric saturated alcohols with no more than 30 carbon atoms. Alcohols can be aliphatic saturated monohydric alcohols and aliphatic saturated polyhydric alcohols with no more than 30 carbon atoms. The term "aliphatic" is used herein to also include alicyclic compounds. Specific examples of such alcohols include octanol, decanol, dodecanol, stearyl alcohol, behenol, ethylene glycol, diethylene glycol, glycerol, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentyl glycol, bis(trimethylolpropane), and dipentaerythritol. The esters mentioned above can be pure or mixtures of various compounds. Each of the aliphatic carboxylic acids and alcohols combined to form an ester can be a single type, or two or more types can be used in any proportion and combination. Specific examples of esters of aliphatic carboxylic acids and alcohols include beeswax (a mixture containing lauryl palmitate as a major component), octadecyl stearate, dodecanyl behenate, octadecyl behenate, glyceryl monopalmitate, glyceryl monostearate, glyceryl distearate, glyceryl tristearate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristearate, and pentaerythritol tetrastearate. Examples of aliphatic hydrocarbons with a number average molecular weight of 200-15,000 include liquid paraffin, paraffin wax, microcrystalline wax, polyethylene wax, Fischer-Tropsch wax, and α-olefin oligomers with 3-12 carbon atoms. Aliphatic hydrocarbons also include alicyclic hydrocarbons. Each of these hydrocarbons can be partially oxidized. Aliphatic hydrocarbons can be paraffin wax, polyethylene wax, and partially oxidized polyethylene wax is preferred. Paraffin wax and polyethylene wax are more preferred. The number average molecular weight of the aliphatic hydrocarbon must not exceed 5,000. Examples of polysiloxane alkyl silicone oils include dimethyl silicone oil, methylphenyl silicone oil, diphenyl silicone oil, and fluorinated alkyl silicone oil. A single type of release agent may be included, or two or more types of release agents may be included in any proportion or combination. Exemplary release agents include at least one of aliphatic carboxylic acids or esters of aliphatic carboxylic acids and alcohols. Release agents may be at least one of pentaerythritol tetrastearate, glyceryl monostearate, and octyl dodecyl stearate. A release agent may be pentaerythritol tetrastearate.

[0061] The polymer composition may contain one or more release agents in amounts of about 0% or more, about 0.01% or more, or about 0.1% or more, based on the polymer composition. The amount of release agent is not limited, and may be about 2% or less, about 1% or less, or about 0.7% or less, based on the weight of the polymer composition. If the content of the release agent is below the lower limit of this range, the release effect may be insufficient; on the other hand, if the content of the release agent exceeds the upper limit of this range, decreased hydrolysis resistance, mold contamination during injection molding, etc., may occur. The polymer composition may contain one or more release agents in amounts of about 0% to about 2% by weight, about 0.01% to about 1% by weight, or about 0.1% to about 0.7% by weight, based on the polymer composition.

[0062] The polymer composition may contain one or more carbide salts. A carbide salt is any compound that helps maintain the original shape of a plastic article by forming char from the compound. The char forms an outer layer of non-combustible material, reducing the melting and dripping of the compounds containing the carbide salt. Any carbide salt that acts as a carbide salt can be used.

[0063] One or more char salts may contain one or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds. Any salt of a perfluorocarbon-based sulfur compound or a salt of an aromatic sulfur compound may be used to improve the flame retardancy of the disclosed compositions. One or more salts of perfluorocarbon-based sulfur compounds may be one or more salts of perfluoroalkane sulfur compounds. One or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds may include one or more alkali metal salts, alkaline earth metal salts, or both. For example, one or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds may include potassium salts, sodium salts, magnesium salts, calcium salts, or any combination thereof. One or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds may include one or more potassium salts or consist substantially of one or more potassium salts. One or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds are salts containing one or more sulfur atoms. One or more salts of perfluorocarbon-based sulfur compounds or aromatic sulfur compounds may be sulfonates. Sulfate salts (e.g., sulfonates) may include one or more carbon-containing groups. The number of carbon atoms in a sulfur-containing salt may be about 15 or fewer, about 13 or fewer, about 7 or fewer, or about 5 or fewer. The number of carbon atoms in a sulfur-containing salt may be 1 or more, 2 or more, 3 or more, or 4 or more. The carbon-containing group may be acyclic or aromatic. The carbon-containing group may contain one or more halogen atoms (e.g., fluorine, chlorine, bromine, or any combination thereof). For example, the carbon-containing group may include fluoroalkanes having one or more fluorine atoms (e.g., perfluoroalkanes, such as perfluorobutane, perfluorohexane, perfluoropentane, perfluoroheptane, perfluoropropane, or perfluorooctane). The carbon-containing group may not include one or more halogen atoms. The sulfur-containing salt may include one or more perfluoroalkane sulfonates (such as potassium perfluorobutane sulfonate, sodium p-toluenesulfonate, or potassium diphenyl sulfone sulfonate), or consist essentially of one or more potassium salts.

[0064] The perfluorocarbon salt may be present in an amount of about 0% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more of the polymer composition. The perfluorocarbon salt may be present in an amount of about 2.0% by weight or less, about 1.0% by weight or less, less than 0.5% by weight, about 0.4% by weight or less, or about 0.25% by weight or less of the polymer composition.

[0065] One or more carbon salts may contain one or more halogenated sulfur salts or one or more non-halogenated sulfur salts. One or more carbon salts may contain one or more halogenated sulfur salts.

[0066] One or more carbon salts may contain one or more halogen-free sulfur-containing salts. One or more organometallic salts may be one or more salts of aromatic sulfur compounds. One or more organometallic salts may be one or more salts of aromatic sulfonates. One or more salts of aromatic sulfur compounds may include one or more salts of alkali metals, alkaline earth metals, or both. One or more salts of aromatic sulfur compounds may include potassium salts, sodium salts, magnesium salts, calcium salts, or any combination thereof. One or more salts of aromatic sulfur compounds may include one or more sodium or potassium salts. One or more salts of aromatic sulfur compounds may be sulfonates. Sulfur-containing salts may include one or more carbon-containing groups. The number of carbon atoms in a sulfur-containing salt may be about 15 or less, about 13 or less, about 7 or less, or about 5 or less. The number of carbon atoms in a sulfur-containing salt may be 1 or more, 2 or more, 3 or more, or 4 or more. The carbon-containing groups may be acyclic or aromatic. Sulfur-containing salts may include or consist substantially of one or more sodium p-toluenesulfonate or potassium diphenyl sulfone sulfonate.

[0067] One or more halogen-free sulfur-containing salts may be present in an amount of about 0% by weight or more, about 0.05% by weight or more, or about 0.1% by weight or more of the polymer composition. One or more halogen-free sulfur-containing salts may be present in an amount of about 2.0% by weight or less, about 1.0% by weight or less, less than 0.5% by weight, about 0.4% by weight or less, or about 0.25% by weight or less of the polymer composition.

[0068] One or more carbon salts may include potassium perfluorobutane sulfonate, sodium p-toluenesulfonate, or potassium diphenyl sulfone sulfonate, or are substantially composed of potassium perfluorobutane sulfonate, sodium p-toluenesulfonate, or potassium diphenyl sulfone sulfonate. One or more carbon salts may include sodium p-toluenesulfonate or potassium perfluorobutane sulfonate, or are substantially composed of sodium p-toluenesulfonate or potassium perfluorobutane sulfonate. One or more carbon salts may include sodium p-toluenesulfonate, or are substantially composed of sodium p-toluenesulfonate. One or more carbon salts may include perfluorobutane sulfonate or are substantially composed of perfluorobutane sulfonate.

[0069] One or more carbide salts may be present in an amount that improves the flame retardancy of the composition. The carbide salts may be present in amounts of about 0% by weight or more, about 0.01% by weight or more, or about 0.05% by weight or more, based on the weight of the polymer composition. The carbide salts may also be present in amounts of about 2.0% by weight or less, about 1.0% by weight or less, about 0.5% by weight or less, about 0.4% by weight or less, or about 0.25% by weight or less, based on the weight of the polymer composition.

[0070] The polymer composition may contain one or more UV absorbers (i.e., UV stabilizers), which in another embodiment are used to stabilize the color of the composition. When a UV absorber is added, polycarbonate, vinylidene-substituted aromatic compounds, or both may absorb light energy from ultraviolet light as heat. The UV absorber can reduce the weathering effect of the polymer composition (e.g., a composition of polycarbonate and vinylidene-substituted aromatic compounds). The UV absorber may include benzotriazole, hydroxyphenyltriazine, benzophenone, mesothiazine, etc., or any combination thereof. The UV absorber may be present in amounts of about 0 ppm or more (0 wt%), 500 ppm or more (0.05 wt%), about 1,000 ppm or more (0.1 wt%), or about 1,500 ppm or more (0.15 wt%) based on the weight of the polymer composition. UV absorbers may be present in amounts of about 10,000 ppm or less (1.0 wt%), about 8,000 ppm or less (0.8 wt%), about 6,000 ppm or less (0.6 wt%), or about 5,000 ppm or less (0.5 wt%).

[0071] The polymer composition may contain one or more second polymers. The one or more second polymers may be one or more of acrylonitrile-butadiene-styrene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate-siloxane copolymer, high molecular weight polysiloxane, liquid crystal polymer (LCP) (a polymer of 1,4-benzenehydrin with 1,4-phthalic acid, 4-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid), or any combination thereof. The polymer composition may contain about 0% by weight or more of one or more second polymers based on the weight of the polymer composition. The polymer compositions disclosed herein may contain about 30% by weight or less, or about 5% by weight or less of an impact modifier based on the weight of the polymer composition. The polymer composition may contain about 0% to about 30% by weight, or about 0% to about 50% by weight of one or more second polymers based on the weight of the polymer composition.

[0072] One or more thermoplastic polymers are composed of one or more styrene-acrylonitrile (SAN), one or more poly(methyl methacrylate) (PMMA), one or more polyolefins, one or more polyarylsulfones (PSU), one or more polypropylenes (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonates, or any combination thereof.

[0073] One or more thermoplastic polymers may be one or more polycarbonates. One or more polycarbonates may be branched, linear, or mixtures thereof. One or more polycarbonates may contain virgin polycarbonate. Virgin polycarbonate is a polycarbonate that has not been previously used in any composition.

[0074] The polymer composition may contain recycled polycarbonate. The polymer composition may contain virgin polycarbonate and recycled polycarbonate. The recycled polycarbonate may contain one or more post-consumer recycled polycarbonates. The polycarbonate may be in the form of powder, flakes, granules, or mixtures thereof. When used in powder form, the particle size is selected for efficient blending of the material. The particle size may be about 0.1 mm or larger, or about 0.5 mm or larger. The particle size may be about 2.0 mm or smaller, or about 1.5 mm or smaller.

[0075] As used herein, polycarbonate refers to a polymer containing carbonate units. As used herein, polycarbonate includes the term one or more polycarbonate polymers and / or copolymers containing carbonate units. Such polymers can be homopolymers consisting essentially of carbonate monomer units or copolymers containing one or more other monomer units (comonomer units) and carbonate units. Such copolymers can be block copolymers containing blocks of two or more different monomer units, or random copolymers with different monomer units randomly distributed along the polymer backbone. Additional monomer units may include any monomer unit that does not negatively affect the inherent properties of polycarbonate, such as heat resistance, impact resistance, moldability, flexural modulus, flexural strength, haze, and transparency, if required by the intended use. Exemplary comonomer units include ester units, polysiloxane units, etc. As disclosed herein, the amount of carbonate monomer units in the copolycarbonate is selected such that the resulting polymer retains the desired properties of polycarbonate. Copolycarbonates may contain more than 50 mol% of carbonate monomer units, about 75 mol% or more of carbonate monomer units, about 80 mol% or more of carbonate monomer units, or about 85 mol% or more of carbonate monomer units. Copolycarbonates may contain about 99 mol% or less of carbonate monomer units, about 97 mol% or less of carbonate monomer units, or about 95 mol% or less of carbonate monomer units. Copolycarbonates may contain about 1 mol% or more of comonomer units, about 3 mol% or more of comonomer units, or about 5 mol% or more of comonomer units. Copolycarbonates may contain less than 50 mol% of comonomer units, about 25 mol% or less of comonomer units, about 20 mol% or less of comonomer units, or about 15 mol% or less of comonomer units. The polycarbonate units may contain aromatic units in the polymer backbone.

[0076] Polycarbonate production is achieved, for example, by using a phase-interval process, optionally employing a chain terminator (e.g., monophenol) and optionally a trifunctional branching agent or a branching agent with a functionality greater than three (e.g., triphenol or tetraphenol), to react the bisphenol with a carbonate halide (preferably phosgene) and / or with an aromatic dicarboxylic acid dihalide (preferably a benzene dicarboxylic acid dihalide). The bisphenols that can be used to produce aromatic polycarbonates and / or aromatic polyester carbonates may correspond to Formula I. Where A represents a single bond, and C represents a single bond. 1-5 Alkylene, C 2–5 Alkyl groups, C 5-6 Cycloalkylidenes, -O-, -SO-, -CO-, -S-, -SO2-, or C 6-12 An aryl group, which may be fused with other aromatic rings optionally containing heteroatoms, or a group of formula II: II Or the group of formula III: III Where B is hydrogen independently in each case, and C 1-12 Alkyl, preferably methyl, or halogen, preferably chlorine and / or bromine; x is 0, 1, or 2 independently in each case; and p is 0 or 1; R c and R d They are independent of each other and for each X 1 It can be selected individually, and is hydrogen or C1-C6 alkyl, preferably hydrogen, methyl or ethyl; X 1 It represents carbon; and m represents an integer from 4 to 7, preferably 4 or 5, provided that R c and R d This also indicates that at least X 1 Alkyl group on an atom.

[0077] Exemplary diphenols include hydroquinone, resorcinol, dihydroxybiphenyl, and bis(hydroxyphenyl)-C. 1-5 Alkanes, bis(hydroxyphenyl)-C 5-6 Cycloalkanes, bis(hydroxyphenyl) ethers, bis(hydroxyphenyl) sulfoxides, bis(hydroxyphenyl) ketones, bis(hydroxyphenyl) sulfones and 4,4 - Bis(hydroxyphenyl)diisopropylbenzene, and its derivatives having brominated and / or chlorinated nuclei. Particularly preferred bisphenols are 4,4'-dihydroxybiphenyl, bisphenol A, 2,4-bis(4-hydroxyphenyl)-2-methyl-butane, 1,1-bis(4-hydroxyphenyl)-cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane, 4,4-dihydroxydiphenyl sulfide and 4,4-dihydroxydiphenyl sulfone, and their dibrominated and tetrabrominated or chlorinated derivatives, such as 2,2-bis(3-chloro-4-hydroxyphenyl)propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)propane or 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane. 2,2-bis-(4-hydroxyphenyl)propane (bisphenol A) is particularly preferred. Biphenols can be used alone or in any mixture. Bisphenols are known from the literature or can be obtained by methods known from the literature. In addition to bisphenol A homopolymers, exemplary polycarbonates include copolymers of bisphenol A having up to 15 mol% of other disclosed bisphenols, such as 2,2-bis(3,5-dibromo-4-hydroxyphenyl)-propane, relative to the total molar amount of the bisphenols.

[0078] Exemplary chain terminators for the production of polycarbonate include phenolic compounds, including phenol, p-chlorophenol, p-tert-butylphenol, 4-(1,3-dimethyl-butyl)phenol, and 2,4,6-tribromophenol; long-chain alkylphenols, such as monoalkylphenols or dialkylphenols containing a total of 8 to 20 carbon atoms in their alkyl substituents, examples being 3,5-di-tert-butylphenol, p-isooctylphenol, p-tert-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)phenol, and 4-(3,5-dimethylheptyl)phenol. The amount of chain terminator used may be about 0.1 mol% or more, based on the total molar amount of bisphenols used in each case. The amount of chain terminator used may be about 10 mol% or less, based on the total molar amount of bisphenols used in each case.

[0079] Polycarbonate can be branched, for example, by incorporating a trifunctional compound or a compound with a functionality greater than three, such as those containing four or more phenolic groups, in an amount of about 0.05 to about 2.0 mol% relative to the total amount of bisphenol used. Branched polycarbonate used in the disclosed compositions can be prepared by known techniques, for example, several methods disclosed in USP 3,028,365, 4,529,791 and 4,677,162 (the patents are hereby incorporated in their entirety by reference). Exemplary branching agents include trifunctional or polyfunctional carboxylic acid chlorides, such as trimesoyl trichloride, cyanuric acid trichloride, 3,3'-,4,4'-benzophenone tetracarboxylic acid tetrachloride, 1,4,5,8-naphthalene-tetracarboxylic acid tetrachloride, or trimesoyl tetrachloride, in an amount of about 0.01 to about 1.0 mol%. (relative to the dicarboxylic acid dichloride used); or trifunctional or polyfunctional phenols, such as phloroglucinol, 4,6-dimethyl-2,4,6-tris(4-hydroxyphenyl)-2-heptene, 4,4-dimethyl-2,4,6-tris(4-hydroxyphenyl)heptane, 1,3,5-tris(4-hydroxyphenyl)benzene, 1,1,1-tris(4-hydroxyphenyl)ethane, tris(4-hydroxyphenyl)phenyl-methane, 2,2-bis[4,4-bis(4-] The amounts of 2,4-bis[1-(4-hydroxyphenyl)-1-methyl-ethyl]phenol, tetra(4-hydroxyphenyl)-methane, 2,6-bis(2-hydroxy-5-methyl-benzyl)-4-methyl-phenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane, or tetra(4-[1-(4-hydroxyphenyl)-1-methylethyl]-phenoxy)-methane are about 0.01 to about 1.0 mol% (relative to the bisphenol used). Phenolic branching agents can be added to the reaction vessel together with the bisphenol. Acyl chloride branching agents can be introduced together with the acyl chloride.

[0080] Copolycarbonates can be prepared by known methods. For example, about 1 to about 25 parts by weight, or about 2.5 to about 25 parts by weight (relative to the total amount of bisphenol to be used), of a polydiorganosiloxane containing hydroxyaryloxy end groups can also be used. These are known (see USP 3,419,634) or can be produced by methods known in the literature. Esterifying monomers can be used in the preparation process of polymers containing polycarbonates. Exemplary esterifying monomers include dicarboxylic acid halides and hydroxycarboxylic acids. The aromatic dicarboxylic acid dihalides used to produce aromatic polyester carbonates can be diacyl chlorides of isophthalic acid, terephthalic acid, diphenyl ether-4,4'-dicarboxylic acid, and naphthalene-2,6-dicarboxylic acid. A mixture of isophthalic acid and terephthalic acid diacyl chlorides in a ratio of about 1:20 to about 20:1 can be used. Carbonyl chlorides, such as phosgene, can be used as bifunctional acid derivatives in the production of polyester carbonates. Aromatic polyester carbonates may also contain incorporated hydroxycarboxylic acids. Polyester carbonates can be linear and / or branched. Branching agents have been disclosed above.

[0081] In addition to monophenols, exemplary chain terminators include chlorocarboxylic acid esters and acyl chlorides of aromatic monocarboxylic acids, which may optionally be C 1-22 Alkyl or halogen atom substitution, and may also include aliphatic C atoms. 2-22 Monocarboxylic acid chloride. The amount of the chain terminator can be from about 0.1 to about 10 mol relative to the molar number of bisphenol (in the case of phenol chain terminator) and relative to the molar number of dicarboxylic acid dichloride (in the case of monocarboxylic acid chloride chain terminator).

[0082] Polycarbonate or copolymers containing carbonate units can be derived from recycled materials, such as post-consumer recycled materials. The composition may contain up to 95% by weight, about 90% by weight or less, or about 80% by weight or less of the polymer composition of recycled polycarbonate, such as post-consumer recycled materials. The composition may contain about 30% by weight or more, about 50% by weight or more, about 75% by weight or more, or about 90% by weight or more of recycled polycarbonate, based on the weight of the polymer composition. Raw materials as used herein refer to materials that have not been previously used. Recycled materials can be linear, branched, or mixtures thereof. Recycled materials can be branched. Recycled materials can be in flake form. Recycled materials can be recycled from bottles or other structures where the structure used is shredded into flake form. Recycled materials can be formed into other structures, such as granules. Using recycled materials in flake form is the most efficient way to utilize the material. Recycled polycarbonate or copolymer containing carbonate units may contain, for example, 0.1 to 1.0 or 0.1 to 0.25% by weight of impurities, such as polyester, based on the recycled polycarbonate or copolymer containing carbonate units.

[0083] The polymer composition may contain about 5% or more, about 10% or more, about 20% or more, about 30% or more, or about 40% or more of virgin polycarbonate or a copolymer containing carbonate units, based on the polymer composition. The composition may contain about 99% or less, about 95% or less, about 65% or less, about 45% or less, about 35% or less, or about 25% or less of virgin polycarbonate or a copolymer containing carbonate units, based on the polymer composition.

[0084] One or more polymers containing carbonate monomer units may include polycarbonate, copolycarbonate, or blends of polycarbonate and copolycarbonate. Polycarbonate and / or copolycarbonate may exhibit a weight-average molecular weight sufficient to provide the desired properties for articles prepared from polycarbonate and / or copolycarbonate. The weight-average molecular weight of polycarbonate and / or copolycarbonate may be about 5,000 amu or greater, about 15,000 amu or greater, or about 20,000 amu or greater. The weight-average molecular weight of polycarbonate and / or copolycarbonate may be about 40,000 amu or less, about 35,000 amu or less, or about 30,000 amu or less. Unless otherwise stated, the term "molecular weight" for polycarbonate and / or copolycarbonate herein refers to the weight-average molecular weight (Mw) determined by gel permeation chromatography (GPC) using laser scattering techniques with bisphenol A polycarbonate standards, and is given in grams per mole (g / mole).

[0085] The polycarbonate and / or copolymers used to prepare the disclosed compositions may have melt flow rates that provide the desired processing characteristics. Mixtures of polycarbonate and / or carbonate-containing copolymers with different melt flow rates may be used to provide composite melt flow rates to enhance the processing of the disclosed compositions. Mixtures of polycarbonate and / or carbonate-containing copolymers with different melt flow rates may comprise: polycarbonate and / or carbonate-containing copolymers with low melt flow rates, polycarbonate and / or carbonate-containing copolymers with medium melt flow rates, and polycarbonate and / or carbonate-containing copolymers with high melt flow rates. The melt flow rate is determined by measuring the number of grams of material passing through a capillary with a diameter of 25.4 mm, as measured according to ASTM D1238, at 300°C and a load of 1.2 kg over a ten-minute period. The melt flow rate of the disclosed compositions can be about 1 g / 10 min or greater, about 3 g / 10 min or greater, about 5 g / 10 min or greater, 10 g / 10 min or greater, or about 15 g / 10 min or greater. The melt flow rate of the disclosed compositions can be about 70 g / 10 min or less, about 30 g / 10 min or less, about 28 g / 10 min or less, about 22 g / 10 min or less, about 20 g / 10 min or less, or about 10 g / 10 min or less. The melt flow rate of the disclosed compositions can be from about 3 g / 10 min to about 30 g / 10 min. The test protocol is based on ASTM D1238. The capillary diameter of the plasticizer is 9.5504 mm, and the die size is 2.095 mm. The low melt flow rate can be from about 0.1 to about 5 g / 10 min; the medium melt flow rate can be from about 5 to about 15 g / 10 min; and the high melt flow rate can be greater than about 15 g / 10 min.

[0086] The disclosed polymer compositions can be produced by mixing specific components in a known manner and melt-compacting and / or melt-extruding them in conventional units such as internal kneaders, extruders, and twin-screw extruders at temperatures of 200°C to 300°C. Individual components can be continuously and simultaneously mixed in known manners at temperatures of about 23°C (room temperature) and higher.

[0087] The disclosed polymer compositions may contain one or more additional additives from the additives previously discussed herein, which are commonly used in compositions of this type. Exemplary additives include: zinc salts, colorants, reinforcing fibers, stabilizers, antistatic agents, silicone oils, flow enhancers, etc. Exemplary flame-retardant additives may also include metal salts of antimony oxide and aromatic sulfur, or mixtures thereof may be used. Compounds may be used to stabilize rubber-modified vinylidene-substituted aromatic copolymer compositions to prevent degradation caused by, but not limited to, heat, light, and oxygen, or mixtures thereof. Some of these additives may adsorb volatile organic compounds, such as, for example, zeolites, activated carbon, bamboo charcoal, etc.

[0088] The polymer composition may optionally include a component for adsorbing volatile organic compounds. The component may be zeolite, activated carbon, bamboo, charcoal, or a combination thereof.

[0089] The polymer composition may contain a stabilizer salt. The stabilizer salt can be any compound that acts as an alkaline buffer, preventing alkaline substances in the composition from causing depolymerization of the polycarbonate or copolymers containing carbonate units. Exemplary types of stabilizer salts include those disclosed in US 2013 / 0131241 (incorporated herein by reference), particularly acids, salts, and esters of phosphorus-containing acids (such as phosphoric acid, phosphorous acid, hypophosphoric acid, diphosphine, phosphonic acid, phosphonic acid, metaphosphoric acid, hexametaphosphoric acid, thiophosphoric acid, fluorophosphoric acid, difluorophosphoric acid, fluorophosphorous acid, difluorophosphorous acid, fluorohypophosphoric acid, fluorodiphosphoric acid, or combinations thereof). Combinations of phosphoric acid and phosphoric acid esters may be used. Alternatively, acids, acid salts, and esters of acids may be used, such as sulfuric acid, sulfites, zinc phosphate, monocalcium phosphate, etc. In certain embodiments, the acid stabilizer is phosphorous acid (H3PO3), phosphoric acid (H3PO4), zinc phosphate (Zn3(PO4)2), zinc dihydrogen phosphate (ZnH4P2O8), monosodium phosphate (NaH2PO4), or sodium acid pyrophosphate (Na2H2P2O7) and sodium dihydrogen phosphate. The stabilizer salt may be present in an amount sufficient to prevent polycarbonate depolymerization. The stabilizer salt may be present in an amount of about 0.05% by weight or greater of the composition comprising one or more polycarbonates and / or copolymers containing carbonate units. The stabilizer salt may be present in an amount of about 0.5% by weight or less of the composition comprising one or more polycarbonates and / or copolymers containing carbonate units.

[0090] The polymer composition may contain one or more fillers. These fillers may be reinforcing or unreinforcing fillers (e.g., talc, clay, etc.). Exemplary fillers include talc, clay, wollastonite, mica, glass, or mixtures thereof. The polymer composition may contain one or more reinforcing fillers. Reinforcing fillers may be used to improve the strength of the polymer composition and / or to reduce the linear coefficient of thermal expansion of the polymer composition. Reinforcing fillers may be any filler material that enhances and positively influences the flame-retardant properties of the polycarbonate composition. Reinforcing fillers may be one or more fibers of any fiber type disclosed herein. Reinforcing fillers may be fibers with an aspect ratio of about 4 or greater. Reinforcing fillers may include glass fibers, carbon fibers, metal fibers, or any combination thereof. Reinforcing fillers may include mineral fillers having a needle-like structure (i.e., needle-shaped structure), such as wollastonite.

[0091] The disclosed polymer compositions may contain one or more carbon-based particles, metals, or metal quasi-oxides. Any carbon-based particles, metals, or metal oxides that can improve the V0@1.5 mm flame retardancy rating can be used. Exemplary metal or metal quasi-oxides include Group 3 or Group 4 metals or metal quasi-oxides. Exemplary metal or metal quasi-oxides include TiO2, MgO, SiO2, Fe2O3, Al2O3, etc. Exemplary metal or metal quasi-oxides include TiO2, MgO, and SiO2. One or more metal or metal quasi-oxides may be a mixture of metals and / or metal quasi-oxides, such as talc containing MgO and SiO2. One or more carbon-based particles may be any particulate carbon material capable of improving the flame retardancy of the compositions disclosed herein. Exemplary carbon-based particles may be carbon black or carbon nanotubes. One or more carbon compounds, metals, or metal quasi-oxides may be present in an amount sufficient to enhance the flame retardancy of the composition. One or more carbon-based particles, metals, or metal quasi-oxides may be present in an amount sufficient to provide a V0@1.5 mm flame retardancy rating. One or more carbon-based particles, metals, or metal oxides may be present in amounts of 0% by weight or greater, about 0.2% by weight or greater, about 0.3% by weight or greater, or about 0.5% by weight or greater, based on the weight of the composition. One or more carbon-based particles, metals, or metal oxides may be present in amounts of 10% by weight or less, about 5% by weight or less, about 3% by weight or less, or about 2% by weight or less, based on the weight of the composition. One or more carbon-based particles, metals, or metal oxides may be in particulate form. One or more carbon-based particles, metals, or metal oxides may be nanoparticles. The particle size may be any size that improves the flame retardant rating of the composition. The particle size may be about 0.2 micrometers or greater, or about 0.35 micrometers or greater. The particle size may be about 2.0 micrometers or smaller, or about 1.0 micrometers or smaller. The particle size may be determined using laser diffraction techniques described in ISO 13322. The determined particle size is the average diameter. The compositions disclosed herein may contain a buffer system.

[0092] The polymer compositions disclosed herein may contain a buffering system. The buffering system described herein may be a proton-providing (i.e., H) system. + Or hydrated hydrogen ions), accepting protons (i.e., H+ ions), + A buffer system can contain a weak acid and its conjugate base. A buffer system can resist pH changes following the addition of a basic or acidic component. A buffer system can be configured based on the total number of protons (i.e., H+). + (or hydrated hydrogen ions), hydroxyl groups (i.e., hydroxide ions or OH-) -The buffer system may be characterized by one or more single-proton, diproton, triproton, or multiproton buffer compounds. Based on the total weight of the composition, the buffer system can stabilize the polycarbonate proportionally to the total amount of buffer system present. The buffer system described herein includes one or more buffers with acidic and basic functions, allowing the pH of the composition to be approximately neutral. The buffer system may include one or more buffer compounds, two or more buffer compounds, three or more buffer compounds, or multiple buffer compounds. The buffer system may contain a single compound. The buffer system may contain a pair of compounds. The buffer system may include inorganic compounds, organic compounds, or both. The buffer system may include counterions. The concentration of the buffer system (i.e., the weight percentage of the total composition) is sufficient to promote increased molecular weight stability of the polycarbonate. The buffer system may include buffer compounds, which are inorganic or organic compounds, that balance the pH of the composition to achieve optimal copolymerization and compounding. Inorganic compounds may include compounds without saturated carbon (i.e., without CH bonds). Inorganic compounds may contain carbon atoms without hydrogen bonds. Organic compounds may include compounds containing saturated carbon (i.e., containing CH bonds). Buffer compounds may include acetates, sulfonates, phosphates, ammonia, formates, or any combination thereof. Buffer systems may include aromatic or aliphatic buffer compounds. Buffer systems may include buffer compound pairs of weak acids and conjugate bases. Buffer compounds may be selected based on a pKa of approximately neutrality. Buffer compounds may maintain the pH of water at approximately neutral. Buffer systems may include Good's buffer.Organic compounds may include 2-(N-morpholino)ethanesulfonic acid (MES), 2-[bis(2-hydroxyethyl)amino]-2-(hydroxymethyl)propane-1,3-diol (bis-trimethylethane), 2-[(2-amino-2-oxoethyl)-(carboxymethyl)amino]acetic acid (ADA), N-(2-acetamido)-2-aminoethanesulfonic acid (ACES), and piperazine-N,N'-bis(2-ethanesulfonic acid). (PIPES), 2-hydroxy-3-morpholinopropanesulfonic acid (MOPSO), 1,3-bis(tris(hydroxymethyl)methylamino)propane (bis-6-tripropane), NN-bis(2-hydroxyethyl)-2-aminoethanesulfonic acid (BES), MOPS, 2-[[1,3-dihydroxy-2-(hydroxymethyl)propyl-2-yl]amino]ethanesulfonic acid (TES), 4-(2-hydroxyethyl)-1-piperazine ethanesulfonic acid (HEPES), 3-(N,N-bis[2-hydroxyethyl]amino)-2-hydroxypropanesulfonic acid (DIPSO), 4-(N-morpholino)butyric acid (MOBS), 3-[[1,3-dihydroxy-2-(hydroxymethyl)propyl-2-yl]amino]-2-hydroxypropane-1-sulfonic acid (TAPSO), 4-(2-hydroxyethyl)piperazine-1-(2-hydroxypropanesulfonic acid) HEPPSO, POPSO, 3-[4-(2-hydroxyethyl)piperazin-1-yl]propane-1-sulfonic acid (EPPS or HEPPS), N-(2-hydroxy-1,1-bis(hydroxymethyl)ethyl)glycine (Tricine), glycylglycine (Gly-Gly), 2-(bis(2-hydroxyethyl)amino)acetic acid (Bicine), N-(2-hydroxyethyl)piperazin-N'-(4-butyric acid) (HEPBS), [tris(hydroxymethyl)ethylamino]propanesulfonic acid (TAPS), 2-amino-2-methyl-1,3-propanediol (Ammediol or AMPD), N-tris(hydroxymethyl)methyl-4-aminobutyric acid (TABS), N-(1,1-dimethyl-2-hydroxyethyl)-3-amino-2-hydroxypropanesulfonic acid (AMPSO), N-cyclohexyl-2-aminoethanesulfonic acid (CHES), 3-(cyclohexylamino)-2-hydroxy-1-propanesulfonic acid (CAPSO), 2-amino-2-methylprop-1-ol (aminomethylpropanol or AMP), N-cyclohexyl-3-aminopropanesulfonic acid (CAPS), 4-(cyclohexylamino)-1-butyric acid (CABS), or any combination thereof. Inorganic compounds include metal phosphates, metal sulfonates, metal acetates, metal formates, etc.

[0093] The buffer system may contain one or more alkali metal phosphates. Any alkali metal phosphate capable of enhancing the thermal stability of the composition may be used. The alkali metal phosphate may be a sodium metal phosphate or a potassium metal phosphate. Exemplary alkali metal phosphates may be one or more of distearate pentaerythritol disodium phosphate, monohydrogen phosphate, or dihydrogen phosphate, and monohydrogen, dihydrogen, or trihydrogen phosphate compounds. Exemplary alkali metal phosphates may be one or more of monohydrogen, dihydrogen, or trihydrogen phosphate compounds. An alkali metal phosphate may be sodium dihydrogen phosphate. Alkali metal phosphates may be used in any amount that can improve the thermal stability of the composition. Alkali metal phosphates may be used in any amount based on the weight of the composition, such as about 0.01% by weight or more, about 0.02% by weight or more, or about 0.03% by weight or more. Alkali metal phosphates may be used in any amount based on the weight of the composition, such as about 1.0% by weight or less, about 0.2% by weight or less, or about 0.1% by weight or less.

[0094] The disclosed polymer compositions may contain colorants. The colorant can be any colorant that provides the desired color to the composition or the product prepared therefrom. The colorant can be a pigment or a dye. Exemplary pigments include carbon black, titanium dioxide, zinc sulfide, kaolin, etc. The colorant may be present in sufficient quantity to provide the desired color to the composition or the product prepared therefrom. The colorant may be present in an amount of about 0.01% by weight or more, or about 0.1% by weight or more, or about 1% by weight or more of the disclosed composition. The colorant may be present in an amount of about 10% by weight or less, about 5% by weight or less, about 1% by weight or less, or about 0.5% by weight or less of the disclosed composition. When the colorant is a pigment, the concentration may be at the higher end of the disclosed range, for example, 0.1-10.0% by weight of the composition. When the colorant is a dye, its amount may be at the lower end of the range, for example, from 0.01% to about 0.5% by weight of the composition. Some pigments may also be microparticles as described herein.

[0095] The disclosed composition can be an organic sheet. The organic sheet can be prepared using any known method for preparing organic sheets, such as extrusion or co-extrusion, lamination, co-lamination, etc. The surface of the organic sheet can be textured using embossing rollers, etc. The organic sheet can be formed by contacting a fibrous material layer with a powder, flake, and / or granule of a polymer composition, and heating the structure of the powder, flake, and / or granule in contact with the fibrous material layer at a temperature above the melting point of the composition, provided that the polymer composition bonds adjacent layers together and becomes embedded within the fibrous material layer. The powder, flake, and / or granule of the polymer composition can be fed into an extruder, heated, and extruded to form one or more layers of the polymer composition. The composition can be formed into an organic sheet by contacting one or more layers of the polymer composition with a fibrous material layer. The polymer composition layers and the fibrous material layer can then be heated above the melting point of the composition, provided that the polymer composition bonds adjacent layers together and becomes embedded within the fibrous material layer. An exemplary temperature for forming the organic sheet can be 150°C or higher. Exemplary temperatures for forming the organic sheet may be 300°C or lower, or 200°C or lower. In addition to heating, the formation of the composition may include applying pressure to the structure in a direction transverse to the sheet surface. The applied pressure may be sufficient to embed one or more polymer compositions into one or more layers of fibrous material. The organic sheet may be further processed, such as by thermoforming, to prepare molded articles.

[0096] The disclosed composition expands upon exposure to fire and reduces heat transfer through the organic sheet. At least one nonwoven fiber layer within the disclosed organic sheet insulates against heat transfer through the organic sheet, and the polymer composition disclosed herein maintains its mechanical properties upon exposure to fire. The organic sheet may have a thickness of about 0.1 mm or greater, about 0.25 mm or greater, or about 0.5 mm or greater. The organic sheet may have a thickness of about 10 mm or less, or about 4.0 mm or less. The organic sheet may have a thickness of about 0.1 mm to about 10 mm, about 0.25 mm to about 4.0 mm, or about 0.5 mm to about 4.0 mm.

[0097] Organic sheets can be molded into any desired form. Organic sheets can be molded for use in articles or molded into articles to insulate against heat from fire, reduce heat transfer from fire, slow fire combustion, and inhibit fire spread. Organic sheets can be molded using any molding process known in the art for molding organic sheets. Organic sheets can be molded using compression molding (stamping), thermoforming, insert molding, injection molding (overmolding), or co-stamping with another composition.

[0098] The disclosed compositions can be combined with polycarbonate compositions to form reinforced organic sheets and / or overmolded organic sheets. The disclosed compositions can be combined with polycarbonate compositions providing additional fire resistance and thermal insulation. The disclosed compositions can be combined with fiber-filled polycarbonates to form reinforced organic sheets and / or overmolded organic sheets. Fiber-filled polycarbonates may contain any reinforcing fillers disclosed herein. Fiber-filled polycarbonates may contain one or more fibers of any fiber type disclosed herein. Fiber-filled polycarbonates may contain one or more glass fibers. The one or more glass fibers may have a length of about 0.1 mm to about 35 mm; about 0.5 mm to about 25 mm; or about 1 mm to about 15 mm. Fiber-filled polycarbonates may contain one or more short glass fibers, one or more long glass fibers, or a combination of one or more short glass fibers and one or more long glass fibers. Fiber-filled polycarbonates may contain one or more long glass fibers. One or more short glass fibers may have a length of less than about 1 mm.

[0099] Fiber-filled polycarbonate: The fiber-filled polycarbonate composition may contain one or more glass fibers in an amount of about 20% by weight or more, or about 30% by weight or more. Fiber-filled polycarbonate: The fiber-filled polycarbonate composition may contain one or more glass fibers in an amount of about 55% by weight or less, about 40% by weight or less, or about 30% by weight.

[0100] Before being combined with a polycarbonate composition, the organic sheet can be molded into a desired shape. When combined with a polycarbonate composition, the organic sheet can be molded into a desired shape. After being combined with a polycarbonate composition, the organic sheet can be molded into a desired shape. The disclosed compositions can be molded together with a polycarbonate composition using any method known to those skilled in the art to form reinforced organic sheets and / or overmolded organic sheets. The disclosed compositions can be compression molded, insert molded, or overmolded with a polycarbonate composition to form reinforced organic sheets and / or overmolded organic sheets. To form reinforced organic sheets and / or overmolded organic sheets, the polycarbonate composition can be molded on top of the organic sheet; molded as a layer between two or more organic sheets; molded on the organic sheet; or molded around the organic sheet. The reinforced organic sheet and / or overmolded organic sheet may contain one or more organic sheets and a polycarbonate composition. The polycarbonate composition may be a reinforcing layer between two or more organic sheets molded together.

[0101] An article having a structure prepared by the composition disclosed herein is disclosed. The composition can be used in or formed into an article to insulate against heat from fire, reduce heat transfer from fire, slow the combustion of fire, and inhibit the spread of fire. The composition can be used as a layer in an article or formed into an article having a structure. The composition can be used as a layer in an article or formed into an article having a structure in which there is a fire risk from within. The composition can be used as a layer in an article or formed into an article having a structure in which it is desired to inhibit fire within the article. The composition can be used as a layer in an article or formed into an article having a structure in which heat transfer through the article is reduced. The composition can be used as a layer in an article or formed into an article having a structure for isolating heat within the article from fire. The composition can be used as a layer in an article or formed into an article having a structure for reducing heat transfer from fire within the article. The composition can be used as a layer in an article or formed into an article having a structure for slowing the combustion of fire. The composition can be used as a layer in an article or formed into an article having a structure for inhibiting the spread of fire. The article can be a shell or enclosure for an object with a possibility of ignition. The article can be a shell or enclosure for a battery. A shell or enclosure for a battery can be a battery pack. The article can be a casing or housing for a lithium-ion battery. The article can be a battery pack. The article can be used as a layer within a battery pack. The composition can be formed as a casing for a battery. The composition can be formed as a casing for a lithium-ion battery. The composition can be used as a layer within a cover of a battery pack. The composition can be attached to a cover of a battery pack. The composition can be formed as a battery pack. The composition can be formed as a cover of a battery pack. The battery pack can be used in electric vehicles. The battery pack can be used to house battery packs in electric vehicles.

[0102] A method for preparing the compositions disclosed herein is disclosed, the method comprising forming a layered stack of one or more layers of fibrous material and one or more layers of polymer composition, wherein at least one fibrous material layer is a nonwoven fibrous material; stacking alternating layers of one or more fibrous material layers and one or more polymer composition layers; pressing and heating the layered stack; embedding one or more fibrous material layers with one or more polymer compositions; and forming an organic sheet. The method may include stacking a fibrous material layer between two or more polymer composition layers.

[0103] The laminations can be pressed and heated using any method known in the art to embed polymer compositions into layers of fibrous material to produce organic sheets. The pressing and heating of the laminations can be carried out using any method known in the art for lamination. The pressing and heating of the laminations can be performed using batch lamination by pressing or two-belt lamination. The pressing and heating of the laminations can be performed using two-belt lamination. When using a through-feed method, the two-belt process is an ideal production system for the continuous production of roll, sheet, and sheet materials. Various processes (such as continuous lamination, compaction, consolidation, and smoothing) allow for the processing of different materials, such as films, fabrics, fiber mats, granules, or powders. The material passes through the press in single or multiple layers between two annular steel belts. At the inlet and outlet, these steel belts encircle a steel drum.

[0104] A layered stack may include multiple polymer composition layers and fiber material layers sufficient to produce a composition with excellent flame retardant and fire-resistant properties. A layered stack may include multiple polymer composition layers sufficient to embed the polymer composition within fiber material layers within the layered stack. The polymer layers may also bond adjacent fiber layers together. A layered stack may include one or more polymer composition layers, two or more polymer composition layers, three or more polymer composition layers, or four or more polymer composition layers. A layered stack may include one polymer composition layer and one fiber material layer. A layered stack may include two polymer composition layers and one fiber material layer. A layered stack may include two polymer composition layers and two fiber material layers. A layered stack may include three polymer composition layers and two fiber material layers. A layered stack may include three polymer composition layers and three fiber material layers. A layered stack may include four polymer composition layers and four fiber material layers. A layered stack may include four or more polymer composition layers and four or more fiber material layers.

[0105] A layered stack design can have a top layer and a bottom layer forming the outer side or top and bottom of an organic sheet. The top layer of the layered stack design can form the top outer side or top side of the organic sheet. The bottom layer of the layered stack can form the bottom outer side or bottom side of the organic sheet. The top or bottom layer of the layered stack design may include a polymer composition layer or a fibrous material layer. The bottom layer of the layered stack design may include a polymer composition layer or a fibrous material layer. At least one outer layer of the layered stack may include a polymer composition layer. The layered stack may include polymer composition layers on both outer layers. The organic sheet may include polymer composition layers on both outer layers.

[0106] One or more layers of fibrous material and polymer composition can be fed into a laminating apparatus to form an organic sheet. The top and bottom layers can be layers of the polymer composition. The layers can be fed at a melting temperature of the composition comprising one or more polycarbonates and / or copolymers containing carbonate units. The temperature can be about 150°C or higher, or about 200°C or higher. Alternatively, the temperature can be about 300°C or lower, about 280°C or lower, or about 200°C or lower. Pressure can be applied during lamination. The pressure can be any pressure that reinforces the formation of the organic sheet.

[0107] This method may include molding an organic sheet into a desired form. The organic sheet can be molded using any method known in the art to mold it into the desired form. The organic sheet can be molded using a thermoforming process. The organic sheet can be molded using a battery casing molder. The organic sheet can be molded using an electric vehicle casing molder. The organic sheet can be molded into a layer of an article of article or formed into an article having a structure. The organic sheet can be molded into a layer of an article of article or formed into an article having a structure as disclosed herein. The organic sheet can be molded into a battery casing. The organic sheet can be molded into a battery housing. The organic sheet can be molded into a battery pack. The organic sheet can be molded into a layer within a battery pack. The organic sheet can be molded into a layer within a cover of a battery pack. The organic sheet can be molded into a cover of a battery pack. The organic sheet can be molded into a casing article. The organic sheet can be molded into a casing article for use with a battery. The organic sheet can be molded into a casing article for use with a lithium-ion battery. The organic sheet can be molded into a casing article for use in an electric vehicle. Battery packs can be molded into battery packs for electric vehicles.

[0108] The disclosed methods may include forming polycarbonate-reinforced organic sheets and / or polycarbonate-coated molded organic sheets. The method may include adding a polycarbonate composition as disclosed herein to one or more organic sheets; and forming reinforced organic sheets and / or overmolded organic sheets. The method may include adding fiber-filled polycarbonate as disclosed herein to one or more organic sheets; and forming reinforced organic sheets and / or overmolded organic sheets. The method may include molding the organic sheet prior to adding the polycarbonate composition. The method may include molding the organic sheet into a desired shape when combined with a polycarbonate composition. The method may include molding the organic sheet into a desired shape after combination with a polycarbonate composition.

[0109] This method may include compression molding, insert molding, or injection molding to form reinforced organic sheets and / or overmolded organic sheets. The method may include placing one or more organic sheets into a mold; extruding a polycarbonate composition together with one or more organic sheets into the mold; and molding one or more organic sheets and polycarbonate; and forming reinforced organic sheets and / or overmolded organic sheets. This method may include placing one or more organic sheets into a mold; injecting a polycarbonate composition into a mold having one or more organic sheets; and molding one or more organic sheets and polycarbonate; and forming reinforced organic sheets and / or overmolded organic sheets. This method may include placing one or more organic sheets into a mold; extruding a polycarbonate composition onto one or more organic sheets; and molding one or more organic sheets and polycarbonate; and forming reinforced organic sheets and / or overmolded organic sheets. When added to a mold along with organic sheets, the polycarbonate composition can be molten. The organic sheets can be heated before being placed in the mold. The organic sheets can be heated to a temperature higher than the glass transition temperature (Tg) of the polymer composition of one or more organic sheets. The polymer composition of the organic sheets can have a glass transition of about -40°C or higher, about 80°C or higher, or about 100°C or higher. The polymer composition of the organic sheets can have a glass transition of about 350°C or lower, about 200°C or lower, or about 160°C or lower. The organic sheets can have a glass transition of about -40°C to about 350°C, about 80°C to about 200°C, or about 100°C to about 160°C.

[0110] This method may include compression molding an organic sheet and a polycarbonate composition; and forming a polycarbonate-reinforced organic sheet and / or a polycarbonate-overmolded organic sheet. The method may include: placing one or more organic sheets into a compression mold; extruding a polycarbonate composition onto one or more organic sheets; and compression molding one or more organic sheets and polycarbonate; and forming a reinforced organic sheet and / or an overmolded organic sheet. The method may also include: placing one or more organic sheets into a compression mold; extruding a polycarbonate composition onto one or more organic sheets; placing a second organic sheet on top of the extruded polycarbonate composition; compression molding one or more organic sheets, polycarbonate, and a second organic sheet together; and forming a reinforced organic sheet and / or an overmolded organic sheet. The method may include: heating one or more organic sheets; placing the heated one or more organic sheets into a compression mold; extruding a polycarbonate composition onto the heated one or more organic sheets; compression molding the heated one or more organic sheets and polycarbonate; and forming a reinforced organic sheet and / or overmolding the organic sheet. The method may also include: heating one or more organic sheets; placing the heated one or more organic sheets into a compression mold; extruding a polycarbonate composition onto the heated one or more organic sheets; heating a second organic sheet; placing a second heated organic sheet on top of the extruded polycarbonate composition; compression molding the heated one or more organic sheets and polycarbonate; and forming a reinforced organic sheet and / or overmolding the organic sheet.

[0111] This method may include injection molding or overmolding an organic sheet and a polycarbonate composition together, and forming a polycarbonate-reinforced organic sheet and / or a polycarbonate-overmolded organic sheet. This method may include placing one or more organic sheets into a mold; injecting a polycarbonate composition into a mold having one or more organic sheets; molding one or more organic sheets and a polycarbonate composition together; and forming a reinforced organic sheet or an overmolded organic sheet. This method may include heating one or more organic sheets; placing the heated one or more organic sheets into a mold; injecting a polycarbonate composition into a mold having one or more organic sheets; molding one or more organic sheets and a polycarbonate composition together; and forming a reinforced organic sheet or an overmolded organic sheet. This method may include heating one or more organic sheets; placing one or more organic sheets into a mold; thermoforming one or more organic sheets within a mold; re-injecting a polycarbonate composition into a mold having one or more organic sheets; and forming a reinforced organic sheet and / or an overmolded organic sheet.

[0112] This method may include inserting a molded organic sheet and a polycarbonate composition, and forming a polycarbonate-reinforced organic sheet and / or a polycarbonate-coated molded organic sheet. The method may include molding the organic sheet into a desired shape before adding the polycarbonate composition. The method may include: placing the organic sheet of the desired shape into a mold; injecting the polycarbonate composition into the mold; and forming the reinforced organic sheet and / or the molded organic sheet.

[0113] The accompanying drawings are provided to illustrate the disclosure herein, but are not intended to limit its scope. Figure 1 The diagram illustrates a layered stacking design 1 with one fiber material layer 2 and one polymer composition 3 before the polymer composition 3 is embedded in the fiber material layer 2. Figure 2 This illustrates a layered stacking design 1 of fiber material layers 2 having the same fiber material before the polymer composition 3 is embedded in the nonwoven fiber material layer 4. Figure 3 The diagram illustrates a layered stacking design 1 of a nonwoven fiber material layer 4 having one fiber material (e.g., nonwoven glass fiber or nonwoven carbon fiber) and two fiber material layers 5 having different woven or nonwoven fiber materials, prior to the embedding of fiber material layers 4 and 5 in the polymer composition 3. Figure 4 The diagram illustrates a layered stacking design 1 of two nonwoven fiber material layers 4 of one fiber type and one fiber material layer 5 of different woven or nonwoven fiber materials prior to the embedding of fiber material layers 4 and 5 in polymer composition 3. Figure 5 This shows the process prior to embedding a nonwoven glass fiber material layer 8 in a polymer composition 7 containing polycarbonate. Figure 6 The layered stacking design of composition 6 1. Figure 6 This is a magnified scanning electron microscope image of the cross-section of composition 9 at x 65, showing the polycarbonate-containing polymer composition 7 embedded between layers of nonwoven glass fiber material 8. Figure 6 As seen, the nonwoven glass fiber material is arranged such that the glass fibers 10 are arranged in different directions. Figure 7 This is a scanning electron microscope image magnified to x 1.00K of the cross-section of composition 9, showing how the polymer composition 7 containing polycarbonate is embedded around the glass fiber 10. Figure 8 A lamination process that can be used to produce organic sheets is shown. A layer of fibrous material 2 and polymer composition 3 is shown being fed between two tracked pressing belts 11 between two heaters 12 to form a fused composite laminate belt 13 having a top side 14 and a bottom side 15.

[0114] Implementation Plan Implementation Scheme 1: A composition comprising: a) One or more fiber material layers, the one or more fiber material layers being composed of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a nonwoven fiber material; b) One or more polymer compositions; and c) Fiber content of approximately 30% to approximately 80% by weight; The one or more polymer compositions are embedded within the one or more fibrous material layers to form an organic sheet.

[0115] Embodiment 2 is a composition as described in Embodiment 1, wherein the one or more polymer compositions are composed of at least one or more thermoplastic polymers, wherein the one or more thermoplastic polymers are rigid at room temperature and melt and expand when exposed to high temperatures.

[0116] Embodiment 3 is a composition as described in Embodiment 1 or 2, having a fiber content of about 45% to about 80% by weight.

[0117] Embodiment 4: The composition as described in any one of Embodiments 1 to 3 has a fiber content of about 50% to about 65% by weight.

[0118] Embodiment 5 is a composition as described in any of the preceding embodiments, wherein the polymer composition bonds adjacent fibrous material layers together.

[0119] Embodiment 6: The composition as described in any of the preceding embodiments, wherein the one or more fibrous materials are composed of continuous or discontinuous fibers.

[0120] Embodiment 7: The composition as described in any of the preceding embodiments, wherein the nonwoven fiber material layer comprises discontinuous fibers.

[0121] Embodiment 8: The composition as described in any of the preceding embodiments, wherein the one or more fibrous materials are composed of woven or nonwoven fibers.

[0122] Embodiment 9: The composition as described in any of the preceding embodiments, wherein the one or more fibrous materials are nonwoven materials, felt or padding materials.

[0123] Embodiment 10: The composition as described in any of the preceding embodiments, wherein the fibers of the fibrous material are composed of one or more fiber types.

[0124] Embodiment 11: The composition as described in any of the preceding embodiments, wherein the fibers of the nonwoven fiber material are nonwoven.

[0125] Embodiment 12 is a composition as described in Embodiment 11, wherein the fibers of the nonwoven fiber material have a diameter of about 0.1 μm to about 18 μm.

[0126] Embodiment 13 is a composition as described in Embodiment 11 or 12, wherein the nonwoven fibers of the nonwoven fiber material layer have a diameter of about 1.0 μm to about 10 μm.

[0127] Embodiment 14 The composition according to any one of Embodiments 10 to 13, wherein the one or more fiber types consist of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal coated fibers, one or more polyacrylonitrile fibers, one or more pre-oxidized polyacrylonitrile fibers, one or more recycled carbon fibers, one or more polyaramid fibers, one or more natural cellulose fibers, one or more mineral fibers, or any combination of one or more fiber types.

[0128] Embodiment 15 is a composition as described in Embodiment 14, wherein the one or more metal fibers are composed of one or more nickel fibers, one or more aluminum fibers, one or more steel fibers, one or more stainless steel fibers, one or more carbon steel fibers, one or more copper fibers, one or more brass fibers, one or more silver fibers, one or more nickel-silver fibers, one or more nickel-iron alloy fibers, one or more magnesium fibers, or a mixture of any one or more metal fibers.

[0129] Embodiment 16 is a composition as described in Embodiment 14, wherein the one or more metal-coated fibers consist of any of the following: one or more aluminum-coated fibers, one or more aluminum-coated glass fibers, one or more aluminum-coated basalt fibers, one or more nickel-coated fibers, one or more nickel-coated carbon fibers, one or more nickel-coated glass fibers, one or more silver-coated fibers, or a mixture of any one or more metal-coated fibers.

[0130] Embodiment 17 is a composition as described in Embodiment 14, wherein the mineral fiber is wollastonite fiber or basalt fiber.

[0131] Embodiment 18 is a composition as described in Embodiment 14, wherein the cellulose fiber is flax fiber.

[0132] Embodiment 19: The composition as described in any of the preceding embodiments, wherein the nonwoven fiber material layer comprises one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, or any combination thereof.

[0133] Embodiment 20: The composition as described in any of the preceding embodiments, wherein the fibers of the nonwoven fiber material are randomly knitted.

[0134] Implementation Scheme 21: The composition as described in any of the preceding embodiments, wherein two or more different fibers are combined to form co-knitted fibers.

[0135] Embodiment 22: The composition as described in any of the preceding embodiments, wherein the nonwoven fiber material comprises co-knitted fibers.

[0136] Embodiment 23 is a composition as described in Embodiment 21 or 22, wherein the co-knitted fiber comprises glass fiber, carbon fiber, polymer spun fiber, or any combination thereof.

[0137] Embodiment 24 is a composition as described in Embodiments 21 to 23, wherein the co-knitted fiber comprises a mixture of the glass fiber and the carbon fiber.

[0138] Embodiment 25 is a composition as described in Embodiments 21 to 24, wherein the co-knitted fiber comprises polymer spun fibers co-knitted into the one or more carbon fibers.

[0139] Embodiment 26 is a composition as described in Embodiment 25, wherein the ratio of the polymer spun fibers to the one or more carbon fibers is 10-90% by weight to 90-10% by weight.

[0140] Embodiment 27: The composition as described in any of the preceding embodiments, wherein the nonwoven fiber material comprises a mixture of the co-knitted fibers, the glass fibers, or the carbon fiber mixture.

[0141] Embodiment 28: The composition as described in any of the preceding embodiments comprises about 30% to about 50% by weight of the polymer composition.

[0142] Embodiment 29: A composition as described in any of the preceding embodiments, wherein the polymer composition comprises one or more halogen-free flame retardants.

[0143] Embodiment 30: A composition as described in any of the preceding embodiments, wherein the polymer composition comprises about 0% to about 25% by weight of one or more halogen-free flame retardants.

[0144] Embodiment 31 is a composition as described in Embodiment 29 or 30, wherein the one or more halogen-free flame retardants are one or more phosphorus-containing flame retardants.

[0145] Embodiment 32 is a composition as described in Embodiment 31, wherein one or more phosphorus-containing flame retardants include phosphate esters or phosphazenes.

[0146] Scheme 33: The composition as described in Scheme 31 or 32, wherein one or more phosphorus-containing flame retardants are bisphenol A bis(diphenyl phosphate), hexaphenoxycyclophosphamide, or a mixture of bisphenol A bis(diphenyl phosphate) and hexaphenoxycyclophosphamide.

[0147] Embodiment 34: A composition as described in any of the preceding embodiments, wherein the polymer composition comprises one or more antioxidants.

[0148] Embodiment 35: A composition as described in any of the preceding embodiments, wherein the polymer composition comprises about 0.1% to about 0.3% by weight of the one or more antioxidants.

[0149] Embodiment 36 is a composition as described in Embodiments 34 or 35, wherein at least one of the one or more antioxidants is octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate.

[0150] Embodiment 37: A composition as described in any of the preceding embodiments, wherein the polymer composition contains one or more release agents.

[0151] Embodiment 38: A composition as described in any of the preceding embodiments, wherein the polymer composition comprises about 0.1% to about 0.7% by weight of the one or more release agents.

[0152] Embodiment 39: The composition as described in Embodiment 37 or 38, wherein at least one of the one or more release agents is pentaerythritol tetrastearate.

[0153] Embodiment 40: A composition as described in any of the preceding embodiments, wherein the polymer composition contains one or more impact modifiers, one or more short glass fibers, one or more additional polymers, one or more carbide salts, one or more UV absorbers, one or more additives commonly used in thermoplastic compositions, or any combination thereof.

[0154] Embodiment 41 is a composition as described in any one of Embodiments 2 to 40, wherein the polymer composition contains about 75% to about 90% by weight of the one or more thermoplastic polymers.

[0155] Embodiment 42 is a composition as described in any one of Embodiments 2 to 41, wherein the one or more thermoplastic polymers melt and expand when exposed to a temperature of about 300°C to about 500°C.

[0156] Embodiment 43 is a composition as described in any one of Embodiments 2 to 42, wherein the one or more thermoplastic polymers are composed of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylenes, one or more polyphenylene sulfides, one or more polyetherimides, one or more polycarbonates, or any combination thereof.

[0157] Embodiment 44 is a composition as described in Embodiment 43, wherein the thermoplastic polymer is composed of one or more polycarbonates.

[0158] Embodiment 45 is a composition as described in Embodiment 44, wherein the one or more polycarbonates are virgin polycarbonates, recycled polycarbonates, or a mixture of both.

[0159] Embodiment 46 is a composition as described in any one of Embodiments 43 to 45, wherein the one or more polycarbonates are branched, linear, or a mixture thereof.

[0160] Embodiment 47 is a composition as described in any one of Embodiments 43 to 46, wherein the one or more polycarbonates comprise one or more polycarbonate siloxane copolymers.

[0161] Embodiment 48 is a composition as described in Embodiment 43, wherein the thermoplastic polymer is composed of one or more polyarylsulfones.

[0162] Embodiment 49 is a composition as described in any one of Embodiments 13 to 48, wherein the polymer spinning fiber is a spinning fiber of the polymer composition.

[0163] Embodiment 50 is the composition according to Embodiments 18 to 49, wherein the nonwoven glass fiber has a diameter of about 6 μm to about 10 μm.

[0164] Embodiment 51 is the composition according to Embodiments 18 to 49, wherein the nonwoven carbon fiber has a diameter of about 4 μm to about 6 μm.

[0165] Embodiment 52: The composition as described in any of the preceding embodiments, wherein one or more layers of the one or more fibrous materials are nonwoven fibrous material layers.

[0166] Embodiment 53: The composition as described in any of the preceding embodiments comprises two or more layers of fibrous material, wherein at least one layer of fibrous material is a nonwoven fibrous material layer.

[0167] Embodiment 54: The composition as described in any of the preceding embodiments comprises three or more layers of fibrous material, wherein at least one layer of fibrous material is a nonwoven fibrous material layer.

[0168] Embodiment 55 is a composition as described in Embodiments 53 or 54, wherein at least one fiber material layer is a woven fiber material layer.

[0169] Embodiment 56 is a composition as described in Embodiment 55, wherein the woven fiber material layer is composed of one or more woven fiber materials.

[0170] Embodiment 57 is a composition as described in Embodiment 55 or 56, wherein the one or more woven fiber materials are composed of one or more woven fibers.

[0171] Embodiment 58 is a composition as described in any one of Embodiments 55 to 57, wherein the woven fibers of the one or more woven fiber materials are composed of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, one or more polymer fibers, one or more metal fibers, or one or more metal-coated fibers.

[0172] Embodiment 59: The composition as described in Embodiment 58, wherein the one or more metal fibers are composed of one or more nickel fibers, one or more aluminum fibers, one or more steel fibers, one or more stainless steel fibers, one or more carbon steel fibers, one or more copper fibers, one or more brass fibers, one or more silver fibers, one or more nickel-silver fibers, one or more nickel-iron alloy fibers, one or more magnesium fibers, or a mixture of any one or more metal fibers.

[0173] Embodiment 60 is a composition as described in Embodiment 58, wherein the one or more metal-coated fibers consist of any of the following: one or more aluminum-coated fibers, one or more aluminum-coated glass fibers, one or more aluminum-coated basalt fibers, one or more nickel-coated fibers, one or more nickel-coated carbon fibers, one or more nickel-coated glass fibers, one or more silver-coated fibers, or a mixture of any one or more metal-coated fibers.

[0174] Embodiment 61 is a composition as described in any one of embodiments 55 to 60, wherein the weaving fibers have a plain weave, a unidirectional weave, a wrinkle-free weave, or a twill weave.

[0175] Embodiment 62: The composition according to any one of the preceding embodiments, wherein at least one layer of the layers of the one or more fibrous materials has a thickness of about 20 μm to about 500 μm.

[0176] Embodiment 63: The composition according to any one of the preceding embodiments, wherein at least one layer of the layers of the one or more fibrous materials has a thickness of about 50 μm to about 500 μm.

[0177] Embodiment 64: The composition according to any one of the preceding embodiments, wherein the polymer composition is one or more polymer composition layers prior to embedding the fibrous material layer.

[0178] Embodiment 65 is the composition according to Embodiment 64, wherein the one or more polymer composition layers are disposed between the one or more fibrous material layers.

[0179] Embodiment 66: The composition according to Embodiment 64, wherein one or more fibrous material layers are disposed between two layers of the polymer composition layer.

[0180] Embodiment 67: The composition according to Embodiments 64 to 66, wherein at least one of the one or more polymer composition layers has a thickness of about 0.05 mm to about 0.15 mm.

[0181] Embodiment 68: The composition according to any one of the preceding embodiments, wherein the one or more polymer composition layers form at least one outer side surface of the organic sheet.

[0182] Embodiment 69: The composition according to any one of the preceding embodiments, wherein the one or more polymer compositions form the top and bottom surfaces of the organic sheet.

[0183] Embodiment 70: A composition according to any one of the preceding embodiments, wherein the organic sheet is combined with a polycarbonate composition to form a reinforced organic sheet.

[0184] Embodiment 71: The composition according to any one of the preceding embodiments, wherein the organic sheet is combined with a fiber-filled polycarbonate composition to form a reinforced organic sheet.

[0185] Embodiment 72 is the composition according to Embodiment 71, wherein the fiber-filled polycarbonate composition is a glass fiber-filled polycarbonate composition.

[0186] Embodiment 73 An article having a structure prepared from the composition as described in any one of the preceding embodiments, comprising: One or more fiber material layers, the one or more fiber material layers being composed of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a nonwoven fiber material layer; One or more polymer compositions; and Fiber content of approximately 30% to approximately 80% by weight. The one or more polymer compositions are embedded within the one or more fibrous material layers to form an organic sheet.

[0187] Embodiment 74 is the article of embodiment 73, wherein the polymer composition retains its mechanical properties when exposed to fire.

[0188] Embodiment 75 is an article of embodiment 73 or 74, wherein the polymer composition bonds adjacent fibrous material layers together.

[0189] Implementation Scheme 76: Article according to any one of Implementation Schemes 73 to 75, wherein the nonwoven fiber material layer isolates heat from fire.

[0190] Implementation Scheme 77 is the article as described in Implementation Schemes 73 to 76, wherein a reduced amount of heat is transferred through the organic sheet.

[0191] Embodiment 78 is an article of any one of embodiments 73 to 77, wherein the organic sheet has a top side and a bottom side.

[0192] Embodiment 79 is an article of any one of embodiments 73 to 78, wherein at least one side of the organic sheet is formed of the polymer composition.

[0193] Embodiment 80 is an article of any one of embodiments 73 to 79, wherein the top and bottom sides of the organic sheet are formed of the polymer composition.

[0194] Implementation Scheme 81: Article according to any one of Implementation Schemes 73 to 80, wherein the organic sheet expands when exposed to fire.

[0195] Embodiment 82 is an article according to any one of embodiments 73 to 81, wherein the organic sheet has an expansion rate of about 4% or greater when exposed to fire.

[0196] Embodiment 83 is an article of any one of embodiments 73 to 82, wherein the organic sheet has a thickness of about 0.1 mm to about 10 mm.

[0197] Embodiment 84 is an article of any one of embodiments 73 to 83, wherein the organic sheet has a thickness of about 0.5 mm to about 4.0 mm.

[0198] Embodiment 85 is an article according to any one of embodiments 73 to 84, wherein after the bottom side has been exposed to fire for 10 minutes, the top side of the organic sheet has a temperature of about 370°C or lower.

[0199] Embodiment 86 is an article according to any one of embodiments 73 to 85, wherein after the bottom side has been exposed to fire for 10 minutes, the top side of the organic sheet has a temperature of about 350°C or lower.

[0200] Embodiment 87 is an article according to any one of Embodiments 73 to 86, wherein the organic sheet has at least one fiber layer composed of nonwoven glass fibers with a diameter of about 10 μm, and the top side has a temperature of about 330°C or lower after the bottom side has been exposed to fire for 10 minutes.

[0201] Embodiment 88 is an article according to any one of embodiments 73 to 87, wherein the organic sheet has at least one fiber layer made of the nonwoven carbon fiber, and the top side has a temperature of about 300°C or lower after the bottom side has been exposed to fire for 10 minutes.

[0202] Implementation Scheme 89: The article according to any one of Implementation Schemes 73 to 88 is used in a battery pack.

[0203] Implementation Scheme 90: The article according to any one of Implementation Schemes 73 to 89 is used as a fireproof layer within the battery pack.

[0204] Implementation Scheme 91: The article according to any one of Implementation Schemes 73 to 90 serves as a fireproof layer for the battery cover of the battery pack.

[0205] Embodiment 92: The article according to any one of embodiments 73 to 91 is glued to the cover of the battery pack or assembled into the cover of the battery pack.

[0206] Implementation Scheme 93: The article according to any one of Implementation Schemes 73 to 92 is molded into the battery cover of the battery pack.

[0207] Implementation Scheme 94: The article according to any one of Implementation Schemes 73 to 93 is molded into the battery pack.

[0208] Embodiment 95 A method for preparing a composition as described in any of the preceding embodiments, comprising: A layered stack of one or more layers forming one or more fiber material layers and one or more polymer compositions, wherein at least one of the fiber material layers is a nonwoven fiber material; Alternating layers of the one or more fibrous material layers and the one or more polymer composition layers are stacked; Press and heat the layered stack; The one or more fiber material layers are embedded with one or more polymer compositions; Adjacent fibrous material layers are bonded together using one or more of the polymer compositions described above; and Form one or more organic sheets having a fiber content of about 30% to about 80% by weight and a top and bottom side.

[0209] Embodiment 96 is the method of Embodiment 95, wherein the one or more polymer compositions are composed of one or more thermoplastic polymers, wherein the one or more thermoplastic polymers are rigid at room temperature and melt and expand when exposed to a temperature between about 300°C and about 500°C.

[0210] Embodiment 97 is the method of Embodiment 96, wherein the one or more thermoplastic polymers are composed of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylenes, one or more polyphenylene sulfides, one or more polyetherimides, one or more polycarbonates, or any combination thereof. Implementation scheme 98 is the method of implementation scheme 97, wherein the one or more thermoplastic polymers are composed of one or more polycarbonates.

[0211] Embodiment 99 is the method of any one of embodiments 95 to 98, wherein the one or more polymer composition layers have a thickness of about 0.05 mm to about 0.15 mm.

[0212] Embodiment 100 is the method of any one of embodiments 95 to 99, wherein at least one layer of the layers of the one or more fibrous materials has a thickness of about 20 μm to about 500 μm.

[0213] Embodiment 101 is the method of any one of embodiments 95 to 100, wherein at least one of the layers of the one or more fibrous materials has a thickness of about 50 μm to about 500 μm.

[0214] Implementation scheme 102 is the method of any one of implementation schemes 95 to 101, wherein the top layer of the layered stack forms the top outer side of the organic sheet.

[0215] Implementation scheme 103 is the method of any one of implementation schemes 95 to 102, wherein the bottom layer of the layered stack forms the bottom outer side of the organic sheet.

[0216] Embodiment 104 is the method of any one of embodiments 95 to 103, wherein two or more layers of polymer composition are used within the layered stack.

[0217] Embodiment 105 is the method of embodiments 95 to 104, which includes stacking one or more layers of fibrous material between two or more polymer composition layers, wherein the layered stack has a top layer and a bottom layer of at least one polymer composition layer.

[0218] Implementation scheme 106 is the method of any one of implementation schemes 95 to 105, wherein two or more layers of fiber material are used in the layered stack.

[0219] Embodiment 107 is the method of Embodiment 105 or 106, wherein the layered stack has at least two or more layers of fibrous material and at least three or more layers of polymer composition.

[0220] Embodiment 108 is the method of any one of Embodiments 105 to 107, wherein the layered stack has at least three or more layers of fibrous material and at least four or more layers of polymer composition.

[0221] Embodiment 109 is the method of any one of embodiments 95 to 108, wherein at least the top layer or the bottom layer of the layered stack is one or more layers of the one or more polymer compositions.

[0222] Implementation scheme 110 is the method of any one of embodiments 95 to 109, wherein the top layer and the bottom layer of the layered stack are one or more layers of the one or more polymer compositions.

[0223] Embodiment 111 is the method of any one of embodiments 95 to 110, wherein at least the top side or the bottom side of the organic sheet is formed by one or more layers of the one or more polymer compositions.

[0224] Embodiment 112 is the method of any one of embodiments 95 to 111, wherein the top and bottom sides of the organic sheet are formed by one or more layers of the one or more polymer compositions.

[0225] Implementation scheme 113 is the method of any one of implementation schemes 106 to 112, wherein at least one of the fiber layers is a woven fiber layer.

[0226] Implementation scheme 114 is the method of any one of implementation schemes 95 to 113, wherein the layered stack is pressed and heated using batch lamination or dual-belt continuous lamination via a press.

[0227] Implementation scheme 115 is the method of any one of implementation schemes 95 to 114, which includes molding one or more organic sheets into a desired form.

[0228] Implementation scheme 116 is the method of implementation scheme 115, wherein the one or more organic sheets are molded using compression molding, insertion molding or overlay molding.

[0229] Implementation scheme 117 is the method of implementation scheme 116, wherein the electric vehicle housing molding machine is used for compression molding, insertion molding or overmolding of the one or more organic sheets.

[0230] Implementation scheme 118 is the method of implementation schemes 115 to 117, wherein the one or more organic sheets are molded into a battery pack or a part of the battery pack.

[0231] Implementation scheme 119 is the method of implementation schemes 115 to 118, wherein the one or more organic sheets are molded into the battery cover of the battery pack.

[0232] Implementation scheme 120 is the method as described in any one of implementation schemes 95 to 119, comprising: Place the one or more organic sheets into the mold; The polycarbonate composition is placed into the mold having the one or more organic sheets; Molding the one or more organic sheets together with the polycarbonate composition; and Forming reinforced organic sheets and / or overmolded organic sheets.

[0233] Embodiment 121 is the method of Embodiment 120, wherein the polycarbonate composition is a molten polycarbonate composition.

[0234] Embodiment 122 is the method of any one of embodiments 95 to 121, which includes compression molding the one or more organic sheets with the polycarbonate composition.

[0235] Implementation scheme 123 is the method as described in any one of implementation schemes 95 to 122, comprising: Heating the one or more organic sheets; Place the one or more organic sheets into a compression mold; The polycarbonate composition is extruded onto one or more heated organic sheets; Compressing the heated one or more organic sheets and the polycarbonate together; and Forming the reinforced organic sheet and / or the overmolded organic sheet.

[0236] Implementation scheme 124, according to the method of implementation scheme 123, includes: Heating the second organic sheet; Prior to compression molding, a second heated organic sheet is placed on top of the extruded polycarbonate composition; and Compressing the heated one or more organic sheets and the polycarbonate together; and Forming the reinforced organic sheet and / or the overmolded organic sheet.

[0237] Embodiment 125 is the method of any one of embodiments 95 to 121, comprising injection molding the organic sheet with the polycarbonate composition.

[0238] Implementation scheme 126 is the method of any one of implementation schemes 95 to 121 or 125, comprising: Place the one or more organic sheets into the mold; The polycarbonate composition is injected into the mold having the one or more organic sheets; Molding the one or more organic sheets together with the polycarbonate composition; and Forming the reinforced organic sheet and / or the overmolded organic sheet.

[0239] Implementation scheme 127 is the method of implementation scheme 115, which includes heating the one or more organic sheets before placing the one or more organic sheets into the mold.

[0240] Implementation scheme 128 is the method of any one of implementation schemes 95 to 121 or 125 to 127, comprising: Heating the one or more organic sheets; Place the one or more organic sheets into the mold; Thermoforming one or more organic sheets; The polycarbonate composition is reinjected into the mold; and Forming the reinforced organic sheet and / or the overmolded organic sheet.

[0241] Embodiment 129 is a method as described in any one of embodiments 95 to 121, comprising inserting the polycarbonate composition into the molding of the organic sheet.

[0242] Implementation scheme 130 is the method of any one of implementation schemes 115 to 121 or 129, comprising: Place the organic sheet of the desired form into the mold; Injecting the polycarbonate composition into the mold; and Forming the reinforced organic sheet and / or the overmolded organic sheet.

[0243] Embodiment 131 is the method of any one of embodiments 120 to 130, wherein the polycarbonate composition is a fiber-filled polycarbonate composition.

[0244] Embodiment 132 is the method according to Embodiment 130, wherein the fiber-filled polycarbonate composition is a glass fiber-filled polycarbonate composition.

[0245] Implementation scheme 133 is the method according to implementation schemes 120 to 132, wherein the one or more organic sheets are heated to a temperature above the glass transition temperature of the one or more organic sheets.

[0246] Implementation scheme 134, as described in any one of implementation schemes 95 to 117, includes attaching the organic sheet to the cover of the battery pack.

[0247] Illustrative Examples The following examples are provided only to illustrate the invention and are not intended to limit its scope. Unless otherwise stated, all parts and percentages are by weight.

[0248] The following materials are used for the experiment.

[0249] A: Flame-retardant polycarbonate (polymer composition) A-1 Calibre 600-3 Branched Bisphenol A Polycarbonate 74.1% by weight A-2 Mitsubishi H-2000F linear polycarbonate powder 5% by weight A-3 20% by weight hexaphenoxycyclophosphamide A-4: 0.1 wt% potassium perfluorobutane sulfonate A-5: 0.2% by weight of a blend of tris(2,4-di-tert-butylphenyl)phosphite and octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, derived from BASF Irganox B-900. A-6: 0.6% by weight pentaerythritol tetrastearate.

[0250] All listed materials A were compounded and granulated in a twin-screw extruder at 300 rpm and 260°C at a yield of 20 kg / h. Sheets of the composition with a thickness of 0.1 mm were prepared by a single-screw extruder with a T-die adapter at 260°C.

[0251] B: Material layer: B1: Glass nonwoven fabric with d = 18 μm B2: Glass nonwoven fabric with d = 8-10μm C: Carbon fiber nonwovens with d = 4-6 μm D: Glass plain weave (d=17 microns) E: Phlogopite sheet, 1.0mm thick Layers of glass fiber or carbon fiber materials and polymer compositions Figure 2 The layers are stacked in a manner disclosed in the table. Table 1 shows the layered design and the fiber materials in the fiber material layers, with each layer designed to have a different fiber material. Then, Figure 8 The apparatus shown draws stacked layers into a continuously heated and pressed chamber. After pressing at 280°C for 10 minutes, the composite material is air-cooled from the apparatus outlet and cut to the desired size. The composite material (organic sheet) is 1.5 mm to 2 mm thick and contains 50-70% by weight of fiber.

[0252] Table 1

[0253] Tests: The organic sheet was burned using a Bunsen burner propane torch with a power of 500 watts. After continuous combustion, thermocouples were used to measure the temperature of the hottest spots on opposite sides of the flame on the organic sheet. The rate of expansion was measured by measuring the change in thickness of the organic sheet before and after combustion, and expressed as a percentage change, indicating that the sheet thickness increased beyond its original thickness after exposure to the fire. Flexural modulus and flexural strength were tested on cut composite sheet plates according to procedure ISO 178. Test results are provided in Table 2 below.

[0254] Table 2

[0255] PC=A: Flame-retardant polycarbonate By combining PC and carbon fiber nonwovens, the composite material expands during combustion and significantly reduces the top temperature. Glass braids and glass nonwovens with fiber diameters of 20 μm do not expand. Randomly knitted pads with fiber diameters <10 μm exhibit the best performance in terms of expansion.

[0256] As used herein, parts by weight refers to 100 parts by weight of the specifically mentioned composition. Any numerical values ​​listed in the preceding application include all values ​​from the lower limit to the upper limit in increments of one unit, provided that there is an interval of at least two units between any lower limit and any upper limit. For example, if the amount of a component or a process variable such as temperature, pressure, time, etc., is indicated as 1 to 90, preferably 20 to 80, more preferably 30 to 70, it is intended to explicitly exemplify values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., in this specification. For values ​​less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 (as the case may be). These are merely examples of specific intent, and all possible combinations of numerical values ​​between the listed minimum and maximum values ​​will be considered to be explicitly indicated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in conjunction with ranges applies to both ends of the range. Therefore, "about 20 to 30" is intended to cover "about 20 to about 30," at least including the specified endpoints. The term "consistently of..." used to describe a combination should include the identified elements, components, parts, or steps, as well as other such elements, components, parts, or steps that do not materially affect the basic and novel features of the combination. The use of the terms "comprising" or "including" herein to describe combinations of elements, components, parts, or steps also contemplates embodiments that are substantially composed of said elements, components, parts, or steps. Multiple elements, components, parts, or steps may be provided by a single integrated element, component, part, or step. Alternatively, a single integrated element, component, part, or step may be divided into separate multiple elements, components, parts, or steps. The disclosure of "a" or "one" describing an element, component, part, or step is not intended to exclude additional elements, components, parts, or steps.

Claims

1. A composition comprising: a) One or more fiber material layers, the one or more fiber material layers being composed of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a nonwoven fiber material, and the fibers of the nonwoven fiber material have a diameter of about 0.1 μm to about 18 μm; b) One or more polymer compositions; and c) Fiber content of approximately 30% to approximately 80% by weight; The one or more polymer compositions are embedded within the one or more fibrous material layers to form an organic sheet.

2. The composition of claim 1, wherein the one or more polymer compositions are composed of at least one or more thermoplastic polymers, wherein the one or more thermoplastic polymers are rigid at room temperature, melt and expand when exposed to high temperatures, and wherein the one or more polymer compositions bond adjacent fibrous material layers together.

3. The composition of any of the preceding claims, wherein the one or more fiber materials are composed of continuous or discontinuous fibers, and the one or more fiber materials are composed of fibers as woven or nonwoven fibers, and wherein the fibers of the fiber materials are composed of one or more fiber types.

4. The composition according to any one of the preceding claims, wherein the fibers of the nonwoven fiber material have a diameter of about 1.0 μm to about 10 μm.

5. The composition of claim 3 or 4, wherein the one or more fiber types comprise one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, one or more polyacrylonitrile fibers, one or more pre-oxidized polyacrylonitrile fibers, one or more recycled carbon fibers, one or more polyaramid fibers, one or more natural cellulose fibers, one or more mineral fibers, or any combination of the one or more fiber types. The one or more metal fibers are composed of: one or more nickel fibers, one or more aluminum fibers, one or more steel fibers, one or more stainless steel fibers, one or more carbon steel fibers, one or more copper fibers, one or more brass fibers, one or more silver fibers, one or more nickel-silver fibers, one or more nickel-iron alloy fibers, one or more magnesium fibers, or a mixture of any of the one or more metal fibers; and The one or more metal-coated fibers consist of one or more aluminum-coated fibers, one or more aluminum-coated glass fibers, one or more aluminum-coated basalt fibers, one or more nickel-coated fibers, one or more nickel-coated carbon fibers, one or more nickel-coated glass fibers, one or more silver-coated fibers, or a mixture of any one or more metal-coated fibers.

6. The composition of any of the preceding claims, wherein the fibers of the nonwoven fiber material are composed of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymer spun fibers, one or more metal fibers, one or more metal-coated fibers, or any combination thereof.

7. The composition of any one of the preceding claims, comprising about 30% to about 50% by weight of the polymer composition, wherein the polymer composition comprises: From about 75% to about 90% by weight of the one or more thermoplastic polymers, From about 0% to about 25% by weight of one or more halogen-free flame retardants. One or more antioxidants, from about 0.1% to about 0.3% by weight. One or more release agents, in amounts of about 0.1% to about 0.7% by weight.

8. The composition of claim 7, wherein the one or more halogen-free flame retardants are one or more phosphorus-containing flame retardants.

9. The composition of claim 8, wherein one or more phosphorus-containing flame retardants comprise phosphate esters or phosphazenes.

10. The composition of claim 8 or 9, wherein the one or more phosphorus-containing flame retardants are bisphenol A bis(diphenyl phosphate), hexaphenoxycyclophosphamide, or a mixture of bisphenol A bis(diphenyl phosphate) and hexaphenoxycyclophosphamide.

11. The composition of claim 7, wherein at least one of the one or more antioxidants is octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate.

12. The composition of claim 7, wherein at least one of the one or more release agents is pentaerythritol tetrastearate.

13. The composition of any of the preceding claims, wherein the one or more polymeric compositions contain one or more impact modifiers, one or more short glass fibers, one or more additional polymers, one or more carbide salts, one or more UV absorbers, one or more additives commonly used in thermoplastic compositions, or any combination thereof.

14. The composition of any one of claims 2 to 13, wherein the one or more thermoplastic polymers melt and expand when exposed to a temperature of about 300°C to about 500°C, and are composed of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylenes, one or more polyphenylene sulfides, one or more polyetherimides, one or more polycarbonates, or any combination thereof.

15. The composition of claim 14, wherein the one or more thermoplastic polymers are composed of one or more polycarbonates or one or more polyarylsulfones or combinations thereof.

16. The composition of claim 14 or 15, wherein the one or more thermoplastic polymers are composed of the one or more polycarbonates, wherein the one or more polycarbonates are branched, linear, or a mixture thereof, virgin polycarbonate, recycled polycarbonate, or a mixture thereof.

17. The composition of claim 14 or 15, wherein the one or more thermoplastic polymers are composed of one or more polyarylsulfones.

18. The composition of claims 5 to 17, wherein the nonwoven fiber material is composed of one or more glass fibers having a diameter of about 6 μm to about 10 μm.

19. The composition of claims 5 to 17, wherein the nonwoven fiber material carbon fiber has a diameter of about 4 μm to about 6 μm.

20. The composition of any of the preceding claims, comprising two or more layers of fibrous material, wherein at least one layer of fibrous material is a nonwoven fibrous material.

21. The composition of claim 20, wherein at least one fiber material layer is a woven fiber material.

22. The composition of claim 21, wherein the woven fibers of the woven fiber material are composed of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, one or more polymer fibers, one or more metal fibers, or one or more metal-coated fibers.

23. The composition of claim 21 or 22, wherein the woven fibers have a plain weave, a unidirectional weave, a wrinkle-free weave, or a twill weave.

24. The composition according to any one of the preceding claims, wherein at least one layer of the layers of the one or more fibrous materials has a thickness of about 20 μm to about 500 μm.

25. The composition of any of the preceding claims, wherein the one or more polymer compositions are one or more polymer composition layers prior to embedding the fibrous material layer.

26. The composition of any one of the preceding claims, wherein the organic sheet is combined with the polycarbonate composition to form a reinforced organic sheet.

27. The composition of any of the preceding claims, wherein the organic sheet is combined with the fiber-filled polycarbonate composition to form a reinforced organic sheet.

28. The composition of claim 27, wherein the fiber-filled polycarbonate composition is a glass fiber-filled polycarbonate composition.

29. An article having a structure prepared from the composition as described in any one of the preceding claims, comprising: One or more fiber material layers, the one or more fiber material layers being composed of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a nonwoven fiber material, the fibers of the nonwoven fiber material having a diameter of about 0.1 μm to about 18 μm; One or more polymer compositions; and Fiber content of approximately 30% to approximately 80% by weight. The one or more polymer compositions are embedded within the one or more fibrous material layers to form an organic sheet.

30. The article of claim 29, wherein the one or more polymer compositions retain their mechanical properties when exposed to fire.

31. The article of claim 29 or 30, wherein a reduced amount of heat is transferred through the organic sheet.

32. The article of any one of claims 29 to 31, wherein the organic sheet has a top side and a bottom side, wherein after the bottom side has been exposed to fire for 10 minutes, the top side of the organic sheet has a temperature of about 370°C or lower.

33. The article of manufacture as claimed in any one of claims 29 to 32, used in a battery pack.

34. A method for preparing a composition as described in any of the preceding claims, comprising: A layered stack of one or more layers forming one or more fibrous material layers and one or more polymer compositions, wherein at least one of the fibrous material layers is a nonwoven fibrous material, and the fibers of the nonwoven fibrous material have a diameter of about 0.1 μm to about 18 μm; Alternating layers of the one or more fibrous material layers and the one or more polymer composition layers are stacked; Press and heat the layered stack; The one or more fiber material layers are embedded with one or more polymer compositions; Adjacent fiber material layers are bonded together using one or more of the polymer compositions described above; as well as Form one or more organic sheets having a fiber content of about 30% to about 80% by weight and a top and bottom side.

35. The method of claim 34, wherein the one or more polymer compositions comprise one or more thermoplastic polymers, wherein the one or more thermoplastic polymers are rigid at room temperature and melt and expand when exposed to a temperature between about 300°C and about 500°C.

36. The method of claim 34 or 35, wherein the layered stacking is pressed and heated using batch lamination or dual-belt continuous lamination via a press.

37. The method of any one of claims 34 to 36, comprising molding one or more organic sheets into a desired form.

38. The method of claim 37, wherein the one or more organic sheets are molded using compression molding, insert molding, or overlay molding.

39. The method of claim 37 or 38, wherein the one or more organic sheets are molded into a battery pack or a portion thereof.

40. The method of claims 37 to 39, wherein the one or more organic sheets are molded into the battery cover of the battery pack.

41. The method of any one of claims 34 to 40, comprising: Place the one or more organic sheets into the mold; The polycarbonate composition is placed into the mold having the one or more organic sheets; The one or more organic sheets and the polycarbonate composition are molded together; as well as Forming reinforced organic sheets and / or overmolded organic sheets.

42. The method of claim 41, wherein the polycarbonate composition is a fiber-filled polycarbonate composition.

43. The method of claim 42, wherein the fiber-filled polycarbonate composition is a glass fiber-filled polycarbonate composition.

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