Fireproof composite as fire activating heat insulating layer for battery enclosure or fire proof layer in battery pack

Abstract

Disclosed are thermoplastic composites or Organosheets comprising polymeric compositions embedded within fiber materials having premium fire retardancy and fire insulating properties. The polymeric compositions may contain one or more thermoplastic polymers. The polymeric compositions may contain recycled or virgin polycarbonate content. Disclosed are methods of preparing such Organosheets. Disclosed are structures prepared from the disclosed Organosheets.

Description

FIREPROOF COMPOSITE AS FIRE ACTIVATING HEAT INSULATING LAYER FORBATTERY ENCLOSURE OR FIRE PROOF LAYER IN BATTERY PACKCROSS REFERENCE

[0001] This application claims priority from United States Provisional Application Serial Number 63 / 562,925 filed March 8, 2024, incorporated herein by reference in its entirety for all purposes.TECHNIAL FIELD

[0002] Disclosed are thermoplastic composites or Organosheets comprising polymeric compositions embedded within fiber materials having premium fire retardancy and fire insulating properties. The polymeric compositions may contain one or more thermoplastic polymers. The polymeric composition may contain recycled or virgin polycarbonate content. Disclosed are methods of preparing such Organosheets. Disclosed are structures prepared from the disclosed Organosheets.BACKGROUND

[0003] Thermoplastic composites or Organosheets comprise continuous and / or discontinuous fiber materials embedded with a polymeric composition and have been used to replace metal because of their superior mechanical properties, low density, recyclability, excellent corrosion resistance and infinite shelf life. Polymeric compositions comprised of a thermoplastic polymer, that are ridged at room temperature, and melt and expand when exposed to high temperatures, are used as a resin to impregnate / embed the continuous and / or discontinuous fiber materials, to form a polymer composite matrix that forms Organosheets. Composites based on a thermoplastic polymer and fiber material can be formed into a variety of structures by thermoforming, net shape drawing, deep drawing and the like. These Organosheets may be used for a variety of uses, including automobile parts, electronics, medical devices, and the like. The fire retardancy and heat insulating properties of an Organosheet are an important safety consideration, especially when the Organosheet is at an elevated risk of fire exposure. The market demands Organosheets with premium fire retardancy and fire insulating properties. Organosheets of special formulated polymeric compositions containing polycarbonate or copolymers thereof in certain applications need to pass flame retardant test, e.g. UL94 V-0, see US 2016 / 25794A1 and WO2019 / 115506 A1. However, the limited glass transition temperature ofmost Organosheets cause the composite to lose form integrity and mechanical strength during burning. Additionally, most Organosheets regardless of their thermoset or thermoplastic type do not adequately reduce the transfer of heat through the Organosheet, requiring the use of additional fire insulating material.

[0004] What is needed are improved Organosheets containing polymeric compositions having a thermoplastic polymer that is ridged at room temperature and melts and expands when exposed to high temperatures, embedded within layers of fiber materials having premium fire retardancy and fire insulating properties. What is needed is an Organosheet having premium fire retardancy and fire insulating properties that can be used as a fireproof layer. What is needed are molded compositions prepared from such Organosheets that exhibit premium fire retardancy and fire insulating properties. What are also needed are Organosheets prepared from such compositions that exhibit improved fire retardancy and fire insulating properties.SUMMARY

[0005] Disclosed are compositions which comprise a) one or more fiber material layers comprised of one or more layers of one or more fiber materials, at least one fiber material layer is a non-woven fiber material, and fibers of the non-woven fiber material have a diameter from about 0.1 pm to about 18 pm; b) one or more polymeric compositions; c) a fiber content from about 30 wt. % to about 80 wt. %; wherein the one or more polymeric compositions embedded within the fiber material layers to form an Organosheet. The compositions may comprise from about 30 wt. % to about 50 wt. % of the polymeric composition. The one or more polymeric compositions may comprise one or more thermoplastic polymers. The one or more polymeric composition may comprise one or more thermoplastic polymers that are rigid at room temperature, and melt and expand when exposed to high temperatures. The one or more thermoplastic polymers may melt and expand when exposed to temperatures of about 300°C to about 500°C. The one or more thermoplastic polymers may comprise of one or more Styreneacrylonitrile (SAN), one or more poly(methyl methacrylate) (PMMA), one or more polyolefins, one or more polyarylsulfones (PSU), one or more polypropylene (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonates (PC), or any combination thereof. The one or more polymeric compositions may comprise at least one or more polyarylsulfones. The one or more polymeric compositions may comprise at least one or more polycarbonates. The one or more polycarbonates may be a virgin polycarbonate, a recycled polycarbonate, or a mixture of both.

[0006] The one or more fiber materials may have continuous fiber or discontinuous fiber.The one or more fiber materials may be comprised of one or more fiber types. The one or morefiber materials may have fibers that are non-woven or woven. The one or more fiber types may be comprised of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymeric fibers, one or more polymeric spun fibers, one or more metal fibers, one or more metal coated fibers, one or more polyacrylonitrile fibers, one or more preoxidized 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. Two or more different fibers may be combined to form a co-knit fiber. The layers of the one or more fiber materials may have a thickness from about 20 pm to about 500 pm.

[0007] The non-woven fiber material may be made of non-woven fibers. The non-woven fiber material may have discontinuous fibers. The one or more fiber materials of the non-woven fiber material may have co-knit fibers. The fibers of the non-woven fiber material may be randomly knitted. The fibers of the non-woven fiber material may have a diameter from about 0.1 pm to about 18 pm. The fibers of the non-woven fiber material may have a diameter from about 1 pm to about 10 pm. The non-woven fibers of the non-woven fiber material may be made of non-woven glass fibers, non-woven carbon fibers, non-woven ceramic fibers, polymeric spun fibers, one or more metal fibers, one or more metal coated fibers, or any combination thereof. The non-woven glass fibers may have a diameter from about 6 pm to about 18 pm. The nonwoven glass fibers may have a diameter from about 6 pm to about 10 pm. The non-woven carbon fibers may have a diameter about 1 pm to about 18 pm. The non-woven carbon fibers may have a diameter from about 4 pm to about 6 pm.

[0008] The polymeric composition may comprise one or more non-halogen containing flame retardants. The one or more non-halogen containing flame retardants may be one or more phosphorus containing flame retardants. The one or more phosphorus containing flame retardant may comprise a phosphate ester, a phosphazene, or a mixture thereof. The one or more phosphorus containing flame retardant may be bisphenol A bis(diphenyl phosphate), hexa-phenoxy-cyclo-phosphazene, or a mixture of bisphenol A bis(diphenyl phosphate) and hexa-phenoxy-cyclo-phosphazene. The polymeric composition may comprise from about 0 wt.% to about 25 wt.% of the one or more non-halogen containing flame retardants. The polymeric composition may comprise one or more antioxidants, one or more mold release agents, one or more charring salts, or any combination thereof. The polymeric composition may comprise from about 0.1 wt.% to about 0.3 wt.% of the one or more antioxidants. The polymeric composition may comprise from about 0.1 wt.% to about 0.7 wt.% of the one or more mold release agents. The polymeric composition may contain from about 75 wt.% to about 90 wt.% of the one or more thermoplastic polymers.

[0009] The polymeric composition may be one or more polymeric composition layers prior to embedding the fiber material layers. The one or more polymeric composition layers may have a thickness from about 0.05 mm to about 0.15 mm.

[0010] The disclosed composition may comprise two or more fiber material layers. The fiber material layers may comprise at least one layer of non-woven fiber material and at least one layer of woven fiber material. The fiber material layers may comprise non-woven fiber material. The one or more polymeric composition layers may be disposed between the fiber material layers. The fiber material layers may be disposed between two layers of the polymeric composition layers.

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

[0012] Disclosed are articles prepared from the composition disclosed herein.

[0013] Disclosed is a method for making the compositions disclosed herein comprising forming a layered stack of one or more fiber material layers and one or more layers of one or more polymeric compositions, at least one fiber material layer is a non-woven fiber material and fibers of the non-woven fiber material have a diameter from about 0.1 pm to about 18 pm; stacking alternating layers of the one or more fiber material layers and the one or more polymeric composition layers; pressing and heating the layered stack to embed the one or more fiber material layers with one or more polymeric compositions, to form one or more Organosheets with a fiber content from about 30 wt.% to about 80 wt.% and a top side and a bottom side. The outside layers of the stack may be layers of the one or more polymeric compositions The pressing and heating the layered stack may be performed using batch lamination by press or double belt continuous lamination. The method may comprise molding the one or more Organosheets into a desired form. The method may comprise molding the one or more Organosheets into a battery pack or a part of the battery pack.

[0014] The disclosed method may comprise adding a polycarbonate composition to the one or more Organosheets to form a reinforced Organosheet and / or an over-molded Organosheet. The disclosed method may comprise heating the one or more Organosheets; placing the one or more Organosheets into a compression mold; extruding the polycarbonate composition onto the heated one or more Organosheets; and compression molding the heated one or more Organosheets and the polycarbonate; and forming the reinforced Organosheet and / or the over-molded Organosheet. The disclosed method may comprise heating a second Organosheet; placing the second heated Organosheet on top of the extruded polycarbonate composition prior to compression molding; and compression molding; and forming the reinforced Organosheet. The disclosed method may comprise molding the polycarbonate composition over the one or more Organosheets to form an over-molded Organosheet. The disclosed method may comprise insert molding the Organosheet with the polycarbonate composition to form the reinforced Organosheet and / or the over-molded Organosheet. The disclosed method may comprise injection molding the Organosheet with the polycarbonate composition to form the reinforced Organosheet and / or the over-molded Organosheet.

[0015] The compositions disclosed and articles prepared from the compositions disclosed exhibit premium fire retardancy and fire insulating properties. When exposed to fire the composition expands and reduces the amount of heat transferred through the composition. The composition has an expanding ratio that may be about 3% or greater, or about 4% or greater when exposed to fire. The composition reduces the amount of heat transferred from one side of an Organosheet, formed from the composition, to the other. The polymeric composition maintains its mechanical properties when exposed to fire and the layer of non-woven fiber material insulates the transfer of heat through the Organosheet.

[0016] An Organosheet about 0.1 mm to about 10 mm thick with at least one layer comprised of non-woven fiber material and a fiber content that may be about 30 wt.% or greater, may be about 50 wt.% or greater, may be about 70 wt.% or greater, and may be about 80 wt.% or less, may have a temperature on the top side that may be about 370°C or less, may be about 330°C or less, may be about 300°C or less, may be about 270°C or less, or may be about 250°C or less after the bottom side of the Organosheet has been exposed to fire for 10 min. An Organosheet about 1.0 mm to about 3.0 mm thick with a fiber content that may be about 45 wt.% or greater, may be about 50 wt.% or greater, may be about 70 wt.% or greater, and may be about 75 wt.% or less, and at least one non-woven glass fiber layer comprised of non-woven glass fiber with a glass fiber diameter that may be about 18 pm or less, may be about 10 pm or less, or may be about 8 pm or less, may have a temperature on the top side that may be about 370°C or less, may be about 350°C or less, or may be about 330°C or less, after the bottom side of the Organosheet has been exposed to fire for 10 min, may have an expanding ratio that may be about 3% or greater, or may be about 4% or greater. An Organosheet about 1 .0 mm to about 3.0 mm thick with a fiber content that may be about 45 wt.% or greater, may be about 50 wt.% or greater, may be about 70wt.% or greater, and may be about 75 wt.% or less, and at least one non-woven glass fiber layer comprised of non-woven glass fiber with a glass fiber diameter that may be between about 6 pm and about 10 pm, may have a temperature on the top side that may be about350°C or less, may be, or may be about 330°C or less, after the bottom side of the Organosheet has been exposed to fire for 10 min. An Organosheet about 1.0 mm to about 3.0 mm thick with a fiber content that may be about 45 wt.% or greater, may be about 50 wt.% or greater, may be about 60 wt.% or greater, and may be about 65 wt.% or less, and at least one non-woven fiber material layer comprised of non-woven carbon fiber, may have a temperature on the top side that may be about 300°C or less, may be about 280°C or less, may be about 260°C or less, or may be about 250°C or less, after the bottom side of the Organosheet has been exposed to fire for 10 min.

[0017] An Organosheet about 2.0 mm thick with a fiber content of about 70 wt.% and at least one non-woven layer comprised of non-woven glass fiber with a glass fiber diameter about 18 pm has a top temperature of about 370 °C, an expanding ratio of about 3% or greater, a flexural modulus of about 15 GPa or greater, and a flexural strength of about 500 MPa or greater. An Organosheet about 2.0 mm thick with a fiber content of about 70 wt.% and a non-woven glass fiber layer with glass fiber having a diameter of about 18 pm, may have a top temperature of about 370 °C or less, an expanding ratio of about 3% or greater, a flexural modulus of about 15 GPa or greater, and a flexural strength of about 230 MPa or greater. An Organosheet about 1 .5 mm thick with a fiber content of about 50 wt.% and a non-woven glass fiber layer with glass fiber having a diameter between about 6 pm and about 10 pm, may have a top temperature of about 330 °C or less, an expanding ratio of about 4% or greater, a flexural modulus of about 12 GPa or greater and a flexural strength of about 150 MPa or greater. An Organosheet about 1 .3 mm thick with a fiber content of about 50 wt.% and a nonwoven carbon fiber layer, may have a top temperature of about 260 °C or less, an expanding ratio of about 4% or greater, a flexural modulus of about 29 GPa or greater, and a flexural strength of about 300 MPa or greater. An Organosheet about 2.0 mm thick with a fiber content of about 50 wt.% and a nonwoven carbon fiber layer, may have a top temperature of about 250 °C or less, an expanding ratio of about 4% or greater, a flexural modulus of about 19 GPa or greater and a flexural strength of about 370 MPa or greater. The articles may be used in a battery pack.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a layered stack design with one fiber material layer and two layers, prior to the polymeric composition embedding the fiber material layer.

[0019] FIG. 2 is a layered stack design having fiber material layers of the same fiber material, prior to the polymeric composition embedding the fiber material layer.

[0020] FIG. 3 is a layered stack design, prior to the polymeric composition embedding the fiber material layer, with fiber material layers of two different fiber materials, at least one fiber material layer is of a non-woven fiber material.

[0021] FIG. 4 is a layered stack design, prior to the polymeric composition embedding the fiber material layer, with fiber material layers of two different fiber materials, at least two fiber material layers being of the same non-woven fiber material.

[0022] FIG. 5 is a layered stack design of the composition in Figure 6, prior to the polymeric composition embedding the fiber material layer.

[0023] FIG. 6 is a Scanning electron microscope micrograph zoomed to x 65 of a cross section of the composition after the polymeric composition has embedded the fiber material layers.

[0024] FIG. 7 is a Scanning electron microscope micrograph zoomed to x 1.00K of a cross section of the composition after the polymeric composition has embedded the fiber material layers.

[0025] FIG. 8 shows the laminating process that may be used to create an Organosheet.DETAILED DESCRIPTION

[0026] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments and is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation to encompass all such modifications and equivalent structures as is permitted under the law.

[0027] One or more as used herein means that at least one, or more than one, of the recited components may be used as disclosed. As used herein percent by weight or parts by weight refer to, or are based on, the weight of the disclosed compositions or laminates unless otherwise specified. Unless otherwise stated such parts by weight are based on 100 parts.

[0028] Disclosed are compositions comprising one or more fiber material layers comprised of one or more layers of one or more fiber materials, with at least one fiber material layer being a non-woven fiber material; one or more polymeric compositions; the one or more polymeric compositions embedded within the fiber material layers to form an Organosheet with a fiber content from about 30 percent by weight based on the weight of the composition to about 80 percent by weight. The compositions may comprise from about 30 percent by weight based on the weight of the composition to about 50 percent by weight of the polymeric composition. The one or more polymeric composition may comprise one or more thermoplastic polymers that is rigid at room temperature and melts and expands when exposed to high temperatures.

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

[0030] The composition may contain a polymeric composition concentration which provides enhanced flame retardancy and reduced heat transfer across the structure containing the fibers and the polymeric composition. The composition may have up to about 70 percent by weight based on the weight of the composition of the polymeric composition, about 50 percent by weight or less of the polymeric composition, or about 45 percent by weight or less of the polymeric composition. The composition may have about 20 percent by weight based on the weight of the composition or more of the polymeric composition, about 25 percent by weight or more of the polymeric composition, or about 30 percent by weight or more of the polymeric composition. The composition may have from about 20 percent by weight to about 70 percent by weight, about 30 percent by weight to about 50 percent by weight, or about 30 percent by weight to about 45 percent by weight of the polymeric composition.

[0031] The fiber material layer may be comprised 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 be comprised of 40 or less layers of one or more fiber materials, 10 or less layers of one or more fiber materials, 5 or less layers of the one or more fiber materials. The fiber material layers may comprise non-woven fiber material layers, woven fiber material layers, or a combination of woven and non-woven fiber material layers. The one or more fiber materials may comprise of continuous fibers or discontinuous fibers. The one or more fiber materials may comprise of discontinuous fibers.

[0032] The layers of the one or more fiber materials may have a thickness of about 500 pm or less, or less, or about 250 pm or less. The layers of the one or more fiber materials may have a thickness of about 20 pm or greater, about 50 pm or greater, or about 250 pm. The layers of the one or more fiber materials may have a thickness of about 20 pm to about 500 pm, about 50 pm to about 500 pm, about 50 pm to about 250 pm, or about 250 pm to about 500 pm.

[0033] The one or more fiber materials may be comprised of fibers that are woven or nonwoven. The non-woven fibers may create a fiber material that is a non-woven fiber material. The woven fibers may create a fiber material that is a woven fiber material. One or more layers of a non-woven fiber material form a non-woven fiber material layer. One or more layers of a woven fiber material form a woven fiber material layer.

[0034] The disclosed composition may be comprised of a number of fiber material layers sufficient to provide the composition with excellent fire retardant and fire resistant properties. The disclosed composition may be comprised of at least one layer of non-woven fiber material. The disclosed composition may be comprised of one or more fiber material layers, two or more fiber material layers, or three or more fiber material layers. The two or more fiber material layers, or the three or more fiber material layers may comprise of at least one layer of non-woven fiber material and at least one layer of woven fiber material. The composition may be comprised of non-woven fiber material layers.

[0035] The one or more fiber materials may be a nonwoven material, a felt, or a mat material that may be made of one or more fibers. The fibers of the one or more fiber materials may comprise one or more fiber types which impart the desired properties. The one or more fiber types may be comprised of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymeric fibers, one or more polymeric 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 may be comprised 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 of the one or more metal fibers. The one or more metal coated fibers may be comprised 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 of the one or more metal coated fibers. The one or more metal coated fibers may be one or more aluminum coated basalt fibers. The mineral fiber may be wollastonite fiber, or basalt fiber. The cellulose fiber may be flax fiber. Two or more different fibers may be combined to form a co-knit fiber. The one or more polymeric fibers may comprise one or more polymers selected from polycarbonate, aramids, polyesters, polyolefins, polyethyleneamines, and the like. The fibers may be formed into substructures such as braided structures, tapes, and the like.

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

[0037] Fiber diameter as used herein may be determined by KEYENCE Digital Microscope VHX-500F equipped with real-time observation, recording, and measurement of diameter on the monitor screen. The composition may be polished with a Struers Tagramin-25 polishing machine and the diameter of fibers may be observed under the digital microscope for measurement.

[0038] The fibers of the non-woven fiber material have a diameter which allows the composition to expand during exposure to burning and reduce the transfer of heat through the composition. The fibers of the non-woven fiber material may have a diameter of about 18 pm or less, about 10 or less, or about 6 pm or less. The fiber of the non-woven fiber material may have a diameter of about 0.1 pm or greater, about 1 pm or greater, about 4 pm or greater, or about 8 pm or greater. The fibers of the non-woven fiber material may have a diameter from about 0.1 pm to about 18 pm, about 1 pm to about 10 pm, about 4 pm to about 10 pm, about 6 pm to about 10 pm, or about 4 pm to about 6 pm.

[0039] The non-woven fiber material layer may be comprised of a number of layers of a nonwoven fiber material sufficient to provide the composition with the desired properties. The nonwoven fiber material layer may be comprised of one or more layers of a non-woven fiber material. The non-woven fiber layer may have discontinuous fibers. The non-woven fiber material may be made of non-woven fibers. The non-woven fibers may be of any fiber type disclosed herein. The non-woven fiber material may be made of glass fibers, carbon fibers, ceramic fibers, polymeric spun fibers, metal fibers, metal coated fibers, or any combination thereof. The metal fibers of the non-woven fiber material may be stainless steel fibers. The metal coated fiber of the non-woven fiber material may be aluminum coated basalt fiber. The fibers of the non-woven fiber material may be randomly knit. The non-woven fiber material may comprise co-knit fibers. The co-knit fibers may contain one or more glass fibers, one or more carbon fibers, one or more polymeric spun fibers, or any combination thereof. The co-knit fibers may be a mixture of glass fibers and carbon fibers. The co-knit fibers may be a polymeric spun fiber co-knit into a carbon fiber. The ratio of the polymeric spun fiber to carbon fiber may be from 10-90 wt.% to 90-10 wt.%. Thepolymeric spun fiber may comprise spun fiber of the polymeric composition as disclosed herein. The non-woven fiber material may be comprised of a mixture of co-knit fibers, glass fibers, or a carbon fiber mixture.

[0040] The glass fibers of the non-woven fiber material have a diameter which allows the composition to expand during exposure to burning and reduce the transfer of heat through the composition. The glass fibers of a non-woven glass fiber material may have a diameter of about 0.1 pm or greater, or about 6 pm or greater. The glass fibers of a non-woven glass fiber material may have a diameter of about 18 pm or less, about 10 or less, or about 8 pm or less. The glass fibers of a non-woven glass fiber material may have a diameter of about 8 pm. The glass fibers of the non-woven glass fiber material may have a diameter of about 0.1 pm to about 18 pm, about 6 pm to about 10 pm, or about 6 pm to about 8 pm.

[0041] The carbon fibers of the non-woven fiber material have a diameter which allows the composition to expand during exposure to burning and reduce the transfer of heat through the composition. The carbon fibers of the non-woven carbon fiber material may have a diameter of about 18 pm or less, about 10 pm or less, about 8 pm or less, or about 6 pm or less. The carbon fibers of the non-woven carbon fiber material may have a diameter of about 1 pm or more, or about 4 pm or more. The carbon fibers of the non-woven carbon fiber material may have a diameter of about 1 pm to about 18 pm, about 1 pm to about 10 pm, about 4 pm to about 8 pm, or about 4 pm to about 6 pm.

[0042] The woven fiber material layers may be comprised of one or more layers of woven fiber material. The woven fiber material may be comprised of fibers of one or more fiber types provided herein. The fibers of the woven fiber material may be woven carbon fibers, glass fibers, ceramic fibers, polymeric fibers, metal fibers, or metal coated fibers. The metal fibers of the woven fiber material may be a stainless steel fiber. The metal coated fiber of the woven fiber material may be aluminum coated basalt fiber. The fibers of the woven fiber material are woven fibers. The woven fibers may have any weave which facilitates achieving the desired properties. The woven fibers may have a plain weave, a unidirectional weave, a non-crimp weave, or twill weave.

[0043] The polymeric composition may be one or more polymeric composition layers prior to embedding the one or more fiber material layers. The polymeric composition layers may be formed from powder, flakes or pellets of the polymeric composition. The polymeric composition layer may be formed from powder, flakes or pellets of the polymeric composition that have been melted in an extruder and extruded. The one or more polymeric composition layers may have a thickness sufficient to embed a portion of the polymeric composition layers in the one or more fiber material layers. The polymeric composition layer may have a thickness to sufficient to partially, or fully embed the polymeric composition layer in the one or more fiber material layers.The polymeric composition layers may have a thickness sufficient to embed a portion of the polymeric composition layer in the one or more fiber material layers when the fiber material layers are between two polymeric composition layers. The polymeric composition layers may have a thickness sufficient to adhere adjacent fiber layers together. The polymeric composition layers may have a thickness sufficient to form an outside polymeric composition layer on each side of the one or more fiber layers. The polymeric composition layers may have a thickness sufficient to embed the polymeric composition between the fibers of the one or more fiber material layers when the layers are exposed to heat and pressure. The one or more polymeric composition layers may have a thickness from about 0.05 mm to about 0.15mm. The one or more polymeric composition layers may be disposed between the fiber material layers. The fiber material layers may be disposed between two layers of the polymeric composition layers. One or more polymeric composition layers may be disposed on one or both of the outside layers of the fiber layers.

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

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

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

[0047] The polymeric composition may comprise one or more thermoplastic polymers that are rigid at room temperature, and melt and expand when exposed to high temperatures. The polymeric composition may comprise one or more thermoplastic polymers that melt and expand when exposed to temperatures between about 300°C and about 500°C. The one or more thermoplastic polymers may comprise 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 polypropylene (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonates (PC), or any combination thereof. The one or more thermoplastic polymers may comprise one or more polycarbonates. The one or more thermoplastic polymers may comprise of at least one or more polycarbonates. The one or more thermoplastic polymers may comprise of at least one or more polycarbonate polymers and / or one or more copolymers containing carbonate units. The one or more thermoplastic polymers may comprise of at least one polyarylsulfones polymer. The one or more thermoplastic polymers may comprise of at least one or more polycarbonate polymers.

[0048] The polymeric compositions may contain one or more flame retardants commonly used in thermoplastic compositions. The polymeric compositions may contain one or more nonhalogenated flame retardants commonly used in thermoplastic compositions. The polymeric compositions containing polycarbonates may contain one or more flame retardants commonly used in polycarbonate compositions. The polymeric compositions containing polycarbonates may contain one or more non-halogenated flame retardants commonly used in polycarbonate compositions. Non-halogenated means that there are no halogen atoms contained in the flame retardant. The use of non-halogenated flame retardants means that no halogens are released during combustion of the compositions containing non-halogenated flame retardants. The flame retardant may be any flame retardant known for use in thermoplastic compositions which provide flame retardant properties, and which do not negatively impact the impact, heat resistance, flexural modulus, bending strength, haze and transparency of the composition. Flame retardants may be used in a sufficient amount to meet the flame retardancy requirements for the final use and in an amount that does not deleteriously impact the properties of articles prepared from the compositions. The one or more non-halogen containing flame retardants may be one or more phosphorus containing flame retardants. The one or more phosphorus containing flame retardant may comprise a phosphate ester, a phosphazene, or a mixture thereof. Exemplary phosphorus flame retardants include phosphorous containing compounds, such as phosphate esters, such as oligomeric phosphates, poly(block-phosphonato-esters), and / or a poly(block-phosphonato-carbonates) see USP 7,645,850 which is incorporated in its entirety. Exemplary oligomeric phosphates include bisphenol-A bis(diphenyl phosphate) (BAPP). Exemplary additional fire retardants include 1 , 3-phenylenetetrakis (2, 6-dimethylphenyl) ester (Daihachi PX-200).

[0049] The one or more non-halogenated flame retardants may be one or more phosphazenes. Any one or more phosphazenes which enhance fire retardancy may be used. The phosphazenes may comprise more than one phosphazene unit. A phosphazene is an organic compound having a -P=N- structure. The phosphazene may be a linear structure containing one or more phosphazene units or a cyclic structure containing structure containing one or more phosphazene units. The phosphorous atoms on the phosphazene structure may have bonded thereto one or more hydrocarbyloxy structures. The hydrocarbyloxy groups may be alkoxy, aryloxy, alkyl substituted aryloxy, alkoxy substituted aryloxy or halo substituted aryloxy. The hydrocarbyloxy groups may be aryloxy or alkyl substituted aryloxy. The hydrocarbyloxy groups may be phenoxy or alkyl substituted phenoxy. The alkyl groups may be C -MO alkyl, C 1.3 alkyl or methyl or ethyl. The cyclic phosphazene compounds may contain 1 or more phosphazene units or 3 or more phosphazene units. The cyclic phosphazene compounds may contain 25 or less phosphazene units, 10 or less phosphazene units or 5 or less phosphazene units. The linear phosphazene compounds may contain 1 or more phosphazene units, 3 or more phosphazene units, 5 or more phosphazene units or 6 or more phosphazene units. The linear phosphazene compounds may contain 10,000 or less phosphazene units, 1 ,000 or less phosphazene units, 100 or less phosphazene units, or 25 or less phosphazene units. Exemplary cyclic phosphazenes include phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene, hexa-phenoxy- cyclo-phosphazene and decaphenoxy cyclopentaphosphazene. The phosphazene compounds may be crosslinked. The phosphazene compounds may be crosslinked by a bisphenol compound such as a 4,4'-diphenylene group, such as a 4,4'-sulfonyldiphenylene (bisphenol S residue), 2,2- (4,4'-diphenylene), isopropylidene group, 4,4'-oxydiphenylene group, and 4,4'-thiodiphenylene group. The phenylene group content of the crosslinked phenoxyphosphazene compound is generally 50 to 99.9 percent by weight or 70 to 90 percent by weight. The crosslinked phenoxyphosphazene compound may not have any free hydroxyl groups in the molecule.

[0050] The one or more non-halogen containing flame retardants may be present in an amount of about 0 percent by weight or greater based on the weight of the polymeric composition, about 3 percent by weight or greater, about 5 percent by weight or greater, about 8 percent by weight or greater, or about 12 percent by weight or greater. The one or more non-halogen containing flame retardants may be present in an amount of about 25 percent by weight or less based on the weight of the composition, about 15 percent by weight or less, or about 13 percent by weight or less. The one or more non-halogen containing flame retardants may be present inan amount from about 0 percent by weight to about 25 percent by weight based on the weight of the polymeric composition.

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

[0052] The one or more phosphazene flame retardants may be present in an amount of about 0 percent by weight or greater based on the weight of the polymeric composition, about 3 percent by weight or greater, about 5 percent by weight or greater, or about 8 percent by weight or greater. The one or more phosphazene containing flame retardants may be present in an amount of about 25 percent by weight or less based on the weight of the composition, about 15 percent by weight or less, or about 13 percent by weight or less. The one or more phosphazene flame retardants may be present in an amount from about 0 percent by weight to about 25 percent by weight; about 5 percent by weight to about 15 percent by weight; or about 8 percent by weight to about 13 percent by weight based on the weight of the polymeric composition.

[0053] The one or more phosphate ester containing flame retardants may be present in an amount of about 0 percent by weight or greater based on the weight of the polymeric composition, about 3 percent by weight or greater, about 5 percent by weight or greater, about 8 percent by weight or greater. The one or more phosphate ester containing flame retardants may be present in an amount of about 25 percent by weight or less based on the weight of the polymeric composition, about 15 percent by weight or less, or about 13 percent by weight or less. The one or more phosphate ester containing flame retardants may be present in an amount from about 0 percent by weight to about 25 percent by weight; about 5 percent by weight to about 15 percent by weight; or about 8 percent by weight to about 13 percent by weight based on the weight of the polymeric composition.

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

[0055] The polymeric composition of the disclosed compositions may contain one of more antioxidants. Antioxidants may be introduced into the compositions from ingredients utilized, such as the impact modifiers and post-consumer recycled polymer. The antioxidants may be added to the compositions separately. The antioxidants may be one or more of phenol, phosphorous, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compound, alkylidenebisphenol, hydroxybenzylated malonate, aromatic hydroxybenzyl compound, triazine compound, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or aminic based antioxidants. The antioxidant may be one or more of phenol, phosphorous, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compound, alkylidenebisphenol, hydroxybenzylated malonate, aromatic hydroxybenzyl compound, triazine compound, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or aminic based antioxidants which do not contain 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'-methylene bis [4-methyl-6-(a- methylcyclohexyl)phenol]; 1 ,1-bis (5-tert- butyl-4-hdyroxy-2-methyl phenyl) butane; 2,2'-methylenebis(4-methyl-6-cyclohexyl phenol); 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-dodecylmercapto butane; ethylene glycol bis[3,3-bis(3-tert-butyl-4-hdyroxyphenyl) butyrate]; 1 ,1-bis(3,5-dimethyl-2-hydroxyphenyl)-3-(n- dodecylthio)butane; 4,4'-thiobis(6-tert-butyl-3-methyl phenol); 1 ,3,5-tris (3, 5-di-tert-butyl-4- hydroxybenzyl)-2,4,6-trimethylbenzene; dioctadecyl 2,2-bis(3,5-di-tert-butyl- 4- hydroxybenzyl)malonate ester; n-octadecyl-3-(4-hydroxy-3,5-di-tert-butylphenyl) propionate; tetrakis[methylene (3,5-di-tert-butyl-4-hydroxy hydrocinnamate) ]methane; and pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate. Hydroquinone and alkylated hydroquinone-based antioxidants include 2,6-di-tert-butyl-4-methoxyphenol, 2,5-di-tert- butylhydroquinone, 2,5-di-tert-amylhydroquinone, 2,6-di phenyl 4-octadecyloxyphenol, 2,6-di- tert-butylhydroquinone, 2,5-di-tert-butyl-4-hydroxy anisole, 3,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyphenyl stearate, bis (3,5-di-tert-butyl-4-hydroxyphenyl) adipate. Tocopherol based antioxidants include a-tocopherol, p-tocopherol, y-tocopherol, 6-tocopherol and mixtures thereof (vitamin E). O- and N-benzyl compounds, based antioxidants include for example 3,5,3',5’-tetra-tert-butyl-4,4'-dihydroxydibenzyl ether, tris(3,5-di-tert-butyl-4- hydroxybenzyl) amine. Alkylidenebisphenol, based antioxidants include, 2,2'-methylenebis(6-tert- butyl-4-methyl phenol), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), 2,2’-methylenebis[4- methyl-6-(a-methyl cyclohexyl) phenol], 2,2'-methylenebis(4-methyl-6-cyclohexylphenol), 2,2'- methylene bis(6-nonyl-4-methylphenol), 2,2'-methylenebis(4,6-di-tert-butylphenol), 2,2'-ethylidenebis (4,6-di-tert-butylphenol), 2,2'-ethylidenebis(6-tert-butyl-4-isobutylphenol), 2,2'- methylene bis[6-(a-methylbenzyl)-4-nonylphenol], 2,2 -methylene bis[6-(a,a-dimethyl benzyl)-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-methyl phenyl) butane, ethylene glycol bis[3,3-bis(3'-tert-butyl-4'-hydroxy phenyl)butyrate], bis[2-(3'-tert-butyl-2'- hydroxy-5'-methylbenzyl)-6-tert-butyl-4-methyl phenyl] terephthalate, 1 , 1 -bis-(3,5-dimethyl-2- hydroxyphenyl)butane, 2,2-bis(3,5-di-tert-butyl-4-hydroxyphenyl)propane, 1 ,1 ,5,5-tetra(5-tert- butyl-4-hydroxy-2-methylphenyl) pentane. Hydroxybenzylated malonate based antioxidants include dioctadecyl-2 ,2-bis(3,5-di-tert-butyl-2-hydroxybenzyl)malonate, di-octadecyl-2-(3-tert- butyl-4-hydroxy-5-methyl benzyl)malonate, bis[4-(1 ,1 ,3,3-tetramethyl butyl)phenyl]-2,2-bis(3,5-d i- tert-butyl-4-hydroxy benzyl)malonate. Aromatic hydroxybenzyl based antioxidants include 1 ,3,5- tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethyl benzene, 1 ,4-bis(3,5-di-tert-buty I-4- hydroxybenzyl)-2,3,5,6-tetramethylbenzene, 2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl)phenol. Triazine compounds based antioxidants include 2,4-bis(octylmercapto)-6-(3,5-di-tert-butyl-4- hydroxyanilino)-1 ,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyanilino)-1 ,3,5- triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyphenoxy)-1 ,3,5-triazine, 2,4,6-tris- (3,5-di-tert-butyl-4-hydroxyphenoxy)-1 ,2,3-triazine, 1 ,3, 5-tris(3,5-di-tert-buty I-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-hydroxyphenyl propionyl)-hexahydro-1 ,3,5-triazine and 1 , 3,5-tris(3,5- dicyclohexyl-4-hydroxybenzyl) isocyanurate. Benzylphosphonates, based antioxidants include dimethyl-2,5-di-tert-butyl-4-hydroxybenzylphosphonate, diethyl-3, 5-di-tert-butyl-4- hydroxybenzylphosphonate, diocta decyl3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-5-tert-butyl-4-hydroxy-3-methylbenzylphosphonate, the calcium salt of the monoethyl ester of 3,5-di-tert-butyl-4-hydroxybenzylphosphonic acid. Acylaminophenol based antioxidants include, for example 4-hydroxylauranilide, 4-hydroxystearanilide, octyl N-(3,5-di-tert- butyl-4-hydroxyphenyl) carbamate. Exemplary antioxidants include esters of D-(3,5-di-tert-buty I- 4-hydroxyphenyl) propionic acid with mono- or polyhydric alcohols, e.g. with methanol, ethanol, n-octanol, i-octanol, octadecanol, 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)oxamide, 3-thiaundecanol, 3-thia pentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7- trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of p-(5-tert-butyl-4-hydroxy-3- methylphenyl)propionic acid with mono- or polyhydric alcohols, e.g. with methanol, ethanol, n- octanol, i-octanol, octadecanol, 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) oxamide, 3-thia undecanol, 3- thiapentadecanol, 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 [3- (3,5-dicyclohexyl-4-hydroxy phenyl)propionic acid with mono- or polyhydric alcohols, e.g. with methanol, ethanol, octanol, octadecanol, 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)oxamide, 3- thiaundecanol, 3-thia pentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1- phospha-2, 6, 7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of 3,5-di-tert- butyl-4-hydroxyphenyl acetic acid with mono- or polyhydric alcohols, e.g. with methanol, ethanol, octanol, octadecanol, 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)oxamide, 3-thiaundecanol, 3-thia pentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7- trioxabicyclo[2.2.2]octane. Exemplary antioxidants include amides of f3-(3,5-di-tert-butyl-4- hydroxyphenyl) propionic acid e.g. N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl) hexamethylene diamide, N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl) tri methylenediamide, N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazide, N,N'-bis[2-(3- [3,5-di-tert-butyl-4-hydroxyphenyl]propionyloxy) ethyl]oxamide (Naugard® XL-1 , supplied by Uniroyal). An exemplary antioxidant is ascorbic acid (vitamin C). Aminic antioxidants include N,N'- di-isopropyl-p-phenylenediamine, N,N'-di-sec-butyl-p-phenylene diamine, 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-phenylene diamine, N-isopropyl-N'-phenyl- p-phenylenediamine, N-(1 ,3-dimethyl butyl)-N'-phenyl-p-phenylenediamine, N-(l-methylheptyl)- N'-phenyl-p-phenylenediamine, N-cyclohexyl-N'-phenyl-p-phenylenediamine, N,N'-dimethyl- N,N'-di-sec-butyl-p-phenylene diamine, diphenylamine, N-allyldiphenylamine, 4- isopropoxydiphenylamine, N-phenyl-1 -naphthyl amine, N-(4-tert-octylphenyl)-1 -naphthylamine, N-phenyl-2-naphthylamine, octylated diphenylamine, p,p'-di-tert-octyldiphenylamine, 4-n- butylaminophenol, 4-butyryl amino phenol, 4-nonanoylaminophenol, 4-dodecanoylaminophenol, 4-octa decanoyl aminophenol, bis(4-methoxyphenyl)amine, 2,6-di-tert-butyl-4- dimethylaminomethylphenol, 2,4 -diamino diphenylmethane, 4,4'- diaminodiphenylmethane, N,N,N',N'-tetramethyl-4,4'-diamino diphenyl ethane, 1 ,2-bis[(2-methylphenyl)amino]ethane, 1 ,2-bis(phenylamino) propane, (o-tolyl)biguanide, bis[4-(1 ',3'-dimethylbutyl)phenyl]amine, tert- octylated N-phenyl-1 -naphthyl amine, a mixture of mono- and dialkylated tert-butyl / tert- octyldiphenylamines, a mixture of mono- and dialkylated nonyldiphenylamines, a mixture of mono- and dialkylated dodecyldiphenylamines, a mixture of mono- and dialkylated isopropyl / isohexyl diphenylamines, a mixture of mono- and dialkylated tert-butyldiphenylamines, N,N,N',N'- tetraphenyl-1 ,4-diaminobut-2-ene, N,N-bis(2,2,6,6-tetramethylpiperid-4-yl-hexa methylene diamine, bis(2,2,6,6-tetramethylpiperid-4-yl)sebacate, 2,2,6,6-tetramethyl piperidin-4-one, 2, 2, 6, 6-tetramethylpiperidin-4-ol. Phosphoric antioxidants include tetrakis(2,4-di-t-butyl phenyl)- 4,4-biphenylene phosphonite, tris(2,4-di-t-butylphenyl) phosphite, 2,2'-methylene bis(4,6-di-t- butylphenyl) octyl phosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, bis(2,6-di-t- butyl-4-methylphenyl)pentaerythritol diphosphite, di(nonylphenyl)pentaerythritol diphosphite, phenyl-bisphenol A-pentaerythritol diphosphite, distearylpentaerythritol diphosphite, dioctylpentaerythritol diphosphite, dilaurylpentaerythritol diphosphite, diphenylpentaerythritol diphosphite, dicyclohexylpentaerythritol diphosphite, bis(2,4,6-tri-t-butylphenyl) pentaerythritol diphosphite, 2,2'-ethylidenebis(4,6-di-t-butylphenyl) fluorophosphite, trisindecyl phosphite, trisdodecyl phosphite, phenylisooctyl phosphite, phenylindecyl phosphite, phenyldodecyl phosphite, diphenylisooctyl phosphite, diphenylisodecyl phosphite, diphenyldodecyl phosphite, triphenyl phosphite, tris(monononylphenyl) phosphite and tris(dinonylphenyl)phosphite. The antioxidant may be octadecyl 3,5-di-(tert)-butyl-4-hydroxyhydrocinnamate which is commercially available as IRGANOX 1076 from BASF.

[0057] Exemplary antioxidant additives include, for example, organophosphites such as tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite (e.g., “IRGAFOS 168” or “1-168”), bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite or the like; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydro cinnamate) methane, or the like; butylated reaction products of para-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of beta-(3,5- di-tert-butyl-4-hydroxyphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl compounds such as distearylthiopropionate, dilaurylthiopropionate, ditridecyl-thio-dipropionate, octadecyl-3-(3,5-di-tert-butyl-4-hydroxy phenyl)propionate, pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate or the like; amides of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, or combinations comprising at least one of the foregoing antioxidants.

[0058] The antioxidants may be one or more of phenol and / or phosphorous based antioxidants. The antioxidants 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] The antioxidants may be present in the polymeric composition and structures formed therefrom in any amount which retards oxidation of the polymers. The antioxidants may be present in an amount based on the weight of the polymeric composition disclosed of about 100 parts per million or greater (0.01 percent by weight), about 200 parts per million or greater (0.02 percent by weight), about 300 parts per million or greater (0.03 percent by weight), about 500 parts per million or greater (0.05 percent by weight) or about 1000 parts per million or greater (0.1 percent by weight). The antioxidants may be present in an amount based on the weight of the polymeric composition disclosed of about 10,000 parts per million or less (1.0 percent by weight) about 8,000 parts per million or less (0.8 percent by weight), about 6,000 parts per million or less (0.6 percent by weight), about 5,000 parts per million or less (0.5 percent by weight) or about 3000 parts per million or less (0.3 percent by weight), about 2,000 parts per million or less (0.2 percent by weight).

[0060] The polymeric composition may contain one or more mold release agents. Exemplary mold release agents include any mold release agent known in the art and combinations thereof. The mold release agents may be internal mold release agents. The mold release agents may include one or more compatibilizing agents such as are taught in now expired United States patent US5, 212, 209A which is incorporated herein by reference in its entirety for all purposes. Exemplary classes of mold release agent include aliphatic carboxylic acids; esters of an aliphatic carboxylic acid and an alcohol; aliphatic hydrocarbon compounds having a number average molecular weight of 200 to 15,000; and polysiloxane-based silicone oils. Examples of the aliphatic carboxylic acids include saturated or unsaturated, aliphatic monovalent, divalent, or trivalent carboxylic acids. The aliphatic carboxylic acids also include alicyclic carboxylic acids. The aliphatic carboxylic acids may be C6-36 monovalent or divalent carboxylic acids. The aliphatic carboxylic acids may be C6-36 aliphatic saturated monovalent carboxylic acids. Specific examples of such aliphatic carboxylic acids include palmitic acid, stearic acid, caproic acid, capric acid, lauric acid, arachic acid, behenic acid, lignoceric acid, cerotic acid, melissic acid, tetratriacontanoic acid, montanic acid, adipic acid, and azelaicacid. Examples of the aliphatic carboxylic acid in the esters of an aliphatic carboxylic acid and an alcohol include the same aliphatic carboxylic acids as described above. Examples of the alcohol include saturated or unsaturated, monohydric or polyhydric alcohols, which may have a substituent such as a fluorine atom or an aryl group. Thealcohols may be monohydric or polyhydric, saturated alcohols having a carbon number of not more than 30. The alcohols may be aliphatic saturated monohydric alcohols and aliphatic saturated polyhydric alcohols having a carbon number of not more than 30. The term “aliphatic” herein is used as a term also including alicyclic compounds. Specific examples of such alcohols include octanol, decanol, dodecanol, stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol, glycerin, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentylene glycol, ditrimethylolpropane, and dipentaerythritol. Each of the above esters may be either a pure substance or a mixture of a plurality of compounds. Each of the aliphatic carboxylic acid and the alcohol bound to each other to constitute one ester may be of a single type, or two or more types thereof may be used in an arbitrary combination at arbitrary ratios. Specific examples of the ester of the aliphatic carboxylic acid and the alcohol include bees waxes (mixtures containing myricyl palmitate as a major component), stearyl stearate, behenyl behenate, stearyl behenate, glycerin monopalmitate, glycerin monostearate, glycerin distearate, glycerin tristearate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristearate, and pentaerythritol tetrastearate. Examples of the aliphatic hydrocarbons having a number average molecular weight of 200 to 15,000 include liquid paraffins, paraffin waxes, microwaxes, polyethylene waxes, Fischer-Tropsch waxes, and a-olefin oligomers having a carbon number of 3 to 12. The aliphatic hydrocarbons also include alicyclic hydrocarbons. Each of these hydrocarbons may be partially oxidized. The aliphatic hydrocarbons may be paraffin waxes, polyethylene waxes, and partially oxidized polyethylene waxes are preferred. Paraffin waxes and polyethylene waxes are more preferred. The number average molecular weight of the aliphatic hydrocarbon may not more than 5000. Examples of the polysiloxane-based silicone oils include dimethyl silicone oils, methylphenyl silicone oils, diphenyl silicone oils, and fluorinated alkyl silicone oils. A single type of mold release agent described above may be included, or two or more types of mold release agents described above may be included in an arbitrary combination at arbitrary ratios. Exemplary mold release agents comprise at least one of aliphatic carboxylic acids or esters of an aliphatic carboxylic acid and an alcohol. The mold release agent may be at least one of at least one of pentaerythritol tetrastearate, glycerol monostearate, and octyldodecyl stearate. The mold release agent may be pentaerythritol tetra stearate.

[0061] The polymeric composition may contain one or more mold release agents in an amount of about 0 percent by weight or greater based on the polymeric composition, about 0.01 percent by weight or greater, or about 0.1 percent by weight or greater. The amount of the mold release agent is not limited and may be about 2 percent by weight or less based on the weight of the polymeric composition, about 1 percent by weight or less, or about 0.7 percent by weight or less. In cases where the content of the mold release agent is less than the lower limit of this range,the mold-releasing effect may be insufficient, while in cases where the content of the mold release agent exceeds the upper limit of this range, a decrease in the hydrolysis resistance, mold contamination during injection molding, and the like may occur. The polymeric composition may contain from about 0 percent by weight to about 2 percent by weight, about 0.01 percent by weight to about 1 percent by weight, or about 0.1 percent by weight to about 0.7 percent by weight based on the polymeric composition of one or more mold release agents.

[0062] The polymeric composition may contain of one or more charring salts. A charring salt is any compound which assist in the retention of the original shape of the plastic article by the formation of char from the compound. The char forms a crust of non-flammable material, reducing the melting and dripping of the compound in which the charring salt resides. Any charring salt which functions as a charring salt may be used.

[0063] The one or more charring salts may contain one or more salts of a perflourohydrocarbyl sulfur compounds or aromatic sulfur compounds. Any salts of perflourohydrocarbyl sulfur compounds or salt of aromatic sulfur compounds that improve the fire retardancy of disclosed compositions may be used. The one or more salts of a perflourohydrocarbyl sulfur compounds may be one or more salts of perflouroalkane sulfur compounds. The one or more salts of a perflourohydrocarbyl sulfur compounds or aromatic sulfur compounds may include one or more an alkali metal salt, an alkaline earth metal salt or both. For example, the one or more salts of a perflourohydrocarbyl sulfur containing compounds or aromatic sulfur compounds may include a potassium salt, a sodium salt, a magnesium salt, a calcium salt, or any combination thereof. The one or more salts of perflourohydrocarbyl sulfur containing compounds or aromatic sulfur compounds may include or consist essentially of one or more potassium salts. The one or more salts of a perflourohydrocarbyl sulfur containing compounds or aromatic sulfur compounds are salts including one or more sulfur atoms. The one or more salts of perflourohydrocarbyl sulfur containing compounds or aromatic sulfur compounds may be a sulfonate. The sulfur-containing salt (e.g., the sulfonate) may include one or more carbon containing groups. The number of carbon atoms in the 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 the 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 include one or more halogen atoms (e.g., a fluorine, a chlorine, a bromine, or any combination thereof). By way of example, the carbon containing group may include a fluoroalkane having one or more fluorine atoms (e.g., a perfluoroalkane, such as a perfluorobutane, a perfluorohexane, a perfluoropentane, a perfluoroheptane, a perfluoropropane, or a perfluorooctane). The carbon containing group may not include one or more halogen atoms. The sulfur-containing salt may include or consistsubstantially of one or more potassium perfluoroalkanesulfonates, such as potassium perfluorobutanesulfonate, sodium p-toluenesulfonate or potassium diphenylsulfone sulfonate.

[0064] The perflourohydrocarbyl salts may be present in an amount of about 0 percent by weight or greater of the polymeric composition or about 0.05 percent by weight or greater, or about 0.1 percent by weight or greater. The perflourohydrocarbyl salts may be present in an amount of about 2.0 percent by weight or less of the polymeric composition, about 1 .0 percent by weight or less, less than 0.5 percent by weight, about 0.4 percent by weight or less, or about 0.25 percent by weight or less.

[0065] The one or more charring salts may contain one or more sulfur-containing salts with a halogen or one or more sulfur-containing without a halogen. The one or more charring salts may contain one or more sulfur-containing salts with a halogen.

[0066] The one or more charring salts may contain one or more sulfur-containing salts without a halogen. The one or more organometallic salts may be one or more salts of aromatic sulfur compounds. The one or more organometallic salts may be one or more salts of aromatic sulfonates. The one or more salts of aromatic sulfur compounds may include one or more salt of an alkali metal, an alkaline earth metal or both. The one or more salts aromatic sulfur compounds may include a potassium salt, a sodium salt, a magnesium salt, a calcium salt, or any combination thereof. The one or more salts of aromatic sulfur compounds may include one or more sodium or potassium salts. The one or more salts of aromatic sulfur compounds may be a sulfonate. The sulfur-containing salt may include one or more carbon containing groups. The number of carbon atoms in the 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 the 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 sulfur-containing salt may include or consist substantially of one or more sodium p- toluenesulfonate or potassium diphenylsulfone sulfonate.

[0067] The one or more sulfur-containing salts without a halogen may be present in an amount of about 0 percent by weight or greater of the polymeric composition, about 0.05 percent by weight or greater, or about 0.1 percent by weight or greater. The one or more sulfur-containing salts without a halogen may be present in an amount of about 2.0 percent by weight or less of the polymeric composition, about 1 .0 percent by weight or less, less than 0.5 percent by weight, about 0.4 percent by weight or less, or about 0.25 percent by weight or less.

[0068] The one or more charring salts may include or consist substantially of potassium perfluorobutanesulfonate, sodium p-toluenesulfonate or potassium diphenylsulfone sulfonate. The one or more charring salts may include or consist substantially of sodium p-toluenesulfonate or potassium perflourobutane sulfonate. The one or more charring salts may include or consistsubstantially of sodium p-toluenesulfonate or perfluorobutanesulfonate. The one or more charring salts may include or consist substantially of sodium p-toluenesulfonate. The one or more charring salts may include or consist substantially of perfluorobutanesulfonate.

[0069] The one or more charring salts may be present in an amount to improve the flame retardancy of the compositions. The charring salts may be present in an amount of about 0 percent by weight or greater, about 0.01 percent by weight or greater, or about 0.05 percent by weight or greater based on the weight of the polymeric composition. The charring salts may be present in an amount of about 2.0 percent by weight or less, about 1 .0 percent by weight or less, about 0.5 percent by weight or less, about 0.4 percent by weight or less, or about 0.25 percent by weight or less based on the weight of the polymeric composition.

[0070] The polymeric composition may contain one or more UV absorbers (i.e., UV stabilizers) that in one more embodiment function to stabilize the color of the composition. When UV absorbers are added, the polycarbonates, vinylidene substituted aromatic compounds, or both may absorb light energy from UV rays as heat. UV absorbers may reduce weathering in polymeric compositions, such as compositions of polycarbonates and vinylidene substituted aromatic compounds. UV absorbers may include benzotriazoles, hydroxyphenyltriazines, benzophenoses, s-triazines, the like, or any combination thereof. UV absorbers may be present in an amount of about 0 ppm or more (0 percent by weight), 500 ppm or more (0.05 percent by weight) based on the weight of the polymeric compositions, about 1 ,000 ppm or more (0.1 percent by weight), or about 1 ,500 ppm or more (0.15 percent by weight). UV absorbers may be present in about 10,000 ppm or less (1 .0 percent by weight), about 8,000 ppm or less (0.8 percent by weight), about 6,000 ppm or less (0.6 percent by weight) or about 5,000 ppm or less (0.5 percent by weight).

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

[0072] The one or more thermoplastic polymers comprise 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 Polypropylene (PP), one or more polyphenylene sulfide (PPS), one or more polyetherimide (PEI), one or more polycarbonates, or any combination thereof.

[0073] The one or more thermoplastic polymer may be one or more polycarbonates. The one or more polycarbonates may be branched, linear, or a mixture thereof. The one or more polycarbonates may contain virgin polycarbonate. Virgin polycarbonate is polycarbonate which has not been used in any previous composition.

[0074] The polymeric composition may contain recycled polycarbonate. The polymeric composition may contain both virgin and recycled polycarbonate. The recycled polycarbonate may contain one or more post-consumer recycled polycarbonates. The polycarbonate may be in the form of a powder, flakes, pellets, or in a mixture thereof. Where used in powder form the particle size is selected for efficiently blending the materials. The particle size may be about 0.1 mm or greater, or about 0.5 mm or greater. The particle size may be about 2.0 mm or less, or about 1.5 mm or less.

[0075] Polycarbonate as used herein means a polymer containing carbonate units. Polycarbonate as used herein includes the terms one or more polycarbonate polymers and / or copolymers containing carbonate units. Such polymers may be homopolymers consisting essentially of carbonate monomer units or copolymers containing one or more other monomer units (co-monomer units) and carbonate units. Such copolymers may be block copolymers containing two or more blocks of different monomer units or may be random copolymers with the different monomer units randomly located along the polymer backbone. The other monomer units may comprise any monomer units that do not negatively impact the inherent properties of polycarbonates, for instance heat resistance, impact resistance, moldability, flexural modulus, bending strength, haze, and transparency, where required for the intended use. Among exemplary comonomer units are ester units, polysiloxane units, and the like. The amount of carbonate monomer units in copolycarbonates is selected such that the resulting polymer retains the desirable properties of polycarbonates, as disclosed herein. The copolycarbonates may contain greater than 50 mole percent carbonate monomer units, about 75 mole percent or greater carbonate monomer units, about 80 mole percent or greater carbonate monomer units or about 85 mole percent or greater carbonate monomer units. The copolycarbonates may contain about 99 mole percent or less carbonate monomer units, about 97 mole percent or less carbonate monomer units or about 95 mole percent or less carbonate monomer units. The copolycarbonates may contain about 1 mole percent or greater co-monomer monomer units, about 3 mole percent or greater co-monomer monomer units or about 5 mole percent or greater co-monomer monomer units. The co polycarbonates may contain less than 50 mole percent comonomer monomer units, about 25 mole percent or less co-monomer monomer units, about 20 mole percent or less co-monomer monomer units or about 15 mole percent or less co-monomer monomer units. The polycarbonate units may contain aromatic units in the backbone of the polymer.

[0076] The production of polycarbonates is affected, for example, by the reaction of diphenols with carbonic acid halides, preferably phosgene, and / or with aromatic dicarboxylic acid dihalides, preferably benzenedicarboxylic acid dihalides, by the phase boundary method, optionally with the use of chain terminators, e.g., monophenols, and optionally with the use of trifunctional branching agents or branching agents with a functionality higher than three, for example triphenols or tetraphenols. Diphenols useful to produce the aromatic polycarbonates and / or aromatic polyester carbonates may correspond to formula Iwherein A denotes a single bond, a C 1.5 alkylene, a C 2-5 alkylidene, a C 5-6 cycloalkylidene, -O-, -SO-, -CO-, -S-, -SO2-, or a C 6-12 arylene, on to which other aromatic rings, which optionally contain hetero atoms, can be condensed, or a radical of formula II:or formula III:wherein B in each case is independently hydrogen, a C 1-12 alkyl, preferably methyl, or a halogen, preferably chlorine and / or bromine; x in each case is mutually independently 0, 1 , or 2; and p is 0 or 1 :Rcand Rdare mutually independent of each other and are individually selectable for each X1and are hydrogen or a Ci - C6alkyl, preferably hydrogen, methyl or ethyl; X1denotes carbon; and m denotes an integer from 4 to 7, preferably 4 or 5, with the proviso that Rcand Rdsimultaneously denote an alkyl on at least one X1atom.

[0077] Exemplary diphenols are hydroquinone, resorcinol, dihydroxybiphenyls, bis (hydroxyphenyl)-C 1.5 alkanes, bis(hydroxyphenyl)-C 5-6 cycloalkanes, bis(hydroxyl-phenyl) ethers, bis(hydroxyphenyl)sulfoxides, bis(hydroxyphenyl)ketones, bis(hydroxyl-phenyl) sulfones and 4,4”-bis(hydroxyphenyl)diisopropylbenzenes, as well as derivatives thereof which have brominated and / or chlorinated nuclei. Diphenols which are particularly preferred 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, as well as di- and tetra-brominated or chlorinated derivatives thereof, such as 2,2-bis(3-chloro-4-hydroxy-phenyl)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. The diphenols can be used individually or as arbitrary mixtures. The diphenols are known in the literature or can be obtained by methods known in the literature. Apart from bisphenol A homopolycarbonates, exemplary polycarbonates include copolycarbonates of bisphenol A with up to 15 mole percent, with respect to the molar sums of the diphenols, of other diphenols which are disclosed, such as 2 ,2-bis(3,5- dibromo-4-hydroxyphenyl)-propane.

[0078] Exemplary chain terminators for the production of the polycarbonates include phenolic compounds, exemplary phenolic compounds include phenol, p-chlorophenol, p-tert-butylphenol, 4-(1 ,3-dimethyl-butyl)-phenol and 2,4,6-tribromophenol; long chain alkyl phenols, such as monoalkylphenols or dialkylphenols which contain a total of 8 to 20 carbon atoms in their alkyl substituents, exemplary are 3,5-di-tert-butyl-phenol, p-iso-octylphenol, p-tert-octylphenol, p- dodecylphenol, 2-(3,5-dimethylheptyl)-phenol and 4-(3,5-dimethylheptyl)-phenol. The amount of chain terminators used may be about 0.1 mole percent or greater based on the molar sum of the diphenols used in each case. The amount of chain terminators used may be about 10 mole percent or less based on the molar sum of the diphenols used in each case.

[0079] The polycarbonates can be branched, for example by the incorporation of about 0.05 to about 2.0 mole percent, with respect to the sum of the diphenols used, of trifunctional compounds or of compounds with a functionality higher than three, for example those which contain four or more phenolic groups. Branched polycarbonates useful for the compositions disclosed can be prepared by known techniques, for example several methods are disclosed in USP 3,028,365; 4,529,791 ; and 4,677,162; which are hereby incorporated by reference in their entirety. Exemplary branching agents include tri- or multi-functional carboxylic acid chlorides, such as trimesic acid trichloride, cyanuric acid trichloride, 3,3'-,4,4'-benzophenone tetracarboxylic acid tetra chloride, 1 ,4,5,8-naphthalene-tetracarboxylic acid tetrachloride or pyromellitic acid tetra chloride, in amounts of about 0.01 to about 1 .0 mole percent (with respect to the dicarboxylic acid dichlorides used) or tri- or multi-functional phenols such as phloroglucinol, 4,6-dimethyl-2,4,6- tris(4-hydroxyphenyl)-2-heptene, 4,4-dimethyl-2,4,6-tris (4-hydroxy phenyl) heptane, 1 ,3,5-tris(4- hydroxyphenyl)-benzene, 1 ,1 ,1-tris(4-hydroxy phenyl)ethane, tris(4-hydroxyphenyl)-phenyl- methane, 2,2-bis[4,4-bis(4-hydroxyphenyl) cyclohexyl]propane, 2,4-bis[1-(4-hydroxyphenyl)-1- methyl-ethyl]phenol, tetrakis(4-hydroxy phenyl)-methane, 2,6-bis(2-hydroxy-5-methyl-benzyl)-4- methyl-phenol, 2-(4-hydroxyphenyl) -2-(2,4-dihydroxyphenyl)propane, or tetrakis(4-[1-(4- hydroxyphenyl)-1-methylethyl]-phen-oxy)-methane in amounts of about 0.01 to about 1.0 mole percent with respect to the diphenols used. Phenolic branching agents can be placed in the reaction vessel with the diphenols. Acid chloride branching agents can be introduced together with the acid chlorides.

[0080] Copolycarbonates may be prepared by known processes. For example, about 1 to about 25 parts by weight, about 2.5 to about 25 parts by weight (with respect to the total amount of diphenols to be used) of polydiorganosiloxanes comprising hydroxy-aryloxy terminal groups can also be used. These are known (see, USP 3,419,634) or can be produced by methods known in the literature. The ester forming monomers may be utilized in the polycarbonate containing polymer preparation process. Exemplary ester forming monomers include dicarboxylic acidhalides and hydroxycarboxylic acids. The aromatic dicarboxylic acid dihalides used for the production of the aromatic polyester carbonates may be the diacid dichlorides of isophthalic acid, terephthalic acid, diphenyl ether-4,4'-dicarboxylic acid and naphthalene-2,6-dicarboxylic acid. Mixtures of the diacid dichlorides of isophthalic acid and terephthalic in a ratio from about 1 :20 to about 20:1 may be used. A carbonic acid halide, such as phosgene, may be used in conjunction as a difunctional acid derivative during the production of the polyester carbonates. The aromatic polyester carbonates may also contain incorporated hydroxycarboxylic acids. The polyester carbonates may be either linear and / or may be branched. Branching agents are disclosed above.

[0081] Apart from the monophenols, exemplary chain terminators include chlorocarboxylic acid esters, as well as the acid chlorides of aromatic monocarboxylic acids which may optionally be substituted by C 1.22 alkyl groups, or by halogen atoms, and also may include aliphatic C 2-22 monocarboxylic acid chlorides. The amount of chain terminator may be about 0.1 to about 10 mole percent, with respect to the moles of diphenols in the case of phenolic chain terminators and with respect to the moles of dicarboxylic acid dichlorides in the case of monocarboxylic acid chloride chain terminators.

[0082] The polycarbonates or copolymers containing carbonate units may be derived from recycled materials, such as post-consumer recycled materials. The composition may contain up to 95 percent by weight of the polymeric composition recycled polycarbonates, such as post consumer recycled materials, about 90 percent by weight or less based on the composition or about 80 percent by weight or less. The composition may contain about 30 percent by weight or more of recycled polycarbonate based on the weight of the polymeric composition, about 50 percent or more, about 75 percent by weight or more or about 90 percent by weight or more. Virgin material as used herein refers to material that has not been previously used. The recycled material may be linear, branched or a mixture thereof. The recycled material may be branched. The recycled material may be in flake form. The recycled material may be recycled from bottles or other structures wherein the used structures are shredded into flake form. The recycled material can be formed into other structures such as pellets. The use of the recycled material in flake form is the most efficient way to utilize the material. The recycled polycarbonates or copolymers containing carbonate units may contain impurities such as polyesters, for instance 0.1 to 1.0 or 0.1 to 0.25 percent by weight based on the recycled polycarbonates or copolymers containing carbonate units.

[0083] The polymeric composition may contain virgin polycarbonates or copolymers containing carbonate units in an amount of about 5 percent by weight or greater based on the polymeric composition, about 10 percent by weight or greater, about 20 percent by weight or greater, about 30 percent by weight or greater, or about 40 percent by weight or greater. Thecomposition may contain virgin polycarbonates or copolymers containing carbonate units in an amount of about 99 percent by weight or less based on the polymeric composition, about 95 percent by weight or less, about 65 percent by weight or less, about 45 percent by weight or less, about 35 percent by weight or less, or about 25 percent by weight or less.

[0084] The one or more polymers containing carbonate monomer units can comprise polycarbonates, co-polycarbonates or blends of polycarbonates and co-polycarbonates. The polycarbonates and / or co-polycarbonates may exhibit a weight average molecular weight sufficient to provide the desired properties to articles prepared from the polycarbonates and / or co-polycarbonates. The polycarbonates and / or co-polycarbonates may have a weight average molecular weights of about 5,000 amu or greater, about 15,000 amu or greater, or about 20,000 amu or greater. The polycarbonates and / or co-polycarbonates may have a weight average molecular weight of about 40,000 amu or less, about 35,000 amu or less, or about 30,000 amu or less. Unless otherwise indicated, the polycarbonate and / or co-polycarbonate “molecular weight” herein refer to weight average molecular weights (Mw) determined by gel permeation chromatography (GPC) using laser scattering techniques with a bisphenol A polycarbonate standard and is given in units of grams per mole (g / mole).

[0085] The polycarbonates and / or copolymers used to prepare the compositions disclosed may have melt flow rates which provide the desired processing properties. A mixture of polycarbonates and / or copolymers containing carbonate units with differing melt flow rates may be used to provide a composite melt flow rate to enhance processing of the compositions disclosed. The mixture of polycarbonates and / or copolymers containing carbonate units having different melt flow rates may contain polycarbonates and / or copolymers containing carbonate units having low melt flow rates, polycarbonates and / or copolymers containing carbonate units having medium melt flow rates and polycarbonates and / or copolymers containing carbonate units having high melt flow rates. Melt flow rates are determined by measuring the grams of a material which passes through a capillary having a diameter of 25.4 mm in a ten-minute period at 300 ° C under a load of 1 .2, kilograms, measured according to ASTM D1238. The melt flow rates of the disclosed compositions may be about 1 gram / 10 minutes or greater, about 3 grams / 10 minutes or greater, about 5 grams / 10 minutes or greater, 10 grams / 10 minutes or greater, or about 15 grams / 10 minutes or greater. The melt flow rates of the disclosed compositions may be about 70 grams / 10 minutes or less, about 30 grams / 10 minutes or less, about 28 grams / 10 minutes or less, about 22 grams / 10 minutes or less, about 20 grams / 10 minutes or less, or about 10 grams / 10 minutes or less. The melt flow rates of the disclosed compositions may be from about 3 grams / 10 minutes to about 30 grams / 10 minutes. The test protocol is based on ASTM D1238. The plastometer has a capillary diameter of 9.5504 mm and bore die size of 2.095 mm. The low meltflow rate may be from about 0.1 to about 5 g / 10 minutes; the medium melt flow rate may be from about 5 to about 15 g / 10 min; and the high melt flow may be greater than about 15 g / 10 min.

[0086] The polymeric compositions disclosed may be produced by mixing the particular components in a known manner and melt-compounding and / or melt-extruding them at temperatures of from 200°C to 300°C in conventional units such as internal kneaders, extruders and twin-screw extruders. The individual components may be mixed in a known manner both in succession and simultaneously and both at approximately 23°C (room temperature) and at a higher temperature.

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

[0088] The polymeric composition may optionally include a component which adsorbs volatile organic compounds. The component may be a zeolite, activated carbon, bamboo, charcoal or combinations thereof.

[0089] The polymeric composition may contain a stabilizer salt. The stabilizer salt may be any compound that is a basic buffer which functions to prevent basic materials in the composition from causing the polycarbonates or copolymers containing carbonate units from depolymerizing. Exemplary classes of stabilizer salts include those disclosed in US 2013 / 0131241 , incorporated herein by reference, in particular acids, acid salts and esters of acids derived from a phosphorous containing acid such as phosphoric acid, phosphorous acid, hypophosphorous acid, hypophosphoric acid, phosphinic acid, phosphonic acid, metaphosphoric acid, hexametaphosphoric acid, thiophosphoric acid, fluorophosphoric acid, difluorophosphoric acid, fluorophosphorous acid, difluorophosphorous acid, fluorohypophosphorous acid, fluorohypophosphoric acid or their combinations. A combination of a phosphorous containing acid and an ester of a phosphorous containing acid may be used. Alternatively, acids, acid salts and esters of acids, such as, for example, sulphuric acid, sulphites, zinc phosphate, mono calcium phosphate, and the like, may be used. In particular embodiments, the acid stabilizer is phosphorous acid (H3PO3), phosphoric acid (H3PO4), zinc phosphate (Zn3(PO4)2), zinc dihydrogen phosphate (ZnH4P2O8), mono sodium phosphate (NaH2PO4), or sodium acid pyrophosphate(Na2H2P2O?), and monosodiumphosphate. The stabilizer salt may be present in sufficient amount to prevent depolymerization of the polycarbonates. The stabilizer salt may be present in an amount of about 0.05 percent by weight or greater of the composition containing one or more polycarbonates and / or copolymers containing carbonate units. The stabilizer salt may be present in an amount of about 0.5 percent by weight or less of the composition containing one or more polycarbonates and / or copolymers containing carbonate units.

[0090] The polymeric composition may contain one or more fillers. The one or more fillers may be reinforcing fillers or non-reinforcing fillers (e.g., such as talc, clay, etc.). Exemplary fillers include talc, clay, wollastonite, mica, glass or a mixture thereof. The polymeric composition may contain one or more reinforcing fillers. The reinforcing fillers may be employed for improving the strength of the polymeric composition and / or for reducing the coefficient of linear thermal expansion of the polymeric composition. The reinforcing filler may be any filler material that reinforces and positively impacts the flame retardant properties of the polycarbonate composition. The reinforcing filler may be one or more fibers of any fiber type disclosed herein. The reinforcing fillers may be fiber having a length to diameter ratio of about 4 or more. The reinforcing filler may include a glass fiber, a carbon fiber, a metal fiber, or any combination thereof. Reinforcing fillers may include mineral fillers having a needle-like structure (i.e., acicular structure), such as wollastonite.

[0091] The polymeric compositions disclosed may contain one or more carbon based particulates, metal or metalloid oxides. Any carbon based particulates, metal of metal oxide which enhances the flame retardancy rating of V0@1.5 mm, may be utilized. Exemplary metal or metalloid oxides include group 3 or 4 metal or metalloid oxides. Exemplary metal or metalloid oxides include TiO2, MgO, SiO2, Fe2O3, AI2Os and the like. Exemplary metal or metalloid oxides include TiO2, MgO and SiO2. The one or more metal or metalloid oxides may be a mixture of metal and / or metalloid oxides, such as talc which contains MgO and SiO2. The one or more carbon based particulates may be any particulate carbon materials which improves the flame retardancy of the compositions disclosed herein. Exemplary carbon based particulates may be carbon black or carbon nanotubes. The one or more carbon compounds, metals or metalloid oxides may be present in a sufficient amount to enhance the flame retardancy of the composition. The one or more carbon based particulates, metal or metalloid oxides may be present in an amount sufficient to provide a flame retardancy rating of V0@1.5 mm. The one or more carbon based particulates, metal or metalloid oxides may be present in an amount of 0 percent by weight by weight or greater based on the weight of the composition, about 0.2 percent by weight by weight or greater, about 0.3 percent by weight or greater, or about 0.5 percent by weight or greater based on the weight of the composition. The one or more carbon based particulates, metal or metal oxides may bepresent in an amount of about 10 percent by weight by weight or less based on the weight of the composition, about 5 percent by weight or less, about 3 percent by weight or less, or about 2 percent by weight or less based on the weight of the composition. The one or more carbon based particulates, metal or metal oxides may be present in particulate form. The one or more carbon based particulates, metal or metal oxides may be nanoparticles. The particle size may be any particle size that enhances the flame retardancy rating of the compositions. The particle size may be about 0.2 micrometers or more or about 0.35 micrometers or more. The particle size may be about 2.0 micrometers or less, or about 1.0 micrometers or less. The particle size may be determined using the laser diffraction technique described in ISO13322. The particle size determined is the average diameter. The compositions disclosed herein may contain a buffer system.

[0092] The polymeric compositions disclosed herein may contain a buffer system. A buffer system as described herewith may be any compound that donates protons (i.e., H+or hydronium ion), accepts protons (i.e., H+or hydronium ion), or both. The buffer system may comprise a weak acid and a conjugate base. The buffer system may resist pH changes upon the addition of basic or acidic components. The buffer system may be characterized based on the total number of protons (i.e., H+or hydronium ion), hydroxyl groups (i.e., hydroxide or OH ), or both. The buffer system may include one or more buffer compounds that are monoprotic, diprotic, triprotic, or polyprotic. The buffer system may proportionally stabilize polycarbonates based on the total amount of buffer system present based on the total weight of the composition. A buffer system as described herewith includes one or more buffers that has an acidic and basic functionality such that the pH of the composition may be directed to about neutral. The buffer system may include one or more buffer compounds, two or more buffer compounds, three or more buffer compounds, or a plurality of buffer compounds. The buffer system may comprise a single compound. The buffer system may comprise a pair of compounds. The buffer system may include an inorganic compound, an organic compound, or both. The buffer system may include a counterion. The buffer system is a present in a concentration (i.e., percentage by weight of the total composition) sufficient to facilitate improved molecular weight stability of polycarbonate. The buffers system may include a buffer compound that is an inorganic compound or organic compound that balances the pH of the composition such that the optimal copolymerization and compounding is achieved. Inorganic compounds may include compounds that are free of saturated carbons (i.e., free of C- H bonds). The inorganic compounds may include carbon atoms that do not include hydrogen bonds. Organic compounds may include compounds that contain saturated carbons (i.e., contains C-H bonds). The buffer compounds may include acetates, sulfonates, phosphates, ammonia, formates, or any combination thereof. The buffer system may include buffer compounds that arearomatic or aliphatic. The buffer system may include pairs of buffer compounds that are weak acids and conjugate bases. The buffer compounds may be chosen based on a pKa that is about neutral. The buffer compounds may control the pH of water to about neutral. The buffer system may include a 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-Tris Methane), 2-[(2-amino-2-oxoethyl)-(carboxy methyl) mino]acetic acid (ADA), N-(2-Acetamido)-2- aminoethanesulfonic acid (ACES), piperazine-N,N'-bis(2-ethanesulfonic acid) (PIPES), 2- Hydroxy-3-morpholino propane sulfonic acid (MOPSO), 1 ,3- bis(tris(hydroxymethyl)methylamino)propane (Bis-6-Tris Propane), N-N-Bis(2-hydroxyethyl)-2- aminoethanesuflonic acid (BES), MOPS, 2-[[1 ,3-dihydroxy-2-(hydroxymethyl)propan-2- yl]amino]ethanesulfonic acid (TES), 4-(2-hydroxy ethyl)-1 -piperazineethanesulfonic acid (HEPES), 3-(N,N-Bis[2-hydroxyethyl]amino)-2-hydroxy ropanesulfonic acid (DIPSO), 4-(N- Morpholino)butanesulfonic acid (MOBS), 3-[[1 ,3-dihydroxy-2-(hydroxymethyl)propan-2-yl]amino]- 2-hydroxypropane-1 -sulfonic acid (TAPSO), 4-(2-Hydroxyethyl)piperazine-1-(2- hyrdoxypropansulfonic 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), Glycyl-glycine (Gly-Gly), 2-(Bis(2-hydroxyethyl) amino)acetic acid (Bicine), N-(2- Hydroxyethyl)piperazine-N'-(4-butanesulfonic acid) (HEPBS), [tris(hydroxymethyl) ethylamino]propanesulfonic acid (TAPS), 2-Amino-2-methyl-1 ,3-propanediol (Ammediol or AMPD), N-tris(Hydroxymethyl)methyl-4-amino butane sulfonic acid (TABS), N-(1 ,1-Dimethyl-2- hydroxyethyl)-3-amino-2-hydroxypropane sulfonic acid (AMPSO), N-Cyclohexyl-2- aminoethanesulfonic acid (CHES), 3-(Cyclohexyl amino)-2-hydroxy-1 -propanesulfonic acid (CAPSO), 2-Amino-2-methylpropan-1-ol (Amino methyl propanol or AMP), N-cyclohexyl-3- aminopropanesulfonic acid (CAPS), 4-(Cyclohexyl amino)-1 -butanesulfonic acid (CABS), or any combination thereof. Inorganic compounds include metal phosphates, metal sulfonates, metal acetates, and metal formats.

[0093] The buffer system may comprise one or more alkali metal phosphates. Any alkali metal phosphates which enhance the thermal stability of the compositions may be used. The alkali metal phosphates may be sodium or potassium metal phosphates. Exemplary alkali metal phosphates may be one or more of distearyl pentaerythritol diphosphate, mono or dihydrogen phosphate and mono-, di-, or trihydrogen phosphate compounds. Exemplary alkali metal phosphates may be one or more of mono-, di-, or trihydrogen phosphate compounds. The alkali metal phosphate may be sodium dihydrogen phosphate. The alkali metal phosphates may be used in any amount which enhances the thermal stability of the compositions. The alkali metal phosphates may be used in any amount of about 0.01 percent by weight or greater based on the weight of the composition,about 0.02 percent by weight or greater, or about 0.03 percent by weight or greater. The alkali metal phosphates may be used in any amount of about 1.0 percent by weight or less based on the weight of the composition, about 0.2 percent by weight or less, or about 0.1 percent by weight or less.

[0094] The polymeric composition disclosed may contain a colorant. The colorant can be any colorant that provides a desired color to the composition or products prepared therefrom. The colorant may be a pigment or a dye. Exemplary pigments include carbon black, titanium dioxide, zinc sulfide, kaolin, and the like. The colorant may be present in a sufficient amount to provide the composition or products prepared therefrom with the desired color. The colorant may be present in an amount of about 0.01 percent by weight or greater of the disclosed composition, about 0.1 percent by weight or greater, or about 1 percent by weight or greater. The colorant may be present in an amount of about 10 percent by weight or less of the disclosed composition, about 5 percent by weight or less, about 1 percent by weight or less, or about 0.5 percent by weight or less. Where the colorant is a pigment, the concentration may be at the higher end of the disclosed range, for example from 0.1 to 10.0 percent by weight of the composition. Where the colorant is a dye, the amount may be at the lower end of the range, for example from 0.01 to about 0.5 percent by weight of the composition. Some of the pigments may also be particulates as described herein.

[0095] The disclosed composition may be an Organosheet. The Organosheets may be prepared using any known process for preparing Organosheets, for example extrusion or coextrusion, lamination, co-lamination and the like. The surface of the Organosheets can be textured using embossing rolls, and the like. The Organosheets may be formed by contacting the fiber material layer with powder, flakes, and / or pellets of the polymeric composition and heating the structure with the powder, flakes and / or pellets in contact with the fiber material layer at a temperature above the melting point of the composition under conditions that the polymeric composition bonds adjacent layers together and becomes embedded within the fiber material layer. The powder, flakes and / or pellets of the polymeric composition may be placed into an extruder, heated, and extruded to form one or more polymeric composition layers. The composition may be formed into an Organosheet by contacting the one or more polymeric composition layers with the fiber material layer. The polymeric composition layer and the fiber material layer may then be heated above the melting point of the composition under conditions that the polymeric composition bonds adjacent layers together and becomes embedded within the fiber material layer. Exemplary temperatures for forming the Organosheet may be 150 °C or greater. Exemplary temperatures for forming the Organosheet may be 300 °C or less, or 200 °C or less. The formation of the composition may in addition to heating may include the application of pressure to the structure in the direction transverse to the sheet faces. The pressure appliedmay be sufficient to embed the one or more polymeric compositions into the one or more fiber material layers. The Organosheets may be further processed to make shaped articles by thermoforming and the like.

[0096] The disclosed composition expands when exposed to fire and reduces the amount of heat transferred through the Organosheet. The disclosed at least one non-woven fiber layer within the Organosheet insulates the transfer of heat through the Organosheet and the polymeric composition disclosed herein maintains mechanical properties when exposed to fire. The Organosheet 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 Organosheet may have a thickness of about 10 mm or less, or about 4.0 mm or less. The Organosheet may have a thickness from 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] The Organosheet may be molded into any desired form. The Organosheet may be molded for use in an article or molded into an article to insulate heat from a fire, reduce the transfer of heat from a fire, slow the burn of a fire, contain the spread of fire. The Organosheet may be molded using any molding process known in the art for molding an Organosheet. The Organosheet may be molded using compression molding (stamp forming), thermoforming, insert molding, injection molding (over-molding), or co-stamped with another composition.

[0098] The disclosed composition may be combined with a polycarbonate composition to form a reinforced Organosheet and / or an over-molded Organosheet. The disclosed composition may be combined with a polycarbonate composition that provides additional fire resistance and heat insulation. The disclosed composition may be combined with a fiber filled polycarbonate to form a reinforced Organosheet and / or an over-molded Organosheet. The fiber filled polycarbonate may contain any reinforcing fillers disclosed herein. The fiber filled polycarbonate may contain one or more fibers of any fiber type disclosed herein. The fiber filled polycarbonate may contain one or more glass fibers. The one or more glass fibers may have a length from about 0.1 mm to about 35 mm; about 0.5 mm to about 25 mm; or about 1mm to about 15 mm. The fiber filled polycarbonate 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. The fiber filled polycarbonate may contain one or more long glass fibers. The one or more short glass fibers may have a length of less than about 1 mm.

[0099] The fiber filled polycarbonate may contain one or more glass fibers in an amount of about 20 percent by weight or greater, or about 30 percent by weight or greater based on the weight of the fiber filled polycarbonate composition. The fiber filled polycarbonate may contain one or more glass fibers in an amount of about 55 percent by weight or less, about 40 percent by weight or less, or about 30 percent by weight based on the weight of the fiber filled polycarbonate.

[0100] The Organosheet may be molded into a desired form prior to being combined with the polycarbonate composition. The Organosheet may be molded into a desired form when combined with the polycarbonate composition. The Organosheet may be molded into a desired form after being combined with the polycarbonate composition. The disclosed composition may be molded with the polycarbonate composition any method known to one skilled in the art to form a reinforced Organosheet and / or an over-molded Organosheet. The disclosed composition may be compression molded, insert molded, or over-molded with a polycarbonate composition to form a reinforced Organosheet and / or an over-molded Organosheet. To form the reinforced Organosheet and / or an over-molded Organosheet the polycarbonate composition may be molded on top of the Organosheet; molded as a layer between two or more Organosheets; molded over the Organosheet; or molded around the Organosheet. The reinforced Organosheet and / or an overmolded Organosheet may contain one or more Organosheets and the polycarbonate composition. The polycarbonate composition may be a reinforcing layer between two or more Organosheets molded together.

[0101] Disclosed is an article with a structure prepared from the composition disclosed herein. The composition may be used in an article or formed into an article to insulate heat from a fire, reduce the transfer of heat from a fire, slow the burn of a fire, contain the spread of fire. The composition may be used as a layer in an article or formed into an article with a structure. The composition may be used as a layer in an article or formed into an article with a structure where there is a risk of fire from within. The composition may be used as a layer in an article or formed into an article with a structure where there is a desire to contain a fire within the article. The composition may be used as a layer in an article or formed into an article with a structure where a reduction in the transfer of heat through the article. The composition may be used as a layer in an article or formed into an article with a structure to insulate the heat from a fire within the article. The composition may be used as a layer in an article or formed into an article with a structure to reduce the transfer of heat from a fire within the article. The composition may be used as a layer in an article or formed into an article with a structure to slow the burn of a fire. The composition may be used as a layer in an article or formed into an article with a structure to contain the spread of fire. The article may be a housing or enclosure for an object that has the potential to catch fire. The article may be a housing or enclosure for a battery. The housing or enclosure for a battery may be a battery pack. The article may be a housing or enclosure for a lithium ion battery. The article may be a battery pack. The article may be used as a layer within the battery pack. The composition may be formed into an enclosure for a battery. The composition may be formed into an enclosure for a lithium-ion battery. The composition may be used as a layer within the lid of the battery pack. The composition may be attached to the lid of the battery pack. The compositionmay be formed into the battery pack. The composition may be formed into the lid of the battery pack. The battery pack may be used in an electric vehicle. The battery pack may be used to house the battery pack of an electric vehicle.

[0102] Disclosed is a method for making the composition disclosed herein comprising: forming a layered stack of one or more fiber material layers and one or more layers of one or more polymeric compositions, at least one fiber material layer is a non-woven fiber material; stacking alternating layers of the one or more fiber material layers and the one or more polymeric composition layers; pressing and heating the layered stack, embedding the one or more fiber material layers with one or more polymeric compositions, and forming an Organosheet. The method may comprise stacking one fiber material layer between two or more polymeric composition layers.

[0103] The layered stack may be pressed and heated using any method known in the art to embed the polymeric composition into the fiber material layer to create an Organosheet. The pressing and heating of the layered stack may be done using any method known in the art for lamination. The pressing and heating of layered stack may be done using batch lamination by press or double belt lamination. The pressing and heating of the layered stack may be done using double belt lamination. The double belt process is the ideal production systems for the continuous production of roll, sheet and plate materials when using the through-feed method. Various processes, such as continuous laminating, compacting, consolidation, smoothing allow different materials to be processed, like films, fabrics, mats of fibers, granulates or powders. The materials run through the press between two endless steel belts, in single or multiple layers. At the inlet and the outlet, these steel belts are looped around steel drums.

[0104] The layered stack may comprise a number of polymeric composition layers and fiber material layers sufficient to create a composition with excellent fire retardant and fire resistant properties. The layered stack may comprise a number of polymeric composition layers sufficient to embed the polymeric composition within the fiber material layers within the layered stack. The polymeric layers may also bond adjacent fiber layers together. The layered stack may comprise one or more polymeric composition layers, two or more polymeric composition layers, three or more polymeric composition layers, or four or more polymeric composition layers. The layered stack may comprise one polymeric composition layer and one fiber material layer. The layered stack may comprise two polymeric composition layers and one fiber material layer. The layered stack may comprise two polymeric composition layers and two fiber material layers. The layered stack may comprise three polymeric composition layers and two fiber material layers. The layered stack may comprise three polymeric composition layers and three fiber material layers. The layered stack may comprise four polymeric composition layers and three fiber material layers.The layered stack may comprise four polymeric composition layers and four fiber material layers. The layered stack may comprise four or more polymeric composition layers and four or more fiber material layers.

[0105] The layered stack design may have a top layer and a bottom layer that form the outside faces, or top and bottom of the Organosheet. The top layer of the layered stack design may form the top outside face or top side of the Organosheet. The bottom layer of the layered stack may form the bottom outside face or bottom side of the Organosheet. The top layer or the bottom layer of the layered stack design may comprise a layer of the polymeric composition or a fiber material layer. The bottom layer of the layered stack design may comprise a layer of the polymeric composition or a fiber material layer. At least one outside layer of the layered stack may comprise a layer of the polymeric composition. The layered stack may comprise a layer of the polymeric composition on both outside layers. The Organosheet may comprise polymeric composition layers on both outside layers.

[0106] The layered stack design of the one or more fiber material layers and the polymeric composition layers may be fed into the laminating device to form the Organosheet. The top and bottom layer may be layers of the polymeric composition. The layers may be fed at temperatures at which the composition containing one or more polycarbonates and / or copolymers containing carbonate units melt. The temperature may be about 150 °C or greater, or about 200 °C or greater. The temperature may be about 300°C or less, about 280 °C or less, or about 200 °C or less. Pressure may be applied during lamination. The pressure may be any pressure that enhances forming of the Organosheet.

[0107] The method may comprise molding the Organosheet into a desired form. The Organosheet may be molded using any method known in the art to mold an Organosheet into a desired form. The Organosheet may be molded using a thermoforming process. The Organosheet may be molded using a battery housing molder. The Organosheet may be molded using an electric vehicle housing molder. The Organosheet may be molded into a layer of an article or formed into an article with a structure. The Organosheet may be molded into a layer of an article or formed into an article with a structure as disclosed herein. The Organosheet may be molded into a housing for a battery. The Organosheet may be molded into a battery enclosure. The Organosheet may be molded into a battery pack. The Organosheet may be molded as a layer within the battery pack. The Organosheet may be molded as a layer within the lid of the battery pack. The Organosheet may be molded into the lid of the battery pack. The Organosheet may be molded into a housing article. The Organosheet may be molded into a housing article for use with a battery. The Organosheet may be molded into a housing article for use with a lithium-ion battery.The Organosheet may be molded into a housing article for use in an electric vehicle. The battery pack may be molded into a battery pack of an electric vehicle.

[0108] The disclosed method may comprise forming a polycarbonate reinforced Organosheet and / or a polycarbonate over-molded Organosheet. The method may comprise adding a polycarbonate composition as disclosed herein to the one or more Organosheets; and forming a reinforced Organosheet and / or an over-molded Organosheet. The method may comprise adding a fiber filled polycarbonate as disclosed herein to the one or more Organosheets; and forming the reinforced Organosheet reinforced Organosheet and / or the over-molded Organosheet. The method may comprise molding the Organosheet before adding a polycarbonate composition. The method may comprise molding the Organosheet into a desired form when combined with the polycarbonate composition. The method may comprise molding the Organosheet into a desired form after being combined with the polycarbonate composition.

[0109] The method may comprise compression molding, insert molding, or injection molding to form the reinforced Organosheet reinforced Organosheet and / or the over-molded Organosheet. The method may comprise placing the one or more Organosheets into a mold; extruding the polycarbonate composition into the mold with the one or more Organosheets; and molding the one or more Organosheets and the polycarbonate; and forming reinforced Organosheet reinforced Organosheet and / or the over-molded Organosheet. The method may comprise placing the one or more Organosheets into a mold; injecting the polycarbonate composition into the mold with the one or more Organosheets; and molding the one or more Organosheets and the polycarbonate; and forming reinforced Organosheet reinforced Organosheet and / or the over-molded Organosheet. The method may comprise placing the one or more Organosheets into a mold; extruding the polycarbonate composition onto the one or more Organosheets; and molding the one or more Organosheets and the polycarbonate; and forming reinforced Organosheet reinforced Organosheet and / or the over-molded Organosheet. The polycarbonate composition may be molten when added to the mold with the Organosheet. The Organosheet may be heated prior to being placed into a mold. The Organosheet may be heated to temperature above the glass transition temperature (Tg) of the polymeric composition of the one or more Organosheets. The polymeric composition of the Organosheet may have a glass transition of about -40° C or more, about 80° C or more, or about 100° C or more. The polymeric composition of the Organosheet may have a glass transition of about 350° C or less, about 200° C or less, or about 160° C or less. The Organosheet may 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] The method may comprise compression molding the Organosheet and the polycarbonate composition; and forming a polycarbonate reinforced Organosheet and / or apolycarbonate over-molded Organosheet. The method may comprise: placing the one or more Organosheets into a compression mold; extruding a polycarbonate composition onto the one or more Organosheets; and compression molding the one or more Organosheets and the polycarbonate; and forming the reinforced Organosheet and / or the over-molded Organosheet. The method may comprise: placing one or more Organosheets into a compression mold; extruding the polycarbonate composition onto the one or more Organosheets; placing a second Organosheet on top of the extruded polycarbonate composition; compression molding the one or more Organosheets, the polycarbonate, and the second Organosheet together; and forming the reinforced Organosheet and / or the over-molded Organosheet. The method may comprise: heating the one or more Organosheets; placing the heated one or more Organosheets into a compression mold; extruding the polycarbonate composition onto the heated one or more Organosheets; compression molding the heated one or more Organosheets and the polycarbonate; and forming the reinforced Organosheet and / or the over-molded Organosheet. The method may comprise: heating the one or more Organosheets; placing the heated one or more Organosheets into a compression mold; extruding the polycarbonate composition onto the heated one or more Organosheets; heating a second Organosheet; placing the second heated Organosheet on top of the extruded polycarbonate composition; compression molding the heated one or more Organosheets and the polycarbonate; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0111] The method may comprise injection molding or over-molding the Organosheet and the polycarbonate composition together and forming a polycarbonate reinforced Organosheet and / or a polycarbonate over-molded Organosheet. The method may comprise placing the one or more Organosheets into a mold; injecting the polycarbonate composition into the mold with the one or more Organosheets; molding the one or more Organosheets and the polycarbonate composition together; and forming the reinforced Organosheet or over-molded Organosheet. The method may comprise heating the one or more Organosheets; placing the heated one or more Organosheets into a mold; injecting the polycarbonate composition into the mold with the one or more Organosheets; molding the one or more Organosheets and the polycarbonate composition together; and forming the reinforced Organosheet or over-molded Organosheet. The method may comprise heating the one or more Organosheets; placing the one or more Organosheets into a mold; thermoforming the one or more Organosheets within the mold; back injecting the polycarbonate composition into the mold with the one or more Organosheets; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0112] The method may comprise insert molding the Organosheet and the polycarbonate composition and forming a polycarbonate reinforced Organosheet and / or a polycarbonate over-molded Organosheet. The method may comprise molding the Organosheet into an Organosheet of a desired form prior to adding a polycarbonate composition. The method may comprise: placing the Organosheet of the desired form into a mold; injecting the polycarbonate composition into the mold; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0113] The Figures are provided to illustrate the disclosure herein, but are not intended to limit the scope thereof. Figure 1 shows a layered stack design 1 with one fiber material layer 2 and two layers of a polymeric composition 3, prior to the polymeric composition 3 embedding the fiber material layer 2. Figure 2 shows a layered stack design 1 with fiber material layers 2 of the same fiber material, prior to the polymeric composition 3 embedding in the non-woven fiber material layers 4. Figure 3 shows a layered stack design 1 , with one non-woven fiber material layer 4 of one fiber material, for example non-woven glass fiber or non-woven carbon fiber, and two fiber material layers of a different woven or non-woven fiber materials 5, prior to the polymeric composition 3 embedding the fiber material layers 4 & 5. Figure 4 shows a layered stack design 1 , with two non-woven fiber material layers 4 of one fiber type and one fiber material layers of a different woven or non-woven fiber material 5, prior to the polymeric composition 3 embedding the fiber material layers 4 & 5. Figure 5 shows a layered stack design 1 of the composition 6 of Figure 6, prior to the polymeric composition containing polycarbonates 7 embedding the layers of the non-woven glass fiber material 8. Figure 6 is a scanning electron microscope micrograph zoomed to x 65 of a cross section of the composition 9 and shows the polymeric composition containing polycarbonates 7 embedded between the layers of the non-woven glass fiber material 8. As seen in the Figure 6 the non-woven glass fiber material is arranged in a way so that the glass fibers 10 have different directions. Figure 7 is a Scanning electron microscope micrograph zoomed to x 1.00K of a cross section of the composition 9 shows how the polymeric composition containing polycarbonates 7 is embedded around the glass fibers 10. Figure 8 shows the laminating process that may be used to create an Organosheet. Shown are fiber material layers 2 and layers of a polymeric composition 3 being fed between two caterpillar pressing bands 11 between two heaters 12 to form a fused composite laminate band 13, having a top side 14 and a bottom side 15.EMBODIMENTS

[0114] Embodiment 1 : A composition comprising: a) One or more fiber material layers comprised of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a non-woven fiber material; b) one or more polymeric compositions; and c) a fiber content from about 30 wt.% to about 80 wt.%; wherein the one or more polymeric compositions is embedded within the one or more fiber material layers to form an Organosheet.

[0115] Embodiment 2 The composition of embodiment 1 , wherein the one or more polymeric compositions is comprised 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 The composition of embodiments 1 or 2, having a fiber content from about 45 wt.% to about 80 wt.%.

[0117] Embodiment 4 The composition of any one of embodiments 1-3, having a fiber content from about 50 wt.% to about 65 wt.%.

[0118] Embodiment 5 The composition of any one of the preceding embodiments, wherein the polymeric composition bonds adjacent fiber material layers together.

[0119] Embodiment 6 The composition of any one of the preceding embodiments, wherein the one or more fiber materials comprise of continuous fibers or discontinuous fibers.

[0120] Embodiment 7 The composition of any one of the preceding embodiments, wherein the non-woven fiber material layer comprises discontinuous fibers.

[0121] Embodiment 8 The composition of any one of the preceding embodiments, wherein the one or more fiber materials are comprised of fibers that are woven or non-woven.

[0122] Embodiment 9 The composition of any one of the preceding embodiments, wherein the one or more fiber materials is a non-woven material, a felt, or a mat material.

[0123] Embodiment 10 The composition of any one of the preceding embodiments, wherein the fibers of the fiber materials are comprised of one or more fiber types.

[0124] Embodiment 11 The composition of any one of the preceding embodiments, wherein the fibers of the non-woven fiber material are non-woven.

[0125] Embodiment 12 The composition of embodiment 11 , wherein the fibers of the nonwoven fiber material have a diameter from about 0.1 pm to about 18 pm.

[0126] Embodiment 13 The composition of embodiment 11 or 12, wherein the non-woven fibers of the non-woven fiber material layer have a diameter from about 1.0 pm to about 10 pm.

[0127] Embodiment 14 The composition of any one of embodiments 10-13, wherein the one or more fiber types comprise of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymeric fibers, one or more polymeric 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.

[0128] Embodiment 15 The composition of embodiment 14, wherein the one or more metal fibers comprise 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.

[0129] Embodiment 16 The composition of embodiment 14, wherein the one or more metal coated fibers comprise 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 nickel coated carbon fibers, one or more nickel coated glass fibers, one or more silver coated fibers, or a mixture of any of the one or more metal coated fibers.

[0130] Embodiment 17 The composition of embodiment 14, wherein the mineral fiber is wollastonite fiber, or basalt fiber.

[0131] Embodiment 18 The composition of embodiment 14, wherein the cellulose fiber is flax fiber.

[0132] Embodiment 19 The composition of any one of the preceding embodiments, wherein the non-woven fibers of the non-woven fiber material layer are comprised of the one or more glass fibers, the one or more carbon fibers, the one or more ceramic fibers, the one or more polymeric spun fibers, one or more metal fibers, one or more metal coated fibers, or any combination thereof.

[0133] Embodiment 20 The composition of any one of the preceding embodiments, wherein the fibers of the non-woven fiber material are randomly knitted.

[0134] Embodiment 21 The composition of any one of the preceding embodiments, wherein two or more different fibers are combined to form a co-knit fibers.

[0135] Embodiment 22 The composition of any one of the preceding embodiments, wherein the non-woven fiber material comprises co-knit fibers.

[0136] Embodiment 23 The composition of embodiment 21 or 22, wherein the co-knit fibers contain glass fibers, carbon fibers, polymeric spun fibers, or any combination thereof.

[0137] Embodiment 24 The composition of embodiments 21-23, wherein the co-knit fibers contain a mixture of the glass fibers and the carbon fibers.

[0138] Embodiment 25 The composition of embodiments 21-24, wherein the co-knit fibers contain polymeric spun fibers co-knit into the one or more carbon fibers.

[0139] Embodiment 26 The composition of embodiment 25, wherein the ratio of the polymeric spun fibers to the one or more carbon fibers is from 10-90 wt.% to 90-10 wt.%.

[0140] Embodiment 27 The composition of any one of the preceding embodiments, wherein the non-woven fiber material is comprised of a mixture of the co-knit fiber, the glass fiber, or a carbon fiber mixture.

[0141] Embodiment 28 The composition of any one of the preceding embodiments, comprising from about 30 wt.% to about 50 wt. % of the polymeric composition.

[0142] Embodiment 29 The composition of any one of the preceding embodiments, wherein the polymeric composition comprises one or more non-halogen containing flame retardants.

[0143] Embodiment 30 The composition of any one of the preceding embodiments, wherein the polymeric composition comprises from about 0 wt.% to about 25 wt.% of one or more nonhalogen containing flame retardants.

[0144] Embodiment 31 The composition of either embodiment 29 or 30, wherein the one or more non-halogen containing flame retardants is one or more phosphorus containing flame retardants.

[0145] Embodiment 32 The composition of embodiment 31 , wherein the one or more phosphorus containing flame retardant comprises a phosphate ester or a phosphazene.

[0146] Embodiment 33 The composition of embodiments 31 or 32, wherein the one or more phosphorus containing flame retardant is bisphenol A bis(diphenyl phosphate), hexa-phenoxy- cyclo-phosphazene, or a mixture of bisphenol A bis(diphenyl phosphate) and hexa-phenoxy- cyclo-phosphazene.

[0147] Embodiment 34 The composition of any one of the preceding embodiments, wherein the polymeric composition comprises one or more antioxidants.

[0148] Embodiment 35 The composition of any one of the preceding embodiments, wherein the polymeric composition comprises from about 0.1 wt.% to about 0.3 wt.% of the one or more antioxidants.

[0149] Embodiment 36 The composition of embodiment 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 The composition of any of the preceding embodiments, wherein the polymeric composition contains one or more mold release agents.

[0151] Embodiment 38 The composition of any one of the preceding embodiments, wherein the polymeric composition comprises from about 0.1 wt.% to about 0.7 wt.% of the one or more mold release agents.

[0152] Embodiment 39 The composition of either embodiment 37 or 38, wherein at least one of the one or more mold release agents is PentaErythritol Tetrastearate.

[0153] Embodiment 40 The composition of any of the preceding embodiments, wherein the polymeric composition contains, one or more impact modifiers, one or more short glass fibers, one or more additional polymers, one or more charring salts, one or more UV absorbers, one or more additives commonly used in a thermoplastic composition, or any combination thereof.

[0154] Embodiment 41 The composition of any one of embodiments 2-40, wherein the polymeric composition contains from about 75 wt.% to about 90 wt.% of the one or more thermoplastic polymers.

[0155] Embodiment 42 The composition of any one of embodiments 2-41 , wherein the one or more thermoplastic polymers melt and expand when exposed to temperatures of about 300 °C to about 500 °C.

[0156] Embodiment 43 The composition of any one of embodiments 2-42, wherein the one or more thermoplastic polymers is comprised of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylene, one or more polyphenylene sulfide, one or more polyetherimide, one or more polycarbonates, or any combination thereof.

[0157] Embodiment 44 The composition of embodiment 43, wherein the thermoplastic polymer is comprised of the one or more polycarbonates.

[0158] Embodiment 45 The composition of embodiment 44, wherein the one or more polycarbonates are a virgin polycarbonate, a recycled polycarbonate, or a mixture of both.

[0159] Embodiment 46 The composition of any one of embodiments 43-45, wherein the one or more polycarbonates is branched, linear, or a mixture thereof.

[0160] Embodiment 47 The composition of any one of embodiments 43-46, wherein the one or more polycarbonates comprises one or more polycarbonate siloxane copolymers.

[0161] Embodiment 48 The composition of embodiment 43, wherein the thermoplastic polymer is comprised of the one or more polyarylsulfones.

[0162] Embodiment 49 The composition of any one of embodiments 13-48, wherein the polymeric spun fiber is spun fiber of the polymeric composition.

[0163] Embodiment 50 The composition according to embodiments 18-49, wherein the non-woven glass fiber has a diameter from about 6 pm to about 10 pm.

[0164] Embodiment 51 The composition according to embodiments 18-49, wherein the non-woven carbon fiber has a diameter from about 4 pm to about 6 pm.

[0165] Embodiment 52 The composition of any one of the preceding embodiments, wherein the one or more layers of the one or more fiber materials are non-woven fiber material layers.

[0166] Embodiment 53 The composition of any one of the preceding embodiments, comprising two or more fiber material layers, wherein at least one fiber material layer is a nonwoven fiber material layer.

[0167] Embodiment 54 The composition of any one of the preceding embodiments, comprising three or more fiber materials layers, wherein at least one fiber material layer is a nonwoven fiber material layer.

[0168] Embodiment 55 The composition of embodiment 53 or 54, wherein at least one fiber material layer is a woven fiber material layer.

[0169] Embodiment 56 The composition of embodiment 55, wherein the woven fiber material layer is comprised of one or more woven fiber materials.

[0170] Embodiment 57 The composition of embodiment 55 or 56, wherein the one or more woven fiber materials are comprised of one or more woven fibers.

[0171] Embodiment 58 The composition of any one of embodiments 55-57, wherein the woven fibers of the one or more woven fiber materials is comprised of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, one or more polymeric fibers, one or more metal fibers, one or more metal coated fibers.

[0172] Embodiment 59 The composition of embodiment 58, wherein the one or more metal fibers comprise 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.

[0173] Embodiment 60 The composition of embodiment 58, wherein the one or more metal coated fibers comprise 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 nickel coated carbon fibers, one or more nickel coated glass fibers, one or more silver coated fibers, or a mixture of any of the one or more metal coated fibers.

[0174] Embodiment 61 The composition of any one of embodiments 55-60, wherein the woven fibers have a plain weave, a unidirectional weave, a non-crimp weave, or twill weave.

[0175] Embodiment 62 The composition according to any one of the preceding embodiments, wherein at least one of the layers of the one or more fiber materials have a thickness from about 20 pm to about 500 pm.

[0176] Embodiment 63 The composition according to any one of the preceding embodiments, wherein at least one of the layers of the one or more fiber materials have a thickness from about 50 pm to about 500 pm.

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

[0178] Embodiment 65 The composition according to embodiment 64, wherein the one or more polymeric composition layers is disposed between the one or more fiber material layers.

[0179] Embodiment 66 The composition according to embodiment 64, wherein the one or more fiber material layers are disposed between two layers of the polymeric composition layers.

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

[0181] Embodiment 68 The composition according to any one of the preceding embodiments, wherein the one or more polymeric composition layers form at least one outside face of the Organosheet.

[0182] Embodiment 69 The composition according to any one of the preceding embodiments, wherein the one or more polymeric composition forms a top face and a bottom face of the Organosheet.

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

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

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

[0186] Embodiment 73 An article with a structure prepared from a composition according to any one of the preceding embodiments comprising:One or more fiber material layers comprised of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a non-woven fiber material layer; one or more polymeric compositions; and a fiber content from about 30 wt.% to about 80 wt.%, wherein the one or more polymeric compositions is embedded within the one or more fiber material layers to form an Organosheet.

[0187] Embodiment 74 The article according to embodiment 73, wherein the polymeric composition maintains its mechanical properties when exposed to fire.

[0188] Embodiment 75 The article according to either embodiment 73 or 74, wherein the polymeric composition bonds adjacent fiber material layers together.

[0189] Embodiment 76 The article according to any one of embodiments 73-75, wherein the non-woven fiber material layer insulates heat from fire.

[0190] Embodiment 77 The article of embodiments 73-76, wherein a reduced amount of heat is transferred through the Organosheet.

[0191] Embodiment 78 The article of any one of embodiments 73-77, wherein the Organosheet has a top side and a bottom side.

[0192] Embodiment 79 The article of any one of embodiments 73-78, wherein at least one side of the Organosheet is formed by the polymeric composition.

[0193] Embodiment 80 The article of any one of embodiments 73-79, wherein a top side and a bottom side the Organosheet is formed by the polymeric composition.

[0194] Embodiment 81 The article according to any one of embodiments 73-80, wherein the Organosheet expands when exposed to fire.

[0195] Embodiment 82 The article according to any one of embodiments 73-81 , wherein the Organosheet has an expanding ratio of about 4% or greater when exposed to fire.

[0196] Embodiment 83 The article according to any one of embodiments 73-82, wherein the Organosheet has a thickness of about 0.1 mm to about 10 mm.

[0197] Embodiment 84 The article according to any one of embodiments 73-83, wherein the Organosheet has a thickness of about 0.5 mm to about 4.0 mm.

[0198] Embodiment 85 The article according to any one of embodiments 73-84, wherein the top side of the Organosheet has a temperature of about 370°C or less, after the bottom side has been exposed to fire for 10 min.

[0199] Embodiment 86 The article according to any one of embodiments 73-85, wherein the top side of the Organosheet has a temperature of about 350°C or less, after the bottom side has been exposed to fire for 10 min.

[0200] Embodiment 87 The article according to any one of embodiments 73-86, wherein the Organosheet has at least one fiber layer comprised of about 10 pm diameter non-woven glass fiber, and the top side has a temperature of about 330°C or less, after the bottom side has been exposed to fire for 10 min.

[0201] Embodiment 88 The article according to any one of embodiments 73-87, wherein the Organosheet has at least one fiber layer comprised of the non-woven carbon fiber and the top side has a temperature of about 300°C or less, after the bottom side has been exposed to fire for 10 min.

[0202] Embodiment 89 The article according to any one of embodiments 73-88, used in a battery pack.

[0203] Embodiment 90 The article according to any one of embodiments 73-89, used as a fireproof layer within the battery pack.

[0204] Embodiment 91 The article according to any one of embodiments 73-90, used as a fireproof layer of a battery lid of the battery pack.

[0205] Embodiment 92 The article according to any one of embodiments 73-91 , glued to the lid or assembled into the lid of the battery pack.

[0206] Embodiment 93 The article according to any one of embodiments 73-92, molded into a battery lid of the battery pack.

[0207] Embodiment 94 The article according to any one of embodiments 73-93, molded into the battery pack.

[0208] Embodiment 95 A method for making the composition of any of the preceding embodiments comprising: forming a layered stack of one or more fiber material layers and one or more layers of one or more polymeric compositions, wherein at least one of the fiber material layers is a non-woven fiber material; stacking alternating layers of the one or more fiber material layers and the one or more polymeric composition layers; pressing and heating the layered stack; embedding the one or more fiber material layers with one or more polymeric compositions; bonding adjacent fiber material layers together with the one or more polymeric compositions; and forming one or more Organosheets with a fiber content from about 30 wt.% to about 80 wt.% and a top side and a bottom side.

[0209] Embodiment 96 The method of embodiment 95, wherein the one or more polymeric compositions is comprised 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 temperatures between about 300 °C to about 500 °C.

[0210] Embodiment 97 The method of embodiment 96, wherein the one or more thermoplastic polymers is comprised of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylene, one or more polyphenylene sulfide, one or more polyetherimide, one or more polycarbonates, or any combination thereof

[0211] Embodiment 98 The method of embodiment 97, wherein the one or more thermoplastic polymers is comprised of one or more polycarbonates.

[0212] Embodiment 99 The method of any one of embodiments 95-98, wherein the one or more polymeric composition layers has a thickness from about 0.05 mm to about 0.15mm.

[0213] Embodiment 100 The method of any one of embodiments 95-99, wherein at least one of the layers of the one or more fiber materials have a thickness from about 20 pm to about 500 pm.

[0214] Embodiment 101 The method of any one of embodiments 95-100, wherein at least one of the layers of the one or more fiber materials have a thickness from about 50 pm to about 500 pm.

[0215] Embodiment 102 The method of any one of embodiments 95-101 , wherein a top layer of the layered stack forms the top outside face of the Organosheet.

[0216] Embodiment 103 The method of any one of embodiments 95-102, wherein a bottom layer of the layered stack forms the bottom outside face of the Organosheet.

[0217] Embodiment 104 The method of any one of embodiments 95-103, wherein two or more polymeric composition layers are used within the layered stack.

[0218] Embodiment 105 The method of embodiment 95-104, comprising stacking one or more fiber material layers between two or more polymeric composition layers, wherein the layered stack has a top layer and a bottom layer of at least one polymeric composition layer.

[0219] Embodiment 106 The method of any one of embodiments 95-105, wherein two or more fiber material layers are used within the layered stack.

[0220] Embodiment 107 The method of embodiment 105 or 106, wherein the layered stack has at least two or more fiber material layers and at least three or more polymeric composition layers.

[0221] Embodiment 108 The method of any one of embodiments 105-107, wherein the layered stack has at least three or more fiber material layers and at least four or more polymeric composition layers.

[0222] Embodiment 109 The method of any one of embodiments 95-108, wherein at least the top layer or the bottom layer of the layered stack is one or more layers of the one or more polymeric composition.

[0223] Embodiment 110 The method of any one of embodiments 95-109, wherein the top layer and the bottom layer of the layered stack is one or more layers of the one or more polymeric composition.

[0224] Embodiment 111 The method of any one of embodiments 95-110, wherein at least the top side or the bottom side of the Organosheet is formed by one or more layers of the one or more polymeric composition.

[0225] Embodiment 112 The method of any one of embodiments 95-111 , wherein the top side and the bottom side of the Organosheet is formed by one or more layers of the one or more polymeric composition.

[0226] Embodiment 113 The method of any one of embodiments 106-112, wherein at least one of the fiber layers is a woven fiber layer.

[0227] Embodiment 114 The method of any one of embodiments 95-113, wherein the layered stack is pressed and heated using batch lamination by press or double belt continuous lamination.

[0228] Embodiment 115 The method of any one of embodiments 95-114, comprising molding one or more Organosheets into a desired form.

[0229] Embodiment 116 The method of embodiment 115, wherein the one or more Organosheets is molded using compression molding, insert molding, or over-molding.

[0230] Embodiment 117 The method of embodiment 116, wherein an electric vehicle housing molder is used for compression molding, insert molding, or over-molding the one or more Organosheets.

[0231] Embodiment 118 The method of embodiments 115-117, wherein the one or more Organosheets is molded into a battery pack, or a part of the battery pack.

[0232] Embodiment 119 The method of embodiments 115-118, wherein the one or more Organosheets is molded into a battery lid of the battery pack.

[0233] Embodiment 120 The method of any one of embodiments 95-119 comprising: placing the one or more Organosheets into a mold; placing a polycarbonate composition into the mold with the one or more Organosheets; molding the one or more Organosheets and the polycarbonate composition together; andforming a reinforced Organosheet and / or an over-molded Organosheet.

[0234] Embodiment 121 The method of embodiment 120, wherein the polycarbonate composition is a molten polycarbonate composition.

[0235] Embodiment 122 The method of any one of embodiments 95-121 , comprising compression molding the one or more Organosheets with the polycarbonate composition.

[0236] Embodiment 123 The method of any one of embodiments 95-122 comprising: heating the one or more Organosheets; placing the one or more Organosheets into a compression mold; extruding the polycarbonate composition onto the heated one or more Organosheets; compressing the heated one or more Organosheets and the polycarbonate together; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0237] Embodiment 124 The method according to embodiment 123 comprising: heating a second Organosheet; placing the second heated Organosheet on top of the extruded polycarbonate composition prior to compression molding; and compressing the heated one or more Organosheets and the polycarbonate together; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0238] Embodiment 125 The method of any one of embodiments 95-121 , comprising injection molding the Organosheet with the polycarbonate composition.

[0239] Embodiment 126 The method of any one of embodiments 95-121 , or 125 comprising: placing the one or more Organosheets into a mold; injecting a polycarbonate composition into the mold with the one or more Organosheets; molding the one or more Organosheets and the polycarbonate composition together; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0240] Embodiment 127 The method of embodiment 115, comprising heating the one or more Organosheets prior to placing it into the mold.

[0241] Embodiment 128 The method of any one of embodiments 95-121 , 125-127 comprising: heating the one or more Organosheets; placing the one or more Organosheets into a mold; thermoforming the one or more Organosheets; back injecting the polycarbonate composition into the mold; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0242] Embodiment 129 The method of any one of embodiments 95-121 , comprising insert molding the Organosheet with the polycarbonate composition.

[0243] Embodiment 130 The method of any one of embodiments 115-121 , or 129, comprising: placing the Organosheet of the desired form into a mold; injecting the polycarbonate composition into the mold; and forming the reinforced Organosheet and / or the over-molded Organosheet.

[0244] Embodiment 131 The method any one of embodiments 120-130, wherein the polycarbonate composition is a fiber filled polycarbonate composition.

[0245] Embodiment 132 The method according to embodiment 130, wherein the fiber filled polycarbonate composition is a glass fiber filled polycarbonate composition.

[0246] Embodiment 133 The method according to embodiments 120-132 wherein, the one or more Organosheets is heated to temperature above the glass transition temperature of the one or more Organosheets.

[0247] Embodiment 134 The method of any one of embodiments 95-117, comprising attaching the Organosheet to a lid of a battery pack.ILLUSTRATIVE EXAMPLES

[0248] The following examples are provided to illustrate the invention but are not intended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated.

[0249] The following materials are used in caring out the experiments.

[0250] A: Flame Retardant Polycarbonate (polymeric composition)A-1 Calibre 600-3 branched Bisphenol A polycarbonate 74.1wt.%A-2 Mitsubishi H-2000F Linear polycarbonate powder 5wt.%A-3 20wt.% Hexa-phenoxy-cyclo-phosphazeneA-4: 0.1wt.%potassium perflourobutane sulfonateA-5: 0.2 wt.% Blend of Tris(2,4-di-tert-butylphenyl) phosphite and Octadecyl 3-(3,5-di- tert-butyl-4-hydroxyphenyl)propionate from BASF Irganox B-900 A-6: 0.6wt.% PentaErythritol Tetrastearate.The listed materials A are all compounded and granulated in a twin screw extruder at a speed of 300 rpm at a throughput of 20kg / h at 260 °C. Thin sheets with a 0.1 mm thickness of the composition referred are prepared by a T-die adapted single-screw extruder at 260 °C.

[0251] :B: Material layers:B1 : Glass non-woven with d = 18 pmB2: Glass non-woven with d = 8-10pmC: Carbon fiber non-woven with d = 4-6 pmD: Glass plain weave (d=17 micron)E: Phlogopite Mica sheet 1.0mm thick

[0252] The layers of glass fiber material or carbon fiber material and the polymeric composition are stacked in the manner disclosed in FIG. 2. Table 1 shows the layered design and fiber material in the fiber material layer, each layer design having a different fiber material. Then the device shown in FIG. 8 pulls the stacked layers into a continuous heating and pressing chamber. After 10 minutes of pressing time under 280°C, the composite from the outlet of the device are air cooled and cut to desired size. The composite (Organosheet) is 1 .5 mm to 2mm thick and contains 50-70 percent by weight fiber.

[0253] Table 1

[0254] Testing: A Bunsen propane torch with 500 watt power is used to burn the Organosheet. After continuous burning a thermocouple is used to measure the temperature of the hottest spot of the Organosheet, on the side opposite of the flame. The Expansion ratio is measured by measuring the thickness change of the Organosheet before and after burning, and expressed in the percent change, the thickness increase of the sheet after exposure to fire over the original thickness. Flexural modulus and flexural Strength are tested on cut composite plaque according procedure ISO 178. Test Results are provided below in Table 2.

[0255] Table 2PC= A: Flame Retardant Polycarbonate

[0256] With the combination of PC and carbon fiber nonwoven, the composite expands during the burning and reduces the top temperature significantly. Glass weave and glass nonwoven with fiber diameter at 20 pm do not expand. Fiber diameter < 10 pm, randomly knitted mat has the best effect in expanding.

[0257] Parts by weight as used herein refers to 100 parts by weight of the composition specifically referred to. Any numerical values recited in the above application include all values from the lower value to the upper value in increments of one unit provided there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value, and the highest value enumerated are to be considered to be expressly stated 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 connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

Claims

CLAIMSWhat is claimed is:

1. A composition comprising: a) one or more fiber material layers comprised of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a non-woven fiber material, and fibers of the non-woven fiber material have a diameter from about 0.1 pm to about 18 pm; b) one or more polymeric compositions; and c) a fiber content from about 30 wt.% to about 80 wt.%; wherein the one or more polymeric compositions are embedded within the one or more fiber material layers to form an Organosheet.

2. The composition of claim 1 , wherein the one or more polymeric compositions comprise 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 the one or more polymeric compositions bond adjacent fiber material layers together.

3. The composition of any one of the preceding claims, wherein the one or more fiber materials comprise of continuous fibers or discontinuous fibers, and the one or more fiber materials are comprised of fibers that are woven fibers or non-woven fibers, and wherein the fibers of the fiber materials are comprised of one or more fiber types.

4. The composition of any of the preceding claims, wherein the fibers of the non-woven fiber material have a diameter from about 1.0 pm to about 10 pm.

5. The composition of claim 3 or 4, wherein the one or more fiber types comprise of one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more polymeric fibers, one or more polymeric 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 comprise 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 silverfibers, 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 comprise 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 nickel coated carbon fibers, one or more nickel coated glass fibers, one or more silver coated fibers, or a mixture of any of the one or more metal coated fibers.

6. The composition of any one of the preceding claims, wherein the fibers of the non-woven fiber material comprise of the one or more glass fibers, the one or more carbon fibers, the one or more ceramic fibers, the one or more polymeric 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 from about 30 wt.% to about 50 wt. % of the polymeric composition, wherein the polymeric composition comprises: from about 75 wt.% to about 90 wt.% of the one or more thermoplastic polymers, from about 0 wt.% to about 25 wt.% of one or more non-halogen containing flame retardants, from about 0.1 wt.% to about 0.3 wt.% of one or more antioxidants, from about 0.1 wt.% to about 0.7 wt.% of one or more mold release agents.

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

9. The composition of claim 8, wherein the one or more phosphorus containing flame retardants comprises a phosphate ester or a phosphazene.

10. The composition of claims 8 or 9, wherein the one or more phosphorus containing flame retardant is bisphenol A bis(diphenyl phosphate), hexa-phenoxy-cyclo-phosphazene, or a mixture of bisphenol A bis(diphenyl phosphate) and hexa-phenoxy-cyclo-phosphazene.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 mold release agents is PentaErythritol Tetrastearate.

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

14. The composition of any one of claims 2-13, wherein the one or more thermoplastic polymers melt and expand when exposed to temperatures of about 300 °C to about 500 °C, and is comprised of one or more styrene-acrylonitrile, one or more poly(methyl methacrylate), one or more polyolefins, one or more polyarylsulfones, one or more polypropylene, one or more polyphenylene sulfide, one or more polyetherimide, one or more polycarbonates, or any combination thereof.

15. The composition of claim 14, wherein the one or more thermoplastic polymers are comprised of one or more polycarbonates or one or more polyarylsulfones, or a combination thereof.

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

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

18. The composition according to claims 5-17, wherein the non-woven fiber material is comprised of one or more glass fibers having a diameter from about 6 pm to about 10 pm.

19. The composition according to claims 5-17, wherein non-woven fiber material carbon fiber has a diameter from about 4 pm to about 6 pm.

20. The composition of any one of the preceding claims, comprising two or more fiber material layers, wherein at least one fiber material layer is a non-woven fiber 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 comprised of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, one or more polymeric fibers, one or more metal fibers, 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 non-crimp weave, or twill weave.

24. The composition according to any one of the preceding claims, wherein at least one of the layers of the one or more fiber materials have a thickness from about 20 pm to about 500 pm.

25. The composition according to any one of the preceding claims, wherein prior to embedding the fiber material layers, the one or more polymeric compositions are one or more polymeric composition layers.

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

27. The composition according to any one of the preceding claims, wherein the Organosheet is combined with a fiber filled polycarbonate composition to form a reinforced Organosheet.

28. The composition according to claim 27, wherein the fiber filled polycarbonate composition is a glass fiber filled polycarbonate composition.

29. An article with a structure prepared from a composition according to any one of the preceding claims comprised of:One or more fiber material layers comprised of one or more layers of one or more fiber materials, wherein at least one of the fiber material layers is a non-woven fiber material, the fibers of the non-woven fiber material have a diameter from about 0.1 pm to about 18 pm; one or more polymeric compositions; and a fiber content from about 30 wt.% to about 80 wt.%, wherein the one or more polymeric compositions is embedded within the one or more fiber material layers to form an Organosheet.

30. The article according to claim 29, wherein the one or more polymeric compositions maintains its mechanical properties when exposed to fire.31 . The article of claim 29 or 30, wherein a reduced amount of heat is transferred through the Organosheet.

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

33. The article according to any one of claims 29-32, used in a battery pack.

34. A method for making the composition of any of the preceding claims comprising: forming a layered stack of one or more fiber material layers and one or more layers of one or more polymeric compositions, wherein at least one of the fiber material layers is a nonwoven fiber material, the fibers of the non-woven fiber material having a diameter from about 0.1 pm to about 18 pm; stacking alternating layers of the one or more fiber material layers and the one or more polymeric composition layers; pressing and heating the layered stack; embedding the one or more fiber material layers with one or more polymeric compositions; bonding adjacent fiber material layers together with the one or more polymeric compositions; and forming one or more Organosheets with a fiber content from about 30 wt.% to about 80 wt.% and a top side and a bottom side.

35. The method of claim 34, wherein the one or more polymeric compositions is comprised 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 temperatures between about 300 °C to about 500 °C.

36. The method of claim 34 or 35, wherein the layered stack is pressed and heated using batch lamination by press or double belt continuous lamination.

37. The method of any one of claims 34-36, comprising molding one or more Organosheets into a desired form.

38. The method of claim 37, wherein the one or more Organosheets is molded using compression molding, insert molding, or over-molding.

39. The method of claim 37 or 38, wherein the one or more Organosheets is molded into a battery pack, or a part of the battery pack.

40. The method of claims 37-39, wherein the one or more Organosheets is molded into a battery lid of the battery pack.41 . The method of any one of claims 34-40 comprising: placing the one or more Organosheets into a mold; placing a polycarbonate composition into the mold with the one or more Organosheets; molding the one or more Organosheets and the polycarbonate composition together; and forming a reinforced Organosheet and / or an over-molded Organosheet.

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.