Fire retardant polycarbonate long glass fiber compositions

Abstract

Disclosed are polycarbonate compositions containing long glass fiber having excellent fire resistance properties. The polycarbonate compositions containing long glass fiber may be combined with a thermoplastic composite to create a fire reducing composite having premium fire retardancy and fire insulating properties. The polycarbonate compositions may contain recycled or virgin polycarbonate content. Disclosed are methods for preparing a polycarbonate compositions containing long glass fibers. Disclosed are methods for preparing a fire reducing composite. Disclosed are structures prepared using the disclosed polycarbonate compositions containing long glass fiber. Disclosed are structures prepared using a fire reducing composite.

Description

FIRE RETARDANT POLYCARBONATE LONG GLASS FIBER COMPOSITIONS CROSS REFERENCE

[0001] This application claims priority from United States Provisional ApplicationSerial Number 63 / 562,928 filed March 8, 2024, incorporated herein by reference in itsentirety for all purposes. TECHNIAL FIELD

[0002] Disclosed are polycarbonate compositions containing long glass fiber havingexcellent fire resistance properties. The polycarbonate compositions containing long glass fiber may be combined with a thermoplastic composite to create a fire reducing compositehaving premium fire retardancy and fire insulating properties. The polycarbonatecompositions may contain recycled or virgin polycarbonate content. Disclosed aremethods for preparing polycarbonate compositions containing long glass fibers. Disclosedare methods for preparing a fire reducing composite. Disclosed are structures preparedusing the disclosed polycarbonate compositions containing long glass fiber. Disclosed arestructures prepared using a fire reducing composite. BACKGROUND

[0003] Polycarbonate and copolymers containing carbonate units are utilized in avariety of molded structures. Polycarbonates and copolymers containing carbonate units form molded structures that are rigid. The molded structures may be used for a variety ofuses, including cases for electronics, automobile parts, medical devices, homeappliances, loudspeakers, home furnishings and the like. Fire retardancy and heatinsulting properties of such structures are important safety consideration, especially whenthe structure is at an elevated risk of fire exposure. The market continues to demand improved fire retardancy of molded structures while the structures also maintain premium properties. Non-halogen containing flame retardants along with fiber materials such as carbon fibers and / or glass fibers may be used in a polycarbonate and copolymers containing carbonate units to improve the fire retardancy of the polycarbonate containing compound, see US20070149661 and JP 2022080749.

[0004] Thermoplastic composites or organosheets comprise continuous and / ordiscontinuous fiber materials embedded with a polycarbonate composition and have beenused to replace metal because of their superior mechanical properties, low density, recyclability, excellent corrosion resistance and infinite shelf life. Polymeric compositions comprised of polycarbonate and copolymers containing carbonate units are used as a resin to impregnate / embed the continuous and / or discontinuous fiber materials, to form apolymer composite matrix that forms organosheets. Composites based on polycarbonatesand fiber material can be formed into a variety of structures by thermoforming, net shapedrawing, deep drawing and the like. These organosheets may also be used for a varietyof uses, including automobile parts, electronics, medical devices, and the like. The fireretardancy and heat insulating properties of an organosheet is an important safetyconsideration, especially when the organosheet is at an elevated risk of fire exposure. Themarket also demands organosheets with premium fire retardancy and fire insulatingproperties. Organosheets of special formulated polymeric compositions containingpolycarbonate or copolymers thereof in certain applications need to pass flame retardanttest, e.g. UL94 V-0, see US 2016 / 25794A1 and WO2019 / 115506 A1. However, the limitedglass transition temperature of most organosheets cause the composite to lose formintegrity and mechanical strength during burning. Additionally, most organosheetsregardless of their thermoset or thermoplastic type do not adequately reduce the transferof heat through the organosheet, requiring the use of additional fire insulating material.

[0005] What is needed are improved polycarbonate compositions that can be usedwith organosheets to form molded structures having premium fire retardancy and fireinsulating properties. What is needed are compositions having premium fire retardancyand fire insulating properties that can be used as a fireproof layer. What is needed aremolded compositions prepared from such organosheets that exhibit premium fireretardancy and fire insulating properties. What are also needed are organosheetsprepared from such compositions that exhibit improved fire retardancy and fire insulating properties. SUMMARY

[0006] Disclosed are compositions which comprise: one or more polycarbonatecompositions and one or more long glass fibers, wherein the one or more long glass fibersare mixed with the one or more polycarbonate compositions to form a polycarbonate longfiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers. Theone or more long glass fibers may have an average length of about 0.5 mm to about 35mm. The composition may comprise from about 30 wt.% to about 80 wt.% of one or more polycarbonate compositions.

[0007] The one or more polycarbonate compositions may comprise of one or morepolycarbonates. The one or more polycarbonates may comprise of one or more polycarbonate polymers and / or one or more copolymers containing carbonate units. The one or more polycarbonates may be a virgin polycarbonate, a recycled polycarbonate, ora mixture of both. The polycarbonate composition may comprise from about 75 wt.% toabout 100 wt.% of one or more polycarbonates. The polycarbonate composition maycomprise 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 polycarbonate composition may comprise from about0 wt.% to about 25 wt.% of the one or more non-halogen containing flame reagents. Thepolycarbonate composition may comprise one or more antioxidants. The polycarbonate composition may comprise from about 0.1 wt.% to about 0.3 wt.% of one or more antioxidants. The polycarbonate composition may comprise one or more mold releaseagents. The polycarbonate composition may comprise from about 0.1 wt.% to about 0.7wt.% of one or more mold release agents. The polycarbonate composition may compriseone or more impact modifiers, one or more anti-drip agents, one or more additional polymers, one or more charring salts, one or more UV absorbers, one or more additionaladditives commonly used in a polycarbonate-based composition, or any mixture thereof.The polycarbonate composition may comprise from about 0 wt.% to about 5 wt.% of one or more impact modifiers. The polycarbonate composition may comprise from about 0 wt.% to about 1 wt.% of one or more anti-drip agents. The polycarbonate composition maycomprise from about 0 wt.% to about 30 wt.% of one or more additional polymers. Thepolycarbonate composition may comprise from about 0 wt.% to about 0.3 wt.% of one ormore charring salts. The polycarbonate composition may comprise from about 0 wt.% toabout 1 wt.% of one or more UV agents.

[0008] The disclosed composition may be pelletized. The disclosed composition maybe chopped into elongate sections. The elongated sections may have a length of about 8mm to about 12 mm. The elongated sections may have a length / diameter ratio of about 700.

[0009] The disclosed composition may be molded into a molded polycarbonate longfiber composition. The molded polycarbonate long fiber composition may be used to reduce the transfer of heat. The molded polycarbonate long fiber composition may be used to insulate heat from a fire. The molded polycarbonate long fiber composition may be used to reduce the temperature on one side when an opposite side is exposed to fire. The molded polycarbonate long fiber composition may be used in a fire containment system. The molded polycarbonate long fiber composition may be used as a fire reducing layer.

[0010] A molded polycarbonate long fiber composition with a thickness that may beabout 1mm to about 10 mm, and a long glass fiber content that may be about 10 wt.% to about 55 wt.% based on the weight of the polycarbonate long fiber composition based on the weight of the composition, may have a temperature on the top side that may be about 370°C or less, may be about 340°C or less, after the bottom side of the molded polycarbonate long fiber composition has been exposed to fire for 10 min.

[0011] The disclosed composition may have a flexural modulus of about 6 GPa orgreater, about 9 GPa or greater, or about 12 GPa or greater. The disclosed compositionmay have a flexural strength of about 80 MPa or greater, about 100, MPa or greater, about120 MPa or greater, or, about 150 MPa or greater. The disclosed composition may havea UL94 rating of V-0 at 1.5 mm.

[0012] The disclosed composition may be combined with one or more composites tocreate a fire reducing composite. The one or more composites may be a non-injection moldable material. The disclosed composition and one or more non-injection moldablematerials may be compression molded, insert molded, or injection molded together to formthe disclosed fire reducing composite.

[0013] Disclosed are articles with structures prepared from the composition disclosedherein. Disclosed are articles prepared using the method disclosed herein. The disclosed articles may maintain their mechanical properties and integrity when exposed to high temperatures. The disclosed articles may be used to reduce the transfer of heat, to insulate heat from a fire; to reduce the temperature on one side when an opposite side is exposed to fire; in a fire containment system; used as a fire reducing layer. The disclosed articles may be used with one or more composites to create a fire reducing composite.

[0014] Disclosed is a method for making the composition disclosed herein comprising:feeding either a polycarbonate formulation, or one or more polycarbonate compositions into a first extruder; extruding a molten polycarbonate composition from the first extruder; feeding the molten polycarbonate composition and filament glass rovings into a second extruder; mixing the molten polycarbonate composition and filament glass rovings together; forming a polycarbonate long fiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers; and extruding the polycarbonate long fiber composition.The one or more long glass fibers may have a length of about 0.1 mm to about 35 mm.The polycarbonate long fiber composition may comprise from about 30 wt.% to about 70wt.% of a polycarbonate composition. The polycarbonate formulation may be one or morepolycarbonates, one or more modifiers and one or more additives. The one or more additives and one or more modifiers may comprise one or more non-halogen containing flame retardants, one or more antioxidants, one or more mold release agents, one or moreimpact modifiers, one or more anti-drip agents, one or more additional polymers, one ormore charring salts, one or more UV absorbers, or any combination thereof. The polycarbonate composition may be comprised of the polycarbonate formulation.

[0015] The disclosed method may comprise chopping the extruded polycarbonatelong fiber composition into elongated sections; and forming pellets of the polycarbonate long fiber composition. The disclosed method may comprise placing the pellets of the polycarbonate long fiber composition into an extruder; melting the pellets of the polycarbonate long fiber composition; and extruding the polycarbonate long fiber composition.

[0016] The disclosed method may comprise extruding the polycarbonate long fibercomposition into a mold; and molding the polycarbonate long fiber composition. The disclosed method may comprise molding the polycarbonate long fiber composition into amolded polycarbonate long fiber composition. The disclosed method may compriseextruding the polycarbonate long fiber composition into a compression mold or an injection mold; and molding the polycarbonate long fiber composition into the moldedpolycarbonate long fiber composition. The molded polycarbonate long fiber compositionmay have a thickness of at least 1 mm.

[0017] The disclosed method may comprise molding the polycarbonate long fibercomposition with one or more composites; and forming a reinforced composite or an over- molded composite. The reinforced composite or the over-molded composite may be a fire reducing composite, wherein a fire reducing composite may mean one or more of a fireexposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof.

[0018] Disclosed are articles having a structure prepared from the compositiondisclosed herein, using the method disclosed herein.

[0019] Disclosed are fire reducing composites comprising the composition disclosedherein and one or more composites. The one or more composites may be one or morenon-injection moldable materials. The one or more non-injection moldable materials maybe one or more organosheets. The fire reducing composites may be formed by compression molding, insert molding, or injection molding the one or more non-injection moldable materials with the composition disclosed herein. The disclosed composition may be molded with the non-injection moldable material to reinforce and / or over-mold the non-injection moldable material. The disclosed composition may co-mold with part of at leastone outside face of the one or more non-injection moldable materials. The disclosedcomposition may co-mold with at least one outside face of the one or more non-injectionmoldable materials. The disclosed composition may co-mold with at least one outside faceand edges of the one or more non-injection moldable materials. The disclosed compositionmay co-mold with at least part of one outside face of the one or more non-injection moldable materials. The disclosed composition may be molded between two or more non- injection moldable materials.

[0020] The disclosed fire reducing composite may mean one or more of a fireexposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof. The disclosed fire reducing composite may have minor deformation after being exposed to fire. The disclosed fire reducing composite may expand when exposed to fire. The disclosed fire reducing composite may expand immediately on fire exposure.

[0021] The one or more non-injection moldable materials may be comprised of one ormore fiber material layers and one or more polymeric compositions. The one or more fibermaterial layers may be embedded with the one or more polymeric compositions. Thepolymeric composition may bond adjacent fiber material layers together. The non-injectionmoldable material may be one or more organosheets. At least one outside face of the on-injection moldable material may the polymeric composition. The one or more on-injectionmoldable material may have a fiber content from about 30 wt.% to about 80 wt.%. Theone or more on-injection moldable material may comprise from about 30 wt.% to about50 wt. % of the polymeric composition. The one or more polymeric compositions maycomprise at least one thermoplastic polymer. The one or more polymeric composition may comprise one or more polycarbonates, one or more polyarylsulfones, 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.

[0022] The one or more fiber material layers may be comprised of one or more layersof one or more fiber materials. The one or more fiber materials may have continuous fiberor discontinuous fiber. The one or more fiber materials may be comprised of fibers that are woven or non-woven. The one or more fiber materials may be comprised of one ormore fiber types. The one or more fiber materials may have fibers that may be non-wovenor 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 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 fibertypes. Two or more different fibers may be combined to form a co-knit fiber. The fibers ofthe fiber material may have a diameter from about 0.1 μm to about 20 μm. The layers ofthe one or more fiber materials may have a thickness from about 20 μm to about 500 μm.

[0023] The one or more fiber layers may be woven fiber material layers, non-wovenfiber material layers, or a mixture of woven fiber material layers and non-woven fiber material layers. At least one of the fiber material layers may be a woven fiber materiallayer. At least one of the fiber material layers may be a non-woven fiber material layer.

[0024] The non-woven fiber material layers may be comprised of one or more layersof one or more non-woven fiber materials. The non-woven fiber material layer may be made of non-woven fibers. The non-woven fiber material layer may have discontinuous fibers. The one or more fiber materials of the non-woven fiber material layer may have co-knit fibers. The fibers of the non-woven fiber material layer may be randomly knit. Thefibers of the non-woven fiber material layer may have a diameter from about 0.1 μm toabout 18 μm. The non-woven fibers of the non-woven fiber material layer may be made ofnon-woven glass fibers, carbon fibers, ceramic fibers, polymeric spun fibers, metal fibers,metal coated fibers, or any combination thereof. The non-woven glass fibers may have adiameter from about 8 μm to about 10 μm. The non-woven carbon fibers may have a diameter from about 4 μm to about 6 μm.

[0025] The woven fiber material layer may be comprised of one or more layers of oneor more woven fiber materials. The woven fiber material layer may be made of woven fibers. The woven fibers may be continuous woven fibers. The woven fibers may be comprised of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, or one or more polymeric fibers. The woven fibers may have a plain weave, aunidirectional weave, a non-crimp weave, or twill weave. The woven fiber material may beone or more glass fibers with a diameter from about 0.1 μm to about 40 μm.

[0026] The polymeric composition may comprise one or more non-halogen containingflame 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 maycomprise from about 0 wt.% to about 25 wt.% of the one or more non-halogen containingflame reagents. The polymeric composition may comprise one or more antioxidants, one or more mold release agents, one or more charring salts, or any combination thereof. Thepolymeric composition may comprise from about 0.1 wt.% to about 0.3 wt.% of the one ormore 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 containfrom about 75 wt.% to about 100 wt.% of the at least one or more polycarbonates. Theone or more polycarbonates may be a virgin polycarbonate, a recycled polycarbonate, or a mixture of both. The polymeric composition may be the polycarbonate composition disclosed here.

[0027] Disclosed are methods for making a fire reducing composite comprising:placing one or more non-injection moldable materials in a mold; adding a polycarbonatelong fiber composition, having from about 10 wt.% to about 50 wt.% of long glass fibers tothe mold; and molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The polycarbonate long fiber composition may be the composition disclosed herein.

[0028] The disclosed method for making the fire reducing composite may compriseplacing the one or more non-injection moldable materials into a compression mold or aninjection mold; adding the polycarbonate long fiber composition to the compression mold or the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The one or more non-injection moldable materials may be preheated prior to being placed into the compression mold or the injection mold.

[0029] The disclosed method for making the fire reducing composite may compriseplacing the one or more non-injection moldable materials into a compression mold; adding a polycarbonate long fiber composition on top of the one or more non-injection moldable materials; compression molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The disclosed method for making the fire reducing composite may comprise adding one or more additional non-injection moldable materials on top of the polycarbonate long fiber composition.

[0030] The disclosed method for making the fire reducing composite may compriseplacing the one or more non-injection moldable materials into the injection mold; injecting the polycarbonate long fiber composition into the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0031] The one or more non-injection moldable materials may be from about 0.1 mmto about 4 mm thick. The fire reducing composite may be from about 1.0 mm to about 50 mm thick.

[0032] The disclosed method for making the fire reducing composite may comprisereinforcing the one or more non-injection moldable materials with the polycarbonate long fiber composition. The disclosed method for making the fire reducing composite may comprise over-molding the one or more non-injection moldable materials with the polycarbonate long fiber composition.

[0033] The one or more non-injection moldable materials may be an organosheetcomprised of one or more fiber material layers and one or more polymeric compositions. The organosheet may comprise of at least one layer of a glass weave fiber material. The organosheet may comprise of at least one layer of a non-woven fiber material.

[0034] Disclosed are fire reducing articles having a structure prepared from the firereducing composite disclosed herein.

[0035] The disclosed composition and articles prepared from the disclosedcomposition maintains its mechanical properties and integrity when exposed to high temperatures, such as the high temperatures generated by a fire.

[0036] The disclosed fire reducing composite and articles prepared from the firereducing composite disclosed exhibits premium fire retardancy and fire insulating properties. When exposed to fire the composition expands and reduces the amount of heat transferred through the fire reducing composite, while also experiencing little deformation.

[0037] The fire reducing composite disclosed herein may have a flexural modulus ofabout 10 GPa or greater, about 20 GPa or greater, about 30 GPa or greater, or about 40 GPa or greater.

[0038] A fire reducing composite having a thickness of about 1 mm to about 50 mmthick with a polycarbonate long fiber composition with a long glass fiber content that maybe about 10 wt.% to about 55 wt.% based on the weight of the polycarbonate long fibercomposition; and one or more non-injection moldable materials comprised of one or more fiber material layers embedded with one or more polymeric compositions, about 0.1 mmto about 4 mm thick with a fiber content that may be about 30 wt.% to about 80 wt.%, mayhave a temperature on the top side that may be about 370°C or less, may be about 340°Cor less, may be about 320°C or less, or may be about 290°C or less, and minordeformation, after the bottom side of the fire reducing composite has been exposed to firefor 10 min.

[0039] A fire reducing composite having a thickness of about 1 mm to about 5 mmthick with a polycarbonate long fiber composition with a long glass fiber content that maybe about 10 wt.% to about 45 wt.% based on the weight of the polycarbonate long fibercomposition; and one or more non-injection moldable materials may be comprised of one or more fiber material layers embedded with one or more polymeric compositions, about0.1 mm to about 1.0 mm thick with a fiber content that may be about 45 wt.% to about75 wt.%, may have a temperature on the top side that may be about 340°C or less, maybe about 320°C or less, or may be about 290°C or less, and may have minor deformation,after the bottom side of the fire reducing composite has been exposed to fire for 10 min.

[0040] A fire reducing composite having a thickness of about 1 mm to about 5 mmthick with a polycarbonate long fiber composition with a long glass fiber content that maybe about 20 wt.% to about 45 wt.% based on the weight of the polycarbonate long fibercomposition; and one or more non-injection moldable materials may be comprised of oneor more fiber material layers embedded with one or more polymeric compositions, about0.1 mm to about 1.0 mm thick with a fiber content that may be about 45 wt.% to about75 wt.%, and at least one glass woven fiber material layer, may have a temperature onthe top side that may be about 370°C or less, or may be about 340°C or less, and may have minor deformation after the bottom side of the fire reducing composite has been exposed to fire for 10 min.

[0041] A fire reducing composite having a thickness of about 1 mm to about 5 mmthick with a polycarbonate long fiber composition with a long glass fiber content that may be about 20 wt.% to about 45 wt.% based on the weight of the polycarbonate long fiber composition; and one or more non-injection moldable materials may be comprised of one or more fiber material layers embedded with one or more polymeric compositions, about 0.1 mm to about 1 mm thick with a fiber content that may be about 45 wt.% to about75 wt.%, and at least one non-woven fiber material layer, may have a temperature on thetop side that may be about 340°C or less, may be about 320°C or less, or may be about 290°C or less, and may have minor deformation, after the bottom side of the fire reducing composite has been exposed to fire for 10 min.

[0042] A fire reducing composite having a thickness of about 1 mm to about 5 mmthick with a polycarbonate long fiber composition with a long glass fiber content that may be about 20 wt.% to about 45 wt.% or less based on the weight of the polycarbonate long fiber composition; and one or more non-injection moldable materials that may be comprised of fiber material layers embedded with one or more polymeric compositions,about 0.1 mm to about 1 mm thick with a fiber content that may be about 45 wt.% to about75 wt.% or less and at least one non-woven glass fiber layer comprised of non-wovenglass fiber with a glass fiber diameter that may be about 0.1 μm to about 10 μm, may havea temperature on the top side that may be about 320°C or less, or may be about 290°C or less, and may have minor deformation, after the bottom side of the fire reducing composite has been exposed to fire for 10 min.

[0043] A fire reducing composite having a thickness of about 1 mm to about 5 mmthick with a polycarbonate long fiber composition with a long glass fiber content that may be about 20 wt.% to about 45 wt.% based on the weight of the polycarbonate long fiber composition; and one or more non-injection moldable materials that may be comprised of fiber material layers embedded with one or more polymeric compositions, about 0.1 mmto about 1 mm thick with a fiber content that may be about 45 wt.% to about 75 wt.% andat least one non-woven carbon fiber layer, may have a temperature on the top side thatmay be about 290°C or less, and may have minor deformation, after the bottom side of the fire reducing composite has been exposed to fire for 10 min.

[0044] The articles prepared from the disclosed composition and the articles preparedfrom the disclosed fire reducing composite may be used in a battery pack. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Fig.1 is an illustration of a two-stage twin screw line that may be used to createthe disclosed composition, where the polycarbonate composition is made within the first extruder.

[0046] Fig.2 is an illustration of a two-stage twin screw line that may be used to createthe disclosed composition, starting with a polycarbonate composition.

[0047] Fig. 3 is an illustration of a top down view of a fire reducing composite wherethe polycarbonate long fiber composition does not cover the entire non-injection moldable material.

[0048] Fig. 4 is an illustration of the side view of the fire reducing composite in Figure3.

[0049] Fig. 5 is an illustration of the bottom view of a fire reducing composite, wherethe polycarbonate long fiber composition over-molds the non-injection moldable material.

[0050] Fig. 6 is an illustration of the side view of the fire reducing composite, wherethe polycarbonate long fiber composition covers a top side and sides of the non-injection moldable material.

[0051] Fig. 7 is an illustration of a fire reducing composite where the polycarbonatelong fiber composition is a reinforcing layer between two or more non-injection moldable materials. DETAILEDDESCRIPTION

[0052] While the disclosure has been described in connection with certainembodiments, 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 arrangementsincluded within the scope of the appended claims, which scope is to be accorded thebroadest interpretation to encompass all such modifications and equivalent structures as is permitted under the law.

[0053] One or more as used herein means that at least one, or more than one, of therecited 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.

[0054] Disclosed are compositions which comprise: one or more polycarbonatecompositions and one or more long glass fibers, wherein the one or more long glass fibersare mixed with the one or more polycarbonate compositions to form a polycarbonate longfiber composition, having a long glass fiber content from about 10 percent by weight basedon the weight of the composition to about 55 percent by weight. The one or more longglass fibers may have a length of about 0.1 mm to about 35 mm. The composition maycomprise from about 30 percent by weight based on the weight of the composition to about 80 percent by weight of one or more polycarbonate compositions. The one or more polycarbonate compositions may comprise one or more polycarbonates. The polycarbonate long fiber composition may reduce the transfer of heat through an article with a structure containing or comprised of the polycarbonate long fiber composition. The polycarbonate long fiber composition may maintain its mechanical properties and integrity when exposed to high temperatures. The polycarbonate long fiber composition may withstand heat from a fire. composition may maintain its mechanical properties and integrity when exposed to fire.

[0055] The disclosed composition may be chopped into elongated sections. Thedisclosed composition may be molded into a molded polycarbonate long fiber composition. The disclosed composition may have a flexural modulus of about 6 GPa or greater, about9 GPa or greater, or about 12 GPa or greater. The disclosed composition may have aflexural strength of about 80 MPa or greater, about 100, MPa or greater, about 120 MPa or greater, or, about 150 MPa or greater. The disclosed composition may have a UL94rating of V-0 at 1.5 mm.Long Glass Fibers

[0056] The composition may comprise one or more long glass fibers. The long glassfibers may improve the strength of the polycarbonate composition and / or may reduce thecoefficient of linear thermal expansion of the composition. The long glass fibers may befilament glass rovings naturally cut during twin screw extrusion. The long glass fibers maybe long chopped glass fiber. The long glass fibers may be any length that positivelyimpacts the flame retardant properties of the composition. The one or more long glassfibers may have a length of about 0.1 mm or more, about 0.5 mm or more, about 1 mm ormore, or about 4 mm or more. The one or more long glass fibers may have a length ofabout 35 mm or less, about 25 mm or less, about 15 mm or less, or 12 mm or less. Theone or more long glass fibers may have a length of about 0.1 mm to about 35 mm, about0.5 mm to about 25 mm, or about 1 mm to about 15 mm, or about 4 mm to about 12 mm.The long glass fibers may have a diameter of about 40 μm or less, or about 17 μm or less.The long glass fibers may have a diameter of about 6 μm or greater or, about 12 μm orgreater. The fibers of the fiber material may have a diameter of about 6 μm to about 40μm, or about 12 μm to about 17 μm.

[0057] The composition may comprise one or more long glass fibers in an amount thatpositively impacts the flame retardant properties of the composition. The composition maycomprise one or more long glass fibers in an amount of about 10 percent by weight orgreater, about 25 percent by weight or greater, about 30 percent by weight or greater,about 35 percent by weight or greater, or about 40 percent by weight or greater based onthe weight of the composition. The composition may comprise long glass fibers in an amount of about 55 percent by weight or less, 50 percent by weight or less, about 45 percent by weight or less, about 40 percent by weight or less, or about 35 percent by weight or less based on the weight of the composition. The composition may compriseone or more long glass fibers in an amount of about 10 percent by weight to about 55percent by weight, about 20 percent by weight to about 40 percent by weight, or about 25percent by weight to about 35 percent by weight based on the weight of the composition.Polycarbonate Composition

[0058] The composition may comprise one or more polycarbonate compositions. Theone or more polycarbonate compositions may comprise: one or more polycarbonates; one or more non-halogen containing flame retardants; one or more impact modifiers; one or more additional polymers; one or more additives commonly used in compositions of this type; or any mixture thereof. The one or more polycarbonate compositions may comprise: one or more polycarbonates; one or more non-halogen containing flame retardants; one or more antioxidants; one or more mold release agents; one or more impact modifiers; one or more anti-drip agents; one or more additional polymers; one or more charring salts; one or more UV absorbers; one or more additional additives commonly used in a polycarbonate-based composition; or any mixture thereof. The one or more polycarbonate compositions may comprise: one or more polycarbonates; one or more non-halogen containing flame retardants; one or more antioxidants; one or more mold release agents;one or more impact modifiers; one or more anti-drip agents; one or more additional polymers; or any mixture thereof. The one or more polycarbonate compositions may comprise: one or more polycarbonates; one or more non-halogen containing flame retardants; one or more antioxidants; one or more mold release agents; one or more impact modifiers; one or more anti-drip agents; or any mixture thereof. The one or more polycarbonate compositions may comprise: one or more polycarbonates; one or more non-halogen containing flame retardants; one or more antioxidants; one or more mold release agents; or any mixture thereof.

[0059] The polycarbonate composition may comprise: about 75 percent by weight toabout 100 percent by weight of one or more polycarbonates; about 0 percent by weight toabout 25 percent by weight of one or more non-halogen containing flame retardants; about0.2 percent by weight to about 2 percent by weight of one or more additives commonlyused in compositions of this type; about 0 percent by weight to about 5 percent by weightof one or more impact modifiers; and / or about 0 percent by weight to about 30 percent byweight of a second polymer, based on the weight of the polycarbonate composition.

[0060] The polycarbonate composition of the disclosed composition may be producedby mixing the particular components in a known manner and melt-compounding and / ormelt-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. Polycarbonates

[0061] The polycarbonate composition of the disclosed composition may compriseone or more polycarbonates. The one or more polycarbonates may comprise one or more polycarbonate polymers and / or one or more copolymers containing carbonate units. The one or more polycarbonates may be branched, linear, or a mixture thereof. The one or more polycarbonates may comprise virgin polycarbonate. Virgin polycarbonate is polycarbonate which has not been used in any previous composition. The polycarbonate composition may comprise recycled polycarbonate. The polycarbonate composition may comprise both virgin and recycled polycarbonate. The recycled polycarbonate maycomprise one or more post-consumer recycled polycarbonates. The polycarbonate maybe in the form of a powder, flakes of pellets or in a mixture thereof. Where used in powder form the particle size is selected for efficiently blending the materials. The particle sizemay be about 0.1 mm or greater, or about 0.5 mm or greater. The particle size may beabout 2.0 mm or less, or about 1.5 mm or less.

[0062] The polycarbonate composition may comprise one or more polycarbonates inan 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 polycarbonate composition. The polycarbonate composition may comprise one or more polycarbonates in an amount ofabout 100 percent by weight or less, about 95 percent by weight or less, about 90 percentby weight or less, or about 85 percent by weight or less. The polycarbonate compositionmay comprise about 75 wt.% to about 100 wt.% of the one or more polycarbonates, about80 wt.% to about 95 wt.% of one or more polycarbonates, or about 80 wt.% to about 85wt.% of one or more polycarbonates.

[0063] 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 berandom copolymers with the different monomer units randomly located along the polymerbackbone. 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 copoly-carbonates is selected such that the resulting polymer retains the desirable properties of polycarbonates, as disclosed herein. The copoly-carbonates 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 copoly-carbonates 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 copoly-carbonates 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 copoly-carbonates may contain less than 50 mole percent co-monomer 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.

[0064] The production of polycarbonates is affected, for example, by the reaction ofdiphenols 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 I: Iwherein A denotes a single bond, a C1-5alkylene, a C2–5alkylidene, a C5-6cycloalkylidene, -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: IIor formula III:wherein B in each case is independently hydrogen, a C1-12alkyl, preferably methyl, or a halogen, preferably chlorine and / or bromine;x in each case is mutually independently 0, 1, or 2; andp is 0 or 1: Rcand Rdare mutually independent of each other and are individually selectable for eachX1 and are hydrogen or a C1 - C6 alkyl, 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.

[0065] 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 asdi- 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 molarsums of the diphenols, of other diphenols which are disclosed, such as 2,2-bis(3,5- dibromo-4-hydroxyphenyl)-propane.

[0066] Exemplary chain terminators for the production of the polycarbonates includephenolic 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 themolar sum of the diphenols used in each case.

[0067] The polycarbonates can be branched, for example by the incorporation ofabout 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 aciddichlorides 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.

[0068] Copolycarbonates may be prepared by known processes. For example, about1 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 acid halides 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 20:1may be used. A carbonic acid halide, such as phosgene, may be used in conjunction as adifunctional acid derivative during the production of the polyester carbonates. The aromatic polyester carbonates may also contain incorporated hydroxycarboxylic acids. The polyester carbon-ates may be either linear and / or may be branched. Branching agents are disclosed above.

[0069] Apart from the monophenols, exemplary chain terminators includechlorocarboxylic acid esters, as well as the acid chlorides of aromatic monocarboxylic acids which may optionally be substituted by C1-22alkyl 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 ofdicarboxylic acid dichlorides in the case of monocarboxylic acid chloride chain terminators.

[0070] The polycarbonates or copolymers containing carbonate units may be derivedfrom recycled materials, such as post-consumer recycled materials. The polycarbonate composition may contain up to 95 percent by weight of the polycarbonate compositionrecycled polycarbonates, such as post-consumer recycled materials, about 90 percent byweight or less based on the polycarbonate composition or about 80 percent by weight or less. The polycarbonate composition may contain about 30 percent by weight or more ofrecycled polycarbonate based on the weight of the polycarbonate composition, about 50percent 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 maybe 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.

[0071] The polycarbonate composition may contain virgin polycarbonates orcopolymers containing carbonate units in an amount of about 5 percent by weight or greater based on the polycarbonate composition, about 10 percent by weight or greater,about 20 percent by weight or greater, about 30 percent by weight or greater, or about 40percent by weight or greater. The polycarbonate composition may contain virgin polycarbonates or copolymers containing carbonate units in an amount of about 99percent by weight or less based on the polycarbonate composition, about 95 percent byweight 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.

[0072] The one or more polymers containing carbonate monomer units can comprisepolycarbonates, 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, about15,000 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).

[0073] The polycarbonates and / or copolymers used to prepare the polycarbonatecompositions 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 containpolycarbonates 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°Cunder a load of 1.2 kilograms, measured according to ASTM D1238. The melt flow ratesof the disclosed polycarbonate 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 / 10minutes or greater, or about 15 grams / 10 minutes or greater. The melt flow rates of thedisclosed polycarbonate 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 / 10minutes or less, about 20 grams / 10 minutes or less, or about 10 grams / 10 minutes or less.The melt flow rates of the disclosed polycarbonate 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 melt flow 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. Non-halogen containing flame retardants

[0074] The polycarbonate composition of the disclosed composition may compriseone or more non-halogen containing flame retardants. The polycarbonate compositionsmay comprise one or more flame retardants commonly used in polycarbonate compositions. The polycarbonate compositions containing polycarbonates may comprise 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 polycarbonate-based 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.

[0075] The one or more non-halogen containing flame retardants may be one or morephosphorus 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).

[0076] The one or more non-halogenated flame retardants may be one or morephosphazenes. Any one or more phosphazenes which enhances fire retardancy may be used. The phosphazenes may comprise more than one phosphazene unit. A phosphazeneis an organic compound having a –P=N- structure. The phosphazene may be a linearstructure 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 hydro-carbyloxy 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 phenoxyoxy or alkyl substituted phenoxy. The alkyl groups may be C 1-10 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, octaphenoxycyclotetraphosphazene, hexa-phenoxy-cyclo-phosphazene, and decaphenoxycyclopentaphosphazene. 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 compoundis generally 50 to 99.9 percent by weight or 70 to 90 percent by weight. The crosslinkedphenoxyphosphazene compound may not have any free hydroxyl groups in the molecule.

[0077] The one or more non-halogen containing flame retardants may be present inan amount of about 0 percent by weight or greater based on the weight of thepolycarbonate composition, about 3 percent by weight or greater, about 7 percent byweight or greater, or about 10 percent by weight or greater. The one or more non-halogencontaining flame retardants may be present in an amount of about 25 percent by weightor less based on the weight of the composition, about 15 percent by weight or less, orabout 13 percent by weight or less. The one or more non-halogen containing flameretardants may be present in an amount from about 0 percent by weight to about 25percent by weight based on the weight of the polycarbonate composition.

[0078] The polymeric composition may comprise one or more phosphate ester flameretardants and one or more phosphazene flame retardants.

[0079] The one or more phosphazene flame retardants may be present in an amountof 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.

[0080] The one or more phosphate ester containing flame retardants may be presentin 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 onthe weight of the polymeric composition, about 15 percent by weight or less, or about 13percent 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 byweight; about 5 percent by weight to about 15 percent by weight; or about 8 percent byweight to about 13 percent by weight based on the weight of the polymeric composition.Modifiers

[0081] The polycarbonate composition disclosed herein may comprise one or moremodifiers. The one or more modifiers may be one or more Impact modifiers or one or more additional polymers. Impact Modifier

[0082] The polycarbonate composition of the disclosed composition may comprise ofone or more impact modifiers. The terms impact modifiers and rubbers are used interchangeably. Various impact modifiers may be used in the compositions disclosed, such as diene rubbers, ethylene propylene rubbers, ethylene propylene diene (EPDM) rubbers, ethylene copolymer rubbers, acrylate rubbers, polyisoprene rubbers, silicon rubbers, silicon-acrylate rubbers, polyurethanes, thermoplastic elastomers, halogen containing rubbers, and mixtures thereof. Also suitable are inter-polymers of rubber- forming monomers with other copolymerizable monomers. The rubbers may be present in the formulated composition in sufficient amount to provide the desired impact properties to the composition. Desired impact properties include increased izod, charpy, gardner, tensile, falling dart, and the like. Compositions, formulated compositions, as used in this context are the formulated compositions containing all of the ingredients for the intended use.

[0083] The rubbers may be diene rubbers such as polybutadiene, polyisoprene,polypiperylene, polychloroprene, and the like or mixtures of diene rubbers, that is, any rubbery polymers of one or more conjugated 1,3-dienes, such as 1,3-butadiene. Such rubbers include homopolymers of 1,3-butadiene and copolymers of 1,3-butadiene with one or more copolymerizable monomers, such as vinylidene substituted aromatic (styrene). The diene rubber may be the homopolymer of 1,3-butadiene. Exemplary copolymers of 1,3-butadiene are block or tapered block rubbers of at least about 30percent by weight 1,3-butadiene, from about 50 percent by weight, from about 70 percentby weight, or from about 90 percent by weight 1,3-butadiene and up to about 70 percentby weight vinylidene substituted aromatic monomer, up to about 50 percent by weight, upto about 30 percent by weight, or up to about 10 percent by weight vinylidene substitutedaromatic monomer, weights based on the weight of the 1,3-butadiene copolymer. The impact modifiers employed may be those polymers and copolymers which exhibit asecond order transition temperature, sometimes referred to as the glass transitiontemperature (Tg), for the diene fragment which is not higher than 0°C or not higher than−20°C. as determined using conventional techniques, for example ASTM Test Method D 746-52 T. The average particle size of the rubber particles may be equal to or greater thanabout 0.05 micrometers (microns) (µm), equal to or greater than about 0.1 micrometers,and equal to or greater than about 0.5 micrometers. The average particle size of the rubberparticles may be equal to or less than about 10 micrometers, equal to or less than about5 micrometers, or equal to or less than about 4 micrometers.

[0084] The impact modifier may be butadiene- or styrene-butadiene rubber-based andmethyl methacrylate-styrene-grafted impact modifiers having a core-shell structure (MBS), siloxane-acrylate rubbers having a core-shell structure, acrylate rubber-based core-shellimpact modifiers, and the like. The butadiene- or styrene-butadiene rubber-based core-shell impact modifiers are butadiene- or styrene-butadiene rubber-based impact modifiersgrafted with methyl methacrylate or methyl methacrylate-styrene copolymers. Siloxane- acrylate rubbers having a core-shell structure may be produced from alkyl methacrylates and / or alkyl acrylates, crosslinkers, and grafting agents. Exemplary alkyl methacrylates and / or alkyl acrylates are C1-5-alkyl esters, e.g., methyl ester, ethyl ester, n-butyl ester, tert-butyl ester, n-propyl ester, n-hexyl ester, n-octyl ester, n-lauryl ester, and 2-ethylhexyl ester; haloalkyl esters, preferably halo C1-5-alkyl esters, e.g., chloroethyl acrylate, and mixtures of these monomers. Particularly preferred is n-butyl acrylate. A monomer having more than one polymerizable double bond can be used as the crosslinker for the polyalkyl(meth)acrylate-rubber component of siloxane-acrylate rubber. Examples of the crosslinking monomers are esters of unsaturated mono-carboxylic acids having 3 to 8 carbon atoms and unsaturated monohydric alcohols having 3 to 12 carbon atoms or saturated polyols having 2 to 4 OH-groups and 2 to 20 carbon atoms, e.g., ethylene glycol dimethacrylate, propanediol dimethacrylate, 1,3-butanediol dimethacrylate, and 1,4- butanediol dimethacrylate. Such crosslinkers may be used alone or as mixtures of at least two crosslinkers. Exemplary grafting agents are allyl methacrylate, triallylcyanurate, triallylisocyanurate or mixtures thereof. The allyl methacrylate may further be used as the crosslinker. Such grafting agents may be used alone or as mixtures of at least two grafting agents. The crosslinker and grafting agent may be present in an amount of from about 0.1 wt.-% to about 20 wt.-% based on the total weight of the polyalkyl(meth)acrylate-rubber component of siloxane-acrylate rubber. The core may be based on a siloxane rubber. The siloxane core may be about 20 percent by weight or greater of the weight of the impact modifier, about 50 percent by weight or greater. The siloxane core may be about 70percent by weight or less of the weight of the impact modifier or about 40 percent by weight or less.

[0085] The polycarbonate composition may comprise one or more impact modifierscomprised of a butadiene, a styrene-butadiene rubber-based methyl methacrylate- styrene, a methyl methacrylate-grafted impact modifier having a core-shell structure, a siloxane-acrylate rubber having a core-shell structure, an acrylate rubber-based core-shell impact modifiers, styrene-butadiene rubber-based methyl methacrylate-styrene core-shell impact modifier, methacrylate-butadiene-styrene grafted impact modifiers having a core-shell structure (MBS) or any combination thereof. The one or more impact modifiers maybe methacrylate-butadiene-styrene grafted impact modifiers having a core-shell structure(MBS). The polycarbonate composition may comprise one or more impact modifiers in an amount of about 0 percent by weight or greater, about 0.5 percent by weight or greater, about 1.0 percent by weight or greater, or about 2.0 percent by weight or greater basedon the weight of the polycarbonate compositions. The polycarbonate compositionsdisclosed herein may comprise one or more impact modifiers in an amount of about 8percent by weight or less, about 6 percent by weight or less, about 5 percent by weight orless, or about 3.0 percent by weight or less based on the weight of the polycarbonatecompositions. The polycarbonate compositions disclosed herein may comprise one or more impact modifiers in an amount of about 0 percent by weight to about 6 percent by weight based on the weight of the polycarbonate compositions. Additional Polymers

[0086] The polycarbonate compositions may comprise one or more additionalpolymers. The one or more additional polymers may be one or more of acrylonitrilebutadiene styrene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate-siloxane copolymer, high molecular weight polysiloxane, liquid crystalpolymer LCP (1,4-Benzenediol polymer with 1,4-benzenedicarboxylic acid, 4-hydroxybenzoic acid and 6-hydroxy-2-naphthalenecarboxylic acid) or any combination thereof. The one or more additional polymers may be acrylonitrile butadiene styrene, polyethylene terephthalate, or polybutylene terephthalate. The Polycarbonate composition may comprise one or more additional polymers in an amount of about 0 percent by weightor greater based on the weight of the polycarbonate composition. The polycarbonatecompositions disclosed herein may comprise one or more additional polymers in anamount of about 30 percent by weight or less, or about 5 percent by weight or less, orbased on the weight of the polycarbonate composition. The Polycarbonate composition may comprise one or more additional polymers in an amount from about 0 to about 30 percent by weight, or about 0 to about 5 percent by weight, based on the weight of the polycarbonate composition. Polycarbonate Additives

[0087] The polycarbonate composition of the disclosed composition may compriseone or more additives commonly used in compositions of this type. Exemplary additives include: zinc salts, colorants, reinforcing fillers, stabilizers, antistatic agents, silicon oils, flow enhancers, mold release agents, charring salts, anti-drip agents, 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, oneor more anti-drip agents, one or more UV absorbers, reinforcing fillers or any combinationthereof. Antioxidants

[0088] The polycarbonate composition of the disclosed compositions may compriseone 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, hydroxybenzylatedmalonate, 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, hydroquinoneand 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.

[0089] 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-(α- 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 α- tocopherol, β-tocopherol, γ-tocopherol, δ-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-(α- 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-(α-methylbenzyl)-4-nonylphenol], 2,2′-methylene bis[6-(α,α-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-di-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-butyl-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-hydroxy phenoxy)-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-butyl-4-hydroxybenzyl)isocyanurate, 2,4,6-tris(3,5-di-tert-butyl-4- hydroxyphenylethyl)-1,3,5-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-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-butyl-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 antioxidantsinclude esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)propionic acid with mono- orpolyhydric 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. Exemplaryantioxidants include esters of β-(3,5-dicyclohexyl-4-hydroxy phenyl)propionic acid withmono- 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 β-(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-hydroxyphenyl propionyl)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-phenylene diamine, 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-(1-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-isopropoxy diphenylamine, 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-dodecanoyl aminophenol, 4-octa decanoyl aminophenol, bis(4-methoxyphenyl)amine, 2,6-di-tert-butyl -4-dimethylaminomethylphenol, 2,4′-diamino diphenylmethane, 4,4′-diaminodiphenyl methane, 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- anddialkylated tert-butyl / tert-octyldiphenylamines, a mixture of mono- and dialkylated nonyldiphenylamines, a mixture of mono- and dialkylated dodecyldiphenylamines, a mixture ofmono- and dialkylated isopropyl / isohexyl diphenylamines, a mixture of mono- anddialkylated 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.

[0090] Exemplary antioxidant additives include, for example, organophosphites suchas tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite (e.g., “IRGAFOS 168” or “I-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-hydroxyhydrocinnamate) methane, or the like; butylated reaction products of para-cresol ordicyclopentadiene; 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; amidesof beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, or combinations comprising at least one of the foregoing antioxidants.

[0091] The antioxidants may be one or more of phenol and / or phosphorous basedantioxidants. 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.

[0092] The antioxidants may be present in the polycarbonate composition andstructures 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 polycarbonate 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 polycarbonate 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). Mold release agents

[0093] The polycarbonate composition of the disclosed composition may compriseone 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 C6-36monovalentor divalent carboxylic acids. The aliphatic carboxylic acids may be C 6-36 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 azelaic acid. 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. The alcohols 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 α-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 beincluded, 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.

[0094] The polycarbonate composition may comprise one or more mold releaseagents in an amount of about 0 percent by weight or greater based on the polycarbonatecomposition, about 0.01 percent by weight or greater, or about 0.1 percent by weight orgreater. 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 polycarbonate composition, about 1 percentby weight or less, or about 0.7 percent by weight or less. In cases where the content ofthe 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 polycarbonate composition maycomprise from about 0 percent by weight to about 2 percent by weight, about 0.01 percentby weight to about 1 percent by weight, or about 0.1 percent by weight to about 0.7 percentby weight based on the polycarbonate composition of one or more mold release agents. Anti-drip agents

[0095] The polycarbonate composition of the disclosed composition one or more anti-drip agents. Any anti-drip agents which positively impact the fire retardancy of the polycarbonate compositions may be utilized. Anti-drip means to reduce the tendency of the composition to form burning drips in the event of a fire. The anti-drip agent may be an Organo-functional liquid siloxane. Exemplary Organo-functional liquid siloxane are marked under the brand name DOWSILTM40-001 by Dow. The polycarbonate composition may comprise a fluorinated anti-drip agent. Fluorinated polyolefins known in the art as anti-drip agents may be used in the compositions. The anti-drip agent may be a fiber- forming fluorine-containing polymer, those forming a fibril construction in polycarbonate containing compositions. Fiber-forming fluorine-containing polymers include polytetrafluoroethylene, tetrafluoroethylene type copolymers (for example, tetrafluoroethylene / hexafluoropropylene copolymers and the like), the partially fluorinated polymers shown in U.S. Pat. No. 4,379,910, relevant parts incorporated herein byreference, polycarbonates manufactured from fluorinated diphenol and the like. Polytetrafluoroethylenes having a molecular weight of at least 1,000,000, a secondary particle size of at least 100 μm and an ability to form fibrils may be used. Exemplary fluorinated polyolefins are described in EP-A 0640655. They are marketed under the brand name Teflon® 30N by DuPont. The anti-drip agent may be a polytetrafluoroethylenes in a styrene-acrylonitrile matrix. The anti-drip agent may be a 50% masterbatch of polytetrafluoroethylenes in a styrene-acrylonitrile matrix. The anti-dripagent may be polytetrafluoroethylene, polytetrafluoroethylene / styrene-acrylonitrilemasterbatch, or an organo-functional liquid siloxane. The amount of the anti-drip agentmay be any amount which enhances the flame retardant properties of the composition. The amount of anti-drip agent may depend on the anti-drip agent used. When an organo- functional liquid siloxane anti-drip agent is used the amount of anti-drip agent may be about 0 percent by weight based on the weight of the composition or greater, about 0.5 percent by weight or greater, or about 1 or greater. When an organo-functional liquid siloxane anti-drip agent is used the amount of anti-drip agent may be about 5 percent byweight or less, about 3 percent by weight or less, or about 2 percent by weight or lessbased on the weight of the composition. When an organo-functional liquid siloxane anti- drip agent is used the amount of anti-drip agent may be about 0 wt.% to about 5 wt.%. When a fluorinated anti-drip agent is used the amount of the anti-drip agent may be 0 percent by weight based on the weight of the composition or greater, about 0.01 percent by weight or greater, or about 0.1 or greater. When a fluorinated anti-drip agent is usedthe amount of the anti-drip agent may be about 1.0 percent by weight or less, about 0.9percent by weight or less, or about 0.5 percent by weight or less based on the weight ofthe composition. Charring salts

[0096] The polycarbonate composition of the disclosed composition may compriseone 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.

[0097] The one or more charring salts may comprise one or more salts of aperflourohydrocarbyl sulfur compounds or aromatic sulfur compounds. Any salts ofperflourohydrocarbyl sulfur compounds or salt of aromatic sulfur compounds that improve the fire retardancy of disclosed compositions may be used. 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 moresalts of perflouroalkane sulfur compounds. The one or more salts of aperflourohydrocarbyl sulfur compounds or aromatic sulfur compounds may include one ormore 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 sulfurcontaining compounds or aromatic sulfur compounds may include or consist essentiallyof 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 consist substantially of one or more potassium perfluoroalkanesulfonates, such as potassium perfluorobutanesulfonate, sodium p- toluenesulfonate or potassium diphenylsulfone sulfonate.

[0098] The perflourohydrocarbyl salts compounds may be present in an amount ofabout 0 percent by weight or greater of the polycarbonate composition or about 0.05 percent by weight or greater, or about 0.1 percent by weight or greater. The perflourohydrocarbyl salts compounds may be present in an amount of about 0.3 percentby weight or less of the polycarbonate or carbonate containing polymer containing composition.

[0099] The one or more charring salts may contain one or more sulfur-containing saltswith 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.

[0100] The one or more charring salts may contain one or more sulfur-containing saltswithout 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.

[0101] The one or more sulfur-containing salts without a halogen may be present inan amount of about 0 percent by weight or greater of the polycarbonate composition, about0.05 percent by weight or greater, or about 0.1 percent by weight or greater. The one ormore sulfur-containing salts without a halogen may be present in an amount of about 0.3 percent by weight or less of the polycarbonate composition.

[0102] The one or more charring salts may include or consist substantially ofpotassium 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 consist substantially 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.

[0103] The one or more charring salts may be present in an amount to improve theflame retardancy of the compositions. The charring salts may be present in an amount ofabout 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 polycarbonate composition.The charring salts may be present in an amount of about 0.3 percent by weight or less,based on the weight of the polycarbonate composition. UV absorbers

[0104] The polycarbonate composition of the disclosed composition may compriseone 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 polycarbonate 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 polycarbonate 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). Additional additives:

[0105] The disclosed polycarbonate compositions may contain one or more additionaladditives from the additives previously discussed herein, that are commonly used inpolycarbonate compositions of this type. Exemplary additives include: zinc salts,colorants, 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.

[0106] The polycarbonate composition may optionally include a component whichadsorbs volatile organic compounds. The component may be a zeolite, activated carbon, bamboo, charcoal or combinations thereof.

[0107] The polycarbonate composition may contain a stabilizer salt. The stabilizersalt may be any compound that is a basic buffer which functions to prevent basic materialsin the polycarbonate composition from causing the polycarbonates or copolymerscontaining 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 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 (Na2H2P2O7), 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 ofthe polycarbonate composition containing one or more polycarbonates and / or copolymerscontaining carbonate units. The stabilizer salt may be present in an amount of about 0.5percent by weight or less of the polycarbonate composition containing one or morepolycarbonates and / or copolymers containing carbonate units.

[0108] The polycarbonate compositions disclosed may contain one or more carbonbased 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, Al2O3 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 anyparticulate 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 morecarbon based particulates, metal or metalloid oxides may be present in an amount of 0percent by weight by weight or greater based on the weight of the polycarbonatecomposition, about 0.2 percent by weight by weight or greater, about 0.3 percent by weightor greater, or about 0.5 percent by weight or greater based on the weight of thepolycarbonate composition. The one or more carbon based particulates, metal or metaloxides may be present in an amount of about 10 percent by weight by weight or less basedon the weight of the polycarbonate composition, about 5 percent by weight or less, about3 percent by weight or less, or about 2 percent by weight or less based on the weight ofthe polycarbonate composition. The one or more carbon based particulates, metal ormetal 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 which enhances the flame retardancy rating of the polycarbonate compositions. The particle size may be about 0.2 micrometers or more or about 0.35micrometers or more. The particle size may be about 2.0 micrometers or less, or about1.0 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.

[0109] The polycarbonate 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 presentbased on the total weight of the polycarbonate composition. A buffer system as describedherewith includes one or more buffers that has an acidic and basic functionality such thatthe pH of the polycarbonate composition may be directed to about neutral. The buffersystem 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 polycarbonate composition) sufficient to facilitateimproved 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 polycarbonate 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 are aromatic 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-ethanesulfonicacid) (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-propanesulfonicacid (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.

[0110] The buffer system may comprise one or more alkali metal phosphates. Anyalkali metal phosphates which enhance the thermal stability of the polycarbonate 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 polycarbonate 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 polycarbonate 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 inany amount of about 1.0 percent by weight or less based on the weight of thepolycarbonate composition, about 0.2 percent by weight or less, or about 0.1 percent byweight or less.

[0111] The polycarbonate composition disclosed may contain a colorant. The colorantcan be any colorant that provides a desired color to the polycarbonate 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 polycarbonate composition or products prepared therefrom with the desired color. The colorant may be present in anamount of about 0.01 percent by weight or greater of the disclosed polycarbonatecomposition, about 0.1 percent by weight or greater, or about 1 percent by weight orgreater. The colorant may be present in an amount of about 10 percent by weight or less of the disclosed polycarbonate composition, about 5 percent by weight or less. about 1percent by weight or less, or about 0.5 percent by weight or less. Where the colorant is apigment, the concentration may be at the higher end of the disclosed range, for examplefrom 0.1 to 10.0 percent by weight of the polycarbonate composition. Where the colorantis a dye, the amount may be at the lower end of the range, for example from 0.01 to about0.5 percent by weight of the polycarbonate composition. Some of the pigments may alsobe particulates as described herein.

[0112] The composition may not contain copolymers of polycarbonate units andpolysiloxane units, polypropylene, modified polypropylene, polyurethane, polycaprolactone, polylactic acid, polysiloxane based fire retardants, halogen containing charring salts, inorganic fillers, flame retardant synergist minerals or fluoropolymers having the ability to form fibrils.

[0113] The composition may be made using any process known in the art for makinga long fiber thermoplastic. Composition used to make Fire reducing composite

[0114] The disclosed composition may be combined with one or more composite toform a fire reducing composite. The one or more composites may be a non-injectionmoldable material. The non-injection moldable material may comprise one or more fiber materials that is impregnated or embedded with a resin. The non-injection moldable material may be an organosheet. The resin may be one or more polymeric compositions that has the ability to impregnate or embed a fire. The organosheet may comprise one or more fiber materials embedded with one or more polymeric compositions. The organosheet may comprise one or more fiber material layers comprised of one or more layers of one or more fiber materials and one or more polymeric compositions embedded within the fiber material layers. The disclosed composition and one or more non-injectionmoldable materials may be molded together using various processes known in the art toform a fire reducing composite, such as compression molding, insert molding, or injection molding. The disclosed fire reducing composition may comprise two or more composites / non-injection moldable materials co-molded together with the disclosed composition. Method for making composition

[0115] Disclosed are methods for making the composition disclosed hereincomprising: feeding either a polycarbonate formulation, or one or more polycarbonate compositions into a first extruder; extruding a molten polycarbonate composition from thefirst extruder; feeding the molten polycarbonate composition and filament glass rovingsinto a second extruder; mixing the molten polycarbonate composition and filament glass rovings together; forming a polycarbonate long fiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers; and extruding the polycarbonate long fibercomposition. The long glass fibers may have a length of about 0.1 mm to about 35 mm.The extruded polycarbonate long fiber composition may be extruded into a mold; or extruded and cooled to form pellets of the polycarbonate long fiber composition.

[0116] The polycarbonate formulation may comprise one or more polycarbonates, oneor more modifiers and one or more additives. The one or more additives and one or more modifiers may comprise one or more non-halogen containing flame retardants, one or more antioxidants, one or more mold release agents, one or more impact modifiers, oneor more anti-drip agents, one or more additional polymers, one or more charring salts, oneor more UV absorbers, or any combination thereof, as disclosed herein. The one or more polycarbonates may be the polycarbonates disclosed herein. The one or more polycarbonate compositions may comprise one or more polycarbonates, one or more modifiers, and one or more additives as disclosed herein. The polycarbonate composition may be comprised of the polycarbonate formulation.

[0117] The disclosed method for making the composition disclosed herein maycomprise: feeding one or more polycarbonates, one or more modifiers, and one or more additives into a first extruder; mixing the one or more polycarbonates, the one or moremodifiers, and the one or more additives together in the extruder to form a polycarbonatecomposition; extruding a molten polycarbonate composition from the first extruder; feeding the molten polycarbonate composition into a second extruder; feeding filament glass rovings into the second extruder; mixing the molten polycarbonate composition and filament glass rovings together; forming a polycarbonate long fiber composition, havingfrom about 10 wt.% to about 55 wt.% of long glass fibers; and extruding the polycarbonatelong fiber composition.

[0118] The one or more polycarbonates, the one or more modifiers, and the one ormore additives may be mixed at a temperature of about 180°C or greater, about 220°C orgreater, about 240°C or greater, or about 275°C or greater. The one or morepolycarbonates, the one or more modifiers, and the one or more additives may be mixedat a temperature of about 350°C or less, or about 285°C or less. The one or morepolycarbonates, the one or more modifiers, and the one or more additives may be mixed at a temperature of about 280°C. The one or more polycarbonates, the one or moremodifiers, and the one or more additives may be mixed at a temperature from about 180°Cto about 350°C, about 220°C to about 280°C, about 240°C to about 280°C, or about 275°Cto about 285°C.

[0119] The disclosed method for making the composition disclosed herein maycomprise: feeding one or more polycarbonate compositions into a first extruder; extruding a molten polycarbonate composition from the first extruder; feeding the molten polycarbonate composition and filament glass rovings into a second extruder; mixing the molten polycarbonate composition and filament glass rovings together; forming apolycarbonate long fiber composition, having from about 10 wt.% to about 55 wt.% of longglass fibers; and extruding the polycarbonate long fiber composition.

[0120] The first extruder in the disclosed method may be a compounding extruder, ora mixing extruder. The first extruder may be a twin-screw extruder. The first extruder may be a laterally attached twin-screw extruder. The first extruder may be charged at a meltflow rate of about 10 kg / h or greater, about 25 kg / h or greater, about 50 kg / h or greater, orabout 100 kg / h or greater, by way of a connecting section to a second extruder. The firstextruder may be charged at a melt flow rate of about 1000 kg / h or less, about 500 kg / h or less, or about 300 kg / h or less, by way of a connecting section to a second extruder. Thefirst extruder may be charged at a melt flow rate of about 10 kg / h to about 1000 kg / h. Thepolycarbonate composition may be melted in the first extruder. The polycarbonatecomposition may be melted in the first extruder at a temperature of about 180°C or greater,about 220°C or greater, about 240°C or greater, or about 275°C or greater. Thepolycarbonate composition may be melted in the first extruder at a temperature of about350°C or less, or about 285°C or less. The polycarbonate composition may be melted inthe first extruder at a temperature of about 280°C. The polycarbonate composition maybe melted in the first extruder at a temperature from about 180°C to about 350°C, about220°C to about 280°C, about 240°C to about 280°C, or about 275°C to about 285°C.

[0121] The second extruder may be a mixing extruder. The mixing extruder may be atwin screw extruder. The mixing extruder may have the melted polycarbonate compositionand endless filament glass rovings feed into the extruder. More than one glass roving maybe fed simultaneously into the mixing extruder. The number of filament glass rovings may be about 5 or more rovings, about 8 or more rovings, or about 10 or more rovings. The number of filament glass rovings may be about 30 rovings or less, about 24 rovings or less, or about 20 rovings or less. The number of filament glass rovings may be about 5 rovings to about 30 rovings, about 8 to about 24 rovings, or about 10 to about 20 rovings.The temperature of the second extruder may be about 180°C or greater, about 220°C orgreater, about 240°C or greater, or about 275°C or greater. The temperature of the secondextruder may be at about 350°C or less, about 290°C or less, or about 280°C or less. Thetemperature of the second extruder may be at about 280°C. The temperature of thesecond extruder may be from about 180°C to about 350°C, about 220°C to about 290°C,or about 240°C to about 280°C.

[0122] The filament glass rovings may be preheated prior to being added to thesecond extruder. The filament glass rovings may be preheated to a temperature of about 100°C or greater, about 150°C or greater, or about 200°C or greater. The filament glassrovings may be preheated to a temperature of about 300°C or less, or about 250°C orless. The filament glass rovings may be preheated to a temperature of about 100°C toabout 300°C, about 150°C to about 300°C, about 200°C to about 300°C, or about 200°Cto about 250°C. The filament glass rovings may be pretensioned to prevent contact between individual glass fibers.

[0123] The filament glass rovings fed into a twin screw extruder may be cut by theshear force of rotating twin screws and mixing with the melted polycarbonate composition. The filament glass rovings may be drawn through the melted polycarbonate composition within the second extruder to completely disperse the filament glass rovings within the polycarbonate composition to form a polycarbonate long fiber composition. The screw speed of the second extruder controls the speed at which the filament glass rovings may be drawn through the melted polycarbonate composition. The screw speed of the second extruder can be about 50 rpm or greater, or 100 rpm or greater. The screw speed of the second extruder can be about 500 rpm or less, about 300 rpm or less, or about 200 rpm or less.

[0124] The filament glass rovings may be fed into the extruder in an amount sufficientto improve the strength of the polycarbonate composition and / or may reduce the coefficient of linear thermal expansion of the composition. The glass roving may be added in an amount sufficient to form a polycarbonate long fiber composition having from about 10 wt.% to about 55 wt.% of long glass fibers. The extruded polycarbonate long fibercomposition may have a temperature of about 240°C to about 280°C.

[0125] The disclosed method may comprise making pellets from the extrudedpolycarbonate long fiber under known conditions in the art. The disclosed method may comprise chopping the extruded polycarbonate long fiber composition into elongated sections; and forming pellets of the polycarbonate long fiber composition. The method may comprise cooling the extruded polycarbonate fiber composition to about roomtemperature; chopping the extruded polycarbonate long fiber composition into elongated sections; and forming pellets of the polycarbonate long fiber composition.

[0126] The disclosed method may comprise placing the pellets of the polycarbonatelong fiber composition into an extruder; melting the pellets of the polycarbonate long fibercomposition; and extruding a molten polycarbonate long fiber composition.

[0127] The disclosed method may comprise extruding the polycarbonate long fibercomposition into a mold; and molding the polycarbonate long fiber composition. The disclosed method may comprise molding the polycarbonate long fiber composition into a molded polycarbonate long fiber composition. The disclosed method may comprise extruding the polycarbonate long fiber composition into a compression mold or an injection mold; and molding the polycarbonate long fiber composition into the molded polycarbonate long fiber composition. The molded polycarbonate long fiber compositionmay have a thickness of about 1.0 mm or greater, about 1.5 mm or greater, or about 2.0mm or greater. The molded polycarbonate long fiber composition may have a thicknessof about 10 mm or less, about 5.0 mm or less, about 3.0 mm or less, or about 2.5 mm orless. The molded polycarbonate long fiber composition may have a thickness of about 1.0 mm to about 10 mm, about 1.0 mm to about 5.0, about 1.5 mm to about 3.0 mm, or about2.0 mm to about 2.5 mm. The compression mold or the injection mold may be an electricvehicle housing molder.

[0128] The disclosed method may comprise extruding the polycarbonate long fibercomposition into a compression mold; compressing the compression mold; and molding the polycarbonate long fiber composition into the molded polycarbonate long fiber composition.

[0129] The disclosed method may comprise injecting the extruded polycarbonate longfiber composition into the injection mold; and demolding the molded polycarbonate long fiber composition from the injection mold.

[0130] The disclosed method may comprise molding the polycarbonate long fibercomposition into a battery pack. The disclosed method may comprise molding the polycarbonate long fiber composition into a lid of the battery pack.

[0131] The disclosed method may comprise molding the polycarbonate long fibercomposition with one or more composites; and forming a reinforced composite or an over- molded composite. The one or more compsites may be one or more non-injection moldable materials. The disclosed method may comprise extruding the polycarbonate long fiber composition into a compression mold or an injection mold containing the one ormore composites; molding the polycarbonate long fiber composition and the one or more composites together; and forming the reinforced composite or the over-molded composite. The reinforced composite or the over-molded composite may be a fire reducing composite, wherein a fire reducing composite may mean one or more of a fire exposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof.

[0132] The disclosed method may comprise comprising extruding the polycarbonatelong fiber composition into a compression mold containing the one or more composites; comprising compressing the compression mold; and forming the reinforced composite or the over-molded composite the polycarbonate long fiber composition into the molded polycarbonate long fiber composition. The disclosed method may comprise injecting the extruded polycarbonate long fiber composition into the injection mold containing the one or more composites; forming the over-molded composite; and demolding the over-molded composite from the injection mold. Composition Article

[0133] The composition disclosed herein may be used in an article or formed into anarticle 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. An article comprised of the composition disclosed herein may maintain its mechanical properties and integrity when exposed to high temperatures. An article comprised of the composition disclosed herein may have a reduced temperature on one side of the article when the opposite side of the article is exposed to 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 the 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 beused as a layer in an article or formed into an article with a structure to contain the spreadof 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 enclosurefor a lithium-ion battery. The article may be a battery pack. The article may be used as alayer 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 formed into the battery pack. The composition may be formed into the lid of thebattery pack. The battery pack may be used in an electric vehicle. The battery pack maybe used to house the battery pack of an electric vehicle. Fire Reducing Composite Composition

[0134] Disclosed are fire reducing composites comprised of a polycarbonate long fibercomposition, having from about 10 wt.% to about 55 wt.% of long glass fibers; and one ormore non-injection moldable materials. The polycarbonate long fiber composition may be the polycarbonate long fiber composition disclosed herein. The one or more long glassfibers may have a length of about 0.1 mm to about 35 mm. The polycarbonate long fibercomposition may comprise a polycarbonate from about 30 percent by weight to about 80 percent by weight based on the weight of the polycarbonate long fiber composition. The one or more polycarbonate compositions may comprise one or more polycarbonates. The polycarbonate long fiber composition may reduce the transfer of heat through an article with a structure containing or comprised of the polycarbonate long fiber composition. The polycarbonate long fiber composition may maintain its mechanical properties and integrity when exposed to high temperatures. The polycarbonate long fiber composition may withstand heat from a fire. composition may maintain its mechanical properties and integrity when exposed to fire.

[0135] The fire reducing composite may be a fire exposure expanding composite, aheat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof. The fire reducing composite may have minor deformation after being exposed to fire. The fire reducing composite may expand when exposed to fire. The fire reducing composite may expand immediately on fire exposure.

[0136] The polycarbonate long fiber composition and one or more non-injectionmoldable materials may be compression molded, insert molded, or injection moldedtogether to form the disclosed fire reducing composite. The polycarbonate long fiber composition may reinforce and / or over-mold the one or more non-injection moldable materials. The polycarbonate long fiber composition may for a bond with at least oneoutside face of the non-injection moldable material. The outside face of the non-injectionmoldable material may be a top side or a bottom side of the non-injection moldable material. The polycarbonate long fiber composition may cover at least a top side or a bottom side of the one or more non-injection moldable materials. The polycarbonate long fiber composition may co-compression mold with a top side or a bottom side of the one or more non-injection moldable materials. The polycarbonate long fiber composition may co- compression mold with a top side or a bottom side, and edges of the one or more non- injection moldable materials. The polycarbonate long fiber composition may over-mold the one or more non-injection moldable materials. The polycarbonate long fiber composition may form ribs and corners of the fire reducing composite. The polycarbonate long fiber composition may be a reinforcing layer between two or more non-injection moldable materials. The fire reducing composite may comprise two or more non-injection moldable materials bound together by the polycarbonate long fiber composition.

[0137] The one or more non-injection moldable material may have a thickness ofabout 0.1 mm or greater, about 0.2 mm or greater, or about 0.5 mm or greater. The one or more non-injection moldable material may have a thickness of about 4 mm or less, orabout 2.0 mm or less, or about 0.5 mm or less. The one or more non-injection moldablematerial may have a thickness of about 0.1 mm to about 4.0 mm, about 0.2 mm to about 2.0 mm, or about 0.2 mm to about 0.5mm.

[0138] The fire reducing composite may have a thickness of about 1.0 mm or greater.The fire reducing composite may have a thickness of about 50 mm or less, about 5 mm or less, or about 3 mm or less. The fire reducing composite may have a thickness of about1.0 mm to about 50 mm. The fire reducing composite may have a thickness of about 1.0mm to about 5 mm. The fire reducing composite may have a thickness of about 1.0 mm to about 3 mm. Organosheet

[0139] The one or more non-injection moldable materials may be one or moreorganosheets comprised of one or more fiber material layers and one or more polymeric compositions. The fiber material layers may be embedded with the one or more polymericcompositions. The polymeric composition may bond adjacent fiber material layers together.

[0140] The organosheet may contain a polymeric composition concentration whichprovides enhanced flame retardancy and reduced heat transfer across the structure containing the fibers and the polymeric composition. The organosheet may have up toabout 70 percent by weight based on the weight of the organosheet of the polymericcomposition, about 50 percent by weight or less of the polymeric composition, or about 45 percent by weight or less of the polymeric composition. The organosheet may have about20 percent by weight based on the weight of the organosheet or more of the polymericcomposition, about 25 percent by weight or more of the polymeric composition, or about30 percent by weight or more of the polymeric composition. The organosheet may fromabout 20 percent by weight to about 70 percent by weight, about 30 percent by weight toabout 50 percent by weight, or about 30 percent by weight to about 45 percent by weightof the polymeric composition.

[0141] The organosheet may contain a fiber concentration which provides enhancedflame retardancy and reduced heat transfer across the structure containing the fibers. The organosheet may have a fiber content of up to 80 percent by weight based on the weightof the organosheet, about 75 percent by weight or less, or about 65 percent by weight orless. The organosheet may contain a fiber content of about 30 percent by weight or more based on the weight of the organosheet, about 35 percent by weight or more, about 50 percent by weight or more, or about 55 percent by weight or more. The organosheet 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 about65 percent by weight, or about 55 percent by weight to about 65 percent by weight.

[0142] The organosheet may be comprised of a number of fiber material layerssufficient to provide the organosheet with excellent fire retardant and fire resistant properties. The organosheet may be comprised of one or more fiber material layers, two or more fiber material layers, or three or more fiber material layers. The organosheet may comprise of one or more non-woven fiber material layers, one or more woven fiber material layers, or a combination of one or more woven fiber material layers and one or more non- woven fiber material layers. The organosheet may comprise of one or more woven fiber material layers. The organosheet may comprise of one or more non-woven fiber material layers. The organosheet may comprise of woven fiber material layers and non-woven fibermaterial layers. The organosheet may comprise of woven fiber material layers. The organosheet may comprise of at least one non-woven fiber material layer.

[0143] The organosheets may be prepared using any known process for preparingorganosheets, for example extrusion or co-extrusion, lamination, co-lamination and the like. The surface of the organosheets can be textured using embossing rolls, and the like. The organosheet 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 organosheet 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 organosheet 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 organosheet under conditions that the polymeric composition bonds adjacent layers together and becomes embedded within the fiber material layer. Exemplary temperatures for forming the organosheet maybe 150°C or greater. Exemplary temperatures for forming the organosheet may be 300°Cor less, or 200°C or less. The formation of the organosheet may in addition to heatinginclude the application of pressure to the structure in the direction transverse to the sheet faces. The pressure applied may be sufficient to embed the one or more polymeric compositions into the one or more fiber material layers. The organosheet may be formed by contacting the fiber material layer with the powder, flakes, pellets of the polymeric composition and heating the structure with the powder, flakes or pellets in contact with the fiber material layer above the melting point of the organosheet under conditions t that the polymeric composition becomes embedded within the fiber material layer. The organosheet may be formed into an organosheet by heating the powder, flakes, or pellets of the polymeric composition in an extruder and extruding a layer of the polymeric composition onto the fiber material layer. The polymeric composition layer and the fiber material layer may then be heated above the melting point of the organosheet under conditions that the polymeric composition becomes embedded within the fiber materiallayer. The organosheets may be further processed to make shaped articles bythermoforming and the like.

[0144] The organosheets of the fire reducing composite expands when exposed tofire and reduces the amount of heat transferred through the fire reducing composite. Theorganosheets insulates the transfer of heat through the fire reducing composite and thepolycarbonate long fiber composition maintains mechanical properties when exposed to fire.

[0145] The organosheets may be molded into any desired form. The fire reducingcomposite 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 thespread of fire. The organosheets may be molded using any molding process known in theart for molding a continuous fiber reinforced thermoplastic composite. The fire reducing composite may be molded using compression molding (e.g. stamp forming), insertmolding, or injection molding (e.g. over-molding).

[0146] The organosheets may be molded into a desired form prior to being combinedwith the polycarbonate long fiber. The organosheets may be molded into a desired formwhen combined with the polycarbonate long fiber. The organosheets may be molded intoa desired form after being combined with the polycarbonate long fiber. The organosheet may be molded with the polycarbonate long fiber using any method known to one skilled in the art to form a reinforced organosheet and / or an over-molded organosheet. The polycarbonate long fiber may reinforce and / or over-mold the organosheet. The organosheet may be compression molded, insert molded, or injection molded to with a polycarbonate long fiber to the fire reducing composite.

[0147] To form the fire reducing composite, the polycarbonate long fiber compositionmay 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 polycarbonate long fiber composition may be a reinforcing layer between two or more organosheets molded together. The fire reducing composite may contain one or more organosheets and the polycarbonate long fiber composition disclosed herein. Polymeric composition

[0148] The one or more polymeric compositions of the organosheet may compriseone or more thermoplastic polymers. 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. The one or more thermoplasticpolymers may melt and expands when exposed to temperatures between about 300°C toabout 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 morepolyolefins, one or more polyarylsulfones (PSU), one or more polypropylene (PP), one ormore 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 polyarylsulfones. The one or more thermoplastic polymers may comprise of at least one or more polycarbonates. The one or more polycarbonates may be a virgin polycarbonate, a recycled polycarbonate, or a mixture of both. The one or more polycarbonates may be the polycarbonate composition disclosed herein.

[0149] The polymeric composition may comprise one or more non-halogen containingflame retardant disclosed herein. The polymeric composition may comprise one or more antioxidants disclosed herein. The polymeric composition may comprise one or more moldrelease agents disclosed herein. The polymeric composition may contain, one or moreimpact modifiers disclosed herein, one or more additional polymers disclosed herein, one or more charring salts disclosed herein, one or more UV absorbers disclosed herein, one or more additives commonly used in a thermoplastic polymer based composition disclosed herein, or any combination thereof. The polymeric composition may comprise one or morethermoplastic polymers, one or more non-halogen containing flame retardants, one ormore antioxidants, and one or more mold release agents. about 75 weight percent to about 100 weight percent of one or more thermoplastic; about 0 weight percent to about 25 weight percent of one or more non-halogen containing flame retardants; about 0.2 weight percent to about 2 weight percent of one or more additives commonly used in compositions of this type; about 0 weight percent to about 5 weight percent of one or more impact modifiers; and / or about 0 weight percent to about 30 weight percent of a second polymer. Weight percent provided for the polymeric composition are based on the weight of the polymeric composition.

[0150] The polymeric composition may be one or more polymeric composition layersprior 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 thepolymeric composition layer in the one or more fiber material layers. The polymeric composition layers may have a thickness sufficient to fully embed 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 fibers. Fiber Material Layers

[0151] The one or more fiber materials of the fiber material layer may comprise ofcontinuous fibers or discontinuous fibers. The one or more fiber materials may comprise of discontinuous fibers. The one or more fiber materials may comprise of continuous unidirectional fibers. The one or more fiber materials may be a woven material, a non-woven material, a felt, mat material, a unidirectional fiber material comprised of one ormore fiber types. The one or more fiber materials may comprise of fibers that are woven, non-woven. 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. Thefiber material layers of the organosheet may comprise of one or more layers of one ormore non-woven fiber materials, one or more layers of one or more woven fiber materials,one or more layers of one or more unidirectional fiber material, or a combination thereof.The fiber material layers of the organosheet may comprise of one or more woven fiber materials. The fiber material layers of the organosheet may comprise of one or morenon- woven fiber materials. The fiber material layers of the organosheet may comprise ofone or more unidirectional fiber materials. The fiber material layers of the organosheetmay comprise of non- woven fiber materials and woven fiber materials. The fiber materiallayers of the organosheet may comprise of at least one non-woven fiber material.

[0152] The fiber material layers of the organosheet may comprise of a number oflayers of a fiber material sufficient to provide the organosheet with excellent fire retardantand fire resistant properties. The fiber material layers of the organosheet may comprise ofone 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 layermay be comprised of forty or less layers of one or more fiber materials, ten or less layersof one or more fiber materials, five or less layers of the one or more fiber materials. Thelayers of the one or more fiber materials may have a thickness of about 500 μm or less,or less, or about 250 μm or less. The layers of the one or more fiber materials may havea thickness of about 20 μm or greater, about 50 μm or greater, or about 250 μm. The layers of the one or more fiber materials may have a thickness of about 20 μm to about500 μm, about 50 μm to about 500 μm, about 50 μm to about 250 μm, or about 250 μm toabout 500 μm.

[0153] The fibers of the one or more fiber materials may comprise one or more fibertypes 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 steelfibers, one or more stainless steel fibers, one or more carbon steel fibers, one or morecopper fibers, one or more brass fibers, one or more silver fibers, one or more nickel silverfibers, one or more nickel-iron alloy fibers, one or more magnesium fibers, or a mixture ofany of the one or more metal fibers. The one or more metal fibers may be comprised of one or more stainless steel fibers. The one or more metal coated fibers may be comprisedof one or more aluminum coated fibers, one or more aluminum coated glass fibers, oneor more aluminum coated basalt fibers, one or more nickel coated fibers, one or morenickel coated carbon fibers, one or more nickel coated glass fibers, one or more silvercoated fibers, or a mixture of any of the one or more metal coated fibers. The one or more metal coated fibers may be comprised of aluminum coated basalt fiber. The mineral fibermay be wollastonite fiber, or basalt fiber. The cellulose fiber may be flax fiber. Two or moredifferent fibers may be combined to form a co-knit fiber. The one or more polymeric fibersmay comprise one or more polymers selected from polycarbonate, aramids, polyesters, polyolefins, polyethylene amines, and the like. The fibers may be formed into substructures such as braided structures, tapes, and the like.

[0154] The fiber material of the fiber material layer may comprise of fibers having adiameter sufficient to allows the organosheet to maintain structural integrity duringburning. The fibers of the fiber material may have a diameter of less than about 20 μm.The fibers of the fiber material may have a diameter of about 18 μm or less, about 10 μmor less, or about 6 μm or less. The fibers of the fiber material may have a diameter ofabout 0.1 μm or greater, about 1 μm or greater, about 4 μm or greater, or about 8 μm or greater. The fibers of the fiber material may have a diameter of about 0.1 μm to about 20 μm, about 1 μm to about 18 μm, about 1 μm to about 10 μm, about 4 μm to about 10 μm, about 8 μm to about 10 μm, or about 4 μm to about 6 μm.

[0155] Fiber diameter as used herein may be determined by KEYENCE DigitalMicroscope 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.

[0156] The fiber material of the fiber material layer may comprise one or more layersof one or more unidirectional fiber materials. A unidirectional fiber material may compriseof continuous fiber that are not woven. The unidirectional fiber material may comprise offibers of one or more fiber types provided herein. The unidirectional fiber material may comprise of carbon fibers, glass fibers, ceramic fibers, polymeric fibers metal fibers, or metal coated fibers. The fibers of a unidirectional fiber material may have a diameter sufficient to allows the organosheet to maintain structural integrity during burning. The fibers of the unidirectional fiber material may have a diameter of about 40 μm or less, orabout 17 μm or less. The fibers of the unidirectional fiber material may have a diameter ofabout 6 μm or greater, or about 12 μm or greater. The fibers of the unidirectional fibermaterial may have a diameter from about 6 μm to about 40 μm, or about 12 μm to about17 μm. The unidirectional fiber materials may be stacked or layered in a way to createangles or orientations with the other layers and form a specific layup. For example, oneunidirectional fiber material may be placed in a + 45 degree orientation and the other may be placed in a -45 degree orientation and stitched together in a 0 degree orientation to form a non-crimp fabric with a plus / minus 45 degree layup. The stacking of unidirectional fiber materials can be weaved into a 0 / 90 degree net, or spot welded.

[0157] The woven fiber material layer may comprise one or more layers of one ormore woven fiber materials. The woven fiber material may comprise of one or more wovenfibers. The woven fibers may have any weave which facilitates maintaining structural integrity during burning. The woven fibers may have a plain weave, a unidirectional weave, a non-crimp weave, or twill weave. The woven fiber material may comprise of any fiberswhich provides the organosheet the ability to maintain structural integrity during burning.The woven fiber material may comprise of fibers of one or more fiber types providedherein. The woven fiber material may comprise of carbon fibers, glass fibers, ceramicfibers, polymeric fibers metal fibers, or metal coated fibers. The metal fibers of the wovenfiber material may be a stainless steel fibers. The metal coated fibers of the woven fibermaterial may be aluminum coated basalt fibers. The woven fiber material layer maycomprise glass fibers. The woven fiber material layer may comprise glass fibers with aplain weave.

[0158] The fibers of the woven fiber material may comprise fibers having a diametersufficient to allows the organosheet to maintain structural integrity during burning. Thefibers of the woven fiber material may have a diameter of about 40 μm or less, about 35μm or less, about 25 μm or less, or about 15 μm or less. The fibers of the woven fibermaterial may have a diameter of about 0.1 μm or greater, about 0.5 μm or greater, orabout 1.0 μm or greater. The fibers of the woven fiber material may have a diameter fromabout 0.1 μm to about 40 μm, about 0.1 μm to about 35 μm, about 0.5 μm to about 25 μm,or about 1.0 μm to about 15 μm.

[0159] The glass fibers of the woven glass fiber material may comprise fibers havinga diameter sufficient to allows the organosheet to expand during burning. The glass fibersof a woven glass fiber material may have a diameter of about 3 μm or greater, about 5 μmor greater, or about 6 μm or greater. The glass fibers of a woven glass fiber material mayhave a diameter of about 40 μm or less, about 33 or less, or about 13 μm or less. Theglass fibers of the woven glass fiber material may have a diameter of about 3 μm to about40 μm, about 5 μm to about 33 μm, or about 6 μm to about 13 μm.

[0160] The non-woven fiber material layer may comprise one or more layers of one ormore non-woven fiber materials. The non-woven fiber material layer may comprise of anumber of layers of a non-woven fiber material sufficient to provide the organosheet withthe desired properties. The non-woven 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. Thenon-woven fibers may be of any fiber types disclosed herein. The non-woven fiber material may be made of glass fibers, carbon fibers, ceramic fibers, polymeric spun fibers, one or more metal fibers, one or more metal coated fibers, or any combination thereof. The metalfibers of the non-woven fiber material may be a stainless steel fabric. The metal coated ofthe non-woven fiber material may be aluminum coated basalt fibers. 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.%. The polymeric 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 the co-knit fibers, glass fibers, or a carbon fiber mixture.

[0161] The fibers of the non-woven fiber material have a diameter which allows theorganosheet to expand during exposure to fire and reduce the transfer of heat through theorganosheet. The fibers of the non-woven fiber material may have a diameter of about 18μm or less, about 10 μm or less, or about 6 μm or less. The fibers of the non-woven fibermaterial may have a diameter of about 0.1 μm or greater, about 1 μm or greater, about 4 μm or greater, or about 8 μm or greater. The fibers of the non-woven fiber material may have a diameter from about 0.1 μm to about 18 μm, about 1 μm to about 10 μm, about 4 μm to about 10 μm, about 8 μm to about 10 μm, or about 4 μm to about 6 μm.

[0162] The glass fibers of the non-woven fiber material have a diameter which allowsthe organosheet to expand during exposure to fire and reduce the transfer of heat throughthe organosheet. The glass fibers of a non-woven glass fiber material may have a diameterof about 0.1 μm or greater, or about 6 μm or greater. The glass fibers of a non-wovenglass fiber material may have a diameter of about 18 μm or less, or about 10 μm or less,8 μm or less. The glass fibers of a non-woven glass fiber material may have a diameter ofabout 8 μm. The glass fibers of the non-woven glass fiber material may have a diameterof about 0.1 μm to about 18 μm, about 6 μm to about 10 μm, or about 6 μm to about 8 μm.

[0163] The carbon fibers of the non-woven fiber material have a diameter which allowsthe organosheet to expand during exposure to fire and reduce the transfer of heat throughthe organosheet. The carbon fibers of the non-woven carbon fiber material may have adiameter of about 18 μm or less, about 10 μm or less, about 8 μm or less, or about 6 μmor less. The carbon fibers of the non-woven carbon fiber material may have a diameter ofabout 1 μm or more, or about 4 μm or more. The carbon fibers of the non-woven carbonfiber material may have a diameter of about 1 μm to about 18 μm, about 1 μm to about 10μm, about 4 μm to about 8 μm, or about 4 μm to about 6 μm.

[0164] The fire reducing composite may have an organosheet with at least one fibermaterial layer comprised of a woven glass fiber material with a diameter of about 5 μm to about 20 μm; a non-woven glass fiber material with a diameter of about 8 μm to about 18 μm; or a non-woven carbon fiber material. The fire reducing composite may have an organosheet with a fiber material layer comprised of the woven glass fiber material with a diameter of about 5 μm to about 20 μm; the non-woven glass fiber material with the diameter of about 8 μm to about 18 μm; the non-woven carbon fiber material; or any combination thereof. The fire reducing composite may have an organosheet with at least one fiber material layer composed of a woven glass fiber with a diameter of about 5 μm to about 20 μm. The fire reducing composite may have an organosheet with at least one fiber material layer composed of a non-woven glass fiber with a diameter of about 8 μm to about 10 μm.

[0165] The fire reducing composite may have a flexural modulus of about 10 GPa ormore. The fire reducing composite may have a flexural modulus may have a flexuralmodulus of about 100 GPa or less, about 40 GPa or less, or about 30 GPa or less. Thefire reducing composite may have a flexural modulus of about 10 GPA to about 100 GPa, about 10 GPa to about 40 GPa, or about 10 GPa to about 30 GPa.

[0166] The fire reducing composite disclosed herein may have minor deformationafter 10 min of fire exposure. The fire reducing composite disclosed herein may have a first side and a second opposite side. The fire reducing composite disclosed herein may have at least the first side is comprised of the polycarbonate long fiber composition. The first side of the fire reducing composite may have a temperature of about 340°C or less, after the second opposite side of the fire reducing composite has been exposed to fire for 10 min. The first side of the fire reducing composite may have a temperature of about 320°C or less, after the second opposite side of the fire reducing composite has been exposed to fire for 10 min. The fire reducing composite with an organosheet with at least one fiber layer composed of a non-woven carbon fiber may have a top side temperature of about 290°C or less, after the bottom side has been exposed to fire for 10 min.Method making fire reducing composite

[0167] Disclosed are methods for making a fire reducing composite comprising:placing one or more non-injection moldable materials in a mold; adding a polycarbonate long fiber composition, having from about 10 wt.% to about 50 wt.% of long glass fibers to the mold; and molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The polycarbonate long fiber composition used in the disclosed method for making a fire reducing composite may comprise a polycarbonate composition and long glass fibers. The polycarbonate composition may be the polycarbonate composition disclosed herein. Thelong glass fibers may have a length of 0.1 mm to 35 mm. The polycarbonate long fibercomposition may be the composition disclosed herein. The polycarbonate long fibercomposition may be in a molten form when added to the mold. The one or more non-injection moldable materials may be one or more non-injection moldable materialsdisclosed herein. The one or more non-injection moldable materials may be pre-heatedprior to being placed into the mold. The one or more non-injection moldable materials may be one or more organosheets comprised of one or more fiber material layers embedded with one or more polymeric compositions. The one or more organosheets may be any organosheet disclosed herein.

[0168] The disclosed method for making the fire reducing composite may compriseplacing the one or more non-injection moldable materials into a compression mold, or an injection mold; adding the polycarbonate long fiber composition to the compression mold or the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. An injection mold may be used for insert molding, or injection molding.

[0169] The disclosed method for making the fire reducing composite may compriseadding pellets of the polycarbonate long fiber composition to an extruder; heating the pellets within the extruder; forming a molten polycarbonate long fiber composition; and extruding the molten polycarbonate long fiber composition into a mold containing the non- injection moldable materials. The pellets of the polycarbonate long fiber composition may be the pellets of the polycarbonate long fiber composition disclosed herein. The pellets of the polycarbonate long fiber composition may be made using the method for making the composition disclosed herein. The extruder may be heated to a temperature high enough to melt the pellets of the polycarbonate long fiber composition and form a molten polycarbonate long fiber composition. The extruded molted polycarbonate long fibercomposition may have a temperature of about 240°C or greater, or about 250°C or greater.The extruded polycarbonate long fiber composition may have a temperature of about280°C or less, or about 270°C or less. The extruded polycarbonate long fiber compositionmay have a temperature of about 240°C to about 280°C, or about 250°C to about 270°C.

[0170] The disclosed method for making the fire reducing composite may compriseusing one or more non-injection moldable materials that have been previously molded (e.g. insert molding), molding the one or more non-injection moldable materials in the mold prior to being molded with the polymeric long fiber composition (e.g. injection molding), or molding the non-injection moldable materials and the polymeric long fiber composition together (e.g. compression molding). The non-injection moldable material may be molded using any method known in the art for molding a non-injection moldable material. Thethermoforming may be used to mold the non-injection moldable material.

[0171] The disclosed method for making the fire reducing composite may compriseplacing the non-injection moldable materials into the mold cold, or pre-heating the one or more non-injection moldable materials prior to being placed into a mold. The one or morenon-injection moldable materials may be heated by infrared radiator. The one or morenon-injection moldable materials may be the one or more organosheets. The one or more non-injection moldable materials may be an organosheet comprised of one or more fiber material layers and one or more polymeric compositions. The organosheet may comprise of at least one layer of a glass weave fiber material. The organosheet may comprise of at least one layer of a non-woven fiber material.

[0172] The one or more non-injection moldable materials may be heated totemperature above the glass transition temperature (Tg) of the polymeric composition of the one or more non-injection moldable materials. The polymeric composition of the non-injection moldable materials may have a glass transition of about -40°C or more, about80°C or more, or about 100°C or more. The polymeric composition of the non-injectionmoldable materials may have a glass transition of about 350°C or less, about 200°C orless, or about 160°C or less. The non-injection moldable materials may have a glasstransition of about -40°C to about 350°C, about 80°C to about 200°C, or about 100°C toabout 160°C. The one or more non-injection moldable materials may be preheated to atemperature of about 100°C or greater, about 130°C or greater, or about 150°C or greater.The one or more non-injection moldable materials may be preheated a temperature ofabout 300°C or less, about 250°C or less, or about 200°C or less. The one or more non-injection moldable materials may be preheated to a temperature about 100°C to about300°C, about 130°C to about 250°C, or about 150°C to about 200°C. The one or morenon-injection moldable materials may be preheated for about 0 seconds to about 10minutes.

[0173] The polycarbonate long fiber composition used in the disclosed method formaking a fire reducing composite may be made using any method known in the art for making a long fiber thermoplastic. The polycarbonate long fiber composition may be made using any method for making the composition disclosed herein. The polycarbonate longfiber composition may be in powder, flakes, and / or pellet form prior to being added to thenon-injection moldable material. The powder, flakes, and / or pellet of the polycarbonate long fiber composition may be heated in an extruder to form a molten polycarbonate long fiber composition. The polycarbonate long fiber composition may be made at the time the fire reducing composite is made; and the extruded directly into the mold with the one or more non-injection moldable materials.

[0174] The disclosed for making the fire reducing composite may comprise formingthe polycarbonate long fiber composition using the method disclosed herein; and extruding a molten polycarbonate long fiber composition into a mold containing the non-injection moldable materials.

[0175] The disclosed method for making the fire reducing composite may comprisereinforcing the one or more non-injection moldable materials with the polycarbonate long fiber composition. The disclosed method for making the fire reducing composite may comprise over-molding the one or more non-injection moldable materials with the polycarbonate long fiber composition. The polycarbonate long fiber composition may form ribs and / or the full rim surrounding the non-injection moldable material.

[0176] The disclosed method for making the fire reducing composite may comprisecompression molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together to form the fire reducing composite. The disclosed method for making the fire reducing composite using compression molding may comprise placing the one or more non-injection moldable materials into a compressionmold; adding the molten polycarbonate long fiber composition on top of the one or morenon-injection moldable materials; compression molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The disclosed method for making the fire reducing composite using compression molding may comprise adding one or more additional non-injection moldable materials on top of the polycarbonate long fiber composition. The moltenpolycarbonate long fiber composition may flow freely during the molding process to form ribs or the full rim surrounding the non-injection moldable material.

[0177] The one or more non-injection moldable materials and the polycarbonate longfiber composition may be compression mold at a pressure of about 20 bar or greater, about 50 bar or greater, about 100 bar or greater, or about 150 bar or greater. The one or more non-injection moldable materials and the polycarbonate long fiber composition maycompression mold at a pressure of about 250 bar or less, or about 200 bar or less. Theone or more non-injection moldable materials and the polycarbonate long fibercomposition may be compression mold at a pressure of about 20 bar to about 250 bar;about 100 bar to about 200 bar; or about 150 bar to about 200 bar.

[0178] The one or more non-injection moldable materials and the polycarbonate longfiber composition may be compression molded for a time long enough until the part solidifies. The one or more non-injection moldable materials may be preheated prior tobeing compression molded or while the one or more non-injection moldable materials iscompression molded with the polycarbonate long fiber composition. When compressionmolding and pre-heating is done at the same time, the non-injection moldable materialsmay be preheated for a time that is equal to or less than the molding time. The pre-heatingtime during compression molding may not exceed the compression molding time. Thenon-injection moldable materials and the polycarbonate long fiber composition may becompression molded for about 0 seconds or more, or about 30 seconds or more. The non-injection moldable materials and the polycarbonate long fiber composition may becompression molded for about 10 minutes or less, about 5 minutes or less, or about 1minutes or less. The non-injection moldable materials and the polycarbonate long fibercomposition may be compression molded for about 0 minutes to about 10 minutes, about1 minute to about 30 seconds, or about 5 minutes to about 30 minutes.

[0179] The disclosed method for making the fire reducing composite may compriseinsert molding or injection molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together to form the fire reducing composite. The disclosed method for making the fire reducing composite may comprise placing the one or more non-injection moldable materials into the injection mold; injecting the polycarbonate long fiber composition into the injection mold; molding the one or more non- injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0180] The disclosed method for making the fire reducing composite using insertmolding may comprise: pre-molding the one or more non-injection moldable materials into a pre-molded composite; placing the pre-molded composite into the injection mold;injecting the polycarbonate long fiber composition into the injection mold containing thepre-molded composite; molding the pre-molded composite and the polycarbonate long fiber composition together; and demolding the fire reducing composite. The one or more non-injection moldable materials may be pre-molded using thermoforming. The pre- molded composite may be cooled prior to being placed into the injection mold.

[0181] The method for making the fire reducing composite using injection moldingmay comprise: heating the one or more non-injection moldable materials; placing theheated one or more non-injection moldable materials into a mold; closing the mold;molding the heated one or more non-injection moldable materials; injecting thepolycarbonate long fiber composition into the mold with the non-injection moldablematerials that has been molded; forming the fire reducing composite within the mold;cooling the molded fire reducing composite; and demolding the fire reducing composite.

[0182] The method for making the fire reducing composite using injection moldingmay comprise: heating the one or more non-injection moldable materials; placing the heated one or more non-injection moldable materials into a mold; closing the mold; thermoforming the heated one or more non-injection moldable materials; injecting the polycarbonate long fiber composition into the mold with the non-injection moldable materials that has been molded; forming the fire reducing composite within the mold;cooling the molded fire reducing composite; and demolding the fire reducing composite.

[0183] The method for making the fire reducing composite may comprise: placing oneor more organosheets in a mold; adding a polycarbonate long fiber composition, havingfrom about 10 wt.% to about 50 wt.% of long glass fibers to the mold; and molding the oneor more organosheets and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0184] The method for making the fire reducing composite may comprise using anorganosheet comprising one or more fiber material layers as disclosed herein, embedded with one or more polymeric compositions as disclosed herein. The organosheet may have at least one non-woven fiber material layer as disclosed herein and a fiber content from about 30 wt% to about 80 wt%. The method for making the fire reducing composite may comprise using any organosheet disclosed herein.Fire Reducing composite Article

[0185] The fire reducing composite disclosed herein may be used in an article orformed 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. An article comprised of the fire reducing composite disclosed herein may maintain its mechanical properties and integrity when exposed to high temperatures. An article comprised of the fire reducing composite disclosed herein may have a reduced temperature on one side of the article when the opposite side of the article is exposed to fire. The fire reducing composite may be used as a layer in an article or formed into an article with a structure. The fire reducing compositemay be used as a layer in an article or formed into an article with a structure where thereis a risk of fire from within. The fire reducing composite may be used as a layer in an article or formed into an article with a structure where the there is a desire to contain a fire within the article. The fire reducing composite 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 fire reducing composite 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 fire reducing composite 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 fire reducing composite 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 fire reducing composite 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 bea housing or enclosure for a lithium-ion battery. The article may be a battery pack. Thearticle may be used as a layer within the battery pack. The fire reducing composite may be formed into an enclosure for a battery. The fire reducing composite may be formed into an enclosure for a lithium-ion battery. The fire reducing composite may be used as a layer within the lid of the battery pack. The fire reducing composite may be formed into the battery pack. The fire reducing composite 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.

[0186] Figure 1 shows an illustration of a two-stage twin screw line that may be usedto create the polycarbonate long fiber composition 1, where a polycarbonate 2, modifiers3, and additives 4 are fed into a first extruder 5 mixed to form a polycarbonate composition 6 that is extruded from the first extruder 5 into a second extruder 7, while filament glassrovings 8 are fed into the second extruder 7 and pulled through the polycarbonatecomposition 6 to form the polymeric long fiber composition 1. Figure 2 shows an illustration of a two-stage twin screw line that may be used to create the polycarbonate long fiber composition 1, where a polycarbonate composition 6 is fed into a first extruder 5 and heated and extruded into a second extruder 7, while filament glass rovings 8 are fed into the second extruder 7 and pulled through the polycarbonate composition 6 to form the polymeric long fiber composition 1. Figure 3 shows an illustration of a top down view of a possible fire reducing composite 9, where the polycarbonate long fiber composition 1 does not cover the entire top of the non-injection moldable material 10. Figure 4 shows an illustration of a side view of the fire reducing composite 9 shown in 3, where the polycarbonate long fiber composition 1 does not cover the entire top of the non-injection moldable material 10. Figure 5 shows an illustration of a possible fire reducing composite 9 from a bottom view, where the polycarbonate long fiber composition 1 over-molds the non-injection moldable material 10. Figure 6 shows an illustration of a possible fire reducing composite 9 from a side view, where the polycarbonate long fiber composition 1 covers a top side and sides of the non-injection moldable material 10. Figure 7 shows an illustration of a possible fire reducing composite 9, where the polycarbonate long fibercomposition 1 is a reinforcing layer between two or more non-injection moldable materials10. EMBODIMENTS

[0187] 1. A composition comprising, one or more polycarbonate compositions andone or more long glass fibers, wherein the one or more long glass fibers are mixed with the one or morepolycarbonate compositions to form a polycarbonate long fiber composition, having fromabout 10 wt.% to about 55 wt.% of long glass fibers.

[0188] 2. The composition of claim 1, wherein the one or more long glass fibershave an average length of about 0.1 mm to about 35 mm.

[0189] 3. The composition of claim 2, wherein at least a portion of the one or morelong glass fibers have a length of about 1 mm to about 15 mm.

[0190] 4. The composition of any one of embodiments 1-3, wherein thepolycarbonate long fiber composition comprises from about 30 wt.% to about 80 wt.% of one or more polycarbonate compositions.

[0191] 5. The composition according to any one of embodiments 1-4, wherein thepolycarbonate long fiber composition reduces the transfer of heat.

[0192] 6. The composition according to any one of the preceding embodiments,wherein the polycarbonate long fiber composition maintains its mechanical properties and integrity when exposed to high temperatures.

[0193] 7. The composition according to any one of the preceding embodiments,wherein the polycarbonate long fiber composition withstands heat from a fire.

[0194] 8. The composition according to any one of the preceding embodiments,wherein the polycarbonate long fiber composition maintains its mechanical properties and integrity when exposed to fire.

[0195] 9. The composition of any of the preceding embodiments, wherein the oneor more polycarbonate compositions comprise one or more polycarbonates.

[0196] 10. The composition of any of the preceding embodiments, wherein the oneor more polycarbonate compositions comprise from about 75 wt.% to about 100 wt.% of the one or more polycarbonates.

[0197] 11. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 80 wt.% to about 95 wt.% of one or more polycarbonates.

[0198] 12. The composition of any one of embodiments 9-11, wherein the one ormore polycarbonates are a virgin polycarbonate, a recycled polycarbonate, or a mixture thereof.

[0199] 13. The composition of any of the embodiments 9-12, wherein the one ormore polycarbonates is branched, linear, or a mixture thereof.

[0200] 14. The composition of any one of embodiments 9-13, wherein the one ormore polycarbonates comprises one or more polycarbonate siloxane copolymers.

[0201] 15. The composition of any one of the preceding embodiments, wherein thepolycarbonate composition comprises one or more non-halogen containing flame retardants.

[0202] 16. The composition of any one of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 25 wt.% of oneor more non-halogen containing flame retardants.

[0203] 17. The composition of embodiment 16, wherein the one or more non-halogen containing flame retardants is one or more phosphorus containing flame retardants.

[0204] 18. The composition of embodiment 17, wherein the one or more phosphoruscontaining flame retardants comprises a phosphate ester or a phosphazene.

[0205] 19. The composition of embodiment 17 or 18, wherein one of the phosphoruscontaining 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.

[0206] 20. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises one or more antioxidants.

[0207] 21. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0.1 wt.% to about 0.3 wt.% ofone or more antioxidants.

[0208] 22. The composition of embodiment 20 or 21, wherein at least one of the oneor more antioxidants is Octadecyl 3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate.

[0209] 23. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises one or more mold release agents.

[0210] 24. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0.1 wt.% to about 0.7 wt.% ofone or more mold release agents.

[0211] 25. The composition of embodiment 23 or 24, wherein at least one of the oneor more mold release agents is PentaErythritol Tetrastearate.

[0212] 26. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises, one or more impact modifiers, one or more anti-drip agents, one or more additional polymers, one or more charring salts, one or more UV absorbers, one or more additives commonly used in a polycarbonate-based composition, or any combination thereof.

[0213] 27. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 5 wt.% of oneor more impact modifiers.

[0214] 28. The composition of either embodiment 26 or 27, wherein the one or moreimpact modifiers comprise a butadiene, a styrene-butadiene rubber-based methyl methacrylate-styrene, a methacrylate-butadiene-styrene grafted impact modifiers having a core-shell structure, a methyl methacrylate-grafted impact modifier having a core-shell structure, a siloxane-acrylate rubber having a core-shell structure, an acrylate rubber-based core-shell impact modifiers, styrene- butadiene rubber-based methyl methacrylate-styrene core-shell impact modifier, or any combination thereof.

[0215] 29. The composition of any one of embodiments 26-28, wherein at least oneof the one or more impact modifiers is a methacrylate-butadiene-styrene grafted impact modifier having a core-shell structure.

[0216] 30. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 1 wt.% of oneor more anti-drip agents.

[0217] 31. The composition of either embodiment 26 or 30, wherein the anti-dripagents comprise polytetrafluoroethylene, polytetrafluoroethylene / styrene- acrylonitrile masterbatch, or an organo-functional liquid siloxane.

[0218] 32. The composition of any one of embodiments 26, 30 or 31, wherein atleast one of the anti-drip agents is polytetrafluoroethylene, or polytetrafluoroethylene / styrene-acrylonitrile masterbatch.

[0219] 33. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 30 wt.% of oneor more additional polymers.

[0220] 34. The composition of either embodiment 26 or 33, wherein the one or moreadditional polymers is acrylonitrile butadiene styrene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate-siloxane copolymer, high molecular weight polysiloxane, liquid crystal polymer LCP (1,4-Benzenediol polymer with1,4-benzenedicarboxylic acid, 4-hydroxybenzoic acid and 6-hydroxy-2- naphthalenecarboxylic acid), or any combination thereof.

[0221] 35. The composition of any one of embodiments 26, 33 or 34, wherein theone or more additional polymers is acrylonitrile butadiene styrene, polyethylene terephthalate, or polybutylene terephthalate.

[0222] 36. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 0.3 wt.% ofone or more charring salts.

[0223] 37. The composition of any of the preceding embodiments, wherein thepolycarbonate composition comprises from about 0 wt.% to about 1 wt.% of oneor more UV agents.

[0224] 38. The composition of any one of the preceding embodiments, wherein thecomposition does not contain copolymers of polycarbonate units and polysiloxane units, polypropylene, modified polypropylene, polyurethane, polycaprolactone, polylactic acid, polysiloxane based fire retardants, halogen containing charring salts, inorganic fillers, flame retardant synergist minerals or fluoropolymers having the ability to form fibrils.

[0225] 39. The composition of any one of the preceding embodiments, wherein thecomposition is chopped into elongated sections.

[0226] 40. The composition of any one of the preceding embodiments, wherein thecomposition is molded into a molded polycarbonate long fiber composition.

[0227] 41. The composition of embodiment 40, wherein the molded polycarbonatelong fiber composition has a thickness of about 1 mm to about 10 mm.

[0228] 42. The composition of embodiment 41, wherein the molded polycarbonatelong fiber composition has a thickness of about 1 mm to about 5 mm.

[0229] 43. The composition of any one of the preceding embodiments, wherein thecomposition had a flexural modulus of about 6 GPa to about 12 GPa.

[0230] 44. The composition of any one of the preceding embodiments wherein thecomposition has a flexural strength of about 80 MPa to about 150 MPa.

[0231] 45. The composition of any one of the preceding embodiments, wherein thecomposition has a UL94 rating of V-0.

[0232] 46. The composition of any one of embodiments 1-45, wherein thepolycarbonate long fiber composition is combined with one or more composites to create a fire reducing composite.

[0233] 47. The composition of embodiment 46, wherein the one or more compositesis one or more non-injection moldable materials.

[0234] 48. The composition of embodiment 47, wherein the one or more non-injection moldable materials are comprised of one or more fiber materials and a polymeric composition.

[0235] 49. A method for making the composition of any one of the precedingembodiments comprising:feeding either a polycarbonate formulation, or one or more polycarbonate compositions into a first extruder; extruding a molten polycarbonate composition from the first extruder; feeding the molten polycarbonate composition and filament glass rovings into a second extruder; mixing the molten polycarbonate composition and filament glass rovings together; forming a polycarbonate long fiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers; and extruding the polycarbonate long fiber composition.

[0236] 50. The method according to embodiment 49, wherein the one or more longglass fibers have a length of about 0.1 mm to about 35 mm.

[0237] 51. The method according to embodiment 49 or 50, wherein thepolycarbonate long fiber composition is comprised of from about 30 wt.% to about 80 wt.% of a polycarbonate composition.

[0238] 52. The method of any one of embodiments 49-51, wherein thepolycarbonate formulation comprising, one or more polycarbonates, one or more modifiers and one or more additives are mixed in the first extruder to form the one or more polycarbonate compositions.

[0239] 53. The method of any one of embodiments 49-52, wherein the one or morepolycarbonate compositions is comprised of the polycarbonate formulation.

[0240] 54. The method of any one of embodiments 49-53, wherein the one or moreadditives and one or more modifiers comprise one or more non-halogen containing flame retardants, one or more antioxidants, one or more mold release agents, one or more impact modifiers, one or more anti-drip agents, one or more additional polymers, one or more charring salts, one or more UV absorbers, or any combination thereof.

[0241] 55. The method of any one of embodiments 49-54, comprising:chopping the extruded polycarbonate long fiber composition into elongated sections; and forming pellets of the polycarbonate long fiber composition.

[0242] 56. The method of embodiment 55, comprising:placing the pellets of the polycarbonate long fiber composition into an extruder; melting the pellets of the polycarbonate long fiber composition; and extruding the polycarbonate long fiber composition.

[0243] 57. The method of any one of embodiments 49-56, comprising:extruding the polycarbonate long fiber composition into a mold; and molding the polycarbonate long fiber composition.

[0244] 58. The method of either embodiment 56 or 57, comprising molding thepolycarbonate long fiber composition into a molded polycarbonate long fiber composition.

[0245] 59. The method of embodiments 57 or 58, comprising extruding thepolycarbonate long fiber composition into a compression mold or an injection mold; and molding the polycarbonate long fiber composition into the molded polycarbonate long fiber composition.

[0246] 60. The method of embodiment 59, comprising extruding the polycarbonatelong fiber composition into a compression mold; compressing the compression mold; and molding the polycarbonate long fiber composition into the molded polycarbonate long fiber composition.

[0247] 61. The method of any one of embodiments 56-60, comprising injecting theextruded polycarbonate long fiber composition into the injection mold; and demolding the molded polycarbonate long fiber composition from the injection mold.

[0248] 62. The method of any one of embodiments 59-61, wherein the compressionmold or the injection mold is an electric vehicle housing molder.

[0249] 63. The method of any one of embodiments 57-62, comprising molding thepolycarbonate long fiber composition into a battery pack.

[0250] 64. The method of any one of embodiment 57-63, comprising molding thepolycarbonate long fiber composition into a lid of the battery pack.

[0251] 65. The method of any one of embodiments 57-64, wherein the moldedpolycarbonate long fiber composition has a thickness of about 1 mm to about 10 mm.

[0252] 66. The method of embodiment 65, wherein the molded polycarbonate longfiber composition has a thickness of about 1 mm to about 5 mm.

[0253] 67. The method of any one of embodiments 57-66, comprising molding thepolycarbonate long fiber composition with one or more composites; and forming a reinforced composite or an over-molded composite.

[0254] 68. The method of embodiment 67, comprising extruding the polycarbonatelong fiber composition into a compression mold, or an injection mold containing the one or more composites; molding the polycarbonate long fiber composition and the one or more composites together; and forming the reinforced composite or the over-molded composite.

[0255] 69. The method of embodiment 68, comprising extruding the polycarbonatelong fiber composition into a compression mold containing the one or more composites compressing the compression mold; compressing the compression mold; and forming the reinforced composite or the over-molded composite the polycarbonate long fiber composition into the molded polycarbonate long fiber composition.

[0256] 70. The method of either embodiment 67 or 68, comprising injecting theextruded polycarbonate long fiber composition into the injection mold containing the one or more composites; forming the over-molded composite; and demolding the over-molded composite from the injection mold.

[0257] 71. The method according to any one of embodiments 67-70, wherein thereinforced composite or the over-molded composite is a fire reducing composite, wherein a fire reducing composite means one or more of a fire exposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or anycombination thereof.

[0258] 72. The method according to any one of embodiments 49-71, wherein thefirst extruder is a compounding extruder, or a mixing extruder.

[0259] 73. The method according to any one of embodiments 49-72, wherein thesecond extruder is a mixing extruder.

[0260] 74. The method according to either embodiment 72 or 73, wherein the mixingextruder is a twin-screw extruder.

[0261] 75. An article with a structure prepared from a composition according to anyone of the preceding embodiments comprising, one or more long glass fibersmixed with one or more polycarbonate compositions to form a polycarbonatelong fiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers.

[0262] 76. The article of embodiment 75, wherein the polycarbonate long fibercomposition maintains its mechanical properties and integrity when exposed to high temperatures.

[0263] 77. The article according to embodiment 75 or 76, used to reduce the transferof heat.

[0264] 78. The article according to any one of embodiments 75-77, used to insulateheat from a fire.

[0265] 79. The article according to any one of embodiments 75-78, used to reducethe temperature on one side when an opposite side is exposed to fire.

[0266] 80. The article according to any one of embodiments 75-79, used in a firecontainment system.

[0267] 81. The article according to any one of embodiments 75-80, used as a firereducing layer.

[0268] 82. The article according to any one of embodiments 75-81, used in a batterypack.

[0269] 83. The article according to any one of embodiments 82, used to improve themechanical properties and integrity of the battery pack when exposed to fire.

[0270] 84. The article according to embodiment 82 or 83, used to reduce the transferof heat from inside the battery pack.

[0271] 85. The article according to any one of embodiments 82-84, used in a firecontainment system within a battery pack.

[0272] 86. The article according to any one of embodiments 82-85, used to reducethe temperature of the outside of a battery pack.

[0273] 87. The article according to any one of embodiments 82-86, used as the firereducing layer in the battery pack.

[0274] 88. The article according to any one of embodiments 82-87, used to insulateheat from a fire within the battery pack.

[0275] 89. The article according to any one of embodiments 82-88, used to reducethe temperature of the outside of the battery pack when a fire is inside the battery pack.

[0276] 90. The article according to any one of embodiments 82-89, used with one ormore composites to create a fire reducing composite.

[0277] 91. The article according to any one of embodiments 82-90, used to reinforcethe one or more composites.

[0278] 92. The article according to any one of embodiments 82-91, used as an over-mold of the one or more composites.

[0279] 93. The article according to any one of embodiments 82-92, used as areinforcing layer of the one or more composites to create the fire reducing composite.

[0280] 94. The article according to any one of embodiments 82-93, used as an over-mold of the one or more composites to create the fire reducing composite.

[0281] 95. A fire reducing composite according to any one of embodiments 46-94,comprising: a polycarbonate long fiber composition, having from about 10 wt.% to about55 wt.% of long glass fibers; andone or more composites, wherein the one or more composites are one or more non-injection moldable materials.

[0282] 96. The fire reducing composite of embodiment 95, wherein thepolycarbonate long fiber composition is the composition according to any one of embodiments 1-94.

[0283] 97. The fire reducing composite of embodiment 95 or 96, wherein a firereducing composite means one or more of a fire exposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof.

[0284] 98. The fire reducing composite of any one of embodiments 95-97, whereinthe fire reducing composite has minor deformation after being exposed to fire.

[0285] 99. The fire reducing composite of any one of embodiments 95-98, whereinthe fire reducing composite expands when exposed to fire.

[0286] 100. The fire reducing composite of any one of embodiments 95-99, whereinthe fire reducing composite expands immediately on fire exposure.

[0287] 101. The fire reducing composite of any one of embodiments 95-100, whereinthe polycarbonate long fiber composition and one or more non-injection moldable materials are compression molded, insert molded, or injection molded together.

[0288] 102. The fire reducing composite of any one of embodiments 95-101, whereinthe polycarbonate long fiber composition is co-molded with at least one outside face of the one or more non-injection moldable materials.

[0289] 103. The fire reducing composite of any one of embodiments 95-102, whereinthe polycarbonate long fiber composition is bonded with the edges of the one or more non-injection moldable materials.

[0290] 104. The fire reducing composite of any one of embodiments 95-103, whereinthe polycarbonate long fiber composition forms flange, ribs, and / or corners around the one or more non-injection moldable materials.

[0291] 105. The fire reducing composite of any one of embodiments 95-104, whereinthe polycarbonate long fiber composition covers at least part of an outside face and the edges of the one or more non-injection moldable materials.

[0292] 106. The fire reducing composite of any one of embodiments 95-105, whereinthe one or more non-injection moldable materials are over-molded with the polycarbonate long fiber composition.

[0293] 107. The fire reducing composite of any one of embodiments 95-106, whereinthe polycarbonate long fiber composition is bonded with a top side or a bottom side of the one or more non-injection moldable materials.

[0294] 108. The fire reducing composite of any one of embodiments 95-107, whereintwo or more non-injection moldable materials are co-molded with the polycarbonate long fiber composition.

[0295] 109. The fire reducing composite of any one of embodiments 95-108, whereinthe polycarbonate long fiber composition is a reinforcing layer between two layers of the one or more non-injection moldable materials.

[0296] 110. The fire reducing composite of any one of embodiments 95-109, whereinthe one or more non-injection moldable materials are from about 0.1 mm to about 4 mm thick.

[0297] 111. The fire reducing composite of any one of embodiments 95-110, whereinthe fire reducing composite is from about 1.0 mm to about 50 mm thick.

[0298] 112. The fire reducing composite of any one of embodiments 95-111, whereinthe polycarbonate long fiber composition is the composition according to any one of embodiments 1-94.

[0299] 113. The fire reducing composite of any one of claims 95-112, wherein the oneor more non-injection moldable materials are comprised of one or more fiber material layers and one or more polymeric compositions.

[0300] 114. The fire reducing composite of embodiment 113, wherein the one or morefiber material layers is embedded with the one or more polymeric compositions.

[0301] 115. The fire reducing composite of either embodiment 113 or 114, whereinthe polymeric composition bonds adjacent fiber material layers together.

[0302] 116. The fire reducing composite of any one of embodiments 113-115, whereinat least one outside face of the organosheet is the polymeric composition.

[0303] 117. The fire reducing composite of any one of embodiments 113-116, whereinone outside face of the organosheet is a fiber material layer.

[0304] 118. The fire reducing composite of embodiment 117, wherein thepolycarbonate long fiber composition forms a bonds with an exterior fiber material layer.

[0305] 119. The fire reducing composite of any one of embodiments 113-118, whereinboth outside faces of the organosheet is the polymeric composition.

[0306] 120. The fire reducing composite of any one of embodiments 113-119, whereinthe one or more organosheet comprises from about 30 wt.% to about 50 wt. % ofthe polymeric composition.

[0307] 121. The fire reducing composite of any one of embodiments 113-120, whereinthe one or more organosheet has a fiber content from about 30 wt.% to about 80 wt.%.

[0308] 122. The fire reducing composite of any one of embodiments 113-121, whereinthe polymeric composition does not lose its mechanical properties when exposed to fire.

[0309] 123. The fire reducing composite of any one of embodiments 113-122, whereinthe one or more fiber material layers are comprised of one or more layers of one or more fiber materials.

[0310] 124. The fire reducing composite of embodiment 123, wherein the one or morefiber materials comprise of continuous fibers or discontinuous fibers.

[0311] 125. The fire reducing composite of any one of embodiments 113-124, whereinthe one or more fiber materials are comprised of fibers that are woven or non- woven.

[0312] 126. The fire reducing composite of any one of embodiments 113-125, whereinthe fibers of the fiber materials are comprised of one or more fiber types.

[0313] 127. The fire reducing composite of any one of embodiments 113-126, whereinthe fibers of the fiber materials have a diameter from about 0.1 μm to about 20 μm.

[0314] 128. The fire reducing composite of any one of embodiments 113-127, whereinthe one or more fiber materials are one or more woven fiber materials, or one or more non-woven fiber materials.

[0315] 129. The fire reducing composite of any one of embodiments 113-128, whereinthe one or more fiber layers are woven fiber material layers, non-woven fiber material layers, or a mixture of woven fiber material layers and non-woven fiber material layers.

[0316] 130. The fire reducing composite of any one of embodiments 113-129, whereinthe one or more organosheets are comprised of at least two or more fiber material layers.

[0317] 131. The fire reducing composite of any one of embodiments 113-130, whereinthe one or more organosheets are comprised of three or more fiber material layers.

[0318] 132. The fire reducing composite according to any one of embodiments 113-131, wherein the one or more fiber material layers acts as a fire insulator.

[0319] 133. The fire reducing composite of any one of embodiments 123-132, whereinthe 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.

[0320] 134. The fire reducing composite of embodiment 133, wherein the one or moremetal 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.

[0321] 135. The fire reducing composite of embodiment 133, wherein the one or moremetal coated fibers comprise of one or more aluminum coated fibers, one ormore aluminum coated glass fibers, one or more aluminum coated basalt fibers, one or more nickel coated fibers, one or more nickel coated nickel coated carbonfibers, 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.

[0322] 136. The fire reducing composite of embodiment 133, wherein the mineral fiberis wollastonite fiber, or basalt fiber.

[0323] 137. The fire reducing composite of embodiment 133, wherein the cellulosefiber is flax fiber.

[0324] 138. The fire reducing composite of embodiments 95-137, wherein two ormore different fibers are combined to form a co-knit fiber.

[0325] 139. The fire reducing composite of any one of embodiments 113-138, whereinthe polymeric composition of the organosheet comprises 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.

[0326] 140. The fire reducing composite of embodiment 139, wherein the polymericcomposition of the organosheet comprises one or more polycarbonates, one or more polyarylsulfones, or any combination thereof.

[0327] 141. The fire reducing composite of embodiment 139 or 140, wherein thepolymeric composition of the organosheet comprises one or more polycarbonates.

[0328] 142. The fire reducing composite of embodiment 139 or 140, wherein thepolymeric composition of the organosheet comprises one or more polyarylsulfones.

[0329] 143. The fire reducing composite of any one of embodiments 113-142, whereinthe polymeric composition of the organosheet comprises one or more non- halogen containing flame retardants.

[0330] 144. The fire reducing composite of any one of embodiments 113-143, whereinthe polymeric composition of the organosheet comprises from about 0 wt.% toabout 25 wt.% of one or more non-halogen containing flame retardants.

[0331] 145. The fire reducing composite of either embodiment 143 or 144, whereinthe one or more non-halogen containing flame retardants is one or more phosphorus containing flame retardants.

[0332] 146. The fire reducing composite of embodiment 145, wherein the one or morephosphorus containing flame retardant comprises a phosphate ester or a phosphazene.

[0333] 147. The fire reducing composite of embodiment 145 or 146, wherein the oneor 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.

[0334] 148. The fire reducing composite of any one of embodiments 113-147, whereinthe polymeric composition of the organosheet comprises one or more antioxidants.

[0335] 149. The fire reducing composite of any one of embodiments 113-148, whereinthe polycarbonate composition comprises from about 0.1 wt.% to about 0.3 wt.%of one or more antioxidants.

[0336] 150. The fire reducing composite of embodiment 148 or 149, wherein at leastone of the one or more antioxidants is Octadecyl 3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate.

[0337] 151. The fire reducing composite of any one of embodiments 113-150, whereinthe polymeric composition of the organosheet comprises one or more moldrelease agents.

[0338] 152. The fire reducing composite of any one of embodiments 113-151, whereinthe polymeric composition of the organosheet comprises from about 0.1 wt.% toabout 0.7 wt.% of one or more mold release agents.

[0339] 153. The fire reducing composite of embodiment 152, wherein at least one ofthe one or more mold release agents is PentaErythritol Tetrastearate.

[0340] 154. The fire reducing composite of any one of embodiments 113-153, whereinthe polymeric composition of the organosheet comprises, one or more impact modifiers, one or more additional polymers, one or more charring salts, one or more UV absorbers, one or more additives commonly used in a polycarbonate- based composition, or any combination thereof.

[0341] 155. The fire reducing composite of any one of embodiments 113-154, whereinthe polymeric composition of the one or more organosheets comprise from about 75 wt.% to about 100 wt.% of the one or more polycarbonates.

[0342] 156. The fire reducing composite of any one of embodiments 113-155, whereinthe polymeric composition of the one or more organosheet comprise from about 80 wt.% to about 95 wt.% of the one or more polycarbonates.

[0343] 157. The fire reducing composite of any one of embodiments 113-156, whereinthe one or more polycarbonate of the polymeric composition is virgin polycarbonate, recycled polycarbonate, or a mixture of both.

[0344] 158. The fire reducing composite of any one of embodiments 113-157, whereinthe one or more polycarbonate of the polymeric composition is branched or linear.

[0345] 159. The fire reducing composite of any one of embodiments 113-158, whereinthe one or more polycarbonate of the polymeric composition comprises one or more polycarbonate siloxane copolymer.

[0346] 160. The fire reducing composite of any one of embodiment 113-159, whereinthe polymeric composition of the one or more organosheets is comprised of the polycarbonate composition according to any one of embodiments 9-38.

[0347] 161. The fire reducing composite of any one of embodiments 113-160, whereinat least one of the fiber material layers of the organosheet is a non-woven fiber material layer.

[0348] 162. The fire reducing composite of embodiment 161, wherein the one or morenon-woven fiber material layers are comprised of one or more layers of one or more non-woven fiber materials.

[0349] 163. The fire reducing composite of embodiment 161 or 162, wherein thefibers of the one or more non-woven fiber materials are non-woven.

[0350] 164. The fire reducing composite of any one of embodiments 161-163, whereinthe fibers of the non-woven fiber material have a diameter from about 0.1 μm to about 20 μm.

[0351] 165. The fire reducing composite of any one of embodiments 161-164, whereinthe fibers of the non-woven fiber material have a diameter from about 1 μm to about 10 μm.

[0352] 166. The fire reducing composite of any one of embodiments 161-165, whereinthe non-woven fibers of the one or more non-woven fiber materials 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.

[0353] 167. The fire reducing composite of any one of embodiments 161-166, whereinthe fibers of the non-woven fiber material are randomly knitted.

[0354] 168. The fire reducing composite of any one of embodiments 161-167, whereinthe non-woven fiber material comprises co-knit fibers.

[0355] 169. The fire reducing composite of embodiment 167 or 168, wherein the co-knit fibers comprise glass fibers, carbon fibers, polymeric spun fibers, or a mixture thereof.

[0356] 170. The fire reducing composite of embodiment 169, wherein the co-knitfibers comprise a mixture of the glass fibers and the carbon fibers.

[0357] 171. The fire reducing composite of embodiment 169, wherein the co-knitfibers comprise polymeric spun fiber co-knit into the carbon fiber.

[0358] 172. The fire reducing composite of embodiment 171, wherein the ratio ofpolymeric spun fiber to non-woven carbon fiber is from 10-90 wt. % to 90- 10 wt. %.

[0359] 173. The fire reducing composite of any one of embodiments 161-172, whereinthe non-woven fiber material is comprised of a mixture of the co-knit fiber, the glass fiber, or a carbon fiber mixture.

[0360] 174. The fire reducing composite of any one of embodiments 161-173, whereinthe non-woven fiber material is one or more glass fibers with a diameter from about 5 μm to about 18 μm.

[0361] 175. The fire reducing composite of any one of embodiments 151-174, whereinthe non-woven fiber material is one or more glass fibers with a diameter from about 6 μm to about 10 μm.

[0362] 176. The fire reducing composite of any one of embodiments 151-172, whereinthe non-woven fiber material is one or more non-woven carbon fibers with a diameter from about 1 μm to about 18 μm.

[0363] 177. The fire reducing composite of embodiment 176, wherein the non-wovencarbon fiber has a diameter from about 4 μm to about 6 μm.

[0364] 178. The fire reducing composite of any one of embodiments 113-177, whereinthe one or more fiber material layers are the one or more non-woven fiber material layers.

[0365] 179. The fire reducing composite of any one of embodiments 113-177 whereinat least one of the fiber material layers of the organosheet is a woven fiber material layer.

[0366] 180. The fire reducing composite of embodiment 179, wherein the one or morewoven fiber material layers are comprised of one or more layers of one or more woven fiber materials.

[0367] 181. The fire reducing composite of embodiment 179 or 180, wherein thefibers of the woven fiber material are woven.

[0368] 182. The fire reducing composite of any one of embodiments 179-181, whereinthe woven fibers of the one or more woven fiber materials are comprised of one or more carbon fibers, one or more glass fibers, one or more ceramic fibers, one or more polymeric fibers, metal fibers, or metal coated fibers.

[0369] 183. The fire reducing composite of any one of embodiments 179-182, whereinthe woven fibers have a plain weave, a unidirectional weave, a non-crimp weave, or twill weave.

[0370] 184. The fire reducing composite of any one of embodiments 179-183, whereinthe woven fiber material is one or more glass fibers with a diameter from about 3 μm to about 40 μm.

[0371] 185. The fire reducing composite of any one of embodiments 113-161 or 179-184, wherein the one or more fiber material layers are one or more woven fiber material layers.

[0372] 186. The fire reducing composite of any one of embodiments 113-185, whereinthe one or more organosheets has a fiber content is about 50 wt.%.

[0373] 187. The fire reducing composite of any one of embodiments 113-186, whereinat least one of the layers of the one or more fiber materials have a thickness from about 20 μm to about 500 μm.

[0374] 188. The fire reducing composite of any one of embodiments 113-187, whereinat least one of the layers of the one or more fiber materials have a thickness from about 50 μm to about 500 μm.

[0375] 189. The fire reducing composite according to any one of embodiments 95-188, wherein the fire reducing composite has minor deformation after 10 min of fire exposure.

[0376] 190. The fire reducing composite of any one of embodiments 95-189, whereinthe fire reducing composite has a first side and a second opposite side.

[0377] 191. The fire reducing composite of any one of embodiments 95-190, whereinat least the first side is comprised of the polycarbonate long fiber composition.

[0378] 192. The fire reducing composite of any one of embodiments 95-191, whereinthe organosheet has at least one fiber material layer comprised of a woven glass fiber material with a diameter of about 5 μm to about 20 μm; a non-woven glass fiber material with a diameter of about 8 μm to about 18 μm; or a non-woven carbon fiber material.

[0379] 193. The fire reducing composite of any one of embodiments 95-192, whereinthe organosheet has fiber material layers comprised of the woven glass fibermaterial with a diameter of about 5 μm to about 20 μm; the non-woven glass fiber material with the diameter of about 8 μm to about 18 μm; the non-woven carbon fiber material; or any combination thereof.

[0380] 194. The fire reducing composite according to embodiment 192 or 193,wherein the first side has a temperature of about 340°C or less, after the second opposite side of the fire reducing composite has been exposed to fire for 10 min.

[0381] 195. The fire reducing composite according to any one of embodiments 192-194, wherein the organosheet has at least one fiber material layer composed of a woven glass fiber with a diameter of about 5 μm to about 20 μm.

[0382] 196. The fire reducing composite according to any one of embodiments 192-194, wherein the organosheet has at least one fiber material layer composed of a non-woven glass fiber with a diameter of about 8 μm to about 10 μm.

[0383] 197. The fire reducing composite according to embodiment 196, wherein thefirst side of the fire reducing composite has a temperature of about 320°C or less, after the second opposite side of the fire reducing composite has been exposed to fire for 10 min.

[0384] 198. The fire reducing composite according to any one of embodiments 192-194, wherein the organosheet has at least one fiber layer composed of a non- woven carbon fiber and the top side has a temperature of about 290°C or less, after the bottom side has been exposed to fire for 10 min.

[0385] 199. The fire reducing composite according to any one of embodiments 95-198, wherein the fire reducing composite is a reinforced composite having the polycarbonate long fiber composition between two or more non-injection moldable materials.

[0386] 200. The fire reducing composite according to embodiment 199, wherein a topside of the reinforced composite comprises at least one non-injection moldable material having one or more woven fiber materials.

[0387] 201. The fire reducing composite according to embodiment 199 or 201,wherein the bottom side of the reinforced composite comprises one or more woven fiber materials, one or more non-woven fiber materials, or a combination thereof.

[0388] 202. The fire reducing composite according to any one of embodiments 95-198, wherein the fire reducing composite is an over-molded composite having a non-injection moldable material over-molded with the polycarbonate long fiber composition.

[0389] 203. The fire reducing composite according to embodiment 202, wherein thepolycarbonate long fiber composition over-molds one or more composite having one or more non-woven fiber material layers, one or more woven material layers, or any combination thereof.

[0390] 204. The fire reducing composite according to embodiment 202 or 203,wherein the polycarbonate long fiber composition over-molds one or more composite having one or more non-woven fiber material layers.

[0391] 205. A method for making a fire reducing composite according to any one ofembodiments 46-204, comprising: placing one or more non-injection moldable materials in a mold; adding a polycarbonate long fiber composition, having from about 10 wt.% to about 50 wt.% of long glass fibers to the mold; and molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0392] 206. The method for making the fire reducing composite of embodiment 205,comprising: placing the one or more non-injection moldable materials into a compression mold or an injection mold; adding the polycarbonate long fiber composition to the compression mold or the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0393] 207. The method for making the fire reducing composite of embodiment 205 or206, comprising:placing the one or more non-injection moldable materials into a compression mold; adding a polycarbonate long fiber composition on top of the one or more non- injection moldable materials; compression molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0394] 208. The method for making the fire reducing composite of embodiment 207,comprising: adding one or more additional non-injection moldable materials on top of the polycarbonate long fiber composition.

[0395] 209. The method for making the fire reducing composite of embodiment 205 or206, comprising: placing the one or more non-injection moldable materials into the injection mold; injecting the polycarbonate long fiber composition into the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

[0396] 210. The method for making the fire reducing composite of any one ofembodiments 205-20209, wherein the one or more non-injection moldable materials is preheated prior to being placed into the compression mold or the injection mold.

[0397] 211. The method for making the fire reducing composite of any one ofembodiments 205-210, wherein the one or more non-injection moldable materials is from about 0.1 mm to about 4 mm thick.

[0398] 212. The method for making the fire reducing composite of any one ofembodiments 205-211, wherein the fire reducing composite is from about 1.0 mm to about 50 mm thick.

[0399] 213. The method for making the fire reducing composite of any one ofembodiments 205-212, wherein the fire reducing composite is from about 1.0 mm to about 5 mm thick.

[0400] 214. The method for making the fire reducing composite of any one ofembodiments 205-213, wherein the fire reducing composite is from about 1.0 mm to about 3 mm thick.

[0401] 215. The method for making the fire reducing composite of any one ofembodiments 205-214, comprising reinforcing the one or more non-injection moldable materials with the polycarbonate long fiber composition.

[0402] 216. The method for making the fire reducing composite of any one ofembodiments 205-215, comprising over-molding the one or more non-injection moldable materials with the polycarbonate long fiber composition.

[0403] 217. The method for making the fire reducing composite of any one ofembodiments 205-216, wherein the compression mold or the injection mold is an electric vehicle housing molder.

[0404] 218. The method for making the fire reducing composite of any one ofembodiments 205-217, comprising molding the polycarbonate long fiber composition and the one or more non-injection moldable materials into an article used in a battery pack.

[0405] 219. The method for making the fire reducing composite of any one ofembodiments 205-218, comprising molding the polycarbonate long fiber composition and the one or more non-injection moldable materials into the battery pack.

[0406] 220. The method for making the fire reducing composite of any one ofembodiments 205-219, comprising molding the polycarbonate long fiber composition and the one or more non-injection moldable materials into a lid of the battery pack.

[0407] 221. The method for making the fire reducing composite of any one ofembodiments 205-220, wherein a non-injection moldable materials are one ormore organosheets comprised of one or more fiber material layers embedded with one or more polymeric compositions.

[0408] 222. The method for making the fire reducing composite of embodiment 221,wherein the one or more organosheets comprise at least one layer of a glass weave fiber material.

[0409] 223. The method for making the fire reducing composite of either embodiment221 or 222, wherein the organosheet comprises at least one layer of a non-woven fiber material.

[0410] 224. A fire reducing article prepared from a fire reducing composite accordingto embodiments 46-223 comprising, a polycarbonate long fiber composition,having from about 10 wt.% to about 55 wt.% of long glass fibers; and one or more non-injection moldable materials.

[0411] 225. The fire reducing article of embodiment 224, used to reduce a transfer ofheat from one side of the fire reducing article to an opposite side of the fire reducing composite.

[0412] 226. The fire reducing article of embodiment 224 or 225, used to reduce atemperature on a first side of the fire reducing article when a second opposite side is exposed to fire.

[0413] 227. The fire reducing article of any one of embodiments 224-226, used as afire reducing layer.

[0414] 228. The fire reducing article according to any one of embodiments 224-227,having minor deformation after being exposed to fire.

[0415] 229. The fire reducing article according to any one of embodiments 224-228,expanding on exposure to fire.

[0416] 230. The fire reducing article of any one of embodiments 224-229, thatmaintains the mechanical properties and integrity of the fire reducing article when exposed to high temperatures.

[0417] 231. The fire reducing article according to any one of embodiments 224-230,used to reduce the transfer of heat.

[0418] 232. The fire reducing article according to any one of embodiments 224-231,used to insulate heat from a fire.

[0419] 233. The fire reducing article according to any one of embodiments 224-232,used to reduce the temperature on a first side when a second side is exposed to fire.

[0420] 234. The fire reducing article according to any one of embodiments 224-233,used in a fire containment system.

[0421] 235. The fire reducing article according to any one of embodiments 224-234,used to reduce the spread of fire.

[0422] 236. The fire reducing article according to any one of embodiments 224-235,used in a battery pack.

[0423] 237. The fire reducing article according to any one of embodiments 224-236,used to improve the mechanical properties and integrity of the battery pack when exposed to fire.

[0424] 238. The fire reducing article according to any one of embodiments 224-237,used to reduce the transfer of heat from inside the battery pack.

[0425] 239. The fire reducing article according to any one of embodiments 224-238,used in a fire containment system within the battery pack.

[0426] 240. The fire reducing article according to any one of embodiments 224-239,used to reduce the temperature of the outside of the battery pack.

[0427] 241. The fire reducing article according to any one of embodiments 224-240,used as a fire reducing layer in the battery pack.

[0428] 242. The fire reducing article according to any one of embodiments 224-241,used to insulate heat from a fire within the battery pack.

[0429] 243. The fire reducing article of any one of embodiments 224-242, used toreduce the temperature of the outside of the battery pack when a fire is inside the battery pack.

[0430] 244. The fire reducing article of any one of embodiments 224-243, used withinthe battery pack to reduce heat transfer from fire inside the battery pack to outside of the battery pack.

[0431] 245. The fire reducing article of any one of embodiments 224-244, used tocontain a fire within the battery pack.

[0432] 246. The fire reducing article of any one of embodiments 224-245, used as alid of the battery pack.

[0433] 247. The fire reducing article of any one of embodiments 224-246, wherein theone or more non-injection moldable materials are one or more organosheets comprised of one or more fiber material layers embedded with one or more polymeric compositions.

[0434] 248. The fire reducing article of claim 247, wherein the one or moreorganosheets comprise at least one layer of a glass weave fiber material.

[0435] 249. The fire reducing article of either claim 247 or 248, wherein theorganosheet comprises at least one layer of a non-woven fiber material.ILLUSTRATIVE EXAMPLES

[0436] The following examples are provided to illustrate the invention, but are notintended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated. Example 1 Polycarbonate Long Fiber Composition for Direct Molding

[0437] The following polycarbonate formulation is fed into a twin-screw extruder tocreate a polymer melt (polycarbonate composition).Polycarbonate Formulation: 80 % PC (MFR > 20g / 10min at 300°C / 1.2kg), 12 % Bisphenol A bis(diphenyl phosphate) 4 % PC powder 3 % Styrene-butadiene rubber-based methyl methacrylate-styrene core-shell impact modifier 0.3 % PTFE / SAN masterbatch 0.2 % Antioxidant 0.5% PentaErythritol Tetrastearate Percent based on weight of polycarbonate composition.

[0438] The above polycarbonate formulation is mixed at 280°C in a laterally attachedtwin-screw extruder and charged at a melt flow rate of 26 kg / h by way of a connecting section to a second twin screw extruder. The temperature of the second twin screwextruder is 285°C. The filament glass rovings are preheated to 220°C and pretensionedin order to prevent contact between the individual glass fibers. The glass rovings aredrawn by the twin screws of the second extruder at a speed from 100 to 200 rpm. Theglass rovings are dispersed within the polymer melt and completely saturate the polymermelt to form the Polycarbonate Long Fiber Composition.

[0439] The Polycarbonate Long Fiber Composition is then cooled to about 100°C andextruded directly into a mold.Example 2 Fire Reducing Composite 10 minute Burn

[0440] The following materials are used in the experiments.

[0441] A: Polycarbonate Long Fiber Composition comprised of PC compound Awith a 30 wt.% Glass FiberPC compound A: A1- 83.6 wt.% PCA2- 3 wt.% impact modifier MBS.A3- 12 wt.% Flame retardant Bisphenol A bis(diphenyl phosphate)A4- 0.6 wt.% PTFEA5- 0.2 wt.% Octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (BASFB900) A6- 0.6 wt.% PentaErythritol Tetrastearate (LOXIOL PETS)

[0442] B: Organosheet- 0.5 mm thick (Flame Retardant Polycarbonate (BA) andMaterial Layers (BB))

[0443] BA: Flame Retardant Polycarbonate (polymeric composition)BA-1 Calibre 600-3 branched Bisphenol A polycarbonate 74.1wt.% BA-2 Mitsubishi H-2000F Linear polycarbonate powder 5wt.% BA-320wt.% Hexa-phenoxy-cyclo-phosphazene BA-4: 0.1wt.% potassium perflourobutane sulfonate BA-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.

[0444] BB: Material layers:BB-B2: Glass non-woven with d = 8-10μm (Sample 2) BB-C: Carbon fiber non-woven with d = 4-6 μm (Sample 3) BB-D: Glass plain weave (d=17 micron) (Sample 1)

[0445] The Polycarbonate Long Fiber Composition comprised of PC Compound A and30 wt.% Glass Fiber is formed in the same manner as Example 1.

[0446] The 0.5 mm Organosheet is preheated to 220°C for 30 seconds and placedonto a tool (mold), and Polycarbonate Long Fiber Composition is the Polycarbonate Long Fiber Composition is extruded and placed over the preheated Organosheet in the tool.The tool compresses the Polycarbonate Long Fiber Composition and Organosheet at 200bar pressure for a pressing time of 1 min at 90°C tool temperature to co-compression moldthe Polycarbonate Long Fiber Composition and Organosheet together. A schematicdiagram of the finished Fire Reducing composite is shown in Figures 4 and 5.

[0447] Testing: A Bunsen propane torch with 500 watt power is used to burn the FireReducing Composite. After continuous burning a thermocouple is used to measure thetemperature of the hottest spot of the Fire Reducing Composite, on the side opposite of the flame. The deformation of the Fire Reducing Composite after 10 minutes of burningwas determined by visual check of flatness of the burned plaque. The plaque should beas flat as possible. Test Results are provided below in Table 1.

[0448] Table 1Example PCGlass OrganosheetOrganosheet Final Top Deformation formulation roving thickness plaque Temp After 10min content (mm) thickness after burning (wt%) (mm) 10 min (oC) Compare. PC30 n / a n / a 3 340 SevereSample 1compound ASample 1 PC 30 PC glass 0.5 3 340 Minorcompound weave A DSample 2 PC 30 PC glass 0.5 3 320 Minorcompound nonwoven A mat (d=10µm) B2Sample 3 PC 30 PC CF 0.5 3 290 Minorcompound nonwoven A mat C

[0449] The process has benefit to make high performance LFT-D part with minimumuse of organosheet. The cost of the final part can be reduced, and design freedom is higher than part made of pure organosheet. Thanks to the flowability of non-continuous glass fiber reinforced LFT-D material.Example 3 Fire Reducing Composite Strength under Fire Load

[0450] A Polycarbonate Long Fiber Composition M1 and Fire Reducing compositesM8 are subjected to Fire Tests designed by AZL Aachen GmbH (AZL Fire Test). The AZLFire Test, evaluates the fire resistance of various composite material, and the suitabilityfor battery pack protection. The AZL Fire Test tests materials at different flametemperatures while also measuring the material strength under fire load. Material of test specimens:

[0451] A: Polycarbonate Long Fiber Composition comprised of PC compound A(of Example 2 with a 40 wt.% Glass Fiber, formed in the same manner as Example 1.

[0452] B1: Plain Glass weave / PC Organosheet - 0.5 mm thick Organosheetcomprised of 40 wt.% Flame Retardant Polycarbonate (BA of Example 2) and 60 wt.%Plain Glass Weave Material Layers. Test specimens:

[0453] Composition M1: Polycarbonate Long Fiber Composition, extruded andformed into a 3 mm thick plague.

[0454] Fire Reducing Composite M4: Polycarbonate Long Fiber-Composition corebetween two (2) different 0.5 mm thick Organosheets. The top organosheet is a glassweave based organosheet and the bottom organosheet is a glass nonwoven basedorganosheet.

[0455] Fire Reducing Composite M8: Polycarbonate Long Fiber-Composition corebetween two (2) 0.5 mm thick glass weave based Organosheets.

[0456] To form the Fire Reducing Composites of this example: The polycarbonatelong fiber composition is extruded between two preheated 0.5 mm thick organosheets,and the polycarbonate long fiber composition and the two (2) organosheets are co-compression molded together to form a 3 mm thick fire reducing composite.Testing Procedure:

[0457] Line heating (flaming) is performed over a test specimen width of 100 mm. Thetest specimen is a rectangular plate with the dimensions L x W = 200 mm x 100 mm. The test specimen is clamped at both ends over the full width of 100 mm with jaws. The jawspull the test specimen to subject the test specimen to a tensil force of 0.5 kN. A tensileforce of 0.5 kN is kept constant for 600 seconds. A gas burner, developed for the test rig, heats the test specimen centrally over the full specimen width on a line approx. 25 mm wide. The test is performed at 800°C. The test specimens’ edges are covered from direct flame exposure by a fire-resistant ceramic insulation material.

[0458] An illustration of the AZL Fire Test Principle is provided below:

[0459] An Illustration of the AZL Fire Test Tensile Test setup is provided below:Results

[0460] The Results of the test are shown in Table 2 below.

[0461] Table 2MaterialCore material Organosheet Thickness Time to failurecode M1 PC compound None 3 mm 38 secA + 40%GF M4 PC compoundOne 0.5mm glass3mm >600 secA + 40%GF weave based organosheet top layer and one 0.5mm glass nonwoven organosheet bottom layer M8 PC compoundTwo 0.5mm glass3 mm >600 secA + 40%GF weave based organosheet layer, top and bottom

[0462] Visual Before and After Results:M1 M4Example 4 Fire Reducing Composite Thermal Runaway Test Fire Reducing Composite Material:

[0463] A: Polycarbonate Long Fiber Composition comprised of PC compound A(of Example 2) with a 40 wt.% Glass Fiber, formed in the same manner as Example 1.

[0464] B2: Glass Non-Crimp Fiber Weave / PC Organosheet - 0.25 mm thickOrganosheet comprised of 35 wt.% Flame Retardant Polycarbonate (BA of Example 2)and 65 wt.% Glass Non-Crimp Fiber Weave Layers with plus / minus 45 degree layup.Test Sample:

[0465] M8-2:1.5 mm Polycarbonate Long Fiber Composition (A) is co-molded with two(2) pieces of 0.25 mm Glass Non-Crimp Fiber Weave / PC Organosheet (B2) to form a 2.0mm Fire Reducing Composite. Test Method:

[0466] The Fire Reducing Composite is tested using UL2596 based on the Box TRAThermal Runaway Material Screening protocol, developed by UL.

[0467] The UL2596 test apparatus consists of a five-sided steel enclosure and anopening for supporting the test sample (e.g., plastic or composite sheet / plaque). The testapparatus contains twenty-five 18650 Li-ion cells (3200mAH) in a 5×5 arrangement asfollows: 1. An approximate 100 mm x 100 mm by 80 mm interior volume of a steel enclosure with an open top. 2. Means for mounting test samples to be tested. 3. Pressure and temperature measurement inside the enclosure during tests. 4. A heating pad to initiate propagating thermal runaway in a 5 x 5 non- electrically connected array of 18650 lithium-ion cells.

[0468] A 200 mm x 200 mm test sample is used for each material and target pressure.A pressure relief orifice is utilized to manage the maximum enclosure pressure duringtesting. A 16mm orifice is used to achieve the target pressure of 250kPa. The actualenclosure pressure is expected to be 250kPa + / -40%. Three replicate tests are performedfor each test sample-target pressure combination.

[0469] The test procedure includes the following:1. Charge Li-ion cells to 100% SOC. 2. Apply flexible tape heater to two cells within the 5x5 arrangement.3. Instrument the test sample with Type K thermocouples. 4. Secure the test sample covering (M8-2 in this example) in the opening of the test apparatus. 5. Seal all the openings used for instrumentation and flexible heater wiring. 6. Initiate the test with heating the target cells between 6°C / min and simultaneously start data acquisition. 7. Terminate test five minutes after thermal runaway and when the conditions inside the apparatus have stabilized. Image of Test of M8-2 in progress: Results:

[0470] Sample M8-2, did not compromise the thermal runaway event from twenty-five 18650 Li-ion cells for 5 minutes. A flame burst in the top direction was prevented and the flame burst exited through the side relief valve.

[0471] The experiment shows that M8-2 is a suitable material to prevent flame burstin an undesired direction (top direction here), and allows the flame burst to exit through arelief valve (side relief valve used in experiment). The control of thermal runaway from aEV battery is necessary to protect passenger from unexpected thermal runaway event.The experiment shows that M8-2 is an ideal EV battery top cover material to potentially protect passenger(s) from an unexpected thermal runaway event.

[0472] Parts by weight as used herein refers to 100 parts by weight of the compositionspecifically 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 that 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 or0.1 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

CLAIMS What is claimed is:

1. A composition comprising:one or more polycarbonate compositions and one or more long glass fibers, wherein the one or more long glass fibers are mixed with the one or more polycarbonatecompositions to form a polycarbonate long fiber composition, having from about 10 wt.%to about 55 wt.% of long glass fibers, and one or more composites.

2. The composition of claim 1, wherein the one or more composites is one or morenon-injection moldable materials comprised of one or more fiber material layers and a polymeric composition.

3. The composition of claim 1 or 2, wherein the one or more long glass fibers havean average length of about 0.1 mm to about 35 mm.

4. The composition of any one of claims 1-3, wherein the polycarbonate long fibercomposition comprises from about 30 wt.% to about 80 wt.% of one or more polycarbonate compositions, and the one or more polycarbonate compositions comprise one or more polycarbonates, the one or more polycarbonates is a virgin polycarbonate, a recycled polycarbonate, or a mixture thereof, and the one or more polycarbonates is branched, linear, or a mixture thereof.

5. The composition of any one of the preceding claims, wherein the one or morepolycarbonate compositions comprise: from about 75 wt.% to about 100 wt.% of the one or more polycarbonates; from about 0 wt.% to about 25 wt.% of one or more non-halogen containing flameretardants; from about 0.1 wt.% to about 0.3 wt.% of one or more antioxidants; andfrom about 0.1 wt.% to about 0.7 wt.% of one or more mold release agentsfrom about 0 wt.% to about 5 wt.% of one or more impact modifiers;from about 0 wt.% to about 1 wt.% of one or more anti-drip agents;from about 0 wt.% to about 30 wt.% of one or more additional polymers;from about 0 wt.% to about 0.3 wt.% of one or more charring salts; andfrom about 0 wt.% to about 1 wt.% of one or more UV agents.

6. The composition of claim 5, wherein the one or more non-halogen containingflame retardants is one or more phosphorus containing flame retardants comprised of a phosphate ester or a phosphazene; the one of the one or more antioxidants is Octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate; at least one of the one or more mold release agents is PentaErythritol Tetrastearate.

7. The composition of claim 5, wherein the one or more impact modifiers comprisea butadiene, a styrene-butadiene rubber-based methyl methacrylate-styrene, a methacrylate-butadiene-styrene grafted impact modifiers having a core-shell structure, a methyl methacrylate-grafted impact modifier having a core-shell structure, a siloxane- acrylate rubber having a core-shell structure, an acrylate rubber-based core-shell impact modifiers, styrene-butadiene rubber-based methyl methacrylate-styrene core-shell impact modifier, or any combination thereof;. the anti-drip agents comprise polytetrafluoroethylene, polytetrafluoroethylene / styrene-acrylonitrile masterbatch, or an organo-functional liquid siloxane; the one or more additional polymers is 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 acidand 6-hydroxy-2-naphthalenecarboxylic acid), or any combination thereof.

8. The composition of any one of the preceding claims, wherein filament glassrovings are fed into an extruder with the one or more polycarbonate compositions to create the polycarbonate long fiber composition.

9. The composition of any one of the preceding claims, wherein the compositiondoes not contain copolymers of polycarbonate units and polysiloxane units, polypropylene, modified polypropylene, polyurethane, polycaprolactone, polylactic acid, polysiloxane based fire retardants, halogen containing charring salts, inorganic fillers, flame retardant synergist minerals or fluoropolymers having the ability to form fibrils.

10. The composition of any one of the preceding claims, wherein the polycarbonatelong fiber composition is molded with the one or more composites to form a reinforced composite or an over-molded composite.

11. The composition of any one of the preceding claims, wherein the polycarbonatelong fiber composition is molded into a molded polycarbonate long fiber compositionprior to being molded with the one or more composites.

12. The composition of any one claim 1-10, wherein the polycarbonate long fibercomposition is extruded into a mold with the one or more composites, and the polycarbonate long fiber composition and the one or more composites are molded together.

13. The composition of any one of the preceding claims, wherein the polycarbonatelong fiber composition and one or more composites are compression molded, insertmolded, or injection molded together.

14. The composition of any one of the preceding claims, wherein the polycarbonatelong fiber composition is a reinforcing layer between two or more composites.

15. The composition of any one of the preceding claims, wherein the one or morecomposite is from about 0.1 mm to about 4 mm thick.

16. The composition of any one of the preceding claims, wherein the compositecomprises the one or more fiber material layers embedded with the one or more polymeric compositions, and the polymeric compositions bond adjacent fiber material layers together.

17. The composition of any one of the preceding claims, wherein the one or morecomposites comprises from about 30 wt.% to about 50 wt. % of the polymericcomposition and has a fiber content from about 30 wt.% to about 80 wt.%.

18. The composition of any one of claims 2-17, wherein the one or more fibermaterial layers acts as a fire insulator.

19. The composition of any one of claims 2-18, wherein the one or more fibermaterial layers comprise of one or more layers of one or more fiber materials, the one ormore fiber materials comprise of continuous fibers or discontinuous fibers; and the one or more fiber materials comprise of fibers that are woven fibers or non-woven fibers.

20. The composition of any one of claims 2-19, wherein fibers of the fiber materiallayers have a diameter from about 0.1 μm to about 20 μm.

21. The composition of any one of claims 2-20, wherein the fibers of the fibermaterial layers are comprised of one or more fiber types and the one or more fiber types comprise one or more glass fibers, one or more carbon fibers, one or more ceramic fibers, one or more 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 ormore 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 ormore silver fibers, one or more nickel silver fibers, one or more nickel-iron alloy fibers,one or more magnesium fibers, or a mixture of any of the one or more metal fibers; and the one or more metal coated fibers comprise of one or more aluminum coatedfibers, one or more aluminum coated glass fibers, one or more aluminum coated basaltfibers, one or more nickel coated fibers, one or more nickel coated nickel coated carbonfibers, 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 fiber.

22. The composition of any one of claims 2-21, wherein at least one of the fibermaterial layers of the composite is a non-woven fiber material layer.

23. The composition of any one of claims 2-22, wherein at least one of the fibermaterial layers of the composite is a woven fiber material layer, and the woven fibers have a plain weave, a unidirectional weave, a non-crimp weave, or twill weave.

24. The composition of any one of claims 2-23, wherein the composite has fibermaterial layers comprised of woven glass fiber material with a diameter of about 5 μm toabout 20 μm; non-woven glass fiber material with the diameter of about 8 μm to about 18 μm; non-woven carbon fiber material; or any combination thereof.

25. The composition of any one of claims 2-24, wherein the polymeric composition ofthe composite comprises one or more thermoplastic polymers 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.

26. The composition of claim 25, wherein the one or more thermoplastic polymerscomprises one or more polycarbonates, one or more polyarylsulfones, or any combination thereof.

27. The composition of claim 25 or 26, wherein the one or more thermoplasticpolymers comprises one or more polycarbonates.

28. The composition of any one of claim 25-27, wherein the one or morethermoplastic polymers comprise the polycarbonate composition according to any one of claims 4-10.

29. The composition of any one of claims 25-28, wherein the polymeric compositioncomprises one or more polyarylsulfones.

30. The composition of any one of claims 2-29, wherein the polymeric composition ofthe composite comprises: from about 75 wt.% to about 100 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, and from about 0.1 wt.% to about 0.7 wt.% of one or more mold release agents.

31. The composition of any one of the preceding claims, wherein the compositionhad a flexural modulus of about 6 GPa to about 12 GPa, a flexural strength of about 80 MPa to about 150 MPa, and a UL94 rating of V-0.

32. The composition of any one of the preceding claims, wherein composition is afire reducing composite, wherein a fire reducing composite means one or more of a fire exposure expanding composite, a heat transfer reducing composite, a fire containing composite, a fire reducing composite layer, a fire controlling composite, or any combination thereof.

33. The composition of any one of the preceding claims, wherein the composition isfrom about 1.0 mm to about 50 mm thick.

34. The composition of any one of claims 10-33, wherein the reinforced compositecomprises the polycarbonate long fiber composition between two or more composites.

35. The composition of claim 34, wherein the composite on a top side of thepolycarbonate long fiber composition comprises one or more woven fiber materials.

36. The composition of claim 34 or 35, wherein the composite on a bottom side ofthe polycarbonate long fiber composition comprises one or more woven fiber materials, one or more non-woven fiber materials, or a combination thereof.

37. The composition of any one of claims 10-33 wherein the over-molded compositecomprises the polycarbonate long fiber composition over-molds one or more composites.

38. The composition of any one of claims 10-33 or 37, wherein the polycarbonatelong fiber composition over-molds one or more composite having one or more non- woven fiber material layers.

39. The composition of any one of claims 2-38, wherein the non-injection moldablematerial is an organosheet.

40. An article with a structure prepared from a composition according to any one ofthe preceding claims comprising, a polycarbonate long fiber composition, having from about 10 wt.% to about 55 wt.% of long glass fibers, and one or more composites.

41. The article of claim 40, wherein the polycarbonate long fiber compositionmaintains its mechanical properties and integrity when exposed to high temperatures, insulates heat from a fire, reduces the transfer of heat, and reduces the reduce the temperature on one side when an opposite side is exposed to fire.

42. The article of claim 40 or 41, wherein the article has minor deformation afterbeing exposed to fire.

43. The article according to any one of claims 40-42, used in a fire containmentsystem.

44. The article according to any one of claims 40-43, used in a battery pack.

45. A method for making the composition according to any one of claims 1-39,comprising: placing one or more composites in a mold; adding a polycarbonate long fiber composition, having from about 10 wt.% to about 50 wt.% of long glass fibers to the mold; and molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding a fire reducing composite.

46. The method of claim 45, comprising:placing the one or more non-injection moldable materials into a compression mold; adding a polycarbonate long fiber composition on top of the one or more non- injection moldable materials; compression molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

47. The method of claim 46, comprising:adding one or more additional non-injection moldable materials on top of the polycarbonate long fiber composition.

48. The method of claim 47, wherein the one or more additional non-injectionmoldable materials comprises at least one glass woven fiber material layer.

49. The method of claim 45, comprising:placing the one or more non-injection moldable materials into the injection mold; injecting the polycarbonate long fiber composition into the injection mold; molding the one or more non-injection moldable materials and the polycarbonate long fiber composition together; and demolding the fire reducing composite.

50. The method of claim 49, wherein the one or more non-injection moldablematerials is one or more non-woven fiber material layers.