WO2025059351A1 - Fireproof battery containers and structures - Google Patents

Abstract

A container, at least a portion of which comprises a continuous fiber and a polymer composition impregnated among the continuous fiber. The polyamide composition comprises a polymer, e.g., a polyamide; an optional flame retardant, e.g., DEPAL; and a crosslinking agent. The container demonstrates a fire containment value such that when an interior of the container is at a temperature greater than 800 °C, an exterior of the portion of the container is at a temperature less than 300 °C and/or the at least a portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates tensile strength greater than 0.3 GPa.

Description

FIREPROOF BATTERY CONTAINERS AND STRUCTURES

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from US Provisional Application No. 63/582,099 entitled “Fireproof Battery Containers and Structures” filed September 12, 2023, the disclosure of which in incorporated herein by reference in its entirety.

FIELD

[0002] The present disclosure relates to containers for batteries, and in particular, to pressurized battery boxes that have improved heat/fire containment performance, as well as tensile strength and tensile modulus, e.g., for use in electric vehicles.

BACKGROUND

[0003] In the past several years, the interest in battery-powered vehicles has skyrocketed and hybrid or electric vehicles have begun populating the roads. Typically, electric vehicles employ battery containers, e.g., enclosures for housing batteries (often known in the industry as battery boxes). The enclosure/container is designed to enable connectivity, to configure the battery with respect to other components of the vehicle and, in some cases, to prevent the hazardous chemicals from leaking into the outside environment generally, and specifically into the passenger cabin.

[0004] As one example, European Patent Application No. 4 167371 A1 discloses an electrical box, a battery and a power consuming device, and relates to the field of batteries. The electrical box is configured for the battery comprising battery cells, and the electrical box comprises a box body, a current interrupter, a first connector, and a switch. The current interrupter is provided in the box body and configured to be disconnected in the case of overcurrent. The first connector is configured for outputting electric energy of the battery. The switch is arranged in the box body and configured for controlling connection or disconnection between the battery cell and the first connector. The first connector is fixed to the box body, and the first connector comprises a first terminal and a second terminal that are configured for outputting the electric energy of the battery, the first terminal being electrically connected to the current interrupter, and the second terminal being electrically connected to the switch. The first connector capable of outputtingthe electric energy of the battery and the electrical box are integrated into a module, such that there is no need to provide a long electrically conductive structure between the electrical box and the first connector, which reduces the occupied space and improves the space utilization. No long electrically conductive structure for adapted coupling is needed between the first connector and the electrical box.

[0005] While electric vehicles may provide for many benefits, a host of battery-related problems have arisen, e.g., problems relating to heat transfer/conductivity (to the outer surface), and/orto mechanical structure. And these operating conditions have saddled car manufacturers with engineering and construction challenges in dealing with high temperature environments and maintenance of safety requirements.

[0006] Some polyamide formulations have been developed for use in molding applications to form molded products. For example, US Patent No. 11 ,118,030 discloses flame retardant thermoplastic polyamide compositions that provide a superior combination of glow wire ignition and elongation/toughness properties. The compositions comprise a polyamide resin, a bromine-containingflame retardant, a hindered phenolic heat stabilizer, and optionally at least one of a flame retardant synergist, a plasticizer, a lubricant, a mold release agent, an acid scavenger and a colorant.

[0007] Additionally, US Patent No. 7,423,080 discloses crosslinkable, flame retardant polymer compositions containing a polyamide or polyester, a flame retardant system, and a crosslinking agent.

[0008] Even in view of these references, the need exists for improved battery containers that demonstrate improved heat/fire containment performance, while maintaining or improving other mechanical/structural performance. SUMMARY

[0009] In some embodiments the disclosure relates to a container, at least a portion of the container (for example, a separator piece, a wall, or a housing, or a combination thereof) comprises a continuous fiber, and a polymer composition impregnated amongthe continuous fiber and optionally has a thickness less than 6 mm and/or a density less than 7 g/cm³.

[0010] In some cases, the disclosure relates to a process of producing a container, the process comprising: contacting a continuous fiber, optionally in the form of a fabric, with the polymer composition to form a matrix sheet; and pressurizing the matrix sheet to form at least a portion of the container; and optionally activating the matrix sheet to effectuate crosslinking of the polymer. The continuous fiber is impregnated with the polymer composition. The process may not employ a molding step.

[0011] The polymer composition comprising a polymer, e.g., a polyamide, a crosslinking agent (for example a compound that comprises two or more groups capable of forming free radicals under beta or gamma radiation, e.g., TAIC), and an optional flame retardant (for example, a metal phosphinate salt or a metal diphosphinate salt or combination thereof, e.g., DEPAL).

[0012] The container demonstrates a fire containment value such thatwhen an interior of the container is at a temperature greater than 800 °C, an exterior of the portion of the container is at a temperature less than 300 °C; and/or the at least a portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates mechanical load performance tensile strength greater than 0.3 GPa. The interior of the container defines a battery zone, and the container may maintain its structure at a pressure greater than 250 KPa and/or a temperature greater than 800 °C in the battery zone. The continuous fiber may have a length greater than 10 mm and/or may be separate and discrete from the polyamide composition before impregnation with the polymer composition and/or may comprise a mineral, preferably basalt and/or does not comprise glass fibers, whiskers, needles, rods, tubes, strands, elongated platelets, lamellar platelets, ellipsoids, micro fibers, nanofibers, nanotubes, elongated fullerenes, or glass powders, or combinations thereof. The polyamide composition may further comprise at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof. The container may be a component of a battery kit that comprises the container and a battery disposed in the interior of the container.

DETAILED DESCRIPTION

Introduction

[0013] As discussed above, the use of larger, high-output batteries as power sources for electric cars has caused manufacturers to engineer battery containers that enable connectivity, configure the battery with respect to other components of the vehicle and, in some cases, prevent the hazardous chemicals from leaking. As batteries were engineered to provide more power, more hazardous chemicals were employed, and battery operation temperatures and heat generation increased significantly, which, in turn, led to increased potential for fire/explosion. Also, the chemicals used as components of the batteries are, in many cases, hazardous. As such, leakage thereof leads to detrimental environmental implications. Thus, it is safe to say that there are a battery of engineering challenges that abound in the development of battery containers that demonstrate improved heat/fire containment performance, e.g., improved thermal runaway performance, while maintaining or improving other mechanical/structural performance metrics, such as tensile strength and/or tensile modulus. [0014] Many polyamide compositions are also known. However, many of these formulations are designed for specific applications, e.g., (injection) molding operations, and are not developed for or useful in other types of applications. In conventional polyamide compositions, discrete glass fibers are dispersed among the polymer composition in the pellets (as manufactured and sold), and eventually in the molded products formed from extruding these pellets. The discrete nature of the shorter glass fibers allows them to be used in molding operations, but typically not elsewhere. Stated another way, nothing in the related art points to the use of conventional molding formulations in non-molding applications.

[0015] Impregnation methods are also known, but the chemistry employed in many of the conventional impregnation processes does not provide for the aforementioned combination of performance features.

[0016] It has now been discovered that the use of specific (thermoplastic) polymer compositions to impregnate a continuous fiber, e.g., not discrete glass fibers, provides for an unexpected and synergistic combination of performance features in a battery container, e.g., heat/fire containment and mechanical properties. Said another way, the heat/fire containment performance is achieved in conjunction with improved mechanical/structural performance, e.g., tensile strength and/or tensile modulus, that is necessary in a battery box application. In some cases, the disclosed polymer compositions themselves (typically sold as pellets or other shapes) comprise little, if any (shorter length) filler/fiber/reinforcement, which is in direct contrast with conventional polymer composition pellets that comprise shorter length reinforcing materials as a component of the polymer composition pellets. Stated anotherway, the disclosed continuous fiber, before impregnation, is separate and discrete from the polymer composition.

[0017] Without being bound by theory, it is postulated thatthe disclosed continuous fiber allows the resultant container to better carry mechanical load, and this load path is important because it affects the structural performance, especially at higher temperatures. In contrast, conventional molding compositions (pellets) contain a high number of individual shorter length bodies, e.g., fibers, or particles, and in this case the load must be carried by the polymer between the bodies - the polymer composition is load-bearing, not the fiber, which is disadvantageous. It is believed that the polymer itself often has weaker structural properties and is more temperature-dependent. As such, conventional polymers have a tendency to lose load-bearing potential in high heat environments. In contrast, with the disclosed continuous fiber, there is little or no interfiber spacing, so significantly less of the mechanical load, if not all of it, is borne by the fiber (without interruption), not the polymer.

[0018] Further, it is known that continuous fibers, unlike typical glass fibers or particles, are not several separate fibers, cannot be formed into individual pellets, and cannot be subsequently molded to make injection molded parts.

Container

[0019] In some cases, the disclosure relates to a container, at least a portion of which comprises a continuous fiber, e.g., a fiber or a tape and a (thermoplastic) polymer composition that is impregnated among the continuous fiber. The portion of the container may be a separator piece, a wall, or a housing, or a combination thereof and these portions demonstrate the aforementioned combination of performance features. In some embodiments, the at least a portion of container may refer to the entire container. The container defines a battery zone, which is a space that contains at least a portion of a battery. The polyamide composition may comprise a (thermoplastic) polymer, e.g., a polyamide; a crosslinking agent; and an optional flame retardant, e.g., DEPAL. The container portion (orthe entire container) demonstrates improved heat/fire containment performance. For example, when the interior of the container is at a temperature greater than 800 °C, e.g., greater than 1000 °C, greater than 1100 °C, or greater than 1200 °C, the exterior of the container, e.g., the portion of the container that is made from the disclosed polymer composition and continuous fiber, is at a temperature less than 300 °C. The container (or portion thereof) may demonstrate a tensile strength greater than 0.3 GPa and/or may achieve a pass rating on at Least one of three test runs, as described in UL 2596 (2022). A battery kit comprising a battery disposed in the battery zone of the container.

[0020] Thermal runaway events are dynamic. An EV battery undergoing thermal runaway can respond in several different ways, including a jet-like flame that erupts from the battery. In conjunction with the flame, the battery ejects particle material that could erode its protective enclosure. Inside the enclosure, these flaming gases build pressure. Thermal runaway tests how a material responds to the combination of high temperature, pressure, and ejected battery particle materials.

[0021] Unlike conventional polymer formulations that contain many shorter, individual reinforcement bodies, e.g., fibers, the disclosed continuous fiber is not part of the polymer composition (it is not part of the polymer composition pellets that are employed during formation of the container), rather it is separate and discrete from the polyamide composition, and the polymer composition is impregnated among/around the continuous fiber. Because of this configuration, the container is able to provide superior performance (see discussion above re: inter-fiber spacing and its deleterious effect on mechanical load performance).

[0022] In some cases, the battery zone maintains structure and/ or structural performance at an internal pressure greater than greater than 250 KPa, e.g., greater than 300 KPa, greater than 500 KPa, and/or a temperature greater than 800 °C, e.g., greater than 1000 °C, greater than 1100 °C, or greater than 1200 °C, in the battery zone.

[0023] The disclosure also relates to a process for producing the container. The process comprises the step of contacting a continuous fiber, optionally in the form of a fabric layer, with the polymer composition to form a matrix sheet. The process further comprises the step of pressurizing the matrix sheet to form at least a portion of the container. The continuous fiber is impregnated with the polymer composition. The pressurized matrix sheet may then be activated, e.g., via ionizing radiation such as beta or gamma radiation, to effectuate crosslinking of the polymer. In some cases, the process does not employ conventional molding steps, e.g., injection molding steps, pultrusion steps (for example, where fibers are shortened or “chopped”), or other related molding steps, which cannot be performed using the continuous fiber (see discussion above).

[0024] In some cases, one or more matrix sheets may be stacked together to provide a portion of the container. The layered stack may comprise 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , or 12 layers. In some cases, the layered stack may comprise more than 12 layers. The layered stack may comprise more than one type of matrix sheet. For example, one or more matrix sheet may comprise fibers at a different angle than other matrix sheets in the stack. For example, a matrix sheet may comprise fibers at 0° and 90° from the edges of the panel. Alternatively, as a further example, a matrix sheet may comprise fibers at +45° and -45° from the edges of the panel.

[0025] In some cases, the layered stack may comprise a first layer comprising a continuous fiber as described herein, and a first polymer composition impregnated among the continuous fiber. The polymer composition may comprise a polymer, an optional flame retardant, and a crosslinking agent. The layered stack may further comprise a sacrificial layer. The sacrificial layer may comprise a second polymer composition, comprising a polymer, an optional flame retardant, and a crosslinking agent. The sacrificial layer may be different from the first layer, e.g., the sacrificial layer may not include a fiber, or may include a non-continuous fiber, such as a discrete glass fiber, for example. The sacrificial layer may provide improved fire/heat containment performance.

[0026] The layered stack may demonstrate a fire containment value such that, when an interior portion of the layered stack is at a temperature greater than 800 °C, an exterior of the portion of the layered stack is at a temperature less than 300 °C. The layered stack may achieve a pass of at least one test run, as described in UL 2596 (2022), and demonstrate a tensile strength of greater than 0.3 GPa.

[0027] Additionally or alternatively, the layered stack may comprise matrix sheets comprising different types of fibers. For example, one or more matrix sheets may comprise basalt fibers, while others may comprise glass.

[0028] Each of these components and steps are discussed in more detail below. [0029] In addition to the mechanical and thermal performance, the disclosed containers contribute to additional advantages, e.g., light-weighting advantages. Due to the physical characteristics of the continuous fiber and the polymer compositions, the resultant container will have less weight than a conventional container. In some cases, the container or a portion of the container will require less thickness, while still achievingthe performance requirements. For example, the container portion or the entire container may have a (wall) thickness less than 25 mm, e.g., less than 22 mm, less than 20 mm, less than 18 mm, less than 15 mm, less than 12 mm, less than 10 mm, less than 8 mm, less than 6 mm, less than 5 mm, less than 4 mm, less than 3 mm, or less than 2 mm.

[0030] In some cases, the container or a portion of the container will have a density less than 8 g/cm³, e.g. less than 7 g/cm³, less than 6 g/cm³, less than 5 g/cm³, less than 4 g/cm³, less than 3 g/cm³, less than 2 g/cm³, or less than 1 g/cm³. As such, the container provides for the aforementioned light-weighting advantages.

Continuous Fiber

[0031] As noted above, the disclosed continuous fiber provides reinforcement, which contributes to improved heat/fire containment performance alongwith improved thermal performance, e.g., thermal runaway performance. Additionally, the continuous fiber provides improvements in mechanical strength, e.g., tensile strength and tensile modulus, in comparison to conventional materials.

[0032] In some embodiments, the continuous fiber is longerthan conventional reinforcement fillers, e.g., glass fibers, which are generally less than 10 mm in length. In some cases, the continuous fiber has a length greater than 10 mm, e.g,. greater than 12 mm, greaterthan 15 mm, greater than 20 mm, greater than 25 mm, greater than 35 mm, greater than 50 mm, greater than 75 mm, greater than 100 mm, greater than 150 mm, greater than 200 mm, or greater than 500 mm.

[0033] The continuous fiber may be in the form of a matrix sheet. Examples of commercial products include BAS220P by Basaltex or BASFIBER by Basalt Fiber Tech. In some cases, a commercially-available organosheet may be utilized, e.g., as the continuous fiber.

[0034] Importantly, the continuous fiber will have few, if any, spaces/interruptions, which is unlike conventional reinforcements, e.g., particles or shorter fibers. The performance advantages of the disclosed continuous fiber are discussed above. In some embodiments, the continuous fiber of the container has no interruptions in it, e.g., it is a single fiber.

[0035] The disclosed continuous fiber provides the advantage of improved wetting performance, which in turn contributes to improves the interface of the fiber and the polymer. It is posited that the polymer, e.g., polyamide, may have a low surface tension, which improves wetting.

[0036] In some embodiments, the continuous fiber comprises (or is made of) a mineralbased compound, a glass compound, or a carbon compound, or combinations thereof. In some embodiments, the continuous fiber comprises (or is made of) a mineral-based compound, e.g., basalt.

[0037] In some cases, the continuous fiber does not comprise conventional, non- continuous molding reinforcements. For example, in some embodiments, the continuous fiber may not comprise short (less than 10 mm, as discussed herein) fibrous fillers, e.g., short glass fibers, whiskers, needles, rods, tubes, strands, elongated platelets, lamellar platelets, ellipsoids, micro fibers, nanofibers, nanotubes, elongated fullerenes, or glass powders. Other examples of conventional, non-continuous molding reinforcements are disclosed in US Patent No. 7,423,080, which is hereby incorporated by reference in its entirety.

[0038] The continuous fiber may be a significant portion of the total weight of the container (or portion thereof). In some cases, the container (or portion thereof) may comprise greater than 10 vol% continuous fiber, based on the total weight of the container (or portion thereof) e.g., greater than 15vol %, greater than 20vol %, greater than 25 vol %, greater than 35 vol %, greater than 40 vol %, greater than 45 vol %, greater than 50 vol %, greater than 55 vol %, greater than 60 vol %, greater than 65 vol %, greater than 75 vol %, or greater than 90 vol %. In terms of upper limits, the container (or portion thereof) may comprise less than 90 vol% continuous fiber, based on the total weight of the container (or portion thereof), e.g., less than 90 vol %, less than 80 vol %, less than 75 vol %, less than 65 vol %, less than 60 vol %, less than 55 vol %, less than 50 vol %, less than 45 vol %, less than 40 vol %, less than 35 vol %, less than 25 vol %, less than 20 vol %, or less than 15 vol %. In terms of ranges, the container (or portion thereof) may comprise from 10 vol% to 90 vol% continuous fiber, based on the total weight of the container (or portion thereof), e.g., from 15 vol% to 85 vol% polymer, from 25 vol% to 75 vol%, from 35 vol% to 65 vol%, or from 40 vol% to 60 vol%.

[0039] In some cases, the continuous fiber may be oriented at a given angle relative to the edges of the container or portion thereof. For example, a fiber may be oriented at an angle of 90° from one edge of the container or portion thereof. In some cases, two or more continuous fibers may be oriented at angles orthogonal to one another. For example, a first set or more continuous fibers may be oriented at 90° from one edge, while a second set of one or more continuous fibers are oriented at 0° from the same edge. Likewise, a first set of one or more continuous fibers may be oriented at +45° from one edge, while a second set of one or more continuous fibers are oriented at -45° from the same edge.

[0040] Without wishing to be bound by theory, it is thought that the orthogonal orientation of continuous fibers in a container or portion thereof may provide further mechanical advantages, e.g., isotropic behavior.

Polymer Composition

[0041] As noted above the particular polymer composition works synergistically with the continuous fiber. The polymer composition comprises a polymer, e.g., a thermoplastic polymer such as a polyamide or a polyester, a crosslinking agent, and an optional flame retardant, e.g., a phosphorus-containing compound and/or a nitrogen containing compound. [0042] In some cases, the polymer composition may be a significant portion of the total weight of the container (or portion thereof). In some cases, the container (or portion thereof) may comprise greater than 10 vol% polymer, based on the total weight of the container (or portion thereof), e.g., greater than 15 vol %, greater than 20 vol %, greater than 25 vol %, greater than 35 vol %, greater than 40 vol %, greater than 45 vol %, greater than 50 vol %, greater than 55 vol %, greater than 60 vol %, greater than 65 vol %, greater than 75 vol %, or greater than 90 vol %. In terms of upper limits, the container (or portion thereof) may comprise less than 90 vol% polymer composition, based on the total weight of the container (or portion thereof), e.g., less than 90 vol %, less than 80 vol %, less than 75 vol %, less than 65 vol %, less than 60 vol %, less than 55 vol %, less than 50 vol %, less than 45 vol %, less than 40 vol %, less than 35 vol %, less than 25 vol %, less than 20 vol %, or less than 15 vol %. In terms of ranges, the container (or portion thereof) may comprise from 10 vol% to 90 vol% polymer composition, based on the total weight of the container (or portion thereof), e.g., from 15 vol% to 85 vol%, from 25 vol% to 75 vol%, from 35 vol% to 65 vol%, or from 40 vol% to 60 vol%.

[0043] In some cases, the polymer composition comprises a thermoplastic polymer, and many of these are discussed below. In some embodiments, the polymer composition does not comprise any thermoset polymer, e.g., urethanes, ureas, or epoxies, or combinations thereof, which are conventionally employed in some applications different from those disclosed herein.

Polymer

[0044] The polymer composition comprises a polymer. In one embodiment, the polymer composition comprises a polymer, e.g., polyamide and/or polyester, in an amount ranging from 20 wt% to 100 wt%, based on the total weight of the polymer composition, e.g., from 30 wt% to 96 wt%, from 40 wt% to 80 wt%, from 50 wt% to 75 wt%, or from 60 wt% to 70 wt%.

[0045] In terms of upper limits, the polymer composition may comprise less than 100 wt.% of the polymer, e.g., less than 96 wt.%, less than 90 wt%, less than 80 wt%, less than 75 wt%, less than 70 wt%, less than 60 wt%, less than 50 wt%, or less than 40 wt%. In terms of lower limits, the polymer composition may comprise greater than 20 wt.% of the polymer, e.g., greater than 30 wt.%, greater than 40 wt.%, greater than 50 wt.%, greater than 75 wt%, or greater than 90 wt%.

[0046] The polymer of the polymer composition may vary widely. The polymer may include but is not limited to, a thermoplastic polymer, polyester, nylon, rayon, polyamide 6, polyamide 6,6, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), co-PET, polybutylene terephthalate (PBT) polylactic acid (PLA), and polytri methylene terephthalate (PTT). In some embodiments, the polymer may be polyamide, e.g., PA6 and/or PA6,6. In some cases, nylon is known to be a stronger fiber than PET and exhibits a non-drip burning characteristic that is beneficial, e.g., in automotive textile applications, and is more hydrophilic than PET. In some cases, the polymer comprises a polyamide and/or a polyester.

[0047] In some cases, the polymer composition may comprise polyamides. Common polyamides include nylons and aramids. For example, the polyamide may comprise PA- 4T/4I; PA-4T/6I; PA-5T/5I; PA-6; PA6,6; PA6,6/6; PA6.6/6T; PA-6T/6I; PA-6T/6I/6; PA-6T/6; PA-6T/6I/66; PA-6T/MPMDT (where MPMDT is polyamide based on a mixture of hexamethylene diamine and 2-methylpentamethylene diamine as the diamine component and terephthalic acid as the diacid component); PA-6T/66; PA-6I; PA-6T; PA-6T/610; PA- 10T/612; PA-10T/106; PA-6T/612; PA-6T/10T; PA-6T/10I; PA-9T; PA-10T; PA-12T; PA- 10T/10I; PA-10T/12; PA-10T/11 ; PA-6T/9T; PA-6T/12T; PA-6,12; PA-6,10; PA-6T/10T/6I;

PA6C, PA-6T/6I/6; PA-6T/6I/12; and copolymers, blends, mixtures and/or other combinations thereof. Additional suitable polyamides, additives, and other components are disclosed in US Patent Application No. 16/003,528.

[0048] The polymer composition may also comprise polyamides produced through the ring-opening polymerization or polycondensation, including the copolymerization and/or copolycondensation, of lactams. Without being bound by theory, these polyamides may include, for example, those produced from propiolactam, butyrolactam, valerolactam, and caprolactam. For example, in some embodiments, the polyamide is a polymer derived from the polymerization of caprolactam. In those embodiments, the polymer comprises greater than 10 wt.% caprolactam, e.g., greater than 15 wt.%, greater than 20wt.%, greater than 25 wt.%, greater than 30 wt.%, greater than 35 wt.%, greater than 40 wt.%, greater than 45 wt.%, greater than 50 wt.%, greater than 55 wt.%, or greater than 60 wt.%. In some embodiments, the polymer includes from 10 wt.% to 60 wt.% of caprolactam, e.g., from 15 wt.% to 55 wt.%, from 20 wt.% to 50 wt.%, from 25 wt.% to 45 wt.%, or from 30 wt.% to 40 wt.%. In some embodiments, the polymer comprises less than 60 wt.% caprolactam, e.g., less than 55 wt.%, less than 50 wt.%, less than 45 wt.%, less than 40 wt.%, less than 35 wt.%, less than 30 wt.%, less than 25 wt.%, less than 20 wt.%, or less than 15 wt.%. Furthermore, the polymer composition may comprise the polyamides produced through the copolymerization of a lactam with a nylon, for example, the product of the copolymerization of a caprolactam with PA6,6.

[0049] In some embodiments, the polymer can be formed by conventional polymerization of the polymer composition in which an aqueous solution of at least one diamine-carboxylic acid salt is heated to remove water and effect polymerization to form an antiviral nylon. This aqueous solution is preferably a mixture which includes at least one polyamide-formingsalt in combination with the other components described herein to produce a polymer composition. Conventional polyamide salts are formed by reaction of diamines with dicarboxylic acids with the resulting salt providingthe monomer. In some embodiments, a preferred polyamide-forming salt is hexamethylenediamine adipate (nylon 6,6 salt) formed by the reaction of equimolar amounts of hexamethylenediamine and adipic acid.

[0050] In some embodiments, the polyamide comprises a combination of PA-6, PA6,6, and PA6,6/6T. In these embodiments, the polyamide may comprise from 1 wt.% to 99 wt.% PA-6, from 30 wt.% to 99wt.% PA6,6, and from 1 wt.% to 99 wt.% PA6,6/6T. In some embodiments, the polyamide comprises one or more of PA-6, PA6,6, and PA6,6/6T. In some aspects, the polymer composition comprises 6 wt.% of PA-6 and 94 wt.% of PA6,6. In some aspects, the polymer composition comprises copolymers or blends of any of the polyamides mentioned herein.

[0051] In some cases, the polymer comprises PA-6; or PA6,6; PA-6,10; or PA-6,12; or combinations thereof. In some cases, the polymer comprises PA-6I6T; PA-6C; or PA66/6C; or combinations thereof. In some embodiments, contemplated polymers include those disclosed in US Patent Publication No. US20210355322A1 , which is hereby incorporated by reference.

[0052] In some cases the polymer composition may comprise polyester. Suitable polyesters include crystalline polyesters such as polyesters derived from an aliphatic or cycloaliphatic diols, or mixtures thereof, containingfrom 2 to about 10 carbon atoms and at least one aromatic dicarboxylic acid. Specific polyesters are derived from an aliphatic diol and an aromatic dicarboxylic acid having repeating units of the following general formula: o o

II II

wherein y is an integer of from 2 to 6, and R is a C₆-C₂₀aryl radical comprising a decarboxylated residue derived from an aromatic dicarboxylic acid. [0053] Examples of aromatic dicarboxcylic acids represented by the decarboxylated residue R are isophthalic orterephthalic acid, 1 ,2-di(p-carboxyphenyl)ethane, 4,4'- dicarboxydiphenyl ether, 4,4'-bisbenzoic acid and mixtures thereof. All of these acids contain at least one aromatic nucleus. Acids containing fused rings can also be present, such as in 1 ,4-, 1 ,5-, or 2,6-naphthalenedicarboxylic acids. Exemplary dicarboxcylic acids are terephthalic acid, isophthalic acid, naphthalene dicarboxcylic acid or mixtures thereof. [0054] Exemplary polyesters are polyethylene terephthalate) (“PET”), and poly(1 ,4- butylene terephthalate), (“PBT”), polyethylene naphthanoate) (“PEN”), poly(butylene naphthanoate), (“PBN”) and poly(propylene terephthalate) (“PPT”).

[0055] Also contemplated herein are the above polyesters with minor amounts, e.g., from about 0.5 to about 5 percent by weight, of units derived from aliphatic acid and/or aliphatic polyols to form copolyesters. The aliphatic polyols include glycols, such as polyethylene glycol). Such polyesters can be made following the teachings of, for example, U.S. Pat. Nos. 2,465,319 and 3,047,539.

[0056] An exemplary poly(1 ,4-butylene terephthalate) resin that can be used herein is one obtained by polymerizing a glycol component of greater than 70 mol %, specifically greater than 80 mol %, of which consists of tetramethylene glycol and an acid component greater than 70 mol %, specifically greater than 80 mol %, of which consists of terephthalic acid, or polyester-forming derivatives therefore.

[0057] The polyesters used herein have an intrinsic viscosity of from about 0.4 to about 2.0 dl/gas measured in a 60:40 phenol/tetrachloroethane mixture or similar solvent at 23°- 30° C. VALOX® 315 polyester available from GE Plastics is suitable having an intrinsic viscosity of 1 .1 to 1.4 dl/g.

[0058] Blends of polyesters may also be employed in the composition. A blended polyester can include the combination of poly(ethylene terephthalate) and poly(1 ,4- butylene terephthalate). When blends of these components are employed the polyester resin component can comprise from about 1 to about 99 parts by weight polyethylene terephthalate) and from about 99 to about 1 part by weight poly(1 ,4-butylene terephthalate) based on 100 parts by weight of both components combined.

[0059] In some cases, the polymer compositions may comprise polyethylene. Suitable examples of polyethylene include linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), and ultra-high-molecular-weight polyethylene (UHMWPE).

[0060] In some cases, the polymer compositions may comprise polycarbonate (PC). For example, the polymer composition may comprise a blend of polycarbonate with other polymers, e.g., a blend of polycarbonate and acrylonitrile butadiene styrene (PC-ABS), a blend of polycarbonate and polyvinyl toluene (PC-PVT), a blend of polycarbonate and polybutylene terephthalate (PC-PBT), a blend of polycarbonate and polyethylene terephthalate (PC-PET), or combinations thereof. [0061] The polymer composition may, in some embodiments, comprise a combination of polymers, e.g., a combination polyamides and/or polyesters. By combining various polyamides, the final composition may be able to incorporate the desirable properties, e.g., mechanical properties, of each constituent.

[0062] Additional exemplary polymers are described, for example in US Patent Nos. 11 ,008,458; 11 ,104,799; 7,423,080, and 10,131 ,757.

Crosslinker

[0063] In some cases, the polymer composition comprises a crosslinking agent that promotes crosslinking of the monomers, oligomers, and polymers. The addition of the crosslinker provides for unexpected benefits in both mechanical performance and flame retardancy.

[0064] In some embodiments, the crosslinking agent has the ability to form free radicals under beta or gamma radiation. In some cases, the crosslinking agents contain two or more unsaturated groups including olefin groups. Suitable unsaturated groups include acryloyl, methacryloyl, vinyl, and allyl. Exemplary polyallylic compounds useful as crosslinking agents include those compounds comprising two or more allylic groups, for example, triallylisocyanurate (TAIC), triallylcyanurate (TAC), trimethylallyl isocyanurate (TMIC), and combinations thereof.

[0065] As used herein, (meth)acryloyl includes both acryloyl and methacryloyl functionality. The crosslinking agents can include polyol poly(meth)acrylates, which are typically prepared from aliphatic diols, triols and/or tetraols containing 2-100 carbon atoms. Examples of suitable polyol poly(meth)acrylates include ethylene glycol diacrylate, 1 ,6-hexanediol diacrylate, neopentylglycol di(meth)acrylate, ethylene glycol dimethacrylate (EDMA), polyethyleneglycol di(meth)acrylates, polypropyleneglycol di(meth)acrylates, polybutyleneglycol di(meth)acrylates, 2,2-bis(4- (meth)acryloxyethoxyphenyl) propane, 2,2-bis(4-(meth)acryloxydiethoxyphenyl) propane, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, trimethylolpropane trimethacrylate, trimethylolpropane triacrylate (TMPTA), di(trimethylolpropane) tetra(meth)acrylate, and combinations thereof. N,N'-alkylenebisacrylamides are also contemplated.

[0066] In some cases, the polymer composition comprises a reactive crosslinking agent, e.g., 9,10-dihydro-9-oxy-10-phosphaphenanthrene-10-oxide (DOPO), optionally epoxy modified. Additionally non-limiting examples include multifunctional epoxy molecules such as Trimethylolethane Triglycidyl Ether, SU8, and/or Erisys GE-31 , GE-30, GE-40, GE-38, and GE-60 (CVC Chemicals). Other potential candidates include, but are not limited to, crosslinking agent may be one or more of those disclosed in US Patent Nos. 11 ,008,458; 11 ,104,799; and 10,131 ,757.

[0067] In some embodiments, the polymer composition comprises the crosslinking agent in an amount rangingfrom 0.01 to 20 weight percent, based on the total weight of the polymer composition, e.g., from 0.1 wt% to 15 wt%, from 0.1 wt% to 10 wt%, from 0.5 wt% to 10 wt%, from 2 wt% to 7 wt%, from 0.5 wt% to 5 wt%, from 1 .0 wt% to 5 wt%, or from 1 .5 wt% to 4wt%. In some cases, the fiber/fabric composition may comprise greater than 0.01 wt% crosslinking agent, e.g., greaterthan 0.1 wt%, greaterthan 0.3 wt%, greater than 0.5 wt%, greater than 0.7 wt%, greaterthan 1.0 wt%, greaterthan 3.0 wt%, greater than 5.0 wt%, greater than 7.0 wt%, or greater than 10 wt%. In some cases, the fiber/fabric composition may comprise less than 20 wt% crosslinking agent, e.g., less than 15 wt%, less than 12 wt%, less than 10 wt%, less than 7 wt%, less than 5 wt%, less than 3 wt%, less than 1 wt%, less than 0.5 wt%, or less than 0.1 wt%.

Optional Flame Retardant

[0068] The composition further comprises a flame retardant (or a flame retardant system), wherein the flame retardant system comprises phosphinate metal salts and/or diphosphinate metal salts. Suitable phosphinate metal salts and diphosphinate metal salts include, for example a phosphinate of the formula (I), a diphosphinate of the formula (II), polymers of the foregoing, or a combination thereof,

wherein R¹ and R²are each independently hydrogen, a linear or branched Ci-C₆alkyl radical, or aryl radical; R³ is a linear or branched C1-C10 alkylene, arylene, alkylarylene, or arylalkylene radical; M is calcium, aluminum, magnesium, strontium, barium, orzinc; m is 2 or 3; n is 1 when x is 1 and m is 2; n is 3 when x is 2 and m is 3. Exemplary salts include Exolit OP1230 by Clariant.

[0069] “Phosphinic salt” or “phosphinate” as used herein includes salts of phosphinic and diphosphinic acids and polymers thereof. Exemplary phosphinic acids as a constituent of the phosphinic salts include dimethylphosphinic acid, ethylmethylphosphinic acid, diethylphosphinic acid, methyl-n-propylphosphinic acid, methanedi(methylphosphinic acid), benzene-1,4-(dimethylphosphinic acid), methylphenylphosphinic acid and diphenylphosphinic acid. The salts of the phosphinic acids of the invention can be prepared by known methods that are described in U.S. Pat. Nos. 5,780,534 and 6,013,707 to Kleiner, etal.

[0070] Exemplary phosphinate metal salts and/or diphosphinate metal salts include aluminum salt of dimethylphosphinic acid, aluminum salt of methylethylphosphinic acid, aluminum salt of methylpropylphosphinic acid, and the like.

[0071] In some cases, the flame retardant system comprises phosphinate metal salts and/or diphosphinate metal salts, and the these compounds contain greater than 6 wt% telomers, e.g., ethylbutylphospinic salts, butylbutylphosphinic salts, ethylhexylphosphinic salts, butylhexylphosphinic salts, and hexylhexylphosphinic salts.

Nitrogen Compounds [0072] The flame retardant system can optionally contain at least one nitrogen compound. In some cases, the nitrogen-containing compound may be selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, includingfor example melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate and/or melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof.

[0073] In some cases, the nitrogen compound may be defined as an organic or inorganic molecule that contains nitrogen. The nitrogen compound may comprise triazine and/or triazine derivatives. For example, the nitrogen compound may comprise 1 ,3,5- triazine, 1 ,3,5-trimethylhexahydro-1 ,3,5-triazine, 3-amino-1 ,2,4-triazine, 2-amino-4,6- dichloro-1 ,3,5-triazine, 3-amino-5,6-dimethyl-1 ,2,4-triazine, 2-amino-4-methoxy-6- methyl-1 ,3,5-triazine, 2,4-diamino-6-methyl-1 ,3,5-triazine (acetoguanamine), 2,4- diamino-6-phenyl-1 ,3,5-triazine (benzoguanamine), 2,4-diamino-6-hydroxypyrimidine, 3,5- diamino-1 ,2,4-triazole, 2,4-diamino-6-[3-(trifluoromethyl)phenyl]-1 ,3,5-triazine, 2,5- diamino-1 ,3,4-thiadiazole, 1 ,2,3-triazole-4,5-dicarboxylic acid, amitrol, 3-amino-1 ,2,4- triazole-5-thiol, 2,4-diamino-6-hydroxypyrimidine, 1,2,4-triazole-3-carboxylic acid, 2,4- diaminopyrimidine, 2,4,6-triaminopyrimidine, ortriamterene, or combinations thereof. In some embodiments, the nitrogen compound comprises acetoguanamine and/or benzoguanamine. In some cases, the nitrogen compound comprises melamine and/or a melamine-based compound, e.g., melamine, melamine cyanurate, melamine phosphate, and derivatives thereof.

[0074] Suitable nitrogen compounds include those of the formula (III) to (VIII) or combinations thereof,

, wherein R⁴, R⁵, and R⁶are independently hydrogen, hydroxy, amino, or mono- or diCi-C₈alkyl amino; or Ci-C₈alkyl, C₅-Ci₆cycloalkyi, -alkylcycloalkyl, wherein each may be substituted by a hydroxyl or a Ci-C₄hydroxyalkyl, C₂- C₈alkenyl, Ci-C₈alkoxy, -acyl, -acyloxy, C₆-C₂aryl, — OR¹² and — N(R¹²)R¹³ wherein R¹² and R¹³ are each independently hydrogen, Ci-C₈alkyl, C₅-Ci₆cycloalkyl, or -alkylcycloalkyl; or are N-alicyclic or N-aromatic, where N-alicyclic denotes cyclic nitrogen containing compounds such as pyrrolidine, piperidine, imidazolidine, piperazine, and N-aromatic denotes nitrogen containing heteroaromatic ring compounds such as pyrrole, pyridine, imidazole, pyrazine; R⁷, R⁸, R⁹, R¹⁰ and R¹¹ are independently hydrogen, Ci-C₈alkyl, C₅- Ci₆cycloalkyl or -alkyl(cycloalkyl), each may be substituted by a hydroxyl or a Ci- C₄hydroxyalkyl, C₂-C₈alkenyl, Ci-C₈alkoxy, -acyl, -acyloxy, C₆-Ci₂aryl, and — O — R¹²; X is phosphoric acid or pyrophosphoric acid; q is 1 , 2, 3, or 4; and b is 1 , 2, 3, or 4.

[0075] In some embodiments, the nitrogen compound comprises allantoin, glycolu ril, melamine, melamine cyanurate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, or urea cyanurate or combinations thereof. Other exemplary flame retardant systems are disclosed in US Patent No. 6,365,071 .

[0076] Some exemplary nitrogen compounds are described, for example in US Patent Nos. 11 ,008,458; 11 ,104,799; and 10,131 ,757 (and all of their respective progenies), all of which are incorporated by reference herein.

[0077] The polymer composition may comprise the flame retardant (flame retardant system) in amount ranging from 3 wt% to 50 wt%, based on the total weight of the polymer composition, e.g., from 5 wt% to 45 wt%, from 5 wt% to 25 wt%, from 10 wt% to 20 wt%, from 10 wt% to 40 wt%, from 15 wt% to 25 wt%, or from 15 wt% to about 18 wt%. In terms of upper limits, the polymer composition may comprise the flame retardant (flame retardant system) in amount less than 50 wt%, e.g., less than 45 wt%, less than 40 wt%, less than 35 wt%, less than 30 wt%, less than 25 wt%, less than 20 wt%, less than 15 wt%, less than 10 wt%, less than 8 wt%, or less than 10 wt%. In terms of lower limits, the polymer composition may comprise the flame retardant (flame retardant system) in amount greater than 5 wt%, e.g., greater than 8 wt%, greater than 10 wt%, greater than 12 wt%, greater than 15 wt%, greater than 20 wt% or greater than 25 wt%.

[0078] In some cases where a multiple-component flame retardant system is employed, the phosphorus-containing compound may be present in an amount ranging from 1 wt% to 75 wt%, e.g., from 5 wt% to 60 wt%, from 10 wt% to 50 wt%, from 15 wt% to 35 wt%, or from 20 wt% to 40 wt%. In terms of upper limits, the multiple-component flame retardant system may comprise the phosphorus-containing compound in amount less than 75 wt%, e.g., less than 65 wt%, less than 60 wt%, less than 50 wt%, less than 40 wt%, less than 35 wt%, less than 30 wt%, or less than 20 wt%. In terms of lower limits, the multiple-component flame retardant system may comprise the phosphorus-containing compound in amount greater than 1 wt%, e.g., greater than 5 wt%, greater than 10wt%, greater than 15 wt%, greater than 20 wt%, greater than 30 wt%, greater than 40 wt%, greater than 50 wt%, or greater than 60 wt%. These ranges and limits are applicable to the nitrogen-containing compound as well.

Performance Characteristics

[0079] The performance of the container portion (or the container as a whole) described herein may be assessed using a variety of conventional metrics.

[0080] In some cases, the portion (or the container as a whole) demonstrates a fire containment value such that when the interior of the container, e.g., the battery zone, is at a temperature greater than 800 °C, e.g., greater than 900 °C, greater than 1000 °C, greater than 1100 °C, or greater than 1200 °C, the exterior of the portion of the container (or the container as a whole) is at a temperature less than 300 C°, e.g., less than 290 °C, less than 280 °C, less than 275 °C, less than 260 °C, or less than 250 °C. [0081] In some cases, the portion (or the container as a whole) demonstrates a demonstrates tensile strength of greater than 0.3 GPa, e.g., greaterthan 0.5 GPa, greater than 0.7 GPa, greater than 1 GPa, greater than 5 GPa, greater thanl 0 GPa, greater than 12 GPa, greater than 15 GPa, greater than 20 GPa, or greater than 25 GPa as measured by the standard test method ASTM D882-18 (2018) or ISO 527-2 (2012), for example.

[0082] In some cases, the portion (or the container as a whole) demonstrates a demonstrates tensile modulus greater than 18 GPa, e.g., greater than 20 GPa, greater than 30 GPa, greater than 50 GPa, greater than 75 GPa, greater than 100 GPa, greater than 125 GPa, greater than 150 GPa, greater than 175 GPa, greater than 200 GPa, greater than 225 GPa, or greater than 250 GPa measured by the standard test method ASTM D882-18 (2018) or ISO 527-2 (2012), for example.

[0083] In some cases, the portion (or the container as a whole) demonstrates a dimensional stability, as measured by the coefficient of linear thermal expansion (CLTE), of less than 1 .5x10⁵; e.g., less than 1 .4x10⁵, less than 1 .3 x1 O'⁵, less than 1 .2x10⁵, less than 1.1x1 O'⁵, less than 1.0 x1 O'⁵, less than 0.9 x1 O'⁵, less than 0.8 x1 O'⁵, less than 0.7 x1 O'⁵, less than 0.6 x10'⁵, less than 0.5 x10⁵, less than 0.4 x1 O'⁵, less than 0.3 x10‘⁵, less than 0.2 x10'⁵, or less than 0.1 x1 O'⁵, as measured by ISO11359-2, for example.

[0084] In some cases, the portion (or the container as a whole) demonstrates a negative coefficient of linear expansion, such as a negative coefficient of linear expansion of greater than -0.1 x10'⁶, for example, as measured by ISO1 1359-2, for example.

[0085] In some cases, the portion (or the container as a whole) demonstrates improved physical properties, such as creep and/or fatigue. In otherwords, the portion (or the container as a whole) demonstrates a low degree of deformation over time, and lessened damage in response to force.

[0086] In some cases, the container achieves a V0 rating, as measured in accordance with UL94 (2021 or current year).

[0087] In some cases, the portion (or the container as a whole) is subjected to test runs as described in UL 2596 (2022). The portion (or the container as a whole) may achieve a pass on at least one of such test runs. As used herein the passage of one or more test runs serves as a performance metric. For example, a rating of zero passed runs may be considered a fail, while passage of one, two, or three runs represents increasing positive performance.

[0088] The present disclosure will be further understood by reference to the following non-limiting examples.

[0089] As used herein, “greater than” and “less than” limits may also include the number associated therewith. Stated another way, “greater than” and “less than” may be interpreted as “greater than or equal to” and “less than or equal to.” It is contemplated that this language may be subsequently modified in the claims to include “or equal to.” For example, “greater than 4.0” may be interpreted as, and subsequently modified in the claims as “greater than or equal to 4.0.”

[0090] In some embodiments, any or some of the components or steps disclosed herein may be considered optional. In some cases, the disclosed compositions may expressly exclude any or some of the aforementioned components or steps in this description, e.g., via claim language. For example, claim language may be modified to recite that the disclosed compositions, materials processes, etc., do not utilize or comprise one or more of the aforementioned additives, e.g., the disclosed materials do not comprise a flame retardant or a delusterant. As another example, the claim language may be modified to recite that the disclosed polymer compositions do not comprise urethanes or epoxies. Such negative limitations are contemplated, and this text serves as support for negative limitations for components, steps, and/or features.

Examples

Examples 1 - 4 and Comparative Examples A- C

[0091] Tables 1 a and 1 b show the components of seven fiber layer configurations (Examples 1 - 4 and Comparative Examples A - C). The configuration of Comparative Examples A, B, and C comprised polyamide 6,6 (PA6,6) alone, PA6,6 with 50 wt.% short glass fibers (SGF), and PA6,6 with 50 wt.% long glass fibers (LGF), respectively. [0092] The configurations of Examples 1 and 2 comprised PA 6,6 with either an organosheet (OS) or 60 wt.% unidirectional glass fibers (UDGF) as the continuous fiber. Example 3 comprised electrical glass (e-glass) and basalt (EG/B) fibers, and Example 4 comprised polyacrylonitrile-based carbon fibers (PAN), as shown in Table 2b. Neither Example 3 nor Example 4 included a resin. These examples further demonstrate the mechanical advantages of employing the compositions comprising continuous fibers as disclosed herein.

[0093] The configurations were then compared to show dimensional stability as measured by coefficient of linear thermal expansion (CLTE), tensile strength (strength), tensile modulus (modulus), creep, and fatigue. Creep and fatigue were characterized in comparison to injection molded PA6,6 impregnated with short glass fibers (Comp. Ex. B); thus Comp. Ex. B was assigned a value of 0. Compositions performing better than Comp. Ex. B are rated as +, ++, and +++, (satisfactory, good, best), while those performing worse than Comp. Ex. B are rated as -. Examples 1 and 2 were modeled by extrapolation from known characteristics of the fibers. The results are shown below in Tables 1 a and 1 b.

[0094] As shown in Tables 1 a and 1 b, the fiber layer configurations of Exs. 1 -4 significantly outperform those of Comp. Exs. A - C in terms of tensile strength and tensile modulus. Comp. Exs. A - C achieved at most 0.27 GPa. Exs. 1 -4 show much higher amounts ranging from 0.76 to 4.14 GPa.

Example 5 and Comparative Example D

[0095] A panel (Ex. 5), e.g., a portion of a container, comprising a continuous fiber was prepared as disclosed herein. Specifically, a continuous fiber support was impregnated with a PA6, 6-based polymer composition comprisingTAIC as the crosslinker and a flame retardant to form a matrix sheet. The matrix sheet was then combined with other layers/sheets and consolidated to form the panel having a thickness of 2 mm. The panel was then subjected to e-beam radiation to effectuate crosslinking of the polymer.

[0096] A comparative panel (Comp. Ex. D) was prepared by injection molding a panel comprising PA6,6 and 30% glass fibers, at a thickness of 3 mm. The panels of Ex. 5 and Comp. Ex. D were then subjected to test runs as described in UL 2596 (2022) to determine tolerances under coincidence of pressure, temperature, and abrasion. The panels were also tested for tensile strength and tensile modulus, as discussed above.

[0097] Each of the panels demonstrated a pass on at least one of three test runs, which was deemed positive fire containment performance. However, Example 5 demonstrated this score even with a much thinner (2 mm) sample in comparison to Comp. Ex. D, which, disadvantageously, required more material (3 mm). Because Example 5 employed a continuous fiber similar to those of Examples 1 - 4, high tensile strength, e.g., greater than 1 .5 GPa and high tensile modulus, e.g., greater than 15 GPa was expected. In comparison, Comp. Ex. D, which employs non-continuous fibers, demonstrated a tensile strength of only 135 MPa and a tensile modulus of only 10 GPa. Ex. 5 significantly outperformed Comp. Ex. D in terms of these mechanical properties.

Example 6 - 12

[0098] Layered stacks (portions of a potential container) (Examples 6 - 9) were prepared with layers comprising the polymer compositions and continuous fibers shown 1 below in Table 2. The angles of the fibers with respect to the edge of each layer is also indicated in Table 2. Each layer comprised a PA6, 6-based polymer composition (with TAIC as the crosslinker and a flame retardant to). And each layered stack demonstrated a final thickness of 2 mm.

[0099] Additional samples of the layered stacks as shown above were prepared both with and without a sacrificial layer comprising PA6,6, a crosslinker, and a flame retardant (no support material). The layered stacks comprised an outer layer and multiple additional layers (similar to the configurations of Exs. 6 - 9. The outer layer of Ex. 10 comprised basalt, PA6,6, a crosslinker, and a flame retardant, with no sacrificial layer. Ex. 11 comprised the composition of Ex. 7 in conjunction with a sacrificial layer atop the basalt outer layer, and Ex. 12 comprised the composition of Ex. 9 in conjunction with a sacrificial layer atop the carbon outer layer. The compositions are shown in Table 3, below.

[0100] The samples were tested for fire containment performance as described above. The score was determined by the number of fabric layers affected by battery explosion - the lesser the number of affected layers, the higher the score. Each of Examples 10 - 12 demonstrated a passing score, with some being better than others. It was noted that both the material of the outer layer and the presence or absence of a sacrificial layer beneficially influenced the results of the testing.

Embodiments

[0101] As used below, any reference to a series of embodiments is to be understood as a reference to each of those embodiments disjunctively (e.g., “Embodiments 1 -4” is to be understood as “Embodiments 1 , 2, 3, or 4”).

[0102] Embodiment 1 is a container, at least a portion of the container comprising a continuous fiber and a polymer composition impregnated amongthe continuous fiber; the polymer composition comprising a polymer, e.g., a polyamide, a crosslinking agent, and an optional flame retardant, e.g., DEPAL; the container demonstrates a fire containment value such that when an interior of the container is at a temperature greater than 800 °C, an exterior of the portion of the container is at a temperature less than 300 °C; and/or the at least a portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of greater than 0.3 GPa .

[0103] Embodiment 2 is an embodiment of embodiment 1 , wherein the continuous fiber, before an impregnation with the polymer composition, is separate and discrete from the polyamide composition.

[0104] Embodiment 3 is an embodiment of embodiment 1 or 2, wherein the continuous fiber has a length greater than 10 mm.

[0105] Embodiment 4 is an embodiment of any of embodiments 1 - 3, wherein the at least a portion of the container comprises a separator piece, a wall, or a housing, or a combination thereof.

[0106] Embodiment 5 is an embodiment of any of embodiments 1 - 4, wherein the continuous fiber does not comprise glass fibers, whiskers, needles, rods, tubes, strands, elongated platelets, lamellar platelets, ellipsoids, micro fibers, nanofibers, nanotubes, elongated fullerenes, or glass powders, or combinations thereof.

[0107] Embodiment 6 is an embodiment of any of embodiments 1 - 5, wherein the container portion has a thickness less than 6 mm.

[0108] Embodiment 7 is an embodiment of any of embodiments 1 - 6, wherein the container portion has a density less than 7 g/cm³.

[0109] Embodiment 8 is an embodiment of any of embodiments 1 - 7, wherein the continuous fiber comprises a mineral, preferably basalt.

[0110] Embodiment 9 is an embodiment of any of embodiments 1 - 8, wherein the interior of the container defines a battery zone; and wherein the container maintains structure at a pressure greater than 250 KPa and/or a temperature greater than 800 °C in the battery zone.

[0111] Embodiment 10 is an embodiment of any of embodiments 1 - 9, wherein the crosslinking agent comprises two or more groups capable of forming free radicals under beta or gamma radiation.

[0112] Embodiment 11 is an embodiment of any of embodiments 1 - 10, wherein the crosslinking agent comprisesTAIC.

[0113] Embodiment 12 is an embodiment of any of embodiments 1 - 11 , wherein the flame retardant comprises a metal phosphinate salt or a metal diphosphinate salt or combination thereof.

[0114] Embodiment 13 is an embodiment of any of embodiments 1 - 12, wherein the flame retardant comprises DEPAL.

[0115] Embodiment 14 is an embodiment of any of embodiments 1 - 13, wherein the polyamide composition further comprises at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof.

[0116] Embodiment 15 is a process of producing a container, the process comprising: contacting a continuous fiber with the polymer composition to form a matrix sheet; and pressurizing the matrix sheet to form at least a portion of the container; the continuous fiber is impregnated with the polymer composition; the container demonstrates a fire containment value such that, when a fire at a temperature greater than 800 °C (temp of a fire) is contained therein, the outside of the at least a portion of the container is at less than 300 °C; and/or the portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of at least 0.3 GPa.

[0117] Embodiment 16 is an embodiment of embodiment 15, the continuous fiber is in the form of a fabric.

[0118] Embodiment 17 is an embodiment of embodiment 15 or 16, wherein the process does not employ a molding step.

[0119] Embodiment 18 is an embodiment of any of embodiments 15 - 17, further comprising activating the matrix sheet to effectuate crosslinking of the polymer.

[0120] Embodiment 19 is a battery kit comprisingthe container and a battery disposed in the interior of the container.

[0121] Embodiment 20 is an embodiment of embodiment 19 wherein the continuous fiber has a length greater than 10 mm.

[0122] Embodiment 21 is a layered stack comprising: a first layer comprising: a continuous fiber; and a first polymer composition impregnated among the continuous fiber, the polymer composition comprising: a polymer; an optional flame retardant; and a crosslinking agent; and a sacrificial layer comprising a second polymer composition, the polymer composition comprising: a polymer; an optional flame retardant; and a crosslinking agent; wherein the layered stack demonstrates a fire containment value such that when an interior portion of the layered stack is at a temperature greater than 800 °C, an exterior of the portion of the layered stack is at a temperature less than 300 °C; and wherein the layered stack achieves a pass of at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of greater than 0.3 GPa.

Claims

We claim:

1 . A container, at least a portion of the container comprising: a continuous fiber; and a polymer composition impregnated amongthe continuous fiber, the polymer composition comprising: a polymer; an optional flame retardant; and a crosslinking agent; wherein the container demonstrates a fire containment value such thatwhen an interior of the container is at a temperature greater than 800 °C, an exterior of the portion of the container is at a temperature less than 300 °C; and wherein the at least a portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of greater than 0.3 GPa.

2. The container of claim 1 , wherein the continuous fiber, before an impregnation with the polymer composition, is separate and discrete from the polyamide composition.

3. The container of claim 1 , wherein the continuous fiber has a length greater than 10 mm.

4. The container of claim 1 , wherein the at least a portion of the container comprises a separator piece, a wall, or a housing, or a combination thereof.

5. The container of claim 1 , wherein the continuous fiber does not comprise glass fibers, whiskers, needles, rods, tubes, strands, elongated platelets, lamellar platelets, ellipsoids, micro fibers, nanofibers, nanotubes, elongated fullerenes, or glass powders, or combinations thereof.

6. The container of claim 1 , wherein the container portion has a thickness less than 6 mm.

7. The container of claim 1 wherein the container portion has a density less than 7 g/cm³.

8. The container of claim 1 , wherein the continuous fiber comprises a mineral, preferably basalt.

9. The container of claim 1 , wherein the interior of the container defines a battery zone; and wherein the container maintains structure at a pressure greaterthan 250 KPa and/or a temperature greaterthan 800 °C in the battery zone.

10. The container of claim 1 , wherein the crosslinking agent comprises two or more groups capable of forming free radicals under beta or gamma radiation.

11 . The container of claim 1 , wherein the crosslinking agent comprises TAIC.

12. The container of claim 1 , wherein the flame retardant comprises a metal phosphinate salt or a metal diphosphinate salt or combination thereof.

13. The container of claim 1 , wherein the flame retardant comprises DEPAL.

14. The container of claim 1 , wherein the polyamide composition further comprises at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof.

15. A process of producing a container, the process comprising: contacting a continuous fiber with a polymer composition to form a matrix sheet; and pressurizing the matrix sheet to form at least a portion of the container; wherein the polymer composition comprises: a polymer; a flame retardant; and a crosslinking agent; and wherein the continuous fiber is impregnated with the polymer composition; wherein the container demonstrates a fire containment value such that, when a fire at a temperature of greater than 800 °C (temp of a fire) is contained therein, the outside of the at least a portion of the container is at less than 300 °C; and wherein the portion of the container achieves a pass on at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of greater than 0.3 GPa.

16. The process of claim 15, wherein the continuous fiber is in the form of a fabric.

17. The process of claim 15, wherein the process does not employ a molding step.

18. The process of claim 15, further comprising activating the matrix sheet to effectuate crosslinking of the polymer.

19. A battery kit comprising: the container of claim 1 , and a battery disposed in the interior of the container.

20. A layered stack comprising: a first layer comprising: a continuous fiber; and a first polymer composition impregnated amongthe continuous fiber, the polymer composition comprising: a polymer; an optional flame retardant; and a crosslinking agent; and a sacrificial layer comprising a second polymer composition, the polymer composition comprising: a polymer; an optional flame retardant; and a crosslinking agent; wherein the layered stack demonstrates a fire containment value such that when an interior portion of the layered stack is at a temperature greater than 800 °C, an exterior of the portion of the layered stack is at a temperature less than 300 °C; and wherein the layered stack achieves a pass of at least one test run as described in UL 2596 (2022), and demonstrates a tensile strength of greater than 0.3 GPa.