I use log.SaveResultsAs (path, 2) in order to save the logresults to the local disk (so I can package and e-mail them). This has worked for years with testcomplete 7 and 9. Since we moved to testcom...
I would be willing to bet that it is because of your file names exceeding the windows 255 character limit as when an error is post, it creating additional files further down your export path.