WO2014030133A1

WO2014030133A1 - Improved polycarbonate compositions

Info

Publication number: WO2014030133A1
Application number: PCT/IB2013/056794
Authority: WO
Inventors: Shun Wan; Dake Shen; Yaming Niu; Ying XI
Original assignee: Sabic Innovative Plastics Ip B.V.
Priority date: 2012-08-23
Filing date: 2013-08-22
Publication date: 2014-02-27
Also published as: KR101949231B1; KR20150046239A; CN104411767A; US20140058023A1; EP2888324B1; US9732217B2; EP2888324A1

Abstract

Disclosed herein are methods arid compositions of blended polycarbonate resins with improved flame resistance and impact strength. The resulting compositions can be used in the manufacture of articles while still retaining the advantageous physical properties of blended polycarbonate compositions with improved flame resistance and impact strength.

Description

IMPROVED POLYCARBONATE COMPOSITIONS

FIELD

[0001] The present disclosure relates generally to polycarbonate compositions. More specifically, the present disclosure relates to improved polycarbonate compositions exhibiting at least one of increased impact strength, improved flame retardance, and improved heat resistance. Also included herein are methods for preparing the disclosed polycarbonate compositions and articles formed from such polycarbonate compositions.

BACKGROUND

[0002] Polycarbonates are synthetic thermoplastic resins that can. for example, be derived from bisphenols and phosgene, or their derivatives. Polycarbonates are a useful class of polymers having many desired properties. They are useful for forming a wide variety of products, such as by molding, extrusion, and thernioforniing processes. Such products include articles and components that include auto parts, electronic appliances, and ceil phone components. Because of their broad use, particularly in electronic applications or visually oriented applications, such as light covers, see-through protective coverings, lenses, and transparent films, it is desirable to provide polycarbonates with improved flame resistance and impact strength while other attractive properties are retained. In particular, it is highly desired to provide polycarbonates that can exhibit improved flame resistance and impact strength for thin samples without requiring the use of halogenated flame retardant additives.

[0003] Non-halogenated flame retardants have been incorporated into polycarbonate resins for this purpose. Exemplary flame retardant agents include phosphorous acid esters, various silicate fillers, and certain salts. It has been difficult, however, to meet the strictest standard of flame retardancy in thin samples with foregoing flame retardants as these flame retardant agents generally adversely affect the desirable physical properties of polycarbonate compositions, particularly in impact strength and/or heat resistance.

[0004] Thus, there remains a continuing need in the art for polycarbonate compositions that can readily produce articles wi th a balance of high impact strength, increased flame retardance for relatively thin samples achieved without the use of halogenated flame retardant agents. SUMMARY

[0005] As described in more detail herein, the present disclosur provides compositions having improved flame retardance, impact strength, and heat resistance. For example in an aspect, provided are polycarbonate compositions that comprise

(a) from 20 to 80 weight percent of a first polycarbonate component;

(b) from greater than 0 to 25 weight percent of a polysiloxane-poiycarbonate block copolymer comprising a polycarbonate block derived from hisphenol A and a

diorganopolysil xane block of the general formula (XVIII):

(XVIII)

wherein "x" is an integer from 40 to 60 and wherein the organopoiysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-poiycarbonate block copoiymer is about 20% and the weight average molecular weight of the poly iloxane-poiycarbonate block copoiymer is from 29,000 to 31 ,000 dal tons using Bisphenol-A polycarbonate absolute molecular weight standards;

(c) from greater than 0 to 5 weight percent of an impact modifier;

(d) from greater than 0 to 5 weight percent of an anti-dripping agent;

(e) from greater than 0 to 25 weight percent of a flame retardant; and.

(f) balance of one or more additional polymer composition additives;

wherein the composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar havi g a thickness of 3,2 mm and wherein the composition exhibits a UL-94 flanimability rating of V0 as measured on. a flame bar having a thickness of 0.60 mm.

[0006] In further aspects, provided are methods for the manufacture of polycarbonate compositions disclosed herein. For example, in an aspect, a method is provided for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0,60 mm. The method generally comprises combining :

(a) a first polycarbonate component, wherein the first polycarbonate component is combined in an amount of from about 20 to 80 weight percent of the composition;

(b) a polysiloxane-po!ycarbonaie block copolymer comprising a polycarbonate block derived from, bisphenol A and a diorganopolysiioxane block of the general formula (XVIII):

wherein "x" is an integer from 40 to 60, wherei n the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxaiie-poSycarbonaie block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31 ,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards, and wherein the polysiloxane-polycarbonate block copolymer is combined in a amount from greater than 0 to 25 weight percent of the composition;

(c) an impact modifier, wherei the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition;

(d) an anti-dripping agent, wherein the anti-dripping agent is combined in an amount from greater than 0 to 5 weight percent of the composition;

(e) a flame retardant, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition; and

(f) a balance amount of one or more additional polymer composition additives.

[0007] In still further aspects, articles of manufacture are provided comprising the disclosed polycarbonate compositions as well as polycarbonate compositions and articles of manufacture produced by the processes disclosed herein,

[0008] In various aspects, the disclosed polycarbonate compositions exhibit at least one of improved flame retardanee, increased impact strength, or improved heat resistance as characterized by an improved heat deflection temperature. For example, according to aspects, the disclosed composition exhibit a notched lzod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and a UL-94 flammabilily rating of V0 as measured on a flame bar having a thickness of 0,60 mm,

[0009] Additional advantages of the disclosure will be set forth in part in the description which follows, and in part will be obvious from the description, or can be learned by practice of the disclosure. The advantages of the disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.

DETAILED DESCRIPTION

[0010] The present disclosure can be understood more readily by reference to the following detailed description of the disclosure and the Examples included therein.

[0011] Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that they are not limited to specific synthetic methods unless otherwise specified, or to particular reagents unless otherwise specified, as such can. of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, example methods and materials are now described.

[0012] Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as. requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for

i terpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0013] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. [0014] Unless defined otherwise, ail technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which (his disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, example methods and materials are now described,

[0015] As used in the specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise, Titus, for example, reference to "a polycarbonate" includes mixtures of two or more polycarbonates.

[0016] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent 'about,' it will be understood that the particular value forms another aspect, it will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 1 1, 12, 13, and 14 are also disclosed.

[0017] As used herein, the terras Optional' or Optionally' means that the subsequently described event or circumstance ca or can not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase "optionally substituted alkyl" means that the alk l group can or can not be substituted and that the description includes both substituted and unsubstituted alky! groups,

[0018] Disclosed are the components to be used to prepare the compositions of the disclosure as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds can not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited each is individually and collecti vely

contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.

[0019] References in the specification and concluding claims to parts by weight, of a particular element or component in a composition or article, denote the weight relationship between the element or component and any other elements or components in the composition or article for which a past by weight is expressed. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a wesght ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.

[0020] A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition i n which the component is included. For example if a particular element or component in a composition or article is said to have 8% weight, it is understood that this percentage is relation to a total compositional percentage of 100%.

[0021] The term "alkyl group" as used herein is a branched or unbranched saturated hydrocarbon group of 1 to 24 carbon atoms, such as methyl, ethyl, n-prapyl, isopropyi, n- butyl, isobutyl, t-butyl, pentyl, hexyl, heptyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and the like. A "lower alkyl" group is an alky] group containing from one to six carbon atoms,

[0022] The term "alkoxy^"' as used herein is an alkyl group bound through a single, terminal ether linkage; that is, an "alkoxy'^' group can be defined as -OR where R is alkyl as defined above. A "lower alkoxy" group is an alkoxy group containing from one to six carbon atoms.

[0023] The term "alkenyl group" as used herein is a hydrocarbon group of from 2 to 24 carbon atoms and structural formula containing at least one carbon -carbon double bond. Asymmetric structures such as (AB)C=C(CD) are intended to include both the B and isomers. This can be presumed in structural formulae herein wherein an asymmetric a!kene is present, or it can be explicitly indicated by the bond symbol C.

[0024] The term "alkynyl group" as used herein i s a hydrocarbon group of 2 to 24 carbon atoms and a structural formula containing at least one carbon -carbon triple bond.

[0025] The term "aryl group¹' as used herein is any carbon-based aromatic group including, but not limited to, benzene, naphthalene, etc. The term "aromatic" also includes "heteroaryl group," which is defined as an aromatic group that has at least one beteroatom incorporated within the ring of the aromatic group. Examples of heteroatoms include, but are not limited to. nitrogen, oxygen, sulfur, and phosphorus. Tire aryl group can be substituted or unsubstituted. The aryl group can be substituted with one or more groups including, but not limited to, alky!, alkynyl, alkenyl, aryl, haiide, nitro, amino, ester, ketone, aldehyde, hydroxy, carboxylic acid, or alkoxy.

[0026] The term "cycloalky group" as used herein is a non-aromatic carbon-based ring composed of at least three carbon atoms. Examples of cycloalkyl groups include, but are not limited to, eyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, etc. The term "heterocycloalkyJ group" is a cycloalkyl group as defined above where at least one of the carbon atoms of the ring is substituted with a heteroatom such as, but not limited to, nitrogen, oxygen, sulphur, or phosphorus.

[0027] The term "aralky!" as used herein i an aryl group having an alkyl, alkynyl, or alkenyl group as defined above attached to the aromatic group. An example of an antlkyl group is a benzyl group. [0028] The term "hydroxyaikyl group" as used herein is art alkyl, alkenyi. alkynyl, aryl, aralkyi, cycloaikyi, haiogenated alkyl, or heterocycloalkyl group descnbed above that has at least one hydrogen atom substituted with a hydroxy! group.

[0029] The term "aikoxyaikyi group" is defined as an alkyl, alkenyi, alkynyl, aryl, aralkyi, cycloaikyi haiogenated alkyl, or heterocycloalkyl group described above that has at least one hydrogen atom substituted with an alkoxy group described above.

[003Θ] The term "ester" as used herein is represented by the formula— C(0)OA, where

A can be an alkyl, haiogenated alkyl, alkenyi, alkynyl, aryl, heteroaryi, cycloaikyi, cycloalkenyl, heterocycloalkyl, or heterocycioalkenyl group described above.

[0031] The term "carbonate group" as used herein is represented by the

formula -OC(0)OR, where R can be hydrogen, an alkyl, alkenyi, alkynyl, aryl, aralkyi, cycloaikyi, haiogenated alkyl, or heterocycloalkyl group described above.

[0032] The term "carboxylic acid" as used herein is represented by the formula -C(0)OH.

[0033] The term "aldehyde" as used herein is represented by the formula -C(0)H.

[0034] The term "keto group" as used herein is represented by the formula -C(0)R, where R is an alkyl. alkenyi, alkynyl, aryl, aralkyi cycloaikyi, haiogenated alkyl, or heterocycloalkyl group described above.

[0035] The term "carbonyl group" as used herein is represented by the formula C~0.

[0036] The term "ether" as used herein is represented by the formula ADA¹, where A and A¹ can be, independently, an alkyl, haiogenated alkyl, alkenyi, alkynyl, aryl, heteroaryi, cycloaikyi, cycloalkenyl, heterocycloalkyl, or heterocycioalkenyl group described above.

[0037] The term "sulfo-oxo group" as used herein is represented by the

formulas -S(O R, -OS(0)aR, or , -OSiOjOR, where R can be hydrogen, an alkyl, alkenyi, alkynyl, aryl, aralkyi, cycloaikyi, haiogenated alkyl, or heterocycloalkyl group described above.

[0038] The term "PPPBP" as used herein refers to a compound having a structure represented by the formula:

PPPBP can also be referred to by the following names: 2-Phenyl-3,3-bis(4- hydroxyphenyliphthalimidine; N-Phenyl-3,3-bis(4-hydroxyphenyl)phtbaIimidine; 3,3-bis(4- hydroxyphenyl)-2-phenylisoindoiin-3 -one; 3,3-bis(4-hydroxyphenyl)-2-phenyI-2,3-dihydro- 1 H-isoindol- 1 -one. PPPBP has the CAS # 6607-41 -6.

[0039] Each of the materials disclosed herein are either commercially available and/or the methods for the production thereof are known lo those of skill in the art.

[0040] It is understood that the compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions, and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

[0041] The disclosed polycarbonate compositions generally comprise a first

polycarbonate component, a second a polysiioxane-poiycarbonate block copolymer component, an impact modifier, an anti-dripping agent, and a flame retardant. The poiycarbonate composi tions can further optionally comprise a balance amount of one or more additives. Still further, the polycarbonate composition can also optionally comprise a third high heat polycarbonate polymer, such as, for example, a polycarbonate comprising repeat units derived from a 3,3-bis(4-hydroxyphenyl)-2-ph.enylisoindolin- 1 -one (PPPBP), also referred to herein as a PPPBP containing polycarbonate (PPPBP- PC). Preferably, the disclosed compositions can be further characterized by exhibiting less than 1000 ppm of a bromine- and/or chlorine-containing compound, including for example exhibiting less than 900 ppm, less than 800 ppm, less than 700 ppm, less than 600 ppm, or even less than 50 ppm of a bromine- and/or chlorine-containing compound.

[0042] As briefly summarized above, the disclosed poiycarbonate compositions exhibit at least one of improved flame retardance, increased impact strength, or improved heat resistance. For example, according to aspects, the disclosed composition exhibit a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and a UL-94 flammability rating of V0 as measured on a flame- bar having a thickness of 0,60 mm. In a still further aspect, the composition exhibits a notched Izod impact strength of greater than about 600 J/m, measured according to ASTM D256 at 0°C on a bar having a thickness of 3.2 mm. In a yet further aspect, the composition exhibits a UL-94 flammability rating of V0 measured at a thickness of 0.60 mm. In an even further aspect, the composition exhibits a heat deflection temperature greater than about 105 °C.

[0043] In an exemplary and non-limiting aspect, a disclosed polycarbonate composition comprises:

(a) from 20 to 80 weight percent of a first polycarbonate component;

(b) from greater than 0 t 25 weight percent of a polysiloxane-polycarbonate block copolymer comprising polycarbonate blocks derived from Bisphenol-A and

diorganopolysiloxane blocks of the general formula (XV III⁾:

wherein "x" is an integer from 40 to 60 and wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average moiecular weight of the polysiloxane-polycarbonate block copolymer is trom 29,000 to 31,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards;

(c) from greater than 0 to 5 weight percent of an impact modifier;

(d) from greater than 0 to 5 weight percent of an anti-dripping agent;

(e) from greater than 0 to 25 weight percent of a flame retardant; and.

(f) a balance of one or more additional polymer composition additives;

wherein the composition exhibits a notched Izod impact strength greater than 400 J/m a measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm. [0044] In a further exemplary and non-limiting aspect, a disclosed polycarbonate composition comprises:

(a) from 20 to 80 weight percent of a first polycarbonate component;

(b) from 10 to 25 weight percent of a polysiloxane-polycarbonate block copolymer comprising polycarbonate blocks derived from Bisphenol-A and diorganopoiysiioxane blocks of the general, formula {XVIII):

(XVIII)

wherein "x." is an integer from 40 to 60 and wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content withi the poiysiloxane-poiycarbonate block copoiymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31,000 c!altons using Bisphenol-A polycarbonate absolute molecular weight standards;

(c) from greater than 0 to 5 weight percent of an MBS impact modifier;

fci) from greater than 0 to 25 weight percent of a bisphenol A dtphenyiphosphate flame retardant;

(e) from greater than 0 to 5 weight percent of an anti-dripping agent; and.

(f) balance of one or more additional polymer composition additives;

wherein the composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0,60 mm.

[0045] In an aspect, the blended polymer compositions disclosed herein possess increased heat deflection temperature relative to polycarbonate polymer blends without the PPPBP polymer. For example, a similarly prepared blended polymer composition with a PPPBP- BPA copolymer has an increased heat deflection temperature of about 7 °C higher when compared to a similar blended polycarbonate composition that does not have a PPPBP-BPA copolymer. In an aspect, disclosed herein are blended polycarbonate compositions having an increased heat deflection temperature relative to a blended polycarbonate composition without a PPPBP-BPA polymer. In a further aspect, disclosed are blended polycarbonate compositions comprising PPPBP-BPA having a heat deflection temperature of at least about 105 °C, at least about 10 ^£,C, at least about ! 07 °C, at least about 108 °C, at least about 109 °C, at least about 1 10 "C. at least about 1 11 °C, at least about 1 12 ^aC, at least about 113 "C, at least about 1 .14 "C, at least about 1 15 °C, or at least about i 16"C. The upper limit of the heal deflection temperature of PPPBP-BPA can be about 180 "C.

[0046] In an aspect, the blended polymer compositions disclosed herein possess increased impact strength and flame retardance rel tive to polycarbonate polymer blends without the polysiloxane-polycarbonate polymer. For example, a similarly prepared blended polymer composition with a the polysiloxane-polycarbonate polymer has an notched Izod impact of about 137 J/m higher (at 0 °C and 3.2 mm thickness) when compared to a similar blended polycarbonate composition that does not have a polysiloxane-polycarbonate polymer, in an aspect, disclosed herein are blended polycarbonate compositions having an increased impact strength relative to a blended polycarbonate compositions without a polysiloxane- polycarbonate polymer. In a further aspect, disclosed are blended polycarbonate

compositions comprising a polysiloxane-polycarbonate polymer having an impact strength of at least about 400 J/m, at least about 500 J/m, at least about 600 J/m, at least about 700 J/m, at least about 800 J/m, or at least about 900 J/m (at 0°C and 3.2 mm thickness), in a still further aspect, the disclosed polycarbonate compositions comprising a . polysiloxane-polycarbonate polymer have an impact strength of at least about 400 J/m, at least about 500 J/m, at least about 600 J/m, at least about 700 J/m, at least about 800 J/m, or at least about 900 J/m (at - i.0°C and 3.2 mm thickness).

[0047] As summarized above, the disclosed polycarbonate compositions comprise a first polycarbonate component. En an aspect, the first polycarbonate can comprise any

polycarbonate material or mixture of materials, for example, as recited in U.S. Patent No. 7,786,246, which h hereby incorporated in its entirety for the specific purpose of disclosing various polycarbonate compositions and methods. The first polycarbonate component can comprise homopolycarbonates and/or copol carbonates derived from one dihydroxy monomer or a combination of two or more dihydroxy aromatic monomers, respectively. To that end, as used herein the term "polycarbonate" and "polycarbonate resin" means compositions having repeating structural carbonate units of the formula (f):

[0048] in which at least about 60 % of the total number of ¹ groups are aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups. In an aspect, each R^! is an aromatic organic group, for example a group of the formula (II):

-A¹ Υ' A² (if)

[0049] wherein each of A¹ and A" is a monocyclic divalent aryl group and Y¹ is a bridging group having one or two atoms that separate A from A^*. For example, one atom may separate A from A', with illustrative examples of these groups including -0-, -S-, - S(OK -S(0)r, -C(OK methylene, cyclohexyl-metbyiene, 2- [2.2.1 j-bieyelohepiyiidene, ethylidene, isopropylidene, neopeotylidene, cyclohexylidene, cyclopentadecylidene, cyclododecySidene, and adamantylidene. The bridging group Yⁱ may be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene, or isopropylidene.

[0050] The polycarbonates may be produced from dihydroxy compounds having the formula HO-R '-OH, wheretn R^] is defined as abov for formula (I). The formula HO-R' -OH includes bisphenoi compounds of formula (ΙΠ):

HO-A ¹— Y¹— A²~OH (JII)

[0051] wherein Υ', A¹ and A² are as described above. Included are bisphenoi compounds of general formula (IV):

wherein R" and R each represent a baiogen atom or a monovalent hydrocarbon group and may be the same or different; p and q are each independently an integer of 0 to 4: and X" represents one of the groups of formula (V):

wherein R and R^d each independently represent a hydrogen atom or a monovalent linear alkyl or cyclic aikylene group and R* is a di valent hydrocarbon group. In an aspect, R^c and

R^D represent a cyclic aikylene group; or a heteroatom-containing cyclic aikylene group comprising carbon atoms and heteroatoms with a valency of two or greater. In still a further aspect, a heteroatom-containing cyclic aikylene group comprises at least one heteroatom with a valency of 2 or greater, and at least two carbon atoms. Suitable heteroatoms for use in the heteroatom-containing cyclic alkylene group include -O, -S-, and -N(Z}-, where Z is a subslituent group selected from hydrogen, C 1.12 alky], Ci-12 alkoxy, or CMS acyl. Where present, the cyclic alkylene group or heteroatom-containing cyclic alkylene group may have 3 to 20 atoms, and may be a single saturated or unsaturated ring, or fused polycyc!ic ring system wherein the f sed rings are saturated, unsaturated, or aromatic.

[0052] Other bisphersols containing substituted or unsubstituted cyclohexane units may be used, for example, bi

wherein each R is independently hydrogen, CM2 alkyl, or halogen; and each R⁸ is independently hydrogen or C M 2 alkyi The substituents may be aliphatic or aromatic, straight-chain, cyclic, bicyc!ic, branched, saturated, or unsaturated.

[0053] Other useful dihydroxy compounds having the formula HO-R'-OH include aromatic dihydroxy compounds of formula (V1T):

[0054] wherein each ^: is independently a halogen atom, a Gt-io hydrocarbyl such as a Ci.io alkyl group, a halogen substituted CMO hydrocarbyl such as a halogen-substituted CMO alkyi group, and rt is 0 to 4. The halogen is usually bromine, though it is not limited to only bromine.

[0055] Some exemplary dihydroxy compounds include: 4,4'-dihydroxybiphenyi, 1 ,6- dihydroxynaphthalene, 2,6-d!hydroxynaphthalene, bis(4~hydroxyphenyi)methane, bis(4~ hydroxyphenyl}dipheny!methane, bis(4-hydroxyphenyl)-l-naphthylmethane, 1 ,2-bts(4- hydiOxyphenyl)ethane, l,l -bis(4-hydroxyphenyl)-l-phenyiethane, 2-(4-hydroxyphenyI)-2-(3- hydroxyphenyl)propane, bis(4-hydroxyphenyl}phenylmethane, 2,2-bis(4-hydroxy-3- bromopheny!)propane, 1 , 1 -bis (hydroxyphenyl)cyclopentane, l,l-bis(4- hydroxyphenyl)eyclohexane, 1 , 1 -bis(4-hydroxyphenyl)isobure«e, 1 , 1 -bis(4- hydroxyphenyJ)cyclododecane, trans-2,3~bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4~ hydroxyphenyl)adanianiine, alpha, aIpha'-bis(4-hydroxyphenyI)toluene, bis(4- hydroxyphen.yl)acelonilrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4~ hydroxyphenyl)propane, 2,2~bis(3-n~propyl-4-hydroxypheny1)propane, 2,2-bis(3-isopropyt-4~ hydroxyphenyI)prapane, 2,2-bis(3-sec-butyi-4-hydroxyphenyl)piOpane, 2_;24¾sC3-t-butyl-4- bydraxypbenyl)propane, 2_>2-bis(3-cye1ohexyl-4-hydroxyphenyl)propane₎ 2,2-bis(3-al1yl-4- hydroxyphenyI)propane, 2,2-bisi3-methoxy-4-hydroxypheny.l)propane, 2,2-bis(4- hydroxypheny hexafluoropropane, 1. , 1 -dicbloro-2,2-bis(4-hydroxyphenyl)etbylene, 1 , 1- dibromo-2,2-bis(4-hydroxyphenyl)ethylene, l,l -dichloro-2,2-bis(5-phenoxy-4- hydroxyphenyl)ethylene, 4,4'-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, l,6-bis(4-bydroxypbenyl)- l ,6-hexanedi.one, ethylene glycol bis(4-hydroxypheny!)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxypbeny!)fl.uorine_> 2,7-dihydroxypyrene, 6,6'- dihydroxy-3,3,3' '- ielTaraethylspito(bis)indane ("sp robiindane bisphenol"), 3,3-bis(4- hydroxyphenyl)phthalide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7- dihydroxyphenoxathin, 2,7-dihydroxy-9,10-diniethyIphen.azine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzotbiophene. and 2,7-dihydroxycarbazole, resorcmoi, substituted resorcino! compounds such as 5-methyi resorcinoi, 5-ethyl resorcinoi, 5-propyl resorcinoi, 5- buty resorcinol, 5-t-butyl resorcinoi, 5 -phenyl resorcinol, 5-curayl resorcinoi. 2,4,5,6- tetrafhioro resorcinoi, 2,4,5,6-tetrabromo resorcinoi, or the like; catechol; hydroquinone; substituted hydroquinones such as 2 -methyl hydroquinone, 2-ethyl hydroquinone, 2-propyi hydroquinone, 2-butyl hydroquinone, 2-t-butyI hydroquinone, 2-phenyl hydroquinone, 2- cumyl hydroquinone, 2,3,5,6-tetramethyS hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, and the like, as well as combinations comprising at least one of the foregoing dihydroxy compounds.

[00563 Specific examples of bisphenol compounds that may be represented by formula (3) include 1 ,l.-bis(4-hydroxyphenyi) methane, l ₁i -bis(4-hydroxyphenyl) ethane, 2,2-bis(4- hydroxypbenyl) propane (hereinafter "bisphenol A" or "BPA"), 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, l ,l -bis(4-hydroxyphenyl) propane, l . l -bis( 4- hydroxyphenyl) n-butane, 2,2-bifi(4-hydroxy- 1 -met.hy!phenyi) propane, 1 , l -bis(4-hydroxy-t- butylphenyl) propane, and 1 , 1 -bis(4-hydroxy~3-methylphenyi)cyciohexane (DMBPC). Combinations comprising at least one of the foregoing dihydroxy compounds may also be used.

[0057] In yet a further aspect, polycarbonates with branching groups can be useful provided that such branching does not significantly adversely affect desired properties of the polycarbonate. Branched polycarbonate blocks can be prepared by adding a branching agent during pol merization. These branching agents include polyfunctional organic compounds containing at least three functional groups selected from hydroxy!, carboxyl, car oxylic anhydride, haioformyl, and mixtures of the foregoing functional groups. Specific examples include trimellitic acid, trimellitic anhydride, trirnellitic trichloride, tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC ( l ,3_f5-tris((p-hydroxyphenyl)isopropy1)benzene), tris-phenol PA (4-(4'-(l ,l -bis(p-hydiOxyphenyi)-ethy!) alpha, aipha-dimethylbenzyl)phenoi), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetraearboxylic acid. In an aspect, a branching agent can be added at a level of aboui 0,05 to about 2.0 wt %. In still another aspect, mixtures comprising linear polycarbonates and branched polycarbonates can be used.

[0058] The first polycarbonate may be a copolymer comprising different R¹ moieties in the carbonate. For example, polycarbonates, including isosorbide-based polyester- polycarbonate, can comprise copolymers comprising carbonate units and other types of polymer units, including ester units, and combinations comprising at least one of

homopolycarbonates and copolycarbonates. An exemplary polycarbonate copolymer of this type is a polyester carbonate, also known as a polyester-polycarbonate. Such copolymers further contain carbonate units derived from oSigomeric ester-containing dihydroxy compounds (also referred to herein as hydroxy end-capped oligomeric acrylate esters).

[0059] A specific type of copolymer can be a polyester carbonate, also known as a polyester-polycarbonate. Such copoiymers further contain, in addition to recurring carbonate chain units of the formula (I) as described above, repeating units of formula (VJII):

O O

li li

C T C O— D— O VHI)

wherein O-D-O is a divalent group derived from a dihydrox compound, and D may be, for example, one or more alkyi containing Q-C20 aromatic group(s), or one or more Q-C20 aromatic group(s), a C2-10 aikylene group, a alicyclic group, a C$.20 aromatic group or a polyoxyalkyiene group in which the aikylene groups contain 2 to about 6 carbon atoms. specifically 2, 3. or 4 carbon atoms; and T divalent, group derived from a dicarboxylic acid, and may be. for example, a C2-io alkylene group, a Cs^o alicyclic group, a C_t.-m alkyi aromatic group, or a C^a aromatic group.

[0960] In an aspect, D may be a Cj.w alkylene group having a straight chain, branched chain, or cyclic (including polycyclic) structure. In another aspect, O-D-0 may be derived from an aromatic dihydroxy compound of formula (3) above. In another aspect, O-D-O may be derived from an aromatic dihydroxy compound of formula (4) above. In another aspect, O-D-O may be derived from an aromatic dih droxy compound of formula (VII) above.

[0061] Examples of aromatic dicarboxylic acids that may be used to prepare the polyester units include isophthalic or terephthalic acid, i,2-di(p-carboxyphenyI)ethane, 4,4'- dicarboxydiphenyl ether, 4,4'-bisbenzotc acid, and combinations comprising at least one of the foregoing acids. Acids containing fused rings can also be present, such as in 1 ,4-, 1 ,5-, or 2,6-naphtha^'lenedicarboxylic acids. Specific dicarboxylic acids may be terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyelohexane dicarboxylic acid, or combinations thereof. A specific dicarboxylic acid comprises a combination of isophthalic acid and terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is about 91:9 to about 2:98. In another aspect, D may be a C2 alkylene group and T is p- phenylene, m-phenylene, naphthalene, a divalent cycloa!iphatic group, or a combination thereof. This class of polyester i ncludes the poiyi alkylene terephthalates).

[0062] The molar ratio of ester units to carbonate units in the copolymers may vary broadly, for example 1 :99 to 99: 3 , specifically 10:90 to 90: J 0, more specificall 25:75 to 75:25, depending on the desired properties of the final composition.

[0063] In a specific aspect, the polyester unit of a polyester-polycarbonate may be derived from the reaction of a combination of isophthalic and terephthalic diacids (or derivatives thereof) with resorcinol. In another aspect, the polyester unit of a polyester- polycarbonate may be derived from the reaction of a combination of isophthalic acid and terephthalic acid with bisphenol-A. In an aspect, the polycarbonate units may be derived from bisphenol A. In another specific aspect, the polycarbonate units may be derived from resorcinol and bisphenol A in a molar ratio of resorcinol carbonate units to bisphenol A carbonate units of 1 :99 to 99: 1. [0064] Useful polyesters may include aromatic polyesters, polyfalkylene esters) including poly(aIkylene arylates), and poiy(cyeloalkylene diesters). Aromatic polyesters may have a polyester structure according to formula (12), wherein D and T are each aromatic groups as described hereinabove. In an aspect, useful aromatic polyesters may include, for example, poly(isophthalate-lerephthalate-resorcino!) esters, poly{isophthalate-terephtha]ate-bisphenol- A) esters, polyl(!sophlhataie-terephthalate-reiiorcinoi) ester-co-(isophlhalale-terephthalate- bisphenol-A)_.] ester, or a combination comprising at least one of these.

[0065] The first polycarbonate component can be present in the disclosed compositions in any desired weight percentage amount relative to the total weight percentage of the

polycarbonate composition. For example, the first polycarbonate polymer component can be present in an amount from greater than 0 weight % to about 85 wt.%, including exemplary amounts of 5 weights, 10 weight%, 15 weight , 20 weight%, 25 weight%. 30 weight%, 35 weight , 40 weight%, 45 weighl . 50 weight%, 55 weight%, 60 weight%, 65 weight , 70 weight , 75 weight%, and 80 weight%. In still further aspects, the first polycarbonate component can be present in any range of amounts derived from the above exemplified amounts. For example, the first polycarbonate component can be present in an amount in the range of from 20 weight % to 80 weight , from 30 weight % to 80 weight %, or even from 50 weight % to 80 weight %. The first polycarbonate component can comprise any one or more polycarbonate polymers described above. For example, the first polycarbonate polymer component can comprise a bisphenoi A polycarbonate homopoiymer. In still a further aspect, the first polycarbonate polymer component can comprise a blend of two or more

polycarbonates.

[0066] The disclosed polycarbonate compositions further comprise a second

polycarbonate component. The second polycarbonate is a polycarbonate polysiloxane copolymer. The polycarbonate polysiloxane copolymer has a polysiloxane structural unit and a polycarbonate structural unit. The polycarbonate structural unit of the polycarbonate polysiloxane copolymer may be derived from carbonate units of formula (1) as described above. The carbonate units may be derived from one or more dihydroxy monomers of formula (III) including bisphenoi compound of formula (TV), both as described and incorporated herein from above. The dihydroxy compound may be bisphenoi-A. [0067] The polysiloxane structural unit may be derived from a siloxane-containing dihydroxy compounds (also referred to herein as "hydroxyaryl end-capped polysiloxanes" that contain diorganosiloxane unit blocks of formul (IX):

wherein each occurrence of R is same or different, and is a CM S monovalent organic group. For example, R can be a Ci-Cu alkyl group, Cj - Cu alkoxy group, Ci- Ct;¾ alkenyl group, Cj- Cj3 alkenyloxy group, C3-Q, cycioalkyl group, Qr , eycioaikoxy group, Q-Cu aryl group, C<,-Cto aryloxy group, C₇- C 13 aralkyl group, C7- Cu aralkoxy group, C7- CB alkylaryl group, or C₆- Cf 3 alkylaryloxy group. The foregoing groups can be fully or partially halogenated with fluorine, chlorine, bromine, or iodine, or a combination thereof. In an aspect, where a transparent polycarbonate is desired, R does not contain any halogen. Combinations of the foregoing R groups can be used in the same polycarbonate.

The value of E in formula (IX) can vary widely depending on the type and relative amount of each of the different units in the polycarbonate, the desired properties of the polycarbonate, and like considerations. Generally, E can hav an average value of about 2 to about 1,000, specifically about 2 to about 500, more specificaily about 2 to about 100, In an aspect, E has an average value of about 4 to about 90, specifically about 5 to about 80, and more specifically about 40 to about 60.

[0068] In an aspect, the polysiloxane blocks are provided by repeating structural unit of formula (X):

wherein E is as defined above; each R is the same or different, and is as defined above; and each Ar is the same or different, and Ar is one or more C6-C30 aromatic group(s), or one or more alkyl containing C₆-C₁₀ aromatic group(s), wherein the bonds are directly connected to an aromatic moiety. The— O— Ar— O— groups in formula (X) can be, for example, a Q-Cjo dihydroxyaromatic compound. Combinations comprising at least one of the foregoing dihydroxyaromattc compounds can also be used. Exemplary dihydroxyarorrtatic compounds are 1 , 1 -bis(4-hydroxyphenyl) methane, l , l-bis(4-hydroxyp enyl)elhane, 2.2-bis(4- hydroxyphenyl)propane, 2,2~bis(4 iydroxyphenyi)butane, 2,2-bis(4-hydroxyphenyl_.)octanc, i , I -bis(4-hydiOxyphenyl)propatie, 1 , Ϊ -bis(4-hydroxyphenyl)n-b tane, 2,2-bis(4-hydroxy- 1 - methylpheny propane, l,l-bis(4-hydroxyphenyl)cyclohexane bis(4-hydroxyphenyI sulfide), 1 , 1 -bis(4-hydiOxy-3-methylphenyl)cyclohexane, and Ϊ ., 1 -bis(4-hydroxy-t- butylphenyDpropane, or a combination comprising at least one of the foregoing dihydroxy compounds.

[0069] Polycarbonates comprising such units can be derived from the corresponding dihydroxy compound of formula (XI):

HO— Ar— O-f—SiO-f— Ar— OB

(XI)

wherein Ar and E are as described above. Compounds of formula (XI) can be obtained by the reaction of a dihydroxyaromatic compound with, for example, an alpha, omega-bis- aeetoxy-po!ydiorganosi!oxane oligomer under phase transfer conditions. Compounds of formula (XI) can also be obtained from the condensation product of a dihydroxyaromatic compound, with, for example, an alpha, omega bLs-ehloro-polydimethylsiloxaoe oligomer in the presence of an acid scavenger.

[0070] In another aspect, polydiorganosiloxane blocks can comprise units of formula (XII):

wherein R and E are as described above, and each R_f) is independently a divalent CrC» organic group such as a Cj-Cjoalkyl, C1-C30 aryl or Ci- o alkylaryi. The polysiloxane blocks corresponding to formula (XII) are derived from the corresponding dihydroxy compound of formula (XIII):

wherein R and E and ¾ are as described for formula (XII) above,

[0071] In another aspect, the po!ydiorganosiloxane blocks are provided by repeating structural units

wherein R and E are as defined above. R? in formula (XIV) is a divalent Cj-Cs aliphatic group. Each M in formula (XIV) can be the same or different, and is a halogen, cyano, mtro, Cj-Cs aikylthio, C_t-Q alkyl, C (¾ alkoxy, <¼-(¼ alkenyi, Ci-Cg alkenyloxy group, Cr-C« cycloalky], ¾-Cs eycloalkoxy, Ce-Cio aryl, Oi-Cto aryloxy, C7-C aralkyl, C7- O2 aralkoxy, C7- Cf 2 alkyiaryi, or C₇- Ci ₂ aikylaryloxy, wherein each n is independently 0. I, 2, 3, or 4.

[0072] In an aspect, M of formula (XiV) is bromo or chloro, an alkyl group such as methyl, ethyl, or propyl, an aikoxy group such as methoxy, ethoxy, or propoxy, or an aryl group such as phenyl, chlorophenyl, or tolyl, n= 0 to 4; R? is a dimeihylene, trimelhylene or tetramethylene group; and R is a Cj_g alkyl, haioalkyl such as trifluoropropyl, cyanoalkyl, or aryl such as phenyl chlorophenyl or tolyl. In another aspect, R is methyl, or a combination of methyl and trifluoropropyl, or a combination of methyl and phenyl. In still another aspect, M is methoxy, 11 is one, R? is a divalent C 1 -C3 aliphatic group, and R is methyl.

[0073] Polysiioxane-polycarbonates comprising units of formula (XIV) can be derived from the corresponding dihydroxy polydiorgariosiloxane of formula (XV):

(XV ) wherein each of R, E, , R₇, and n are as described above. Such dihydroxy poiysiloxanes can be made by effecting a platinum-catalyzed addition between a siloxane hydride of formula (XVf):

wherein R and E are as previously defined, and an aliphatieally unsaturated monohydric phenol Exemplary aliphaticaliy unsaturated monohydric phenols included, for example, eugenoi, 2-ally!phenoL 4-a.llyl-2-methy1phenol, 4-ai1yi-2-phenylphenol. 4-allyl-2- bromophenol, 4-alIyi-2-t-butoxyphenoi, 4-phenyl-2-phenylphenol. 2-methyl-4-propyiphenol, 2-aliy]-4,6-dimethy1phenol, 2-allyi-4-bfomo-6-methyiphenol, 2-aMy!-6-rrtethoxy-4- niethylphenol , 4-al!ylphenol, and 2-a]tyl-4,6-diinethyiphenoL Combinations comprising at least one of the foregoing can also be used.

[0001] In still a further aspect, the polysiloxane polycarbonate copolymer can be a block copolymer of polycarbonate and eugenoi capped poiydimethylsilioxane (PD S) having the genera) structure (XVII) as shown below:

wherein the polysiloxane-polycarbonate block copolymer comprises polycarbonate blocks derived from Bispheiiol-A and diorgaiiopolysiloxaiie blocks of the general formula (XVIli):

According to exemplary aspects, the polysiioxane block length "X" of formula (XVIil) is from about 40 to about 60. Still further, the diorganopolysiloxane blocks of formula (XVItl) are randomly distributed in the polysiloxane-polycarbonate block copolymer of formula (XVIi) such that the si!oxane content of the polysiloxane-polycarbonate block copolymer is about 20 wt%. Still further, the weight average molecular weight of the polysiloxane- polycarbonate block copolymer of formula (XVII) can be from about 29 kDa to about 31 kDa when determined using bisphenoi-A polycarbonate absoiute molecular weight standards. As describe above, the polysiloxane-polycarbonate block copolymer can optionally be end- capped with p-cumyl-phenol.

[0074] Diorganopoiysiioxane blocks of formula ( XVI 11) can be derived from the corresponding

[0075] wherein x is as described above. Compounds of this type and others are further described in U.S. Patent 4,746,701 to Kress, et ai and US 8.017,0697 to Carrilio. Compounds of this formula can, for example, be obtained by the reaction of the appropriate

dihydroxyarylene compound with, for example, an alpha, otnega- bisacetoxypolydiorangonosiloxane under phase transfer conditions.

[0076] The polycarbonate-polysiloxane copolymer may be manufactured by reaction of a dihydroxy poiysiloxane with a carbonate source and a dihydroxy aromatic compound such as bisphenol-A, optionally in the presence of a phase transfer catalyst as described above.

Suitable conditions are similar to those useful in forming polycarbonates as described above. For example, the copolymers are prepared by phosgenarion, at temperatures from below 0°C to about 100°C, preferably about 25 °C to about 50°C. Since the reaction is exothermic, the rate of phosgene addition may be used to control the reaction temperature. The amount of phosgene required will generally depend upon the amount of the dihydrie reactants.

Alternatively, the polycarbonate-polysiloxane copolymers may be prepared by co-reacting in a molte state, the dihydroxy monomers and a diary! carbonate ester, such as dipheiiyl carbonate, in the presence of a transesterificatiorc catalyst as described above.

[0077] In the production of the polycarbonate-polysiloxane copolymer, the amount of dihydroxy diorganopoiysiioxane is selected so as to provide the desired amount of diorganopoiysiioxane units in the copolymer. The particular amounts used will therefore be determined depending on desired physical properties of the composition, the value of x (within the range of about 40 to about 60), and the type and relative amount of each component in the composition, including the type and amount of polycarbonate, type and amount of impact modifier, type and amount of polycarbonate-polysiloxane copolymer, and type and amount of any other additives. Suitable amounts of dihydroxy diorgaiiopolysiloxane can be determined by one of ordinary skill in the art without undue- experime tal ion using the guidelines taught herein. For example, the amount of di hydroxy polydiorganosi!oxane may be selected so as to produce a copolymer comprising about 20 wt.% polydimethylsiioxane. In an aspect, the copolymer may comprise about 20 wt.% siloxane.

[0078] The polysiloxane-polycarbonate copolymer component can be present in the disclosed compositions in any desired weight percentage amount relative to the total weight percentage of the polycarbonate composition. For example, the first polycarbonate polymer component can be present in an amount from greater than 0 weight % to about 25 wt.%, including exemplary amounts of 5 weight%, 10 weigbt%, 15 weight%, and 20 weight . In still further aspects, the polysiloxane-polycarbonate copolymer component can be present in any range of amounts derived from the above exemplified amounts. For example, the first polycarbonate component can be present in an amount in the range of from 10 weight % to 25 weight %, from 5 weight % to 20 weight %, or even from 5 weight % to 15 weight %.

[0079] The disclosed polycarbonate compositions can further comprise an optional third polycarbonate component comprising a high heat (XHT) polycarbonate material. The optional high heat polycarbonate can advantageously increase the heat resistance of the disclosed polycarbonate compositions as reflected by measurement of the heat deflection temperatures.

[0080] An exemplary high heat polycarbonate can be derived from di hydroxy compounds of general formula {111} as described above further having the following formula (XXI):

wherein R¾ and R5 are each independently a halogen or a C1 -6 alkyl group, R_;l is a Cj__& alkyl, phenyl or phenyl substituted with up to five halogens or Q.*, alkyl groups, and c is 0 to 4. in a specific aspect, R4 is a ·..,^■■. alkyl or phenyl group, in still another aspect, R4 is a methyl or phenyl group. In another specific aspect, each c is 0. [0081] In as specific exemplary aspect, a high heat polycarbonate can be derived from a d .hydroxy compound of the ^'following formula (XXII):

(also known as 3,3- is(4-hydroxyphenyl)-2-phenylisoindorin-l -one (PPPBP)). The term "PPPBP -PC" refers to a polycarbonate copolymer comprising repeating carbonate units derived from PPPBP and at least one other dihydroxy monomer such as a bisphenol A. For example, PPPBP-PC can be a polycarbonate copolymer comprising PPPBP and bisphenol A monomer units.

[0082] The term "PPPBP" as used herein refers to a compound having a structure represented by the formula:

PPPBP can also be referred to by the following names: 2-Phenyl-3,3-bis(4- hydroxyphenyDphthalimidine; N-Phenyl-3.3-bis(4-hydiOxyphenyi)phthalimidine; 3,3-bis(4- hydroxyphenyI)-2-phenylisoindoiin- l-one; 3,3-bis(4-hydroxyphenyl)-2-phenyI-2,3-dihydro- 1 H-isoindol- 1 -one. PPPBP has the CAS # 6607-41 -6.

[0083] In an aspect, the polymer compositions disclosed herein possess increased heat deflection temperature relative to a reference polycarbonate composition in the absence of the high heat polycarbonate (PPPBP-PC) copolymer. For example, a similarly prepared blended polymer composition with a PPPBP-BPA copolymer can exhibit an increased heat deflection temperature of at least about 7 °C higher when compared to a similar blended polycarbonate composition that does not have a PPPBP-BPA copolymer. In an aspect, disclosed herein are blended polycarbonate compositions having an increased heat deflection temperature relative to a blended polycarbonate composition without, a PPPBP-BPA polymer. In a further aspect, disclosed are blended polycarbonate compositions comprising PPPBP-BPA having a heat deflection temperature of at least about 105 °C, at least about Ι 06 ¾, at least about 107 C. at least about 108 °C, at least about 109 "C, at least about 1 10 "C, at least about 1 1 1 °C, at least about 1 i 2 °C, at least about 1 13 °C, at least about 1 14 °C, at least about 1 15 "C, or at least about 1 16 "C. The upper limit of the heat deflection temperuale of PPPBP-BPA can be about 180.

[0084] The optional high heat pol carbonate polymer, when used, can be present in an amount from greater than 0 weight % to about 30 weight %, including exemplary amounts of 5 weight %, 10 weight , 15 weight %, 20 weight %, and 25 weight %. In a still further aspect, the high heat polycarbonate component can be present in an amount within any range of derived from the above values, including for example, an amount of from about 10 weight % to about 20 weight %.

[0085] The pol carbonates disclosed and described above can be manufactured using an interfacial phase transfer process or melt polymerization. Although the reaction conditions for interfacial polymerization can vary, an exemplary process generally involves dissol ving or dispersing a dihydric phenol reactanl in aqueous caustic soda or potash, adding the resulting mixture to a water-immiscible solvent medium such as for example methylene chloride, and contacting the reaetants with a carbonate precursor (such as phosgene) in the presence of a catalyst such as, for example, triethylamine or a phase transfer catalyst salt, under controlled pH conditions of, for example, from about 8 to about 10,

[0086] The polycarbonate compounds and polymers disclosed herein can. in various aspects, be prepared by a melt polymerization process. Generall , in the melt polymerization process, polycarbonates are prepared by co-reacting, in a molten state, the dihydroxy reactant(s) (i.e., isosorbide, aliphatic diol and/or aliphatic diacid, and any additional dihydroxy compound) and a diary! carbonate ester, such as diphenyi carbonate, or more specifically in an aspect, an activated carbonate such as bis(methyl salicyl)carbonate, in the presence of a Iran esterifi cation catalyst. The reaction can be carried out in typical polymerization equipment, such as one or more continuously stirred reactors (CSTRs), plug flow reactors, wire wetting fall polymet izers, free fall polymerizers, wiped film polymerizers, BANBURY® mixers, single or twin screw extruders, or combinations of the foregoing. In an aspect, volatile monohydric phenol can be removed from the molten reactants by distillation and the polymer is isolated as a molten residue,

[0087] The melt polymerization can include a transesterification catalyst comprising a first catalyst, also referred to herein as an alpha catalyst, comprising a metal cation and an anion. In an aspect, the cation is an alkali or alkaline earth metal comprising Li, Na, , Cs, Rb, Mg, Ca, Ba, Sr, or a combination comprising at least one of the foregoing. The anion is hydroxide (OH^"), superoxide (0'~), thiolate (HS , sulfide (S~^"), a C 1-20 alkoxide, a C^o aryloxide, a Cj.jo carboxylate, a phosphate including triphosphate, a Ct.20 phosphonate, a sulfate including bisuifate, sulfites including bisulfites and metabisuifites, a Ct^o sulfonate, a carbonate including bicarbonate, or a combination comprising at least one of the foregoing. In another aspect, salts of an organic acid comprising both alkaline earth metal ions and alkali metal ions can also be used. Salts of organic acids useful as catalysts are illustrated by alkali metal and alkaline earth metal salts of formic acid, acetic acid, stearic acid, and

ethyelet ediaminetetraacetic acid. The catalyst can also comprise the salt of a non-volatile inorganic acid. By "nonvolatile", it is meant that the referenced compounds have no appreciable vapor pressure at ambient temperature and pressure, in particular, these compound are not volatile at temperatures at which melt polymerizations of polycarbonate are typically conducted. The salts of nonvolatile acids are alkali metal salts of phosphites; alkaline earth metal salts of phosphites; alkali metal salts Di hosphates; and alkaline earth metal salts of phosphates. Exemplary transesterification catalysts include, lithium hydroxide, sodium hydroxide, potassium hydroxide, cesium hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, lithium formate, sodium formate, potassium formate, cesium formate, lithium acetate, sodium acetate, potassium acetate, lithium carbonate, sodium carbonate, potassium carbonate, lithium methoxide, sodium methoxide, potassium methoxide, lithium ethoxide. sodium ethoxide, potassium ethoxide, lithium phenoxide, sodium

phenoxide, potassium phenoxide, sodium sulfate, potassium sulfate, NaH₂PO N HiPOi, Na₂H₂PO_s, KH2PO4, CsH₂P0 , Cs₂H₂P0 , Na₂SO¾ Na₂S₂0₅, sodium mesylate, potassium mesylate, sodium tosylate, potassium tosylate, magnesium di odium

ethyienediami netetraacetate (EDT A magnesium disodium salt), or a combi ation comprising at least one of the foregoi ng. It will be understood that the foregoing list is exemplary and should not be considered as limited thereto. In an aspect, the transesterification catalyst is an alpha catalyst comprising an alkali or alkaline earth salt. In an exemplary aspect, the transesterification catalyst comprises sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium raethoxide, potassium methoxide, NaHaPO*. or a combination comprising at least one of the foregoing.

[0088] The amount of alpha catalyst can vary widely according to the conditions of the melt poiymerization, and can be about 0.001 to about 500 μηιοΐ. in an aspect, the amount of alpha catalyst can be about 0.01 to about 20 μνηοΐ, specifically about 0.1 to about 10 pmol, more specifically about 0.5 to about 9 pmol, and still more specifically about 1 to about 7 umol, per mole of aliphatic diol and any other dihydroxy compound present in the melt polymerization.

[0089] In another aspect, a second transesterification. catalyst, also referred to herei as a beta catalyst, can optionally be included in the melt poiymerization process, provided that the inclusion of such a second transesterification catalyst does not significantly adversely affect the desirable properties of the polycarbonate-. Exemplary transesterification catalysts can further include a combination of a phase transfer catalyst of formula ( ³),iQ⁺X above, wherein each R³ is the same or different, and is a Ci__fo alkyi group; Q is a nitrogen or phosphoru atom; and X i a halogen atom or a Ci.g alkoxy group or ig aryloxy group. Exemplary phase transfer catalyst salts include, for example,

r.CH3<CH₂M*PX, ICH;;(CH₂)5UN , [CH₃(CH&UNX, [CHaiCHjkkNX,

CHj[CH3(CH₂)₃j3NX, and CRi[CH₃(C¾)2]3 X, wherein X is CI.^", Br^", a C_f .₈ alkoxy group or a Q is aryloxy group. Examples of such transesterification catalysts include

tetrabuty I ammonium hydroxide, methyltributyiammonium hydroxide, tetrabutylammonium acetate, tetrabutylphosphonium hydroxide, tetrabutylphosphonium acetate,

tetrabutylphosphoniiira phenolate, or a combination comprising at least one of the foregoing. Other melt transesterification catalysts include alkaline earth metal salts or alkali metal salts. In various aspects, where a beta catalyst is desired, the bet catalyst can be present in a molar ratio, relative to the alpha catalyst, of less than or equal to 10, specifically less than or equal to 5, more specifically less than or equal to 1, and still more specifically less than or equal to 0.5. In other aspects, the melt polymerization reaction disclosed herein uses only an alpha catalyst as described hereinabove, and is substantially free of any beta catalyst. As defined herein, "substantially free of can mean where the beta catalyst has been excluded from the melt polymerization reaction. In an aspect, the beta catalyst is present in an amount of less than about 10 ppm, specifically less than .1 ppm, more specifically less than about 0.1 ppm, more specifically less than or equal to about 0.01 ppm, and more specifically less than or equal to about 0.001 ppm, based on the total weight of all components used in the melt polymerization reaction.

[0090] In an aspect, an end-capping agent (also referred to as a chain-stopper) can optionally be used to limit molecular weight growth rate, and so control molecular weight in the polycarbonate. Exemplary chain-stoppers include certain monophenohc compounds (i.e., phenyl compounds having a single free hydroxy group), monocarboxylic acid chlorides, and/or monochloroformates. Phenolic chain-stoppers are exemplified by phenol and O-C22 alkyl-substituted phenols such as p-curnyl-phenol, resorcinol monobenzoate, and p- and tertiary-butyl phenol, cresol, and monoethers of diphenols, such as p-methoxyphenol. Alkyl- substiluted phenols with branched chai alky I substiluents having 8 to 9 carbon atoms can be spccitlcall mentioned,

[0i 91 ] In another aspect, endgroups can be derived from the carbonyl source (i.e., the diaryl carbonate), from selection of monomer ratios, incomplete polymerization, chain scission, and the like, as well as any added end-capping groups, and can include derivattzabie functional groups such as hydroxy groups, earboxylic acid groups, or the like. In an aspect, the endgroup of a polycarbonate, including an polycarbonate polymer as defined herein, can comprise a structural unit derived from a diaryl carbonate, where the structural unit can be an endgroup. In a further aspect, the endgroup is derived from an activated carbonate. Such endgroups can be derived from the transesterification reaction of the alkyl ester of an appropriately substituted activated carbonate, with a hydroxy group at the end of a polycarbonate polymer chain, under conditions in which the hydroxy group reacts with the ester carbonyl from the activated carbonate, instead of with the carbonate carbonyl of the activated carbonate. In this way, structural units derived from ester containing compounds or substructures derived from the acti ated carbonate and present in the melt polymerization reaction can form ester endgroups.

[0092] In an aspect, the melt polymerization reaction can be conducted by subjecting the reaction mixture to a series of temperature-pressure-time protocols, in some aspects, this involves gradually raising the reaction temperature in stages while gradually lowering the pressure in stages. In an aspect, the pressure is reduced from about atmospheric pressure at the start of the reaction to about 1 millibar (100 Pa) or lower, or in another aspect to 0.1 millibar (10 Pa) or lower in several steps as the reaction approaches completion. The temperature can be varied in a stepwise fashion beginning at a temperature of about the melting temperature of the reaction mixture and subsequently increased to final temperature. In an aspect, the reaction mixture is heated from room temperature to about 150 °C. In such an aspect, the polymerization reaction starts at a temperature of about 150 "C to about 220 ^"C. In another aspect, the polymerization temperature can be up to about 220 "C. In other aspects, the polymerization reaction can then be increased to about 250 C and then optionally further increased to a temperature of about 320 °C, and ail subranges there between. In an aspect, the total reaction time can be from about 30 minutes to about 200 minutes and all subranges there between. This procedure will generall ensure that the reactants react to gi e polycarbonates with the desired molecular weight, glass transition temperature, and physical properties. The reaction proceeds to build the polycarbonate chain with production of ester-substituted alcohol by-product such as methyl salicylate. In an aspect, efficient removal of the byproduct can be achieved by different techniques such as reducing the pressure. Generally the pressure starts relatively high in the beginning of the reaction and is lowered progressively throughout the reaction and temperature is raised throughout the reaction.

[0093] In an aspect, the progress of the reaction can be monitored by measuring the melt viscosity or the weight average molecular weight of the reaction mixture using techniques known in the art such a,s gel permeation chromatography. These properties can be measured by taking discrete samples or can be measured on-line. After the desired meit viscosit and/or molecular weight is reached, the final polycarbonate product can be isolated from the reactor in a solid or molten form. It will be appreciated by a person skilled in the art, that the method of making aliphatic homopolycarbonate and aliphatic-aromatic copolycarbonates as described in the preceding sections can be made in a batch or a continuous process and th process disclosed herein is preferably earned out in a sol vent free mode. Reactors chosen should ideally be self-cleaning and should minimize any "hot spots." However, vented extruders similar to those thai are commercially available can be used.

[0094] Polycarbonates with branching groups are also contemplated as being useful, provided that such branching does not significantly ad versely affect desired properties of the polycarbonaie. Branched polycarbonate blocks can be prepared by adding a branching agent during polymerization. These branching agents include polyfunctions! organic compounds containing at least three functional groups selected from hydroxy!, carboxyl, carboxylic anhydride, haloformyl, and mixtures of the foregoing functional groups. Specific examples include trimellitic acid, irimelluic anhydride, trimeiiitic trichloride, tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC (l,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-pheno! PA (4(4( 1 , l-bis{p-hydroxypheny])-ethy])alpha, alpha-dimethyl benxyl)pIienol), 4- chloroformyl phthaiic anhydride, trimestc acid, and betizophenone tetracarboxyiic acid. The branchi ng agents can be added at a level of about 0.05 to about 2.0 wt , Mixtures comprising linear pol carbonates and branched polycarbonates can be used.

[0095] The disclosed polycarbonate compositions further comprise an impact modifier component comprising one or more suitable impact modifiers. Suitable impact modifiers can include, for example, relatively high molecular weight elastomeric materials derived from olefins, monovinyl aromatic monomers, acrylic and methacryiic acids and their ester derivatives, as well as conjugated dienes. The polymers formed from conjugated dienes can be fully or partially hydrogenated. The elastomeric materials can be i n the form of homopolymers or copolymers, including random, block, radial block, graft, and core-shell copolymers, In another aspect, a combination of any two or more individual impact modifiers can be used. In a yet further aspect, the impact modifier can be emulsion, polymerized.

[0096] An exemplary type of impact modifier suitable for use in the disclosed compositions is an elastomer-modified graft copolymer comprising an elastomeric (i.e., rubbery) polymer substrate having a T_g less than about 10 "C, less than about -10 "C, or about -40 ^*C to -80 "C, and a rigid polymeric superstate grafted to the elastomeric polymer substrate. Materials suitable for use as the elastomeric phase include, for example, conjugated diene rubbers, for example polybutadtene and polyisoprene; copolymers of a conjugated diene with less than, about 50 wt % of a copolymerizable monomer, for example a monovinyl ic compound such as styrene, acry!onitrile, n-butyl acrylate, or ethyl acrylate; olefin rubbers such as ethylene propylene copolymers (EPR) or ethylene-propylene-diene monomer rubbers (EPDM); ethylene- vinyl acetate rubbers; silicone rubbers; elastomeric d ._¾ a!kyi(meth)aerylates; elastomeric copolymers of Ο,» alkyl(meth)acrylates with butadiene and/or styrene; or combinations comprising at least one ol^" the foregoing elastomers.

Materials suitable for use as the rigid phase include, for example, monovinyl aromatic monomers such as styrene and alpha-methyl styrene, and monovinylic monomers such as acrylonitriie, acrylic acid, methacryiic acid, and the C_t-6 esters of acrylic acid and methaerylic acid, specifically poly methyl methaeryiate (PMMA) and polystyrene acrylonitriie (SAN).

[0097] Exemplary elastomer-modified graft copolymers include those formed from styrene-butadiene-styrene (SBS), styrene-butadiene rubber (SBR), styrene-ethyiene- butadiene-styrene (SEBS), ABS (aerylonitrik-butadiene-styrene), acrylonitrile-ethylene- propy!ene-diene-styrene (AES), styrene-isoprene-styrene (SIS), methyl methacrylate- butadiene-styrene (MBS), methyl methaerylate-butadiene (MB) and styrene- crylonitriie (SAN). Such impact modifiers are generally commercially available, and one of skill in the art, in possession of this disclosure, could readily select an appropriate impact modifier without requiring undue experimentation,

[0098] According to some aspects, the impact modifier comprises a methaeryi te- butadiene-styrene (MBS) polymer composition, The MBS polymer composition can be an emulsion polymerized MBS or, alternatively, the MBS polymer composition can be a bulk polymerized MBS. In an even further aspect, the MBS poiyiner composition may be derived from the monomers selected from styrene, butadiene, or methylmethacrylate. In a still further aspect, the MBS polymer can be characterized by a butadiene content of from about 20% to about 85%. In a yet further aspect, the butadiene content of the MBS polymer is from about 30% to about 65%. In an even further aspect, the butadiene content of the MBS polymer is from about 40% to about 55%. In a still further aspect, the butadiene content of the MBS polymer is from about 10% to about 25%. in a yet further aspect, the methylmethacrylate content of the MBS polymer is from about 5% to about 25%. In an even further aspect, the methylmethacrylate content of the MBS polymer is from about 7% to about 17%.

[0099] Exemplary commercially available impact modifiers that are suitable for use in the disclosed compositions include: (l) Paraloid EXL2650A methyl methaeryiate butadiene styrene core-shore copolymer available from Rohm and Haas Trading Co., Ltd: (2) HR 181 acryionitriie-butadiene- tyrene co-polymer available from Kumho Petrochemical; (3) KD i lOl stryene-butadiene block copolymer available from Kraton Polymers GmBh; and (4) Metableii-S2001 methy methacrylate core shell copolymer with butyl aery late rubber and dimethylsiloxane as the core, available from Mitsubishi Corp. (H ) Ltd.

[00100] The impact modifier co onent can be present in the disclosed polycarbonate compositions in an amount of from greater than 0 weight % to 5 weight %. including exemplary amounts of 0.1 weight %, 0.5 weight , 1 weight %, 1.5 weight , 2 weight %, 2,5 weight %, 3 weight %, 3.5 weight , 4.0 weight , and 4.5 weight %. In still further aspects, the impact modifier component can be present in any range of amounts derived from the above exemplified amounts. For example, the impact modifier can be present in an amount in the range of from 0.5 weight % to 5 weight % or 0.5 weight % to 2.5 weight %, In still further aspects, it should be appreciated that the impact modifier component can comprise two or more suitable impact modifiers as described herein.

[00101] The disclosed polycarbonate compositions further comprise an anti-dripping agent (also referred to herein as an anti-drip agent). For example a fibril forming or non-fibril forming fluoropoiymer such as polytetrafluoroethylene (PTFE) can be used. The anti-drip agent may be encapsuiated by a rigid copolymer, for example styrcne-acrylonitrile (SAN). PTFE encapsuiated in SAN is know as TS AN. Encapsulated nuoropoiymers may be made by polymerizing the encapsulating polymer in the presence of the fluoropoiymer, for example, in an aqueous dispersion, TSAN may provide significant advantages over PTFE, in that TSAN may be more readily dispersed in the composition, A suitable TSA may comprise, for example, about 50 wt % PTFE and about 50 wt % SAN, based on the total weight of the encapsulated fluoropoiymer. The SAN may comprise, for example, about 75 wt % styrene and about 25 wt % aerylonitriie based on the total weight of the copolymer. Alternatively, the fluoropoiymer may be pre-biended in some manner with a second polymer, such as for, example, an aromatic polycarbonate resi or SAN to form an agglomerated material for use as an anti-drip agent. Either method may be used to produce an encapsulated fluoropoiymer.

[00102] The anti-dripping agent is present in an amount from greater than 0 weight % to about 5 weight %, including exemplary amounts of about 0.5 weight , about 1.0 weight %, about 1.5 weight %, about 2.0 weight %, about 2.5 weight %, about 3.0 weight , about 3.5 weight , about 4.0 weight %, and about 4.5 weight %. In still further aspects, the anti- dripping agent can be present in any range of amounts derived from the above exemplified amounts. For example, the anti-dripping agent can be present in an amount in the range of from 0.5 weight % to 5 weight %, or from 0.5 weight % to 2.5 weight .

[00103] The disclosed polycarbonate compositions further comprises a flame retardant additive. In various aspects, the flame retardant additive can comprise any flame retardant material or mixture of flame retardant materials suitable for use in the inventive composition. In another aspect, the flame retardant additive comprises a phosphate containing material. In various further aspects, the disclosed polycarbonate compositions comprise a phosphorus- containing flame retardant. for example an organic phosphates and/or an organic compound containing phosphorus-nitrogen bonds. In another aspect, the flame retardant additive comprises a halogen containing material, in other aspects, the flame retardant additive is free of or substantially free of one or more of phosphate and/or a halogen. In various aspects, the flame retardant additive is selected from oligomeric phosphate, polymeric phosphate, aromatic polyphosphate, oligomeric phosphonate, or mixed phosphaie/phosphonate ester flame retardant compositions. In a still further aspect, the flame retardant is selected from oligomeric phosphate, polymeric phosphate, oligomeric phosphonate, or mixed

phosphate/phosphonate ester flame retardant compositions.

[00104] In a further aspect, the flame retardant additive is bisphenol-A bis(diphenyl phosphate). In an even further aspect, the flame retardant additive is resorcinol dipheny] phosphate ("RDP"), In a still further aspect, the ilame retardant additive is resorcinol aromatic polyphosphate {CAS# 139 ! 89-30-3). The resorcinol aromatic polyphosphate assigned CAS# 139189-30-3 is commercially available under the tradename PX200 (Daiichi Chemical Industry Co., Ltd.), In still another aspect, the flame retardant additive comprises an oligomer organophosphorous flame retardant, including for example, bisphenol A diphenyl phosphate (BPADP). In a yet further aspect, the flame retardant addttive is selected from bisphenol A diphenyl phosphate ("BPADP"), resorcinol diphenyl phosphate ("RDP"), triphenyl phosphate; cresyldiphenylpbosphate; and tri(isopropylphenyl)phosphate. In an even further aspect, the flame retardant additive is selected from bisphenol A dipheny! phosphate ("BPADP") and resorcinol diphenyl phosphate ("RDP"). In a still further aspect, the flame retardant additive is selected from bisphenol A diphenyl phosphate ("BPADP"), resorcino! diphenyl phosphate ("RDP"), and resorcinol aromatic polyphosphate (CAS# 139189-30-3). [00105] The phosphorus-containing flame retardant of the disclosed polycarbonate compositions can be an organic phosphate and/or an organic compound containing phosphorus-nitrogen bonds. One type of exemplary organic phosphate is an aromatic phosphate of the formula (GOh — . wherein each G is independently an aikyl, eycloalky!, aryi, alkaryl, or ara!kyl group, provided that at least one G is an aromatic group. Two of the G groups may be joined together to provide a cyclic group, for example, diphenyi pentaerythritol diphosphate, which is described by Axelrod in U.S. Pat. No. 4, 154,775. Other suitable aromatic phosphates may be, for example, phenyl bis(dodecyl)phosphate, phenyl bis(neopentyl)phosphate, phenyl bis(3,5,5'-lrimethylhexyl)phosphate, ethyl diphenyi phosphate, 2-ethylhexyl di(p-toly1)phosphate, bis(2-ethylhexyl)p-toly! phosphate, tritolyi phosphate, bis(2-ethylhexyl)phenyi phosphate, tri(ttonylphenyl)phosphate, bis(dodecyl)p- tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyi phosphate, p-tolyl bis(2,5,5'-trimethyihexyl)phosphate, 2-ethylhexyl diphenyi phosphate, or the tike. A specific aromatic phosphate is one in which each G is aromatic, for example, triphenyl phosphate, tricresyi phosphate, isopropylated triphenyl phosphate, and the like.

[00106] Di- or polyfunctional aromatic phosphorus-containing compounds are also useful, for example, compounds of the formulas below:

wherein each G¹ is independently a hydrocarbon having I to about 30 carbon atoms; each G² is independently a hydrocarbon or hydrocarbonoxy having 1 to about 30 carbon atoms; each X is independently a bromine or chlorine; m 0 to 4, and n is 1 to about 30. Examples of suitable di- or polyfunctiona! aromatic phosphorus-containing compounds include resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl)phosphate of hydrocjuinone and the bis(diphenyl)phosphate of bisphenol-A, respectively, their oligomeric and polymeric counterparts, and the like. Methods for the preparation of the aforementioned di- or polyfunctional aromatic compounds are described in British Patent No. 2,043,083.

[00107] Additional flame retardants may be added as desired. Suitable flame retardants that may be added may be organic compounds that include phosphorus, bromine, and/or chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants may be desired in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds;.

[00108] Exemplary flame retardants may include: 2,2-bis-(3,5-dichlorophenyl)-propane; bLs-(2-chlorophenyl j-methane; bis(2,6-dibromophenyl)-methane; 1 , 1 -bis-(4-iodopfienyl)- ethane; 1 ,2-bis-(2,6-diehlorophenyl)-ethane; 1 , 1 -bis-(2-chloro-4-iodophenyl)ethane; 1 , 1 -bis- (2-ch]oro-4-methylphenyl)-elhane; 1 J -bis-(3,5-dichioiOphenyl)-ethane; 2,2-bis-(3-phenyi-4- bromophenyl)-ethane; 2,6-bis-(4,6-dichloronaphthyl)-propane; 2,2-bis-(2,6-dichlorophenyI)- pentane; 2,2-bis-(3,5-di^'bromophenyl)-hexane; bis-(4-chlorophenyl)-phenyi-methane: bis- (3,5-dichion phenyl)-cyclohexylniethane; bis-{3~mtro-4-bromophenyl)-metbane; bis-(4- hydiOxy-2,6-dichiofo-3-methoxyphenyi)-methane; and 2,2-bis-(3,5-dichlor -4- hydroxyphenylj-propane 2,2bis-(3-bromo-4-hydroxyphenyl)-propane. Also included within the above structural formula are: 1 ,3-dichlorobenzene, 1,4-dibromobenzene, l,3-dichloro-4~ hydroxybenzene, and biphenyis such as 2,2'-dichlorobiphenyl, polybrominaied 1,4- diphenoxybenzene, 2,4 -dibromobipbenyl, and 2,4 -dichlorobiphenyI as well as decabromo diphenyl oxide, arid the like.

[00109] Also useful are oligomerie and polymeric halogenated aromatic compounds, such as a eopolycarbonate of bisphenol A and tetrabromobisphenol A and a carbonate precursor, e.g., phosgene,

[00110] The concentration of a flame retardant additive can vary, and the present disclosure is not intended to be limited to any particular flame retardant concentration. In an aspect, the disclosed composition composes from about 5 weight % to about 20 .% of flame retardant additive, including or example, about 6, 7, 8, , 10, 1 1, 12, 33, 14, 15, 16, 17, 18, or 19 weight %. In still further aspects, the flame retardant additive can be present in any range of amounts derived from the above values. For example, the flame retardant additive can be present in the polycarbonate composition in an amount in the range of from about 5 weight % to about 15 weight %, or event from about 10 weight percent to about 20 weight %. Flame retardant additives are commercially available, and one of skill in the art could readily select an appropriate flame retardant additive.

[00111] In addition to the foregoing components, the disclosed polycarbonate

compositions can optionally comprise a balance amount of one or more additive materials ordinarily incorporated in polycarbonate resin compositions of this type, with the proviso that the additives are selected so as to not significantly adversely affect the desired properties of the polycarbonate composition. Combinations of additives can be used. Such additives can be mixed at a suitable time during the mixing of the components for forming the composition. Exemplary and non-limiting examples of additive materials that can be present in the disclosed polycarbonate compositions include an antioxidant, a stabilizer (including for example a heal stabilizer or a light stabilizer), UV absorbing additive, plastieizer, lubricant, mold release agent, antistatic agent, colorant (e.g., pigment and/or dye), filler, reinforcing component, or any combination thereof.

[00112] In a further aspect, the disclosed polycarbonate compositions comprise an antioxidant additive. In various further aspects, the antioxidant additive can comprise a primary antioxidant or "stabilizer" (e.g., a hindered phenol and/or secondary aryl amine) and, optionally, a secondary antioxidant {e.g., a phosphate and/or thioester). According to various aspects, the antioxidant can be a primary antioxidant. For example, a primary antioxidant can be present in an amount of from about 0.001 weight % to about 0,5 weight %. In a still further aspect, the primary antioxidant can be selected from hindered phenols, phosphites, phosphona.es, and any mixture thereof. In a yet further aspect, the primary antioxidant is a hindered phenol. In an even further aspect, the primary antioxidant is tetrakis

(methylene(3,5-di-tert-butyl-4-.hydroxy-hydrocinnarimte)methane,

[00113] In a further aspect, the disclosed polycarbonate composition can further comprise a secondary antioxidant in an amount from about 0.001 weight % to about 0.500 weight . In a still further aspect, the secondary antioxidant can be a thioester or thioether. In a yet further aspect, the secondary antioxidant is selected from pentaerythritoi tetrakis (3- (dodecylthio)propionate), pentaerythritoi tetrakis j 3-{3,5-di-tert-buty1~4- hydroxyphenyl)propionate], di!auryl thiodipropionate, distearyl thiodipropionate, dimyristyl thiodipropionate, ditiidecyl thiodipropionate, pentaerythritoi octylthiopropionate, and dioctadecy! disuiphide. In an even further aspect, the secondary antioxidant is pentaerythritoi tetrakis (3-(dodecylthio)propionate).

[00114] Suitable antioxidant additives include, for example, organophosphites such as tris(nonyI phenyf)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t- butylpheny pentaerythritol diphosphite, distearyl pentaerythritoi diphosphite or the like; alkylated monophenols or polyphenols; alkylated reaction products of pol henols with dienes, such as tetrakisrmethy]ene(3^-di-tert-butyl-4-hydroxyhydroctnnamate)_.lmethane. or the like; butyiated reaction products of par -cresol or dicyclopentadiene; alkylated

hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of beta-(3,5-di-teit-buty!-4-hydroxyphenyl)-propionic acid with nionohydric or poJyhydiic alcohols; esters of beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with nionohydric or polyhydric alcohols; esters of thioalkyi or thioaryl compounds such as distearyithiopropionate, dilaurySthiopropionate, ditrid cylthiodipropionate, octadecyI-3-(3,5- di-tert-butyl-4-hydroxyphenyi)propionate, pentaerytorityl-tetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate or the like; amides of beta-(3,5-di-tert-butyl.-4~hydroxyphenyl)- propionic acid or the like, or combinations comprising at least one of the foregoing antioxidants.

[00115] In another aspect, the inventive polycarbonate composition can comprise a filler, such as, for example, an inorganic filler. The specific composition of a filler, if present, can vary , provided that the filler is chemical ly compatible with the remaining components of the polycarbonate composition. In an aspect, the polycarbonate composition comprises a filler, such as, for example, talc. If present, the amount of filler can comprise any amount suitable for a polycarbonate composition that does not adversely affect the desired properties thereof. In an aspect, the inventive polycarbonate comprises about 1 wt.% to about 10 vvt.% of a filler.

[00116] In another aspect, a filler can comprise silicates and silica powders such as aluminum silicate (muiiite), synthetic calcium silicate, zirconium silicate, fused siiica, crystalline siiica graphite, natural silica sand, or the like; boro powders such as boron-nitride powder, boron-silicate powders, or the like; oxides such as TiOj, aluminum oxide, magnesium oxide, or the like; calcium sulfate (a its anhydride, dihydrate or trihydrate); calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, including fibrous, modular, needle shaped, lamellar talc, or the like: wollastonite; surface-treated wollastonite; glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), or the like; kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymeric matrix resin, or the like; single crystal fibers or "whiskers" such as silicon carbide, alumina, boron carbide, iron, nickel, copper, or the like; fibers (including continuous and chopped fibers) such as asbestos, carbon fibers. glass fibers, such as E, A, C, ECR, R, S, D, or NE glasses, or the like; sulfides such as molybdenum sulfide, zinc sulfide or the like; barium compounds such as barium litanate, barium fertile, barium sulfate, heavy spar, or the tike; metals and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel or the like; ilaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes or the like; fibrou fillers, for example short inorganic fibers such as those derived from blends comprising at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate hemihydraie or the like; natural fillers and reinforcements, such as wood flour obtained by pulverizing wood, fibrous products such as cellulose, cotton, sisal, jute, starch, cork flour, lignin, ground nut shells, corn, rice grain husks or the like; organic fillers such as polytetrafiuoiOethyiene; reinforcing organic fibrous fillers formed from organic polymers capable of forming fibers such as poiy(ether ketone), polyimide, polybenzoxazole, polyfphenylene sulfide), polyesters, polyethylene, aromatic poiyamides, aromatic polyimides, po!yetherimides, polytetrafluoroethylene, acrylic resins, polyf vioyl alcohol) or the like; as well as additional fillers and reinforcing agents such as mica, clay, feldspar, flue dust, fiilite, quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black, or the like, or

combinations comprising at least one of the foregoing fillers or reinforcing agents.

[00117] In an aspect, a filler, if present, can be coated with a layer of metallic materia] to facilitate conductivity, or surface treated with sj lanes to improve adhesion and dispersion with the polymeric matrix resin. In addition, the reinforcing fillers can be provided in the form of monofilament or multifilament fibers and can be used individually or in combination with other types of fiber, through, for example, co- weaving or core/sheath, side-by-side, orange-type or matrix and fibril constructions, or by other methods known to one skilled in the ait of fiber manufacture. Exemplary co-woven structures include, for example, glass fiber-carbon fiber, carbon fiber-aromatic polyimide (aramid) fiber, and aromatic polyimide fiberglass fiber or the like. Fibrous fillers can be supplied in the form of, for example, rovings, woven fibrous reinforcements, such as 0-90 degree fabrics or the like; non-woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or the like; or three-dimensional reinforcements such as braids,

[00118] In a still further aspect, the disclosed polycarbonate compositions comprise a lubricant (also referred to herein as a moid release agent). Any commercially available lubricant suitable for use in polycarbonate compositions can be used. According to aspects, the lubricant can be selected from methyl stearate; stearyi stearate, and pentaerythritol tetrastearate. In a still further aspect, the lubricant is pentaerythritol tetrastearate.

[00119] The disclosed polycarbonate compositions can be used in the manufacture of various end use articles. The polycarbonate compositions can be formed into useful shaped articles by a variety of means such as; injection molding, extrusion, rotational molding, compression molding, blow molding, sheet or film extrusion , profile extrusion, gas assist molding, structural foam molding and thermoforming. The blended polycarbonate compositions described herein resin can also be made into film and sheet as well as components of laminate systems.

[00120] Formed articles include, for example, computer and business machine housings, home appliances, trays, plates, handles, helmets, automotive parts such as instrument panels, cup holders, glove boxes, interior coverings and the like. In various further aspects, formed articles include, but are not limited to, food service items, medical devices, animal cages, electrical connectors, enclosures for electrical equipment, electric motor parts, power distribution equipment, communication equipment, computers and the like, including devices that have molded in snap fit connectors. In a further aspect, articles of the present disclosure comprise exterior body panels and parts for outdoor vehicles and devices including automobiles, protected graphic such as signs, outdoor enclosures such as telecommunication and electrical connection boxes, and construction applications such as roof sections, wail panels and glazing. Multilayer articles made of the disclosed polycarbonates particularly include articles which will be exposed to UV-iight, whether natural or artificial, during their lifetimes, and most particularly outdoor articles; i.e., those intended for outdoor use. Suitable articles are exemplified by enclosures, housings, panels, and parts for outdoor vehicles and devices; enclosures for electrical and telecommunication devices; outdoor furniture; aircraft components; boats and marine equipment, including trim, enclosures, and housings; outboard motor housings; depth finder housings, personal water-craft; jet-skis; pools; spas; hot-tubs: steps; step coverings; building and construction applications such as glazing, roofs, windows, floors, decorative window furnishings or treatments; treated glass covers for pictures, paintings, posters, and like display items; wall panels, and doors; protected graphics; outdoor and indoor signs; enclosures, housings, panels, and parts for automatic teller machines (ATM); enclosures, housings, panels, and parts for lawn and garden tractors, lawn mowers, and tools, including lawn and garden tools; window and door trim; sports equipment and toys; enclosures, housings, panels, and parts for snowmobiles; recreational vehicle panels and components; playground equipment; articles made from plastic-wood combinations; golf course markers; utility pit covers; computer housings; desk-top computer housings; portable computer housings; lap-top computer housings; palm-held computer housings; monitor housings; printer housings; keyboards; facsimile ^'machine housings; copier housings;

telephone housings; mobile phone housings; radio sender housings; radio receiver housings; light fixtures; lighting appliances; network interface device housings; transformer housings; air conditioner housings; cladding or seating for public transportation; cladding or seating for trains, subways, or buses; meter housings; antenna housings; cladding for satellite dishes; coated helmets and personal protective equipment; coated synthetic or natural textiles; coated photographic film and photographic prints; coated painted articles; coated dyed articles;

coated fluorescent articles; coated foam articles; and like applications.

[00121] In an aspect, the present disclosure pertains to articles comprising the disclosed blended polycarbonate compositions. In a further aspect, the article comprising the disclosed blended polycarbonate compositions is used in automotive applications. In a still further aspect, the article used in automotive applications is selected from instrument panels, overhead consoles, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliques, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, and running boards. In a yet further aspect, the article used in automotive applications is selected from seats, seat backs, cargo floors, door panels, steering wheels, radio speaker grilles, instrument panel bezels, steering columns, drip rails, energy absorbers, kick panels, mirror housings, grille opening

reinforcements, steps, hatch covers, knobs, buttons, and levers. In an eve further aspect, the article used in automotive applications is selected from seats, seat backs, cargo floors, door panels, steering wheels, radio speaker grilles, instrument panel bezels, steering columns, drip rails, energy absorbers, kick panels, mirror housings, grille opening reinforcements, steps, hatch covers, knobs, buttons, and levers. In an even further aspect, article is selected from instrument panels, overhead consoles, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliques, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, running boards, seats, seat backs, cargo floors, door panels, steering wheels, radio speaker grilles, instrument panel bezels, steering columns, drip rails, energy absorbers, kick panels, mirror housings, grille opening reinforcements, steps, hatch covers, knobs, buttons, and levers.

[00122] In various aspects, the disclosure relates to articles comprising a disclosed composition. In a further aspect, the article is used in electrical and electronic applications. In a still further aspect, the article is selected from components for cell phones and cell phone covers, components for batteries, components for computer housings, computer housings and business machine housings such as housings for monitors, handheld electronic device housings such as housings for cell phones, electrical connectors, and components of lighting fixtures, ornaments, home appliances, roofs, greenhouses, sun rooms, swimming pool enclosures, Light Emitting Diode (LEDs) and light panels, extruded film and sheet articles, and the like. In a yet further aspect, the compositions are of particular utility in the manufacture of thin walled articles such as housings for electronic devices. In a still further aspect, additional examples of articles that can be formed from the compositions include electrical parts, such as relays, batteries, capacitors, and enclosures, consumer electronics such as enclosures and parts for laptops, desktops, docking stations, PDAs, digital cameras, desktops, and telecommunications parts such as parts for base station terminals.

[00123] The disclosed polycarbonate compositions of the present disclosure can be manufactured by various methods. The compositions of the present disclosure can be blended with the aforementioned ingredients by a variety of methods involving intimate admixing of the materials with any additional additives desired in the formulation. Because of the availability of melt blending equipment in commercial polymer processing facilities, mel processing methods can be used. In various further aspects, the equipment used in such melt processing methods includes, but is not limited to, the following: co-rotating and counter-rotating extruders, single screw extruders, eo-kneaders, disc-pack processors and various other types of extrusion equipment. In a further aspect, the extruder is a twin-screw extruder. In various further aspects, the melt processed composition exits processing equipment such as an extruder through small exit holes in a die. The resulting strands of molten resin are cooled by passing the strands through a water bath. The cooled strands can be chopped into small pellets for packaging and further handling.

[00124] The temperature of the melt is minimized in order to avoid excessive degradation of the resins. For example, it can be desirable to maintai n the melt temperature between about 230°C and about 35 °C in the molten resin composition, although higher temperatures can be used provided that the residence time of the resin in the processing equipment is kept short. In a still further aspect, the extruder is typically operated at a temperature of about 180 °C to about 385 °C. In a yet further aspect, the extruder is typically operated at a temperature of about 200 °C to about 330 °C. In an even further aspect, the extruder is typically operated at a temperature of about 220 °C to about 300 °C.

[00125] In various aspects, the polycarbonate compositions of the present disclosure can be prepared by blending the first polycarbonate polymer, the second polycarbonate polymer, the impact modifier, the anti-dripping agent, the flame retardant, and any polymer composition additive, e.g. a HENSCHEL-Mfxer® high speed mixer or other suitable mixer/blender. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The mixture can then be fed into the throat of a single or twin screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidestuffer. Additives can also be compounded into a masterbatch desired polymeric resin and fed into the extruder. The extruder generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water bath and palletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

[00126] Without further elaboration, it is believed that one skilled in the art can, using the description herein, utilize the present disclosure. The following examples are included to provide addition guidance to those skilled in the art of practicing the claimed disclosure. The examples provided are merely representative of the work and contribute to the teaching of the present disclosure. Accordingly, these examples are not intended to limit the disclosure in any manner.

[00127] While aspects of the present disclosure can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present disclosure can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it i no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational How. plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

EXAMPLES

[00128] The following examples are put forth so as to provide those of ordinary skill in the art with a compiete disclosure and description of how the compounds, compositions, articles, devices and/or methods clai med herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should he accounted for. Unless i dicated otherwi e, pails are parts by weight, temperature is in °C or is at ambient temperature, and pressure is at or near atmospheric. Unless indicated otherwise, percentages referring to composition are in terms of wt%.

[00129] The component materials used to prepare both the comparative and representative inventive compositions evaluated in the following examples are shown in Table 1 below.

Tabic I .

Acronym/Name Chemical Name (Use) Trade Name/ Source CAS #

LEX AN* 105-1 UN Resin

POWDER (MFl 5.5-7.5) 30

POLYCARBONATE RESIN g/lO min @ ί .2 Kg /300"C.

PC 1 1 1 121 1-39-3

(29.9K MW) SABIC INNOVATIVE

PLASTICS MT VERNO IN USA.

LEXAN* ML522 i -H iN

PC 2 POLYCARBONATE RESIN (21.9 K MW) 1 1 121 1-39-3

Resin Powder (MFI 20 - 30

Using the above component materials, comparative and inventive compositions were prepared accosxting to the fonnuiations shown in Tables 2, 3 and 4. Representative

(experimenta!) examples of the pi esent disclosure are designated by letter E (El through E52), and comparative (control) examples are designated by letter C (CI through CI 6), Sample batches of approximately 40 pounds for each composition were prepared by pre-biendmg all constituents in a dry-blend and turobk mixed for 20 minutes. The pre-blend was fed directly to a co-rotation twin screw extruder (37 mm) operated under standard processing conditions well known to one skilled in the art. The organic phosphorus flame retardant component (BPA-DP and RDP) was added to the middle part of the extruder from a liquid feed pump. The composition was then melt-kneaded and extruded. The extrudate was cooled through a water bath prior to pelletizing. The obtained pellets were then dried at 100 °C for 4 hours. All the testing of specimens were prepared in accordance with ASTM standards using a 150 T injection molding machine at a melt temperature 265°C and at mold temperature 80 °C except that bar specimens measuring 127 mm x 12 mm x 0,60 mm were molded 35 °C higher that the rest.

Table 2.

Note: a. Rubber cotifem was calculated based on the recognition: EXL-PC contains -20% silicone-based rubber, IM {{MBS). IM 2(HRG), IM 3(SBS block copolymer) and IM4 (Metablen S-2001) contain 78%, 58.5%, 69% and 78% poJybutadtene {or Silicone/ Acrylic) rubber, respectively, h. NV denotes noil vertical rating available doe to the issues of long burning time, or burn to ciamp or flame dripping.

[00130] The samples were tested for various mechanical, thermal, and flame retardant properties using the testing standards shown in Table 4, In addition to the formulation components shown in Tables 2 and 3, each composition was also formulated with 0.08 weight % phosphite stabilizer (PS), 1.0 weight % anti dripping agent (TSAN), and 0.08 weight % antioxidant (AO). Results of the testing are also shown for the respective compositions in Tables 2 and 3, respectively.

Table 4,

[00131] It can be seen from the data in Tables 2 and 3 that since EXL resin is alone used as impact modifier in the composition of C I to C5, the composition all obtain a fiammabiiity rating of V0, but high impact was not included in properly profile at temperature 10 °C for low visicosity composition CI (MFR at -20 g/i niin) and at temperature 0°C for high visicosity composition C2 to C5 ( MFR at -1 1 g/i Omin) in terms of notched Izod impact

(NI1>=400 J/m). In Comparative Examples C6-C15, where impact modifiers, IM1 (MBS), IM2 (HRG), IM3 (SBS) and IM4 (S2Q01), are used as the sole impact modifier separately, I^'M 1 , 1M2 and 1M4 all show higher efficiency in terms of impact strength per unit amount of rubber, particularly at temperature 0°C and -i0°C, while IM3 (SBS) show the contrary result. However, all these compositions including high visicosity composition (CI 2 to CI 5) still present brittle behaviors at temperature 0°C. Note that though there is an exceptional composition C I 1 , which retained high impact in terms of notched izod impact (NII>=500 J/m), it like the other failed to include in property profile the desired V0 fiammabiiity rating at 0.6 mm, primarily due to 'bum to clamp issue' and/or 'dripping issue' upon flame application. In particular, C13 provides an example comprising a higher ¾~,wt composition of flame retardants. The additional flame retardant added into composition is able to markedly reduce total 'flame out time' during vertical flame test but can't improve fiammabifity rating of composition. Moreover, C 13 exhibits a marked reduction in both materia! heat distortion temperature and impact strength.

[00132] In contrast, when all these impact modifiers are separate! y used in combination with EXL resin, as seen in the compositions of Example E1 -E43, all the compositions including the one based on TM4 (SBS) attained a significantly improvement of impact strength at all temperature (- 10°C, 0°C and 23°C) in comparison with Comparative Example CI to C I 5. even when the compositions are all of the same total amount of rubber at 4,63% and of the same viscosity level. This data suggests that combinational use of EXL resin and rubber-based impact modifier shows the highest rubber efficiency in terms of impact strength per unit amount of rubber, likely due to the synergistic effect among them. Moreover, compositions comprising less than 2% or 3% impact modifier achieved the desired V0 flammability rating at 0.60 mm, while other properties like heat distortion temperature and moid flow-ability are substantially unchanged.

[00133] Further, as exemplified by examples E44 and E45, heat resistance of such a composition can be further boosted by replacing general polycarbonate with high heat polycarbonate copolymer, while no marked impairment is made to the desired property balance of impact resistance and flame resistance.

[00134] Set forth below are some embodiments of the polycarbonate compositions, methods of manufacture and articles comprising the same.

[00135] in an embodiment, a polycarbonate composition comprises: (a) from 20 to 80 weight percent of a first polycarbonate component, optionally comprisi ng a blend of two or more polycarbonate polymers; (b) from greater than 0 to 25 weight percent of a polysiioxane- poiyearbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula (XVIII):

(XVIII)

wherein "x" is an integer from 40 to 60 and wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-poiycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31 ,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards; (c) from greater than 0 to 5 weight percent of an impact modifier, optionally comprising a methyl metfiacrySate-butadiene-styrene copolymer; (d) from greater than 0 to 5 weight percent of an anti-dripping agent, optionally comprising a floor? nated polyolefin anti-dripping agent; (e) from greater than 0 to 25 weight percent of a flame retardant, optionally comprising bisphenol A diphenylphosphaie; and (f) balance of one or more additional polymer composition additives; wherein the composition optionally comprises less than 1000 ppm of a bromine and/or chlorine containing compound; and wherein the composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammabiiity rating of V0 as measured on a flame bar having a thickness of 0.60 mm.

[00136] The polycarbonate composition of the foregoing embodiment optionally further comprises a high heat polycarbonate component, for example, a high heat polycarbonate component comprising units derived from 2-phenyi-3,3-bis(4-hydroxyphenyi)phthalimidine.

[00137] In another embodiment, a polycarbonate composition comprises: (a) from 20 to 80 weight percent of a first pol carbonate component, optionally comprising a blend of two or more polycarbonate polymers; (b) from from 10 to 25 weight percent of a polysiloxane- polycarbonate block copolymer comprising a polycarbonate block derived from Bisphenol-A and diorganopoiysiloxane block of the general formula (XVIII):

(XVIII)

[00138] wherein "x" is an integer from 40 to 60 and wherein the organopolysi!oxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31 ,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards; (c) from greater than 0 to 5 weight percent of a methyl methacrylate-butadiene- styrene impact modifier; (d) from greater than 0 to 25 weight percent of a bisphenol A dipbenylphosphate; (e) from greater than 0 to 5 weight percent of an anti-dripping agent, optionally comprising a fiuorinated polyoiefin anti-dripping agent: and (f) balance of one or more additional polymer composition additives; wherein the composition optionally comprises less than 1000 ppm of a bromine and/or chlorine containing compound; and wherein the composition exhibits a notched Ixocl impact strength greater than 400 i/ as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm.The polycarbonate composition of the above embodiment further optionally comprises from greater than 0 to 15 weight percent of a high heat polycarbonate component, specifically a high heat polycarbonate component comprising units derived from2-phenyi-3,3~bis(4-hydiOxyphenyl)phtha1imidine.

[00139] I another embodiment, a method for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3,2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm, comprises combining (a) a first polycarbonate component, optionally comprising a blend of two or more polycarbonate polymers, wherein the first polycarbonate component is combined in an amount of from about 20 to 80 weight percent of the composition; (b) a polysiloxane-poiycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula ( XV) 11):

(XVIII)

where in "x" is an integer from 40 to 60, wherein the organopolysiloxane block is randomly distributed in a Bisphenol- polycarbonate block copolymer such that the siloxane content within the polysiloxane-poiycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-poiycarbonate block copolymer is from 29,000 to 31 ,000 daltons using Bisphenol- A polycarbonate absolute molecular weight standards, and wherein the polysiloxane-polycarbonate block copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition; (c) an impact modifier, optionally comprising a methyl niethaerylate-butadiene-styrene copolymer, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition; (d) an anti-dripping agent, optionally comprising a fluorinated polyolefm anti-dripping agent, wherein the anti-dripping agent is combined in an amount from greater than 0 to 5 weight percent of the composition; (e) a fiame retardant, optionally comprising bisphenoi A diphenylphosphate, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition; and (f) a balance amount of one or more additional polymer composition additives.

[00140] In specific embodiments of the foregoing method, one or more of the following conditions can apply: the method further comprises combining a high heat polycarbonate component into the composition, wherein the high heat polycarbonate component comprises units deri ved from 2-phenyl-3,3-bis(^'4-hydrox>'phenyl)pbthalimidme; or the composition comprises less than 1000 ppm of a bromine and or chlorine containing compound,

[00141] In another embodiment, a method for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 fiammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm, comprises combining (a) a first polycarbonate component, optionally comprising a blend of two or more polycarbonate polymers, wherein the first polycarbonate component is combined in an amount of from about 20 to 80 weight percent of the composition; (b) a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenoi A and a diorganopolysiloxane block of the general formula (XVIII):

wherein V is an integer from 40 to 60, wherein the organopoly iloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the poiysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the poiysiloxane-polycarbonate block copolymer is from 29,000 to 31.000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards, and wherein the poiysiloxane-polycarbonate b!ock copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition; (c) a methyl methacrylate-bittadiene- styrene impact modifier, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition; (d) an anti-dripping agent, optionally comprising a fluorinated polyolefm anti-dripping agent, wherein the anti-dripping agent is combined in an amount from greater than 0 to 5 weight percent of the composition; (e) a bisphenol A diphenylphosphate flame retardaot, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition; and (e) a balance amount of one or more additional polymer composition additives.

[00142] I specific embodiments of the foregoing method, one or more of the following conditions can apply: the method further comprises combining a high heat polycarbonate component into the composition, wherein the high heat polycarbonate component comprises units derived from 2-phenyl-3,3-bis{4-hyclroxyphenyl)phtha3imiditie; or the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.

[00143] In another embodi ment, an article of manufacture compri ses various embodiments of the polycarbo ate composition.

[00144] Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this pertains. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon. Nothing herein is to be construed as an admission that the present disclosure is not entitled to antedate such publication by virtue of prior disclosure. Further, the dates of publication provided herein may be different from the actual publication dates, which can require independent confirmation.

[00145] It will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. It is intended (hat the specification and examples be considered as exeniplai y oniy, with a true scope and spirit of the disclosure being indicated by the following claims.

Claims

CLAIMS What is claimed is:

1. A polycarbonate composition comprising:

(a) from 20 to 80 weight percent of a first polycarbonate component;

(b) from greater than 0 to 25 weight percent of a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula (XVIII):

(XVIII)

wherein "x" is an integer from 40 to 60 and wherein the organopolysiioxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiioxane- polycarbonate block copolymer is from 29,000 to 3 ,000 daStons using Bisphenol- A polycarbonate absolute molecular weight standards;

(c) from greater than 0 to 5 weight percent of an impact modifier;

(d) from greater than 0 to 5 weight percent of an ami -dripping agent;

(e) from greater than 0 to 25 weight percent of a flame retardant; and

(f) balance of one or more additional, polymer composition additives;

wherein the composition exhibits a notched lzod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the compositio exhibits a UL-94 ftammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm.

2. The polycarbonate composition of claim 1, wherein the flame retardant comprises

bisphertoi A dlphertylphosphate.

3. The polycarbonate composition of claim 1 or claim 2, wherein the impact modifier

comprises a methyl methacrylate-butadiene-styrene copolymer.

4. The polycarbonate composition of any one of claims 1 to 3, further comprising a high heat polycarbonate component.

5. The polycarbonate composition of claim 4, wherein the high heat polycarbonate

component comprises units derived from 2-piienyi-3,3-bis(4- hydroxypheny phthalimidine.

6. The polycarbonate composition of any one of claims 1 to 5, wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound,

7. The polycarbonate composition of any one of claims 1 to 6, wherein the first

polycarbonate component comprises a blend of two or more polycarbonate polymers.

8. The polycarbonate composition of any one of claims 1 to 7. further comprising from

greater than 0 to 5 weight percent of a fluorinated polyoleftn anti-dripping agent.

9. A polycarbonate composition comprising:

(a) from 20 to 80 weight percent of a first polycarbonate component;

(b) from 10 to 25 weight percent of a polysi.loxane-polycarbo.nate block copolymer comprising a polycarbonate block deri ed from Bisphenol-A and

diorganopolysiloxane block of the general formula (XVIO):

(xviii)

wherein "x" is an integer from 40 to 60 and wherein the organopolysiioxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxatie content within the polysiioxane- olycarbonate block copolymer is about 20% and the weight average molecular weight of the poiysiloxane- polycarbonate block copolymer is from 29,000 to 31 ,000 daltons using Bisphenol- A polycarbonate absolute molecular weight standards;

(c) from greater than 0 to 5 weight percent of a methyl methacrylate-butadiene- styrene impact modifier;

(d) from greater than 0 to 25 weight percent, of a bisphenol A diphenylphosphate .flame retardant;

(e) from greater than 0 to 5 weight percent of an anti-dripping agent; and.

(f) balance of one or more additional polymer composition additives; wherein the composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of VQ as measured on a flame bar having a thickness of 0.60 mm.

10. The polycarbonate composition of claim 9, further comprising from greater than 0 to 15 weight percent of a high heat polycarbonate component.

1 1. The polycarbonate composition of claim 10, wherein the high heat polycarbonate

component comprises units derived from 2-phenyi-3,3-bis(4- hydroxypheny1)phtnalimidine,

12. The polycarbonate composition of any one of claims 9 to ί 1, wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound,

13. The polycarbonate composition of any one of claims 9 to 12, wherein the first

polycarbonate component comprises a blend of two or more -polycarbonate polymers.

14. The polycarbonate composition of any one of claims 9 to 13, further comprising from greater than 0 to 5 weight percent of a fluorinated polyolefin anti-dripping agent.

15. A method for the manufacture of a polycarbonate composition that exhibits a notched Izod im act strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm. wherein the method comprises combining

(b) a polys loxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiioxane block of the general formula (XV Hi):

where in "x" is an integer fro 40 to 60, wherein the organopolysiloxane block is randomly distributed i a Bisphenol- A polycarbonate block copolymer such that the siioxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the poiysiloxane- polycarbonate block copolymer is from 29,000 to 31.000 daltons using Bisphenoi- A polycarbonate absolute molecular weight standards, and wherein the poiysiloxane-polycarbonate block copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition;

(c) an impact modifier, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition;

(d) an a anti-dripping agent, wherein the anti-dripping agent is combined in an

amount iron; greater than 0 to 5 weight percent of the composition;

(f) a balance amount of one or more additional polymer composition additives,

16. The method of claim 15, wherein the flame retardant comprises bisphenol A

diphenyiphosphate,

17. The method of claim 15 or claim 1 , wherein the impact modifier comprises a methyl methacrylate-butadiene-styrene copolymer.

18. The method of any one of ciaims 15 to 17, further comprising combining a high heat polycarbonate component, into the composition.

19. The method of claim 18, wherein the high heat polycarbonate component comprises units derived from 2-phenyl-3,3-bis<4-hydroxyphenyj)phthaIimidme.

20. The method of any one of ciaims 15 to 1 , wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.

21. The method of any one of ciaims 15 to 20, wherein the first polycarbonate component comprises a blend of two or more polycarbonate polymers.

22. The method of any one of claims 15 to 21, wherein the anti-dripping agent comprises a I hionnated polyolefin anti -dripping agent.

23. A method for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to ASTM D256 on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammabiiity rating of VO as measured on a flame bar having a thickness of 0.60 mm, wherein the method comprises combining

(b) a polysi.ioxane-polycarbo.nate block copolymer comprising a polycarbonate block derived from bisphenoi A and a diorganopolysUoxane block of the general formula (XVIII):

(XVIII)

wherein "x" is an integer from 40 to 60, wherein the organopolysiloxane block is randomly distributed in a Bisphenoi- A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane- polycarbonate block copolymer is from 29,000 to 1 ,000 daitons using Bisphenoi- A polycarbonate absolute molecular weight standards, and wherein the polysiloxane-polycarbonate block copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition;

(c) a methyl methaerylate-butadiene-styrene impact modifier, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition;

(e) a bisphenoi A dipbenylphosphate flame retardant, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition; and

(f) a balance amount of one or more additional polymer composition additives.

24. The method of claim 23, further comprising combining a high heat polycarbonate

component into the composition.

25. The method of claim 24, wherein the high heat polycarbonafe component comprises units derived from 2- heny 3 - ίs{4 ^ d oxy ben ·i) htha^raidiile,

26. The method of any one of claims 23 to 25, wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound,

27. The method of any one of claims 23 to 26, wherein the first polycarbonate component comprises a blend of two or more polycarbonate poly mers.

28. The method of any one of claims 23 to 27, wherein the anti-dripping age t comprises a fhtormated polyolefin anti-dripping agent.

29. An article of manufacture comprising the polycarbonate composition of any one of claims \ to 14.