WO2020047392A1 - Non-halogenated flame retarded blends of polycarbonate and thermoplastic polyesters and method to prepare thereof - Google Patents

Abstract

Disclosed are polymer compositions comprising one or more polycarbonate, one or more thermoplastic polyester, and one or more phosphonate. The compositions can further comprise anti-dripping agent, impact modifier, or combination thereof. The composition can have at least in part flame retardant property, chemical resistant property, or combination thereof. Compositions, methods of making and using them are disclosed.

Description

NON-HALOGENATED FLAME RETARDED BLENDS OF POLYCARBONATE AND THERMOPLASTIC POLYESTERS AND METHOD TO PREPARE THEREOF

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims benefit of priority to the filing date of U.S.

Provisional Patent Application No. 62/725,617 filed August 31, 2018, entitled,“NON- HALOGENATED FLAME RETARDANT BLENDS OF POLYCARBONATE AND THERMOPLASTIC POLYESTERS,” the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

[0002] Blends of polycarbonate (PC) with thermoplastic polyesters (PESTs), such as but not limited to poly(ethylene terephthalate) (PET) and poly(butylene terephthalate) (PBT), are of great commercial importance. The blends are characterized by a set of properties to which each of its components contribute, namely excellent impact strength from PC, and good solvent resistance from semi-crystalline PEST - each compensating for the inherent weakness of the other. The main advantage of PC/PEST blend is increased stiffness, low susceptibility to stress cracking on contact with fuels, and an improved resistance to chemicals and fuels. They are mainly used in automotive industry for automotive body panels that require toughness at low temperatures, chemical resistance, heat resistance and dimensional stability, such as dashboard, pillars, head lamp housings and luggage racks. They are also used in outdoor power equipment, telecommunications and many others, such as electronic medical-device housings and hardware. Medical-device housing needs superior chemical resistance due to its repeated exposure to disinfectants, solvents, and other agents. According to the CDC, on any given day 1 in 25 hospital patients has at least one healthcare- associated infection (HAI). Aggressive disinfectants are often used by hospitals and clinics to reduce the risk of HAEs. High chemical resistant materials help resist more frequent cleaning and more aggressive disinfectants on medical housings.

[0003] PC/PEST blends are immiscible and brittle. Owing to possible

transesterification the system does not necessarily require additional compatibilization.

However, controlling the extend of reaction is critical - too much of it eliminate crystallinity of PEST, reducing the mechanical performance as well as solvent and chemical resistance, whereas too little leads to poor interphase adhesion and brittleness. As a result, most modem blends rely rather on reactive compatibilization than on a transesterification. The

compatibilization is usually combined with incorporation of a multicomponent impact modifier to improve the impact strength of the resulting blend. The latter resin can be modified polyethylene (PE), acrylonitrile butadiene styrene copolymer (ABS), or an acrylic copolymer such as methylmethacrylate butadiene styrene copolymer (MBS).

[0004] Many of the applications mentioned above also require flame retardant property for fire safety reasons. Most commercial flame-retardant PC/PESTs products use brominated flame retardants to achieve flame retardancy. There is a demand for plastics that are more environmentally friendly and thus that are halogen-free. In this invention, phosphonates such as without limitation polyphosphonates and phosphonate oligomers are used as efficient flame retardants to meet such demand, and unexpectedly improve the chemical resistance of PC/PEST blends.

SUMMARY

[0005] In some embodiments, a polymeric composition comprising (i) about 20 wt.% to about 75 wt.% of one or more polycarbonate, (ii) about 20 wt.% to about 50 wt.% of one or more thermoplastic polyester, and (iii) about 5 wt.% to about 30 wt.% of one or more phosphonate is disclosed

[0006] In some embodiments, the composition can comprise about 30 wt.% to about

70 wt.% of the one or more polycarbonate, about 40 wt.% to about 60 wt.% of the one or more polycarbonate, or about 40 wt.% to about 50 wt.% of the one or more polycarbonate.

[0007] In some embodiments, the one or more thermoplastic polyester can be selected from the group consisting of poly(butylene terephthalate), poly(ethylene terephthalate), poly(trimethylene terephthalate), poly(ethylene naphthalate), or combinations thereof. The one or more thermoplastic polyester can be a poly(butylene terephthalate), poly(ethylene terephthalate), or combination thereof. The one or more thermoplastic polyester can be a poly(butylene terephthalate). The one or more thermoplastic polyester can be a poly(ethylene terephthalate).

[0008] In some embodiments, the composition cam comprise about 25 wt.% to about

50 wt.% of the one or more thermoplastic polyester, about 25 wt.% to about 45 wt.% of the one or more thermoplastic polyester, or about 30 wt.% to about 40 wt.% of the one or more thermoplastic polyester. [0009] In some embodiments, the one or more phosphonate is a polyphosphonate, phosphonate oligomer, or combination thereof. The polyphosphonate, phosphonate oligomer, or combination thereof can comprise structural units of Formula (I):

wherein (i) Ar is an aromatic group, (ii) -O-Ar-O- is derived from an aromatic dihydroxy compound or aromatic diol, (iii) R is a Ci_-2o alkyl, C2-20 alkene, C2-20 alkyne, C5-20 cycloalkyl, or C6-20 aryl, and (iv) nl is an integer from 2 to 200. The -O-Ar-O- can be derived from a compound selected from the group consisting of resorcinols, hydroquinones, and bisphenols, and combinations thereof. The group consisting of resorcinols, hydroquinones, bisphenols, and combinations thereof can include bisphenol A, bisphenol F, 4,4'-biphenol,

phenol phthalein and its derivatives, 4,4'-thiodiphenol, 4,4'-sulfonyldiphenol, 1,1 -bis-(4- hydroxyphenyl)-3,3,5-trimethylcyclohexane, and combinations thereof. The nl can be an integer from 2 to about 100, an integer from 2 to about 50, an integer from 2 to about 20, or an integer from 2 to about 5.

[00010] In some embodiments, the one or more polyphosphonate, phosphonate oligomer, or combination thereof can have a weight average molecular weight of about 10,000 g/mole to about 100,000 g/mole or a weight average molecular weight of about 12,000 g/mole to about 80,000 g/mole

[00011] In some embodiments, the one or more polyphosphonate, phosphonate oligomer, or combination thereof can have a number average molecular weight of about 5,000 g/mole to about 50,000 g/mole, a number average molecular weight of about 8,000 g/mole to about 15,000 g/mole, or a number average molecular weight greater than about 9,000 g/mole.

[00012] In some embodiments, the composition can comprise about 5 wt.% to about 20 wt.% of the one or more phosphonate, about 5 wt.% to about 15 wt.% of the one or more phosphonate, or about 5 wt.% to about 10 wt.% of the one or more phosphonate.

[00013] In some embodiments, the composition can have a phosphorus content of about 0.1 wt.% to about 5.0 wt.%, a phosphorus content of about 0.5 wt.% to about 4.0 wt.%, a phosphorus content of about 0.5 wt.% to about 3.0 wt.%, or a phosphorus content of about 1.0 wt.% to about 2.5 wt.%. [00014] In some embodiments, the composition can have a ductile notched Izod impact at l.6mm.

[00015] In some embodiments, the composition can pass UL 94 VO at 0.8mm and above.

[00016] In some embodiments, the composition can comprise one or more antidripping agent. The antidripping can be a polytetrafluoroethylene.

[00017] In some embodiments, the composition can comprise an impact modifier. The impact modifier can be selected from the group consisting of polyethylene, acrylonitrile butadiene styrene copolymer, acrylic copolymer, or combinations thereof. The acrylic copolymer can be a methylmethacrylate butadiene styrene copolymer.

[00018] In some embodiments, a polymeric composition comprising (i) about 10 wt.% to about 75 wt.% of one or more poly carbonate, (ii) about 20 wt.% to about 70 wt.% of one or more thermoplastic polyester, (iii) about 5 wt.% to about 30 wt.% of one or more

polyphosphonate, (iv) one or more anti-dripping agent, (v) and one or more impact modifier is disclosed. In these embodiments and other embodiments, the composition can have a UL94 rating of V0 at 0.8mm and a ductile failure in an Izod notched impact test at l.6mm. In these embodiments and other embodiments, the one or more thermoplastic polyester can be a poly(ethylene terephthalate), poly(butylene terephthalate), or combination thereof. In these embodiments and other embodiments, the one or more thermoplastic polyester can be a poly(ethylene terephthalate). In these embodiments and other embodiments, the one or more thermoplastic polyester can be a poly(butylene terephthalate).

[00019] In some embodiments, a method for preparing a polymeric composition comprising combining by melt processing (i) one or more polycarbonate, (ii) one or more thermoplastic polyester, and (iii) one or more phosphonate is presented. The one or more polycarbonate can comprise about 20 wt.% to about 75 wt.% of the polymeric composition, the one or more thermoplastic polyester can comprise about 20 wt.% to about 50 wt.% of the polymeric composition, and the one or more phosphonate can comprise about 5 wt.% to about 30 wt.% of the polymeric composition. No bubble can be formed during melt processing and the melt processing can be done with a single screw extruder or a twin screw extruder. The one or more thermoplastic polyester and the one or more phosphonate can form a compatibilized melt.

[00020] In some embodiments, an article of manufacturing comprising (i) about 20 wt.% to about 75 wt.% of one or more polycarbonate, (ii) about 20 wt.% to about 50 wt.% of one or more thermoplastic polyester, and (iii) about 5 wt.% to about 30 wt.% of one or more phosphonate is presented. The article can be a molded article. The article can be a fiber reinforced composite. The article can be a film, sheet, fiber, foam, adhesive, or filament.

BRIEF DESCRIPTION OF THE DRAWINGS

[00021] The present disclosure is described with reference to the following figures, which are presented for the purpose of illustration only and are not intended to be limiting.

[00022] In the drawings:

[00023] FIG. 1 is an image depicting a setup for testing the environmental stress chemical resistance in accordance with aspects of the present disclosure;

[00024] FIG. 2A is a graph presenting the Differential Scanning Calorimetry (DSC) diagram of the compounded pellets of EX 3 in accordance with aspects of the present disclosure; and

[00025] FIG. 2B is a graph presenting the Differential Scanning Calorimetry (DSC) diagram of the compounded pellets of EX 10 in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

[00026] This disclosure is not limited to particular systems, devices, and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope.

[00027] As used in this document, the singular forms“a,”“an,” and“the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term“comprising” means“including, but not limited to.”

[00028] The following terms shall have, for the purposes of this application, the respective meanings set forth below. [00029] “Optional” or“optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[00030] “Substantially no” means that the subsequently described event may occur at most about less than 10 % of the time or the subsequently described component may be at most about less than 10 % of the total composition, in some embodiments, and in others, at most about less than 5 %, and in still others at most about less than 1 %.

[00031] The term“alkyl” or“alkyl group” refers to a branched or unbranched hydrocarbon or group of 1 to 20 carbon atoms, such as but not limited to methyl, ethyl, n- propyl, isopropyl, n-butyl, isobutyl, t-butyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and the like.“Cycloalkyl” or“cycloalkyl groups” are branched or unbranched hydrocarbons in which all or some of the carbons are arranged in a ring such as but not limited to cyclopentyl, cyclohexyl, methylcyclohexyl and the like. The term“lower alkyl” includes an alkyl group of 1 to 10 carbon atoms.

[00032] The term“aryl” or“aryl group” refers to monovalent aromatic hydrocarbon radicals or groups consisting of one or more fused rings in which at least one ring is aromatic in nature. Aryls may include but are not limited to phenyl, naphthyl, biphenyl ring systems and the like. The aryl group may be unsubstituted or substituted with a variety of substituents including but not limited to alkyl, alkenyl, halide, benzylic, alkyl or aromatic ether, nitro, cyano and the like and combinations thereof.

[00033] “Substituent” refers to a molecular group that replaces a hydrogen in a compound and may include but are not limited to trifluoromethyl, nitro, cyano, C_l-2o alkyl, aromatic or aryl, halide (F, Cl, Br, I), Ci_-2o alkyl ether, Ci_-2o alkyl ester, benzyl halide, benzyl ether, aromatic or aryl ether, hydroxy, alkoxy, amino, alkylamino (-NHR’), dialkylamino (- NR’R”) or other groups which do not interfere with the formation of the intended product.

[00034] As defined herein, an“arylol” or an“arylol group” is an aryl group with a hydroxyl, OH substituent on the aryl ring. Non-limiting examples of an arylol are phenol, naphthol, and the like. A wide variety of arlyols may be used in the embodiments of the invention and are commercially available.

[00035] The term“alkanol” or“alkanol group” refers to a compound including an alkyl of 1 to 20 carbon atoms or more having at least one hydroxyl group substituent.

Examples of alkanols include but are not limited to methanol, ethanol, 1- and 2-propanol, 1,1- dimethylethanol, hexanol, octanol and the like. Alkanol groups may be optionally substituted with substituents as described above. [00036] The term“alkenol” or“alkenol group” refers to a compound including an alkene 2 to 20 carbon atoms or more having at least one hydroxyl group substituent. The hydroxyl may be arranged in either isomeric configuration (cis or trans). Alkenols may be further substituted with one or more substituents as described above and may be used in place of alkenols in some embodiments of the invention. Alkenols are known to those skilled in the art and many are readily available commercially.

[00037] As used herein, the term“about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%.

[00038] The terms "flame retardant", "flame resistant", "fire resistant" or "fire resistance", as used herein, mean that the polymer exhibits a limiting oxygen index (LOI) of at least 27. The LOI of a material is indicative of its ability to bum once ignited. The test for LOI is performed according to a procedure set forth by the American Society for Test Methods (ASTM). The test, ASTM D2863, provides quantitative information about a material's ability to bum or "ease of bum". If a polymeric material has an LOI of at least 27, it will, generally, bum only under very high applied heat. Fire resistance may also be tested both by measuring the 02 index in accordance with ASTM D 2863-70 and/or by measuring the after-burning time in accordance with the UL test (Subject 94). In this test, the tested materials are given classifications of UL-94 V0, UL-94 VI and UL-94 V2 based on the results obtained with the ten test bars of a given thickness. Briefly, the criteria for each of these UL-94V-classifications are as follows:

[00039] UL-94 V0: the total flaming combustion for each specimen after removal of the ignition flame should not exceed 10 seconds and the total flaming combustion for 5 specimens should not exceed 50 seconds. None of the test specimens should release any drips which ignite absorbent cotton wool.

[00040] UL-94 V 1 : the total flaming combustion for each specimen after removal of the ignition flame should not exceed 30 seconds and the total flaming combustion for 5 specimens should not exceed 250 seconds. None of the test specimens should release any drips which ignite absorbent cotton wool.

[00041] UL-94 V2: the total flaming combustion for each specimen after removal of the ignition flame should not exceed 30 seconds and the total flaming combustion for 5 specimens should not exceed 250 seconds. Test specimens may release flaming particles, which ignite absorbent cotton wool. [00042] Fire resistance may also be tested by measuring after-burning time. These test methods provide a laboratory test procedure for measuring and comparing the surface flammability of materials when exposed to a prescribed level of radiant heat energy to measure the surface flammability of materials when exposed to fire. The test is conducted using small specimens that are representative, to the extent possible, of the material or assembly being evaluated. The rate at which flames travel along surfaces depends upon the physical and thermal properties of the material, product or assembly under test, the specimen mounting method and orientation, the type and level of fire or heat exposure, the availability of air, and properties of the surrounding enclosure. If different test conditions are substituted or the end-use conditions are changed, it may not always be possible by or from this test to predict changes in the fire-test-response characteristics measured. Therefore, the results are valid only for the fire test exposure conditions described in this procedure.

[00043] Both number average (Mn) and weight average molecular weight (Mw) as used herein, can be determined by gel permeation chromatography (GPC). GPC provides information about the molecular weight and molecular weight distribution of a polymer based on size exclusion chromatography. Typically, the molecular weight of a polymer is based on the calibration of the chromatograph columns using known molecular weights of polystyrene standards. It is known that the molecular weight distribution of a polymer is important to properties such as thermo-oxidative stability (due to different amount of end groups), toughness, melt flow, and fire resistance, for example, low molecular weight polymers drip more when burned.

Description general phosphonate structures

[00044] Embodiments of the invention are not limited by the type of phosphonate component included and may include, for example, polyphosphonates, branched

polyphosphonates, or random or block copolyphosphonates, co-oligo(phosphonate ester)s, or co-oligo(phosphonate carbonate)s, phosphonate oligomers, branched phosphonate oligomers, and in certain embodiments, the phosphonate component may have the structures described and claimed in U.S. Patent Nos. US7,645,850, US7,8l6,486, US8,389,664, US8,563,638, US8,648,l63, US8,779,04l, US8,530,044, each of which is hereby incorporated by reference in its entirety.

[00045] Such phosphonate components may include repeating units derived from diaryl alkylphosphonates or diaryl arylphosphonates. For example, in some embodiments, such phosphonate components include structural units illustrated by Formula (I):

where Ar is an aromatic group and -O-Ar-O- may be derived from an aromatic dihydroxy compound or aromatic diol, R is a Ci_-2o alkyl, C2-20 alkene, C2-20 alkyne,€5.20 cycloalkyl, or C6-20 aryl, and nl is an integer from 2 to about 200, 2 to about 100, 2 to about 75, 2 to about 50, 2 to about 20, 2 to about 10, or 2 to about 5, or any integer between these ranges.

[00046] The term“aromatic diol” is meant to encompass any aromatic or

predominately aromatic compound with at least two associated hydroxyl substitutions of the Formula (II):

wherein n2, p2, and q are each independently 0, 1, 2, 3, or 4; Ra is independently at each occurrence unsubstituted or substituted Ci-io hydrocarbyl; and X^a is a single bond,— O— ,— S— ,— S(O)— ,— S(0)2— ,— C(O)— , or a Ci-ighydrocarbylene, which can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise one or more heteroatoms selected from oxygen, nitrogen, sulfur, silicon, or phosphorus. As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen unless it is specifically identified as“substituted hydrocarbyl”. The hydrocarbyl residue can be aliphatic or aromatic, straight- chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. The term“substituted” means including at least one substituent such as a hydroxyl, amino, thiol, carboxyl, carboxylate, amide, nitrile, sulfide, disulfide, nitro, Ci_

18 alkyl, C_l-l8 alkoxyl, C_6-i8 aryl, C_6-i8 aryloxyl, C_7-l8 alkylaryl, or C_7-l8 alkylaryloxyl. The term “substituted” further permits inclusion of halogens (i.e., F, Cl, Br, I).

[00047] Some illustrative examples of specific dihydroxy compounds include the following: bisphenol compounds such as 4, 4'-dihydroxy biphenyl, l,4-dihydroxynaphthalene, l,5-dihydroxynaphthalene, l,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 2,7- dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)phenylmethane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxy-3,5-dimethylphenyl)methane, bis(4- hydroxy-3,5-dichlorophenyl)methane, bis(4-hydroxy-3,5-dibromophenyl)methane, bis(4- hydroxy-3-methylphenyl)methane, bis(4-hydroxy-3-chlorophenyl)methane, bis(4- hy droxyphenyl)- 1 -naphthylmethane, 1 ,2-bis(4-hydroxyphenyl)ethane, 1 , 1 -bis(4- hydroxyphenyl)-l-phenylethane, 2,2-bis(4-hydroxyphenyl)propane (“bisphenol A” or “BPA”), 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, l,l-bis(4- hy droxyphenyl)cy clopentane, 1 , 1 -bis(4-hy droxyphenyl)cy clohexane, 1 , 1 -bis(4-hydroxy-3- methylphenyl)cyclohexane, l,l-bis-(4-hydroxyphenyl)-3, 3, 5-trimethylcy clohexane, 1,1- bis(4-hydroxyphenyl)isobutene, l,l-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4- hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, alpha, alpha'-bis(4- hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4- hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4- hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl- 4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl- 4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2-bis(3-methoxy-4- hydroxyphenyl)propane, 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane, 2,2-bis(4-hydroxy- 3-chlorophenyl)propane, 2,2-bis(4-hydroxy-3,5-dichlorophenyl)propane, 4,4'- dihydroxybenzophenone, bis(4-hydroxy-3,5-dimethylphenyl)ketone, bis(4-hydroxy-3,5- dichlorophenyl)ketone, 3,3-bis(4-hydroxyphenyl)-2-butanone, l,6-bis(4-hy droxyphenyl)- 1,6- hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4- hy droxyphenyl) sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9- bis(4-hydroxyphenyl)fluorene, 2,7-dihydroxypyrene, 6,6'-dihydroxy-3,3,3',3'- tetramethylspiro(bis)indane (“spirobiindane bisphenol”), phenolphthalein and

phenolphthalein derivatives, 3,3-bis(4-hydroxyphenyl)phthalimide, 2, 6-dihydroxy dibenzo-p- dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,l0- dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7- dihydroxycarbazole; resorcinol, substituted resorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5- phenyl resorcinol, 5-cumyl resorcinol, or the like; catechol; hydroquinone; substituted hydroquinones such as 2-methyl hydroquinone, 2-ethyl hydroquinone, 2-propyl

hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone, 2-phenyl hydroquinone, 2- cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, chlorohydroquinone, acetoxyhydroquinone, and nitrohydroquinone. [00048] In particular embodiments, the Ar may be derived from bisphenol A and R may be a methyl group providing polyphosphonates, phosphonate copolymers, random and block co-oligo(phosphonate carbonate)s and co-oligo(phosphonate ester)s, and oligomeric phosphonates that may have structures such as, but not limited to, structures of Formulae (III):

[00049] In some embodiments, a single aromatic diol may be used, and in other embodiments, various combinations of such aromatic diols may be incorporated into the polymer. The phosphorous content of phosphonate component may be controlled by the molecular weight (MW) of the aromatic diol used in the oligomeric phosphonates, polyphosphonates, or copolyphosphonates. A lower molecular weight aromatic diol may produce an oligomeric phosphonate, polyphosphonate, or copolyphosphonate with a higher phosphorus content. An aromatic diol, such as resorcinol, hydroquinone, or a combination thereof or similar low molecular weight aromatic diols may be used to make oligomeric phosphonates or polyphosphonates with high phosphorous content. The phosphorus content, expressed in terms of the weight percentage, of the phosphonate oligomers, phosphonates, or copolyphosphonates may be in the range from about 2 wt. % to about 18 wt. %, about 4 wt. % to about 16 wt. %, about 6 wt. % to about 14 wt. %, about 8 wt. % to about 12 wt. %, or a value between any of these ranges. In some embodiments, phosphonate oligomers, polyphosphonates, or copolyphosphonates prepared from bisphenol A or hydroquinone may have phosphorus contents of 10.5 wt. % and 18 wt. %, respectively.

Description polyphosphonates

[00050] In certain embodiments, the phosphonate component may be a

polyphosphonate, phosphonate oligomer, or combination thereof containing long chains of the structural unit of Formula (I). In some embodiments, the polyphosphonates may have a weight average molecular weight (Mw) of about 10,000 g/mole to about 100,000 g/mole as determined by GPC, and in other embodiments, the polyphosphonates may have an Mw of from about 12,000 to about 80,000 g/mole as determined by GPC. The number average molecular weight (Mn) in such embodiments may be from about 5,000 g/mole to about 50,000 g/mole, or from about 8,000 g/mole to about 15,000 g/mole, and in certain

embodiments the Mn may be greater than about 9,000 g/mole. The molecular weight distribution (i.e., Mw/Mn) of such polyphosphonates may be from about 2 to about 10 in some embodiments and from about 2 to about 5 in other embodiments.

[00051] In certain embodiments, the phosphonate component may be a

polyphosphonate containing branched structures of the structural unit of Formula (I). In some cases, a branching agent (i.e. tri or tetrahydroxy aromatic compound) may be added or it may be generated in-situ via a reaction of bisphenol A and an appropriate catalyst. In some embodiments, the branched polyphosphonates may have a molecular weight distribution (i.e., Mw/Mn) of from about 2 to about 10 in some embodiments and from about 2.3 to about 3.2 in other embodiments.

Description phosphonate copolymers

[00052] In some embodiments, the phosphonate component may be copolymers containing carbonate linkages [i.e., copoly (phosphonate carbonate)] or ester linkages [i.e., copoly (phosphonate esters)].

[00053] For example, copoly(phosphonate carbonate)s may include repeating units derived from at least 20 mole percent high purity diaryl alkylphosphonate or optionally substituted diaryl alkylphosphonate, one or more diaryl carbonate, and one or more aromatic dihydroxy compounds, wherein the mole percent of the high purity diaryl alkylphosphonate is based on the total amount of transesterification components, i.e., total diaryl

alkylphosphonate and total diaryl carbonate. As indicated by the term“random” the monomers of the copoly(phosphonate carbonate)s of various embodiments may be incorporated into polymer chain randomly. Therefore, the polymer chain may include alternating phosphonate and carbonate monomers linked by one or more aromatic

dihydroxide and/or various segments in which several phosphonate or several carbonate monomers form phosphonate or carbonate segments. Additionally, the length of various phosphonate or carbonate segments may vary within individual copoly(phosphonate carbonate)s.

[00054] The phosphonate and carbonate content of the copoly(phosphonate

carbonate)s may vary among embodiments, and embodiments are not limited by the phosphonate and/or carbonate content or range of phosphonate and/or carbonate content. For example, in some embodiments, the copoly(phosphonate carbonate)s may have a phosphorus content of from about 1% to about 20% by weight of the total copoly (phosphonate carbonate), and in other embodiments, the phosphorous content of the copoly(phosphonate carbonate)s of the invention may be from about 2% to about 10% by weight of the total polymer. [00055] In other embodiments, the copoly(phosphonate carbonate)s or copoly (phosphonate ester)s, may have structures such as, but not limited to, those structures of Formula (IV) and (V), respectively:

(V) and combinations thereof, where Ar¹ and Ar² are each, independently, an aromatic group and -O-Ar'-O- and -0-Ar²-0- may be derived from a dihydroxy compound as described by structure (II). R is a Ci_-2o alkyl, C_2-20 alkene, C_2-20 alkyne,€_5.20 cycloalkyl, or C_6-20 aryl. R¹ may be a Ci_₂o alkylene or cycloalkylene, such as methylene, ethylene, propylene, butylene, pentylene, and the like, and in particular embodiments, R¹ can be derived from aliphatic diols such as, but not limited to, l,4-cyclohexyldimethanol, 1, 4-butane diol, 1, 3-propane diol, ethylene diol, ethylene glycol, and the like and combinations thereof. R² is, independently, a Ci-₂₀ alkylene, C_2-20 alkylenylene, C_2-20 alkylynylene, C_5-20 cycloalkylene, or Ce-₂₀ arylene. In certain embodiments, R² can be derived from adipic acid, dimethyl terephthalic acid, terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid and the like or derivatives thereof or combinations thereof. In certain embodiments, R² may be an aromatic group such as naphthalene, phenylene, biphenylene, propane-2, 2-diyldibenzylene, and in some embodiments, R² can be derived from, for example, dimethyl terephthalate, dimethyl isophthalate, dimethyl naphthalate, and the like and combinations thereof. Thus, R² may be, for example, naphthalene, phenyl, both of which may be substituted at any position on the rings.

[00056] Such copoly(phosphonate carbonates) or copoly(phosphonate esters) may be block copoly(phosphonate carbonates) or copoly(phosphonate esters) in which each m, n, and p is greater than about 1, and the copolymers contain distinct repeating phosphonate and carbonate blocks or phosphonate and ester blocks. In other embodiments, the

copoly (phosphonate carbonates) or copoly(phosphonate esters) can be random copolymers in which each m4, n4, and p5 are each, independently, an integer from 1 to about 200, 1 to about 100, 1 to about 75, 1 to about 50, 1 to about 20, 1 to about 10, or 1 to about 5, or any integer between these ranges.

[00057] In particular embodiments, the Ar¹ and Ar² may be derived from bisphenol A and R may be a methyl group providing random and block co(phosphonate carbonate)s and co(phosphonate ester)s that may have structures such as, but not limited to, structures of Formula (VI) and (VII):

and combinations thereof, where each of m, n, p, and R¹ and R² are defined as described above.

[00058] The copoly(phosphonate carbonate)s of various embodiments exhibit both a high molecular weight and a narrow molecular weight distribution (i.e., low polydispersity). For example, in some embodiments, the copoly(phosphonate carbonate)s may have a weight average molecular weight (Mw) of about 10,000 g/mole to about 100,000 g/mole as determined by GPC, and in other embodiments, the copoly(phosphonate carbonate)s may have a Mw of from about 12,000 to about 80,000 g/mole as determined by GPC. The number average molecular weight (Mn) in such embodiments may be from about 5,000 g/mole to about 50,000 g/mole, or from about 8,000 g/mole to about 15,000 g/mole, and in certain embodiments the Mn may be greater than about 9,000 g/mole. The narrow molecular weight distribution (i.e., Mw/Mn) of such copoly(phosphonate carbonate)s may be from about 2 to about 7 in some embodiments and from about 2 to about 5 in other embodiments.

Additional description of phosphonate oligomers

[00059] In some embodiments, the molecular weight (weight average molecular weight as determined by gel permeation chromatography based on polystyrene calibration) range of the oligophosphonates, random or block co-oligo(phosphonate ester)s and co- oligo(phosphonate carbonate)s may be from about 500 g/mole to about 18,000 g/mole or any value within this range. In other embodiments, the molecular weight range may be from about 1,500 g/mole to about 15,000 g/mole, about 3,000 g/mole to about 10,000 g/mole, or any value within these ranges. In still other embodiments, the molecular weight range may be from about 700 g/mole to about 9,000 g/mole, about 1,000 g/mole to about 8,000 g/mole, about 3,000 g/mole to about 4,000 g/mole, or any value within these ranges.

[00060] The oligomeric phosphonates can have about 60% to about 100% of the total of oligomeric phosphonates have two or more reactive end-groups. In other embodiments, about 75% to about 99% of the total of oligomeric phosphonates have two or more reactive end-groups. In some embodiments, the reactive end-groups may be, for example, epoxy, vinyl, vinyl ester, isopropenyl, isocyanate, or combinations thereof, and in certain embodiments, about 80% to about 100% of the total oligomeric phosphonates may have two or more hydroxyl end groups. In various embodiments, the oligomeric phosphonates or portions thereof may include oligophosphonate, random co-oligo(phosphonate ester), block co-oligo(phosphonate ester), random co-oligo(phosphonate carbonate), block co- oligo(phosphonate carbonate), or combinations thereof. In some embodiments, the oligomeric phosphonates may include linear oligomeric phosphonates, branched oligomeric

phosphonates, or a combination thereof, and in other embodiments, such oligomeric phosphonates may further include hyperbranched oligophosphonates.

Description polymer compositions

[00061] The term "polymer composition", as used herein, refers to a composition that comprises at least one of the present invention and at least one other polymer, oligomer, or monomer mixture. The other polymer, oligomer, or monomer mixture may include those that comprise, or are partially comprised of, or are comprised of monomers intended to produce the following polymer families including but not limited to a polycarbonate, polyacrylate, polyacrylonitrile, polyester, polyether, polyamide, polystyrene, polyurethane, polyurea, polyurethane urea, polyepoxy, poly(acrylonitrile butadiene styrene), polyimide, polyarylate, poly(arylene ether), polyethylene, polypropylene, polyphenylene sulfide, poly(vinyl ester), polyvinyl chloride, bismaleimide polymer, polyanhydride, liquid crystalline polymer, cellulose polymer, benzoxazine resin, another polyphosphonate, or a combination of any two or more of these. The other polymer, oligomer, or monomer may contain functional groups that will react chemically.

[00062] It is contemplated that the polymer compositions of the present invention may comprise other components, such as but not limited to other flame retardants, chopped or continuous glass, metal, carbon based, or ceramic fibers; fillers, surfactants, mold release agents, organic binders, polymeric binders, crosslinking agents, coupling agents, anti dripping agents, colorants, inks, dyes, antioxidants or other stabilizers, or any combination thereof. [00063] The present invention can be used as coatings on plastics, metals, ceramic, or wood products or they can be used to fabricate articles, such as free-standing films and extruded sheets, fibers, foams, molded articles, adhesives, filaments, and fiber reinforced composites. These articles may be well-suited for applications requiring fire resistance.

[00064] The present invention and polymer compositions including them exhibit outstanding flame resistance, good chemical resistance, and good melt processability. Such improvements make these materials useful in applications in the automotive and electronic sectors that require outstanding fire retardancy, high temperature performance, and melt processability.

[00065] Chemical resistance can be assessed by many different methods, including those recognized by standard setting bodies, such as ASTM (e.g. ASTM D543-14, ASTM D1239-14, etc.) Standard testing aside, real world chemical resistance is often assessed against every day products, thus, improved chemical resistance may be found against 409 Glass and Surface Cleaner; Alcohol Prep Pad; CaviCide liquid/CaviWipes; CaviWipes;

Cidex Plus liquid; Clorox Bleach; Clorox Wipes; Envirocide liquid; For Pro liquid; Gentle dish soap and water; Hydrogen Peroxide Cleaner Disinfectant Wipes; Isopropyl Alcohol wipes; MadaCide-l liquid; Mar-V-Cide liquid to dilute; Sani-Cloth Bleach Wipes; Sani-Cloth HB Wipes; Sani-Cloth Plus Wipes; Sodium Hypochlorite liquid; Super Sani-Cloth Wipes; Viraguard liquid and Wipes; Virex 256; Windex Blue; Fuel C; Toluene; Heptane; Ethanol; Isopropanol; Windex; Engine oil; WD40; Transmission fluid; Break fluid; Glass wash; Diesel; Gasoline; Banana Boat Sunscreen (SPF 30); Sebum; Ivory Dish Soap; SC Johnson Fantastik Cleaner; French's Yellow Mustard; Coca-Cola; 70% Isopropyl Alcohol; Extra Virgin Olive Oil; Vaseline Intensive Care Hand Lotion; Heinz Ketchup; Kraft Mayonnaise; Chlorox Formula 409 Cleaner; SC Johnson Windex Cleaner with Ammonia; Acetone; Artificial Sweat; Fruits & Passion Cucina Coriander & Olive Hand Cream; Loreal Studioline Megagel Hair Gel; Maybelline Lip Polish; Maybelline Expert Wear Blush— Beach Plum Rouge; Purell Hand Sanitizer; Hot coffee, black; iKlear; Chlorox Wipes; Squalene; Palmitic Acid; Oleic Acid; Palmitoleic Acid; Stearic Acid; and Olive Oil, and other substances.

Examples

[00066] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description and the preferred versions contained within this specification. Various aspects of the present invention will be illustrated with reference to the following non-limiting examples. Materials

[00067] Nofia^® HM1100, HM9000, HM7000 - polyphosphonate homopolymers,

FRX Polymers^®

[00068] Lexan 141R - Polycarbonate, Sabic Innovative Plastics

[00069] Auriga 7800 - 0.89 IV PET, Auriga USA

[00070] Auriga 7804 - 0.89 IV PET, Auriga USA

[00071] Teflon^® PTFE 6C - Polytetrafluoroethylene (PTFE), DuPont

[00072] Lotader 8900 - impact modifier, Arkema

Compounding

[00073] A 27 millimeter twin screw extruder (TSE) was used to compound a variety of compositions of polycarbonate, Nofia polyphosphonates, PESTs, and other components. The temperature for the extruder started at 200° C at the feeding block, and the subsequent zones were set at a reverse temperature profile from 275°C to 260°C. The compounding was conducted at 20 lbs/hour with a screw speed of 100 rpm. All ingredients were used after being dried overnight in a desiccant dryer with -40°C dewpoint and mixed before putting into the feed hopper.

Characterization

[00074] MVR - Melt volume ratio (MVR) was measured on Dynisco LMI 4000 Melt Indexer.

[00075] UL-94 - All samples were tested for FR performance according the UL94 test protocol. Whether samples showed no drips, flammable drips or nonflammable drips is reported as ND, FD, NF, respectively. If a sample did not qualify for a V0, VI, or V2 rating, a qualification of NR (No Rating) was assigned.

[00076] DSC - The materials were heated at a rate of l0°C/min to 280°C. After keeping the sample at this temperature for 1 minute, the temperature of the sample was decreased at a rate of 40°C/min to 30°C. The crystallization peaks were determined during the cooling cycle (40°C/min from 280°C to 30°C). Subsequently, the samples were heated again for a second time at a rate of l0°C/min.

[00077] FRX Polymers Internal Environmental Stress Chemical Resistance (ESCR) testing method - The setup for testing is shown in Figure 1. When the length (L) and thickness of the specimen are fixed, adjust the distance between the support (C) will determine the strain exerted on the specimen. For example, when the thickness is l.6mm, the strain in this set up is 1%. The protocol for the testing is as follows:

1. Immerse cotton soaked with solvent mixture (IPA/MEK=50/50) and apply on bar. 2. Let the cotton sit on top of the bar for 1 minute, use a stopwatch to record the time to buckle.

3. Review bars for damage, i.e. degree of whitening/crazing, and rate it from 0 to 3:

0- no damage; 1- little damage; 2- some damage; 3 - severe damage.

4. If the damage is not easily compared, apply the cotton with solvent for another minute, i.e. repeat steps 1-3.

Example 1

Effect of PET Loading on PC/PET Blends

[00078] Table 1 shows the PC/PET blends as a function of PET loading. It is interesting to see that ESCR became worse first and then better as PET loading increased. When PET loading was increased up to 30%, time-to-buckle was shortened compared to pure PC, e.g CEX 1. However, as PET loading was further increased to 40-50%, ESCR was greatly improved. At 50% of PET, whitening/crazing could hardly be seen. The addition of PET reduced notched Izod at 3.2mm, making the blends brittle.

Table 1.

Example 2

Effect of Nofia Polyphosphonate on PC/PET/Nofia FR Blends at 30% PET

[00079] With total loading of PET fixed at 30%, Nofia HM9000 was added at different levels from 10 to 20wt%. As it can be seen in Table 2, the addition of Nofia flame retardant improved ESCR with longer time-to- buckle and reduced whitening and crazing. With 10% of Nofia HM9000 added, robust UL 94 V0 was reached at both 0.8mm and l.6mm thicknesses.

Table 2.

Example 3

Effect of Nofia Polyphosphonate on PC/PET/Nofia FR Blends at 40% PET

[00080] As shown in Table 3, with addition of Nofia HM9000, the 40% PET blends increased in its UL 94 ratings. At l2wt%, robust V0 at l.6mm was reached. ESCR also improved with less whitening and crazing. The addition of impact modifier Lotader AX8900 increased both the impact properties and ESCR but reduced the flame retardancy.

Optimization of impact modifier and Nofia flame retardant shall lead to a sweet space where good FR, impact and ESCR could be reached simultaneously.

Table 3.

Example 4

Effect of Nofia Polyphosphonate Grades on PC/PET/Nofia Blends at 40% PET

[00081] As shown in Table 4, all Nofia grades of different molecular weight provide robust UL 94 V0 at l.6mm at 12 wt.% of Nofia additives. Although they all improved ESCR, different degree of improvement can be seen depending on the grades. Nofia HM1100 appears to be the best to improve ESCR.

Table 4.

Example 5

Effect of PET Type on PC/PET/Nofia FR Blends at 30% PET

[00082] There are many different types of PET and the choice of it can make a difference in the blends. Table 5 shows two different grades of PET from the same manufacturer. One produced injection molded parts with lots of bubbles (EX 9). This blend also showed poor FR and low impact strength in addition to high MVR. The bubbles may be cyclic ethylene carbonate formed from the transesterification reaction due to residual catalyst, which has been reported for PC/PET blends. The PET type therefore needs to be carefully chosen.

Table 5.

Example 6

Effect of Order of Addition in PC/PET/Nofia Blends at 30% PET

[00083] Table 6 shows the different ways of adding the ingredients to make the blends. In EX 10, PC and Nofia polyphosphonate together with PTFE were first compounded to make a master batch (MB). Then this MB was compounded together with PET and remaining PC to make the blend. Large die swell and low melt strength were encountered and the melt could not form strand to be pelletized. Different from EX 10, EX 3 added all ingredients at same time in the hopper of the twin screw extruder and the blend was made smoothly. Order of addition has changed the dynamics of reaction between PC/PET, PC/Nofia FR, PET/Nofia FR, which in turn affects compatibilization, processability and properties. Figures 2A and 2B show the DSC of the compounded pellets of EX 3 and EX 10. EX 3 showed two Tg’s while EX 10 showed three Tg’s that correspond to the Tg of PET, Nofia polyphosphonate and PC. The two Tg’s in EX 3 are further away from the Tg’s of the original polymer component, an indication of greater reaction between the polymer species. Tm in EX 3 is lower than that of EX 10, again an indication of more reaction in EX 3. The reaction in EX 10 is so insufficient that incompatibility between three polymers caused low melt strength and difficulty in stranding.

Table 6.

Example 7

Effect of Polyphosphonates on PC/PBT Blends

[00084] PC and PBT blends were also made and compared to

PC/PBT/polyphosphonate blends. See Table 7. Addition of Nofia polyphosphonates greatly improved the flame retardancy of PC/PBT blends, but the notched izod was reduced. The PC/PBT blends went through the same ESCR test as the PC/PET blends. As it can be seen in Table 7, ESCR increases with PBT loading, and PC/PBT blends showed much better chemical resistance than PC/PET blends when the loading of PBT and PET are the same. Improvement of ESCR could also be seen with the addition of polyphosphonates, for example, in EX 17 vs. CX 9, and EX 16 vs. CX 8. Table 7.

Claims

CLAIMS What is claimed:

1. A polymeric composition comprising:

about 20 wt.% to about 75 wt.% of one or more polycarbonate; about 20 wt.% to about 50 wt.% of one or more thermoplastic polyester; and about 5 wt.% to about 30 wt.% of one or more phosphonate.

2. The composition of claim 1, wherein the composition comprises about 30 wt.% to about 70 wt.% of the one or more polycarbonate.

3. The composition of claim 1, wherein the composition comprises about 40 wt.% to about 60 wt.% of the one or more polycarbonate.

4. The composition of claim 1, wherein the composition comprises about 40 wt.% to about 50 wt.% of the one or more polycarbonate.

5. The polymeric composition of claim 1, wherein the one or more thermoplastic polyester is selected from the group consisting of poly(butylene terephthalate), poly(ethylene terephthalate), poly(trimethylene terephthalate), poly(ethylene naphthalate), or combinations thereof.

6. The polymeric composition of claim 5, wherein the one or more thermoplastic polyester is a poly(butylene terephthalate), poly(ethylene terephthalate), or combination thereof.

7. The polymeric composition of claim 6, wherein the one or more thermoplastic polyester is a poly(butylene terephthalate).

8. The polymeric composition of claim 6, wherein the one or more thermoplastic polyester is a poly(ethylene terephthalate).

9. The composition of claim 1, wherein the composition comprises about 25 wt.% to about 50 wt.% of the one or more thermoplastic polyester.

10. The composition of claim 1, wherein the composition comprises about 25 wt.% to about 45 wt.% of the one or more thermoplastic polyester.

11. The composition of claim 1 , wherein the composition comprises about 30 wt.% to about 40 wt.% of the one or more thermoplastic polyester.

12 The composition of claim 1, wherein the one or more phosphonate is a

polyphosphonate, phosphonate oligomer, or combination thereof.

13. The polymeric composition of claim 12, wherein the polyphosphonate, phosphonate oligomer, or combination thereof comprises structural units of Formula (I):

wherein:

Ar is an aromatic group;

-O-Ar-O- is derived from an aromatic dihydroxy compound or aromatic diol; R is a Ci -₂o alkyl, C_2-2o alkene, C_2-20 alkyne, C_5-2o cycloalkyl, or C_6-2o aryl; nl is an integer from 2 to 200.

14. The composition of claim 13, wherein -O-Ar-O- is derived from a compound selected from the group consisting of resorcinols, hydroquinones, and bisphenols, and combinations thereof.

15. The composition of claim 14, wherein the group consisting of resorcinols,

hydroquinones, bisphenols, and combinations thereof includes bisphenol A, bisphenol F, 4,4'-biphenol, phenolphthalein and its derivatives, 4,4'-thiodiphenol, 4,4'- sulfonyldiphenol, l,l-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, and combinations thereof.

16. The composition of claim 15, wherein nl is an integer from 2 to about 50.

17. The composition of claim 15, wherein nl is an integer from 2 to about 20.

18. The composition of claim 15, wherein nl is an integer from 2 to about 5.

19. The composition of claim 15, wherein the one or more polyphosphonate, phosphonate oligomer, or combination thereof have a weight average molecular weight of about 10,000 g/mole to about 100,000 g/mole.

20. The composition of claim 15, wherein the one or more polyphosphonate, phosphonate oligomer, or combination thereof have a weight average molecular weight of about 12,000 g/mole to about 80,000 g/mole.

21. The composition of claim 15, wherein the one or more polyphosphonate, phosphonate oligomer, or combination thereof have a number average molecular weight of about 5,000 g/mole to about 50,000 g/mole.

22. The composition of claim 15, wherein the one or more polyphosphonate, phosphonate oligomer, or combination thereof have a number average molecular weight of about 8,000 g/mole to about 15,000 g/mole.

23. The composition of claim 15, wherein the one or more polyphosphonate, phosphonate oligomer, or combination thereof have a number average molecular weight greater than about 9,000 g/mole.

24. The composition of claim 1, wherein the composition comprises about 5 wt.% to about 20 wt.% of the one or more phosphonate.

25. The composition of claim 1, wherein the composition comprises about 5 wt.% to about 15 wt.% of the one or more phosphonate.

26. The composition of claim 1, wherein the composition comprises about 5 wt.% to about 10 wt.% of the one or more phosphonate.

27. The polymeric composition of claim 1, wherein the composition has a phosphorus content of about 0.1 wt.% to about 5.0 wt.%.

28. The polymeric composition of claim 1, wherein the composition has a phosphorus content of about 0.5 wt.% to about 4.0 wt.%.

29. The polymeric composition of claim 1, wherein the composition has a phosphorus content of about 0.5 wt.% to about 3.0 wt.%.

30. The polymeric composition of claim 1, wherein the composition has a phosphorus content of about 1.0 wt.% to about 2.5 wt.%.

31. The polymeric composition of claim 1, wherein the composition has ductile notched Izod impact at l.6mm.

32. The polymeric composition of claim 1, wherein the composition passes UL 94 V0 at 0.8mm and above.

33. The polymeric composition of claim 1, further comprising one or more anti dripping agent.

34. The polymeric composition of claim 33, wherein the antidripping is a polytetrafluoroethylene.

35. The polymeric composition of claim 1, further comprising an impact modifier.

36. The polymeric composition of claim 35, wherein the impact modifier is selected from the group consisting of polyethylene, acrylonitrile butadiene styrene copolymer, acrylic copolymer, or combinations thereof.

37. The polymeric composition of claim 36, wherein the acrylic copolymer is a

methylmethacrylate butadiene styrene copolymer.

38. A polymeric composition comprising:

about 10 wt.% to about 75 wt.% of one or more poly carbonate; about 20 wt.% to about 70 wt.% of one or more thermoplastic polyester; about 5 wt.% to about 30 wt.% of one or more polyphosphonate; one or more anti-dripping agent; and

one or more impact modifier.

39. The polymeric composition of claim 38, wherein the composition has a UL94 rating of V0 at 0.8mm and a ductile failure in an Izod notched impact test at l.6mm.

40. The polymeric composition of claim 38, wherein the one or more thermoplastic polyester is poly(ethylene terephthalate), poly(butylene terephthalate), or combination thereof.

41. The polymeric composition of claim 41, wherein the one or more thermoplastic polyester is poly(ethylene terephthalate).

42. The polymeric composition of claim 41, wherein the one or more thermoplastic polyester is poly(butylene terephthalate).

43. A method for preparing a polymeric composition comprising:

combining by melt processing one or more polycarbonate, one or more thermoplastic polyester, and one or more phosphonate,

wherein the one or more polycarbonate comprises about 20 wt.% to about 75 wt.% of the polymeric composition, the one or more thermoplastic polyester comprises about 20 wt.% to about 50 wt.% of the polymeric composition, and the one or more phosphonate comprises about 5 wt.% to about 30 wt.% of the polymeric composition.

44. The method for preparing a polymeric composition of claim 43, wherein no bubble is formed during melt processing.

45. The method for preparing a polymeric composition of claim 43, wherein the melt processing is done with a single screw extruder or a twin screw extruder.

46. The method for preparing a polymeric composition of claim 43, wherein the one or more thermoplastic polyester and the one or more phosphonate form a compatibilized melt.

47. An article of manufacturing comprising about 20 wt.% to about 75 wt % of one or more polycarbonate, about 20 wt.% to about 50 wt.% of one or more thermoplastic polyester, and about 5 wt.% to about 30 wt.% of one or more phosphonate.

48. The article of manufacturing of claim 47, wherein the article is a molded article.

49. The article of manufacturing of claim 47, wherein the article is a fiber reinforced composite.

50. The article of manufacturing of claim 47, wherein the article is a film, sheet, fiber, foam, adhesive, or filament.