Filler reinforced polyester composition with improved sustainable content, surface aesthetics and NMT bond strength

Abstract

The present invention relates to a thermoplastic composition comprising: from about 20 wt% to about 65 wt% of a resin component comprising polybutylene terephthalate (PBT), poly (cyclohexyldimethylene terephthalate) (PCT), polyethylene terephthalate (PET), or a combination thereof; from about 10 wt% to about 30 wt% of a polyestercarbonate copolymer, the polyestercarbonate copolymer including resorcinol units; from about 5 wt% to about 50 wt% of a glass fiber component, the glass fiber component comprising regenerated round glass fibers; and from about 5 wt% to about 10 wt% of at least one additive component. The composition has a higher nanomolding technology (NMT) bond strength than a comparative composition that includes flat glass fibers rather than the regenerated round glass fibers. The dielectric constant (Dk) of the composition is at least 3.3, as evaluated at 2.5 gigahertz (GHz) or 5.0 GHz according to the SPDR method, or at least 3.24, as evaluated at 60 GHz according to the coaxial method.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to thermoplastic compositions with improved Nano-Molding Technology (NMT) bond strength, particularly NMT compositions including a glass fiber component including recycled round glass fibers. BACKGROUND

[0002] Consumers are demanding materials with increased recycled content and reduced carbon footprint, especially in consumer electronics applications. However, many recycled materials tend to adversely affect mechanical properties, color, or other properties such as Nano-Molding Technology (NMT) bond strength (plastic-metal adhesion). Surface appearance of the part after the computer numerical control (CNC) milling step of the NMT process has also been a concern for consumers. This process exposes the glass fibers, making the appearance more lightweight. Surface appearance issues can be addressed by polishing or laser ablation. However, each of these steps is an additional process that increases the time and cost of the manufacturing process.

[0003] Aspects of the present disclosure address these and other drawbacks. SUMMARY

[0004] Aspects of the present disclosure relate to a thermoplastic composition including: about 20 wt% to about 65 wt% of a resin component including polybutylene terephthalate (PBT), poly(cyclohexylene dimethylene terephthalate) (PCT), polyethylene terephthalate (PET), or a combination thereof; about 10 wt% to about 30 wt% of a polyester carbonate copolymer including resorcinol units; about 5 wt% to about 50 wt% of a glass fiber component including recycled round glass fibers; and about 5 wt% to about 10 wt% of at least one additive component. The composition has a higher Nano-Molding Technology (NMT) bond strength compared to a comparative composition including flat glass fibers instead of the recycled round glass fibers. The composition has a dielectric constant (Dk) of at least 3.3, as evaluated at 2.5 gigahertz (GHz) or 5.0 GHz according to the SPDR (split post dielectric resonator) method, or at least 3.24, as evaluated at 60 GHz according to the coaxial method. BRIEF DESCRIPTION OF DRAWINGS

[0005] In the drawings, which are not necessarily drawn to scale, like numerals describe similar components throughout the several views. Like numerals having different letter suffixes can represent different instances of the like component. The drawings illustrate generally, by way of example, various aspects discussed in the present document.

[0006] Figure 1A-1D are optical microscope images of the interface between the milled region and the non-milled region of samples prepared from compositions C1,

[0007] Figure 2 A and 2B are optical microscope images of the interface between the milled region and the non-milled region of samples prepared from compositions C1 Figure 2 A) and Ex2 Figure 2 B). DETAILED DESCRIPTION

[0008] There is a strong demand from consumers for higher sustainable content materials, especially for consumer electronics applications, including Nano Molding Technology (NMT). There is also a need to improve the surface appearance of filled NMT grades after secondary operations such as CNC milling / machining. The present disclosure relates to compositions based on recycled resin and recycled filler building blocks for achieving maximum sustainable content and improving surface appearance due to the geometry and amount of filler, while maintaining NMT bonding strength and other physical properties.

[0009] The present disclosure demonstrates that surface aesthetics can be improved by changing the geometry of the glass fiber or by reducing the amount of glass fiber, and that sustainable content can be increased by using recycled glass fiber that does not result in significant loss of NMT bonding strength, colorability, or other properties.

[0010] The present disclosure describes, among other things, compositions for NMT applications that include 100% pre-consumer recycled glass fiber with a round cross-section as a replacement for flat cross-section (low warp) glass fiber that is free of recycled content. The recycled round glass fiber is significant for increasing the overall sustainable content of the composition. However, the recycled round glass fiber also unexpectedly improves the surface appearance of the milled part and slightly increases the NMT bonding strength compared to flat glass fiber. The use of recycled resin or filler can typically result in degradation of properties and color, but as demonstrated by the present disclosure, the properties are maintained compared to virgin materials with only slight differences due to the geometry of the glass fiber.

[0011] Compositions according to the present disclosure can reduce the need for additional processing steps such as polishing and laser ablation. Such sustainable fillers also have the advantage of reduced carbon footprint with comparable or better NMT bonding strength and mechanical performance.

[0012] 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.

[0013] The present disclosure encompasses various combinations of elements of the present disclosure, e.g., combinations of elements from dependent claims annexed to the same independent claim.

[0014] Furthermore, it should be understood that any method disclosed herein need not necessarily be performed in the order listed in the various embodiments. Accordingly, unless otherwise stated the order of any process described is not limitations.

[0015] 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.

[0016] Definitions 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. As used in the specification and in the claims, the term "comprising" can include the aspects "consisting of and "consisting essentially of." Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which should be defined herein.

[0017] As used in the specification and in the claims, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a resin component" includes mixtures of two or more resin components.

[0018] As used herein, the term "combination" is inclusive of blends, mixtures, alloys, reaction products, and the like.

[0019] Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes one or both of the first value and the second value in some aspects. Similarly, when values are expressed as approximations by using 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 will be further understood that the disclosure of a range includes every value and subrange within the range. For example, if a range of "10 to 15" is disclosed, then "11" and "12" are also disclosed. It will be further understood that the disclosure of a range includes every unit between the two particular units. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0020] As used herein, the terms "about" and "at or about" mean an amount that is similar to or nearly the same as a stated value or range. It is generally understood, as used herein, that a numerical value encompasses ±10% unless otherwise indicated or inferred. The term is intended to convey usage of a similar value promotes equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors that are well-known to those skilled in the art. It will be understood that amounts, sizes, formulations, parameters, or other quantities and characteristics are "about" or "approximate" whether or not expressly stated to be such. It is understood that the recitations "about" preceding a quantitative value, unless specifically stated otherwise, the parameter also includes the specific quantitative value itself.

[0021] Disclosed are components used to make the compositions of the present disclosure, as well as the compositions themselves used in the methods disclosed herein. Disclosed herein are these materials and other materials and that when combinations, subsets, interactions, groups, etc. of these materials are disclosed herein, though not explicitly disclosed in the specification, are specifically contemplated and described herein. Thus, if a particular compound is disclosed and discussed, and a number of modifications that can be made to a number of molecules including the compound are discussed, it is explicitly contemplated that each and every combination and permutation of the compound is specifically contemplated unless specifically indicated to the contrary. For example, if a markovitzky, 1994, principles of polymer chemistry, 2nd ed., academic press, san diego, ca, incorporated by reference herein in its entirety, class of molecules A, B, and C is disclosed, and a class of molecules D, E, and F is disclosed, and an example of combining molecules A-D is disclosed, then, it is explicitly contemplated that each and every combination and permutation of the components eluded to (e.g., A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F) is specifically contemplated unless specifically indicated to the contrary. Likewise, any subset or combination of these is also specifically contemplated. Thus, for example, the sub-group of A-E, B-F, and C-E is explicitly contemplated as is a combination of A-E, B-F, and C-E. 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.

[0022] 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 part by weight measurement 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 weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.

[0023] A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

[0024] As used herein, "polycarbonate" means an oligomer or polymer that includes residues of one or more dihydroxy compounds (e.g., dihydroxy aromatic compounds) linked by carbonate linkages; it also encompasses homopolycarbonates, copolycarbonates, and (co)polyestercarbonates.

[0025] The terms "residue" and "structural unit" used in reference to the constituents of a polymer are synonymous throughout the specification.

[0026] As used herein, unless otherwise specified, the terms "weight percent," "wt%," and "wt.%" are used interchangeably to indicate the weight percentage of a given constituent, based on the total weight of the composition. That is, unless otherwise specified, all wt% values are based on the total weight of the composition. It is understood that the sum of the wt% values of all constituents in a disclosed composition or formulation equals 100.

[0027] Unless otherwise indicated herein, all test standards are the most recent standard in effect at the time of submission of this application.

[0028] Each of the raw materials used in the examples and / or comparative compositions described herein are commercially available and / or methods of making the same are known to those skilled in the art.

[0029] It is understood that the compositions disclosed herein have certain functions. Certain structural requirements for performing the disclosed functions are also disclosed herein, and it is understood that various structures can perform the same function and that these structures will generally achieve the same result.

[0030] Thermoplastic composition Aspects of the present disclosure are directed to a thermoplastic composition comprising: about 20 wt% to about 65 wt% of a resin component comprising polybutylene terephthalate (PBT), poly(cyclohexylene dimethylene terephthalate) (PCT), polyethylene terephthalate (PET), or a combination thereof; about 10 wt% to about 30 wt% of a polyester carbonate copolymer comprising resorcinol units; about 5 wt% to about 50 wt% of a glass fiber component comprising recycled round glass fiber; and about 5 wt% to about 10 wt% of at least one additive component. The composition has a higher nano-molding technology (NMT) bond strength compared to a comparative composition comprising flat glass fiber instead of the recycled round glass fiber, where the NMT bond strength is evaluated according to a modified ISO 19095 procedure. The composition has a dielectric constant (Dk) of: at least 3.3, as evaluated at 2.5 gigahertz (GHz) or 5.0 GHz according to the SPDR (split post dielectric resonator) method, or at least 3.24, as evaluated at 60 GHz according to the coaxial method.

[0031] As used herein, "polybutylene terephthalate" can be used interchangeably with poly(l,4-butylene terephthalate).

[0032] As used herein, "polyethylene terephthalate" can be used interchangeably with poly(l,4-ethylene terephthalate). Like polybutylene terephthalate, polyethylene terephthalate is a type of polyester.

[0033] As used herein, poly(cyclohexyl dimethylene terephthalate) (PCT) is a crystalline polyester formed from cyclohexanedimethanol (CHDM) and dimethyl terephthalate (DMT) or terephthalic acid (TPA). PETG and PCTG are copolyesters formed by the addition of ethylene glycol (EG) in the polymerization reaction. PETG is formed if less than 50% of the diol content in the copolyester is CHDM; PCTG is formed if greater than 50% of the diol content in the copolyester is CHDM. PCTA is formed by the addition of another diacid such as isophthalic acid (IPA). In a particular aspect, the polyester component includes PBT, PET, or a combination thereof.

[0034] The resin component including polybutylene terephthalate (PBT), poly(cyclohexyl dimethylene terephthalate) (PCT), polyethylene terephthalate (PET), or a combination thereof can include virgin resin or recycled resin.

[0035] In some aspects, the resin component includes a chemically recycled polymer. An exemplary chemically recycled polymer is chemically recycled PBT. Chemically recycled PBT is a copolymer containing 1-20% of comonomers such as ethylene glycol, isophthalic acid (IPA), and diethylene glycol (DEG). In a particular aspect, the chemically recycled PBT, branded as iQ PBT, is derived from chemically upgraded recycled (or post-consumer recycled) PET. Compositions formed from iQ PBT have environmental advantages and can provide desirable elastic modulus, stress at break, and elongation at break.

[0036] Commercial examples of upgraded recycled PBT include ELCRIN TMPBT of iQ resin. The PBT can be derived from a poly(ethylene terephthalate) component by any method that involves depolymerizing the poly(ethylene terephthalate) component and polymerizing the depolymerized poly(ethylene terephthalate) component with 1,4-butanediol to provide the PET-derived PBT. For example, the PET-derived poly(butylene terephthalate) component can be made by a process that involves depolymerizing a poly(ethylene terephthalate) and / or a poly(ethylene terephthalate) copolymer with a 1,4-butanediol component at an elevated temperature under agitation in the presence of a catalyst component at a pressure of at least atmospheric pressure in an inert atmosphere at a temperature of 180 °C to 230 °C to produce a molten mixture containing oligomers containing ethylene terephthalate moieties, oligomers containing ethylene isophthalate moieties, oligomers containing diethylene terephthalate moieties, oligomers containing diethylene isophthalate moieties, oligomers containing butylene terephthalate moieties, oligomers containing butylene isophthalate moieties, covalently bonded oligomer moieties containing at least two of the aforementioned moieties, 1,4-butanediol, ethylene glycol, or combinations thereof; and agitating the molten mixture under sub-atmospheric pressure and increasing the temperature of the molten mixture to an elevated temperature under conditions sufficient to form the PET-derived PBT containing at least one residue derived from the poly(ethylene terephthalate) component.

[0037] In certain aspects, the resin component includes at least two chemically recycled PBT components, such as, but not limited to, a chemically recycled PBT having a low inherent viscosity (IV) of 0.63-0.68 (e.g., iQ 195B), and a second chemically recycled PBT having a high inherent viscosity (IV) of 1.15-1.22 (iQ 315B).

[0038] The thermoplastic composition includes about 20 wt% to about 65 wt% of the resin component. In some aspects, the composition includes at least 20 wt%, or at least 25 wt%, or at least 30 wt%, or at least 40 wt%, or at least 45 wt%, or no more than 65 wt%, or no more than 60 wt%, or no more than 55 wt% of the resin component.

[0039] The copolyester carbonate copolymer can include ester units of the formula: where D is a divalent radical derived from a dihydroxy compound and can be, for example, C 2-30 alkylene, C 3-30 cycloaliphatic radical, C 6-30aromatic group or polyoxyalkylene, wherein the alkylene contains 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and T divalent groups derived from a dicarboxylic acid, and can be, for example, C 2-30 alkylene, C 6-30 cycloaliphatic group, C 6-30 alkyl aromatic group or C 6-30 aromatic group.

[0040] Examples of aromatic dicarboxylic acids from which the T groups in the esters are derived include isophthalic acid or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-biphenyl dicarboxylic 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-naphthalene dicarboxylic acid. A specific dicarboxylic acid is terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyclohexane 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 99: 1 to 1:99. In one aspect, D is C 2-6 alkylene, and T is p-phenylene, m-phenylene, naphthalene, a divalent cycloaliphatic group, or combinations thereof. Such polyesters include poly(alkylene terephthalate).

[0041] In one aspect, the ester units of the polyester or polyester block comprise aryl ester units derived from the reaction product of one equivalent of an isophthalic acid derivative and / or a terephthalic acid derivative and resorcinol of the formula wherein each R f is independently C 1-12 alkyl or halogen, and u is 0 to 4. It is understood that when u is 0, R f is hydrogen. Typically, the halogen can be chlorine or bromine. In one aspect, wherein the —OH groups are meta to each other, and wherein R fCompounds like u described above are also commonly referred to herein as resorcinol. Examples of compounds that can be represented by this formula include resorcinol (where u is 0), substituted resorcinol compounds such as 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-tert-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, 2,4,5,6-tetrabromoresorcinol, etc.; catechol; hydroquinone; substituted p-phenylene... Diphenols such as 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-tert-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetratert-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone, etc.; or combinations including at least one of the above compounds.

[0042] Such aryl ester units are also referred to herein as isophthalate-terephthalate-resorcinol ester units, and sometimes simply as ITR ester units. As used herein, the isophthalate-terephthalate-resorcinol ester unit comprises a combination of isophthalate, terephthalate, and resorcinol ester. In one particular aspect, the isophthalate-terephthalate-resorcinol ester unit comprises a combination of isophthalate-resorcinol ester units and terephthalate-resorcinol ester units, wherein the molar ratio of the isophthalate-resorcinol ester unit to the terephthalate-resorcinol ester unit is 99:1 to 1:99, or 95:5 to 5:95, or 90:10 to 10:90, or 80:20 to 20:80. In one specific aspect, when u is 0, the aryl ester unit comprises an isophthalate-terephthalate-resorcinol ester unit, wherein the resorcinol is 1,3-dihydroxybenzene. Exemplary aromatic polyester blocks comprise poly(isophthalate-terephthalate-resorcinol) ester, poly(isophthalate-terephthalate-bisphenol-A) ester, poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol-A)] ester, or combinations comprising at least one of these. In one aspect, a useful aryl ester polyester block is poly(isophthalic acid-terephthalic acid-resorcinol) ester. In one specific aspect, the copolyester carbonate copolymer comprises an ITR block and a polycarbonate block, as shown in the following formula: Where x is the mol% of the ITR ester block and y is the mol% of the polycarbonate block. An exemplary copolyester carbonate copolymer is SLX 90 / 10 resin, available from SABIC. SLX 90 / 10 comprises 90 mol% of ITR block and 10 mol% of PC block.

[0043] In yet further aspects, the copolyestercarbonate copolymer has a ratio of ITR ester units to polycarbonate monomer units of 20:80 to 95:5, or 85:15 to 95:5, or 88:12 to 92:8, or about 90:10.

[0044] The composition includes about 10 wt% to about 30 wt% of a polyester carbonate copolymer that includes resorcinol units. In some aspects, the composition includes at least 10 wt%, or at least 11 wt%, or at least 12 wt%, or at least 13 wt%, or at least 14 wt%, or no more than 30 wt%, or no more than 25 wt%, or no more than 24 wt%, or no more than 23 wt%, or no more than 22 wt%, or no more than 21 wt%, or no more than 20 wt%, or no more than 19 wt%, or no more than 18 wt%, or no more than 17 wt% of a polyester carbonate copolymer that includes resorcinol units.

[0045] The composition includes about 5 wt% to about 50 wt% of a glass fiber component that includes recycled round glass fibers. In certain aspects, the composition includes at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or at least 16 wt%, or at least 17 wt%, or at least 18 wt%, or at least 19 wt%, or at least 20 wt%, or no more than 50 wt%, or no more than 45 wt%, or no more than 40 wt%, or no more than 35 wt%, or no more than 34 wt%, or no more than 33 wt%, or no more than 32 wt%, or no more than 31 wt%, or no more than 30 wt% of a glass fiber component. The recycled round glass fibers can be pre-consumer (also known as post-industrial) recycled glass fibers in some aspects. Such glass fibers are formed through a chemical recycling type process, and thus the properties do not degrade as much as through a mechanical recycling process.

[0046] According to conventional understanding, “round glass fibers” can be described as glass fibers having a cross-section that is generally circular or substantially circular. In some aspects, the round glass fibers have an aspect ratio of less than 1.5: 1, where the aspect ratio is described as the ratio of the major axis length to the minor axis length of an elongated non-circular cross-section. In contrast, flat glass fibers have an aspect ratio of greater than 1.5: 1, such as 2: 1, or 3: 1, or 4: 1, or 5: 1, or 6: 1, or 7: 1, or 8: 1, or 9: 1, or 10: 1. In the comparative compositions described herein, the flat glass fibers have an aspect ratio of about 4: 1.

[0047] In some aspects, the recycled round glass fiber has a length of less than 8 millimeters (mm) and a diameter of less than 15 micrometers (pm). In particular aspects, the recycled round glass fiber has a length of less than 7 mm, or less than 6 mm, or less than 5 mm, or about 4 mm. In further aspects, the recycled round glass fiber has a length of less than 14 pm, or less than 13 pm, or less than 12 pm, or less than 11 pm, or about 10 pm.

[0048] In some aspects, the round glass fiber is a conventional glass fiber. In further aspects, the round glass fiber does not have low dielectric constant (Dk) properties. It has been found that compositions having conventional glass fibers have improved melt volume rate (MVR) properties in certain aspects compared to compositions including low Dk glass fibers. Such compositions can be desirable in certain applications. Accordingly, in some aspects, the MVR of the composition is 20-200% higher, or at least 20% higher, or at least 25% higher, or at least 30% higher, or at least 35% higher, or at least 50% higher, or at least 60% higher, or at least 70% higher, or at least 80% higher, or at least 90% higher, or at least 100% higher, or at least 110% higher compared to a comparative composition including low Dk glass fibers but not the conventional recycled round glass fiber. The MVR can be evaluated according to ISO 1133 at 250°C and 5 kg.

[0049] It has also been found that compositions having conventional glass fibers have improved flexural modulus properties in certain aspects compared to compositions including low Dk glass fibers. Such compositions can be desirable in certain applications. Accordingly, in some aspects, the flexural modulus of the composition is 5-50% higher, or at least 5% higher, or at least 5.5% higher, or at least 6% higher, or at least 7% higher, or at least 7% higher, or at least 7% higher, or at least 7% higher, or at least 11% higher compared to a comparative composition including low Dk glass fibers but not the conventional recycled round glass fiber. The flexural modulus can be evaluated according to ASTM D790.

[0050] Accordingly, the dielectric constant (Dk) of a composition not including low Dk glass fibers according to aspects of the present disclosure can be at least 3.3, as evaluated according to the SPDR (split post dielectric resonator) method at 2.5 gigahertz (GHz) or 5.0 GHz. In certain aspects, the Dk of the composition is no greater than 6, or no greater than 5, or no greater than 4, as evaluated according to the SPDR (split post dielectric resonator) method at 2.5 gigahertz (GHz) or 5.0 GHz.

[0051] In further aspects, the composition has a dielectric constant of at least 3.24, as evaluated at 60 GHz according to the Coaxial Method. In particular aspects, the composition has a Dk of no greater than 6, or no greater than 5, or no greater than 4, as evaluated at 60 GHz according to the Coaxial Method.

[0052] The additive component can include, but is not limited to, impact modifiers, mold release agents, quenchers, UV stabilizers, impact modifiers, heat stabilizers, antioxidants, colorants, transesterification inhibitors, acid scavengers, anti-drip agents, antistatic agents, chain extenders, flow promoters, lubricants, plasticizers, flame retardants, UV reflective additives, blowing agents, reinforcing agents, or combinations thereof. In particular aspects, the additive component includes impact modifiers, mold release agents, quenchers, UV stabilizers, impact modifiers, heat stabilizers, antioxidants, colorants, or combinations thereof.

[0053] In certain aspects, the composition does not include carbon-based fillers, including but not limited to carbon black, and especially electrically conductive carbon black. In further aspects, the composition includes less than 5 wt%, or less than 4 wt%, or less than 3 wt%, or less than 2 wt%, or less than 1 wt% of carbon black. Compositions that include carbon-based fillers, and especially electrically conductive carbon black, are expected to have higher electrical conductivity than compositions according to the aspects of the disclosure described herein; such compositions can not be suitable for certain electronic device applications where high electrical conductivity can interfere with signal transmission properties.

[0054] Metal bond strength is used to evaluate NMT performance. In the NMT process, plastic resin is injected onto a metal surface that has been treated with a special chemical solution. This NMT process is developed from the integration technology of metal and plastic. The process can manufacture certain parts of consumer goods and replace the traditional insert molding or die casting process.

[0055] In certain aspects, the composition has a higher nano-molding technology (NMT) bond strength compared to a comparative composition that includes flat glass fibers instead of the recycled round glass fibers, where the NMT bond strength is evaluated according to a modified ISO 19095 procedure. The modified ISO 19095 procedure is described in PCT Publication WO 2015 / 200272, the disclosure of which is incorporated herein by reference in its entirety. ISO 19095 is a standard for “Evaluation of Bonded Interface Performance of Plastic-Metal Assemblies” and is considered to be a widely accepted industry standard for bar testing. Two types of bar parts are used, including a lap joint and a butt joint. The modified ISO 19095 procedure includes the following steps: i) pre-treating the metal part to form nano- and micro-sized pores on the metal surface by a chemical etching process; ii) the plastic is injection molded onto the pre-treated aluminum insert within an effective processing time; iii) the bond force is measured by recording the force on a standard tensile testing machine as the molded part is pulled to the point of breakage; and iv) the bond strength is thus calculated by dividing the bond force by the bond area (e.g., in MPa).

[0056] The metal can be pre-treated by a metal surface treatment, which can include one of two main processes: T (Taisei Plas) treatment and TRI (Technology Rising from IWATE) treatment. These methods were developed by different companies in Japan. The TRI treatment involves both physical anchoring of the plastic in the metal nanopores and a chemical reaction between the chemical film on the metal surface and the plastic. In contrast, the T treatment relies mainly on physical anchoring.

[0057] In some aspects, the surface appearance of the composition is improved compared to a comparative composition comprising flat glass fibers instead of the recycled round glass fibers. The improved surface appearance can be evaluated as described herein.

[0058] The composition can include, in some aspects, a recycle content of at least 20 wt%, or in further aspects, at least 25 wt%, or at least 30 wt%, or at least 35 wt%, or at least 40 wt%, or at least 45 wt%, or at least 50 wt%, or at least 55 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt%, or at least 75 wt%.

[0059] Manufacturing method One or any of the foregoing components described herein can be first dry blended with each other, or with any combination of the foregoing components, and then fed into the extruder from one or more feeders, or fed individually from one or more feeders into the extruder. The fillers used in the present disclosure can also be first processed into a masterbatch and then fed into the extruder. The components can be fed into the extruder from a throat hopper or any side feeder.

[0060] The extruder used in the present disclosure can have a single screw, multiple screws, intermeshing co-rotating or counter-rotating screws, non-intermeshing co-rotating or counter-rotating screws, reciprocating screws, screws with pins, screws with screens, barrels with pins, rollers, plungers, screw rotors, co-kneaders, disc-pack processors, various other types of extrusion equipment, or combinations including at least one of the foregoing components.

[0061] The components can also be mixed together and then melt blended to form the thermoplastic composition. Melt blending of the components involves the use of shear forces, tensile forces, compressive forces, ultrasonic energy, electromagnetic energy, thermal energy, or a combination comprising at least one of the foregoing force or energy forms.

[0062] If the resin is a semi-crystalline organic polymer, the barrel temperature on the extruder during compounding can be set at a temperature at which at least a portion of the polymer has reached a temperature greater than or equal to about the melting temperature, or if the resin is an amorphous resin, the barrel temperature can be set at the flow point (e.g., glass transition temperature).

[0063] If desired, the mixture including the above ingredients can go through multiple mixing and shaping steps. For example, the thermoplastic composition can first be extruded and shaped into pellets. The pellets can then be fed into a molding machine where they can be shaped into any desired shape or product. Alternatively, the thermoplastic composition produced from a single melt blender can be shaped into a sheet or strand and subjected to an extrusion post process, such as annealing, uniaxial or biaxial orientation.

[0064] In some aspects, the temperature of the melt in the process can be kept as low as possible to avoid excessive thermal degradation of the components. In certain aspects, the melt temperature is kept between about 230 °C and about 350 °C, although higher temperatures can be used provided that the residence time of the resin in the processing equipment is kept relatively short. In some aspects, the melt-processed composition exits the processing equipment extruder through a small exit orifice in the die. The resulting strand of molten resin can be cooled by passing the strand through a water bath. The cooled strand can be cut into pellets for packaging and further handling.

[0065] Articles In certain aspects, the present disclosure relates to shaped, formed, or molded articles comprising the thermoplastic composition. The thermoplastic composition can be molded into useful shaped articles by a variety of means, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming to form articles and structural components of, for example, personal or commercial electronic devices, including but not limited to to cell phones, tablets, personal computers, laptops, and portable computers, and other such devices, medical applications, RFID applications, automotive applications, and the like. In further aspects, the article is extrusion molded. In still further aspects, the article is injection molded.

[0066] In particular aspects, the article is a component of a consumer electronics application. In specific aspects, the article is an internal or external component of a cell phone, tablet, computer, or watch.

[0067] The present disclosure encompasses various combinations of elements of the present disclosure, e.g., combinations of elements from dependent claims annexed to the same independent claim.

[0068] Aspects of the disclosure In various aspects, the present disclosure relates to and includes at least the following aspects.

[0069] Aspect 1. A thermoplastic composition comprising: about 20 wt% to about 65 wt% of a resin component comprising polybutylene terephthalate (PBT), poly(cyclohexylene dimethylene terephthalate) (PCT), polyethylene terephthalate (PET), or a combination thereof; about 10 wt% to about 30 wt% of a polyester carbonate copolymer comprising resorcinol units; about 5 wt% to about 50 wt% of a glass fiber component comprising recycled round glass fibers; and about 5 wt% to about 10 wt% of at least one additive component, wherein the composition has a higher nano-molding technology (NMT) bond strength compared to a comparative composition comprising flat glass fibers instead of the recycled round glass fibers, wherein NMT bond strength is evaluated according to a modified ISO 19095 procedure, and wherein the composition has a dielectric constant (Dk) of: a. at least 3.3, as evaluated at 2.5 gigahertz (GHz) or 5.0 GHz according to the SPDR (split post dielectric resonator) method, or b. at least 3.24, as evaluated at 60 GHz according to the coaxial method.

[0070] Aspect 2. The thermoplastic composition of aspect 1, wherein the composition has an improved surface appearance compared to a comparative composition comprising flat glass fibers instead of the recycled round glass fibers.

[0071] Aspect 3. The thermoplastic composition of aspect 1 or 2, wherein the resin component comprises a chemically recycled polymer.

[0072] Aspect 4. The thermoplastic composition of aspect 3, wherein the chemically recycled polymer comprises at least two chemically recycled PBT polymers.

[0073] Aspect 5. The thermoplastic composition of any one of aspects 1 to 4, wherein the polyester carbonate copolymer comprising resorcinol units comprises isophthalic acid-terephthalic acid-resorcinol (ITR) ester units.

[0074] Aspect 6. The thermoplastic composition of any one of aspects 1 to 5, wherein the composition comprises about 20 wt% to about 30 wt% of the glass fiber component.

[0075] Aspect 7. The thermoplastic composition of any one of aspects 1 to 6, wherein the recycled round glass fiber has a length of less than 8 millimeters (mm) and a diameter of less than 15 micrometers (pm).

[0076] Aspect 8. The thermoplastic composition of any one of aspects 1 to 7, wherein the composition is suitable for NMT bonding applications.

[0077] Aspect 9. The thermoplastic composition of any one of aspects 1 to 8, wherein the additive component comprises an impact modifier, a mold release agent, a quenching agent, a UV stabilizer, an impact modifier, a heat stabilizer, an antioxidant, a colorant, a transesterification inhibitor, an acid scavenger, an anti-dripping agent, an anti-static agent, a chain extender, a flow promoter, a lubricant, a plasticizer, a flame retardant, a UV reflective additive, a blowing agent, a reinforcing agent, or a combination thereof.

[0078] Aspect 10. The thermoplastic composition of any one of aspects 1 to 9, wherein the additive component comprises an impact modifier, a mold release agent, a quenching agent, a UV stabilizer, an impact modifier, a heat stabilizer, an antioxidant, a colorant, or a combination thereof.

[0079] Aspect 11. The thermoplastic composition of any one of aspects 1 to 10, wherein the composition comprises at least 40 wt% of a recycled content.

[0080] Aspect 12. The thermoplastic composition of any one of aspects 1 to 11, wherein the composition comprises: about 40 wt% to about 55 wt% of the resin component; about 10 wt% to about 20 wt% of the polyester carbonate copolymer; about 20 wt% to about 35 wt% of the glass fiber component; and about 5 wt% to about 10 wt% of the at least one additive component.

[0081] Aspect 13. An article comprising the thermoplastic composition of any one of aspects 1 to 12.

[0082] Aspect 14. The article of aspect 13, wherein the article is a component of a consumer electronics application.

[0083] Aspect 15. The article of aspect 13, wherein the article is an internal or external component of a cell phone, a tablet, a computer, or a watch.

[0084] Example The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and evaluate the compounds, compositions, articles, devices, and / or methods claimed 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 used (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in °C or at ambient temperature, and pressure is at or near atmospheric. Unless indicated otherwise, references to percentages of a composition are in terms of wt%.

[0085] There are many variations of reaction conditions and combinations, e.g., component concentrations, desired solvents, solvent mixtures, temperatures, pressures, and other reaction ranges and conditions that can be used to optimize the purity and yield of the products from the processes described. To optimize such process conditions, only reasonable and routine experimentation is required.

[0086] PBT-based glass-filled compositions were prepared and tested according to Tables 1A and 1B: Table 1A - Comparative and Example Compositions Table 1B - Properties of Table 1A Compositions Comparative Composition CI included 30 wt% flat glass fiber. The impact strength, as well as the tensile and flexural modulus, of the comparative composition were slightly higher compared to 30 wt% round recycled glass fiber (Exl). However, the NMT bond strength of composition Exl was unexpectedly improved compared to comparative composition CI treated by TRI metalization. This can be attributed in part to the difference in glass fiber sizing chemistry. As shown below, the post-milling surface appearance was also unexpectedly improved.

[0087] To further improve the surface appearance of flat or round recycled glass fiber (C2 and Ex2, respectively), the glass fiber loading was reduced to 20 wt%. As expected, the mechanical properties (including tensile, flexural, and notched Izod impact) were significantly reduced, and the flowability was increased, at lower glass loading. However, the NMT bond strength was higher compared to the 30 wt% glass-filled samples, and the recycled round glass fiber (Ex2) again showed higher bond strength compared to the flat glass fiber (C2) in the case of both types of surface treatment. While it was expected that the 30 wt% glass-filled samples would have higher bond strength due to higher modulus and lower shrinkage than the 20 wt% glass-filled samples, the 20 wt% glass-filled samples, with reduced glass fiber amount and higher flowability, can have helped to more effectively fill the nanometer-sized pores in the metal, and improve the NMT adhesion.

[0088] To simulate the milling process that these materials would be subjected to in NMT applications, swatches were molded and a portion of the swatches were milled to observe the effect on the part surface appearance. It is expected that the simulated milling process will closely correspond to the actual milling process. Optical microscope images of the milled areas of C1 (30% flat glass fiber) and Ex1 (30% round recycled glass fiber) are shown in Figures 1A and 1B. Optical microscope images of the milled areas of C2 (20% flat glass fiber) and Ex2 (20% round recycled glass fiber) are shown in Figures 1C and 1D. The milled areas of Ex1 (30% round recycled glass fiber) and Ex2 (20% round recycled glass fiber) appear to have a more uniform surface appearance than C1 (30% flat glass fiber) and C2 (20% flat glass fiber), respectively. This is likely due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 1 A and 1B. Optical microscope images of the milled areas of C2 (20% flat glass fiber) and Ex2 (20% round recycled glass fiber) are shown in Figure 1 C and 1D. The milled areas of Ex1 (30% round recycled glass fiber) and Ex2 (20% round recycled glass fiber) appear to have a more uniform surface appearance than C1 (30% flat glass fiber) and C2 (20% flat glass fiber), respectively. This is likely due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 1 B) and Ex2 (D) appear to have a more uniform surface appearance than C1 (A) and C2 (C), respectively. This is likely due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 1 B) and Ex2 (D) appear to have a more uniform surface appearance than C1 (A) and C2 (C), respectively. This is likely due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 1 A) and C2 (C) appear to have a larger exposed area of the flat glass fibers. The round glass fibers have more area that appears to be hidden beneath the resin surface, which would result in less light reflection off the surface and improve the surface appearance. This can be due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 1 A) and C2 (C) appear to have a larger exposed area of the flat glass fibers. The round glass fibers have more area that appears to be hidden beneath the resin surface, which would result in less light reflection off the surface and improve the surface appearance. This can be due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin.

[0089] The microscope was used to quantify the exposed surface area and the results are shown in Table 2. There was a significant difference in the exposed area in the 20% GF samples. There was no significant difference in the exposed area of the 30% GF samples, but the difference was apparent to the naked eye when viewing the parts. Additionally, the surface appearance of compositions C2 and Ex2 containing 20% glass fiber was significantly improved compared to the 30 wt% samples because the amount of glass fiber that reached the surface of the part, which would negatively affect the appearance, was reduced.

[0090] Table 2 - Quantification of glass fiber exposed area by microscope Figure 2 Figures 2A and 2B show optical microscope images of the interface between the milled area and the unmilled area of the part. The border of the composition Ex2 (B) with round glass fiber is more distinct and complete compared to the comparison composition C1 (A) with flat glass fiber; this can also affect the surface appearance. Figure 2 A) and C2 (C) appear to have a larger exposed area of the flat glass fibers. The round glass fibers have more area that appears to be hidden beneath the resin surface, which would result in less light reflection off the surface and improve the surface appearance. This can be due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin. Figure 2 A) and C2 (C) appear to have a larger exposed area of the flat glass fibers. The round glass fibers have more area that appears to be hidden beneath the resin surface, which would result in less light reflection off the surface and improve the surface appearance. This can be due to the difference in surface area of the glass fibers and the difference in sizing chemistry of the glass fibers, which can affect the compatibility with the resin.

[0091] The specific process for evaluating visual appearance is described as follows: (i) The color chips were milled on an ACRA LCM-50 mill specifically designed for milling plastic parts. The cutter was 2.5 inches. The feed rate of the plastic chip was 10 inches / minute with a cutter speed of 1350 RPM. The plastic color chip was inserted into the holder. The cutter was lowered to cut the lower half of the color chip. Typically, 50 microns to 125 microns of a smooth resin-rich surface was removed by this milling procedure. Removal of the resin-rich surface revealed a rough surface of exposed glass fibers. This simulated milling process approximates a commercial milling process, and the results of this simulated process correlate and / or are comparable to the results that would be obtained by the composition milled in a commercial mill.

[0092] (ii) Optical microscope micrographs of the exposed surface were captured by a Keyence VHX-5000. The instrument is equipped with a super-bright LED light source, motorized XYZ stage, 20x-200x VH zoom lens, VHX-5100 camera unit with 1 / 1.8 type 195 million pixel CMOS image sensor. The images were collected and formed by reflected light. Magnification: 200X.

[0093] (iii) Visual observation of the micrographs showed that the amount of flat glass fibers was higher, which in turn reflected more light and looked less aesthetic. The higher the amount of exposed glass fibers, the worse the visual rating. The round glass fiber samples had less exposed glass fibers, reflected less, and therefore were more aesthetic.

[0094] Milling of the resin without fill was very difficult and therefore could not be used as a control, but the number of fibers visible in the optical microscope image at 200x magnification could be quantified. The exposed fibers counted were the fibers that appeared black in the image. A rating system as described in Table 3 could be used: Table 3 - Rating system for evaluating surface appearance According to this rating system, the ratings for flat glass samples C1 and C2 were “1” and the ratings for round glass samples Ex1 and Ex2 were “4”. Thus, in some aspects, the surface appearance of the composition is improved as compared to a comparative composition comprising flat glass fibers rather than recycled round glass fibers, where the improved surface appearance is characterized by at least a 2 or 3 grade improvement in visual surface rating as evaluated on a scale of 1 to 4, as described herein. In further aspects, the visual surface rating of the composition is at least 3 or at least 4, as evaluated according to the description herein.

[0095] Overall, the recycled round glass fiber has a significantly improved sustainable content (100% pre-consumer recycled), but unlike many other recycled materials, the recycled round glass fiber has mechanical properties comparable to virgin glass fiber. The recycled glass fiber with a round geometry unexpectedly has an improved surface appearance after milling compared to the standard flat geometry glass fiber used in many commercial NMT grades. The NMT bond strength is also unexpectedly slightly improved by using recycled glass fiber with a round geometry and / or by reducing the amount of glass fiber to 20%.

[0096] As shown in Table 4A, additional comparative compositions (C3 and C4) were prepared that included low dielectric constant (Dk) glass fiber, rather than recycled round glass fiber. Additional example compositions Ex3 and Ex4 were included for comparison: Table 4A - Comparative compositions including low Dk glass fiber Certain properties of these compositions were evaluated and provided in Table 4B: Table 4B - Properties of Table 4A compositions NMT bond strength and surface appearance were not evaluated for the Table 4A compositions - due to the similar geometry of the glass fiber, the comparative and example compositions were expected to have similar performance in these properties. From the results, it was observed that while most properties were comparable, the melt volume rate (MVR) of the example compositions Ex3 and Ex4, which included conventional glass fiber, was significantly higher than the MVR of the comparative compositions C3 and C4, which included low Dk glass fiber (Ex3 was 111% higher than C3 and Ex4 was 36% higher than C4). The flexural modulus properties of Ex3 and Ex4 were also slightly improved compared to the comparative compositions (Ex3 was 11% higher than C3 and Ex4 was 5.6% higher than C4). Thus, in some aspects, compositions including conventional glass fiber rather than low Dk glass fiber are desirable.

[0097] As shown in Table 5, the dielectric constant (Dk) was evaluated for several of the compositions described herein: Table 5 - Dielectric Constant Properties (SPDR Method) Dk was evaluated according to the SPDR (split post dielectric resonator) method at the specified frequency, which includes using a QWED split post dielectric resonator and an Agilent network analyzer to measure these values. For 2.5 gigahertz (GHz) measurements, the minimum sample size was 70 mm x 70 mm; the maximum sample thickness was 4 mm. For 5.0 GHz measurements, the minimum sample size was 30 mm x 30 mm; the maximum sample thickness was 2 mm.

[0098] The dielectric properties of these compositions were also evaluated using the coaxial method. The results are shown in Table 6: Table 6 - Dielectric Constant Properties (Coaxial Method) The "coaxial method" for determining Dk includes using a coaxial probe and network analyzer to measure these values. The sample size was at least 50 mm; the sample thickness was 0.1-20 mm (preferably 2-3 mm); the testing was performed in a temperature and humidity controlled dust-free room using 100 mm x 100 mm x 3.0 mm plaques.

[0099] From the Dk results in Tables 5 and 6, it can be observed that the Dk values of the example compositions are higher compared to the comparative compositions including low Dk glass fibers. The Dk of the example compositions at 60 GHz is also higher compared to the comparative compositions including flat glass fibers when evaluated according to the coaxial method.

[0100] While the examples prepared and discussed herein are based on PBT, a higher heat polyester, PCT (polyhexamethylene terephthalate) or polyethylene terephthalate (PET) can be used. PCT is expected to reduce the NMT bond strength, but the impact on surface appearance is yet to be determined.

[0101] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) can be used in combination with each other. Other aspects can be apparent to those of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b) to allow a reader to quickly ascertain the nature of the technical disclosure. It is understood that the described embodiments are not intended to be limiting or to exclude other embodiments that can be apparent to a person of ordinary skill in the art upon reading the above description. Moreover, in the above DETAILED DESCRIPTION, various features can be grouped together or described in a single implementation for the purposes of streamlining the disclosure. This should not be interpreted as intending that an unclaimed aspect is essential to any claim. Rather, inventive subject matter can reside in less than all features of a single disclosed aspect. The following claims are hereby incorporated into the detailed description, where each claim can stand as a separate aspect or embodiment. The scope of the disclosure should be determined, therefore, with reference to the appended claims and corresponding statutory equivalents, rather than the contents of the above detailed description.

Claims

1. A thermoplastic composition comprising: about 20 wt% to about 65 wt% of a resin component comprising polybutylene terephthalate (PBT), polycyclohexylenedimethylene terephthalate (PCT), polyethylene terephthalate (PET), or a combination thereof; about 10 wt% to about 30 wt% of a polyester carbonate copolymer comprising resorcinol units; about 5 wt% to about 50 wt% of a glass fiber component comprising recycled round glass fibers; and about 5 wt% to about 10 wt% of at least one additive component, wherein the composition has a higher nano-molding technology (NMT) bond strength compared to a comparative composition comprising flat glass fibers instead of the recycled round glass fibers, wherein NMT bond strength is evaluated according to a modified ISO 19095 procedure, and wherein the composition has a dielectric constant (Dk) of: a. at least 3.3, as evaluated at 2.5 gigahertz (GHz) or 5.0 GHz according to the SPDR (split post dielectric resonator) method, or b. at least 3.24, as evaluated at 60 GHz according to the coaxial method.

2. The thermoplastic composition of claim 1, wherein the composition has improved surface appearance compared to a comparative composition comprising flat glass fibers instead of the recycled round glass fibers.

3. The thermoplastic composition of claim 1 or 2, wherein the resin component comprises chemically recycled polymers.

4. The thermoplastic composition of claim 3, wherein the chemically recycled polymers comprise at least two chemically recycled PBT polymers.

5. The thermoplastic composition of any one of claims 1 to 4, wherein the polyester carbonate copolymer comprising resorcinol units comprises isophthalic acid-terephthalic acid-resorcinol (ITR) ester units.

6. The thermoplastic composition of any one of claims 1 to 5, wherein the composition comprises about 20 wt% to about 30 wt% of the glass fiber component.

7. The thermoplastic composition of any one of claims 1 to 6, wherein the recycled round glass fibers have a length of less than 8 millimeters (mm) and a diameter of less than 15 micrometers (pm).

8. The thermoplastic composition of any one of claims 1 to 7, wherein the composition is suitable for NMT bonding applications.

9. The thermoplastic composition of any one of claims 1 to 8, wherein the additive component comprises an impact modifier, a mold release agent, a quenching agent, a UV stabilizer, an impact modifier, a heat stabilizer, an antioxidant, a colorant, a transesterification inhibitor, an acid scavenger, an anti-dripping agent, an anti-static agent, a chain extender, a flow promoter, a lubricant, a plasticizer, a flame retardant, a UV reflecting additive, a blowing agent, a reinforcing agent, or a combination thereof.

10. The thermoplastic composition of any one of claims 1 to 9, wherein the additive component comprises an impact modifier, a mold release agent, a quenching agent, a UV stabilizer, an impact modifier, a heat stabilizer, an antioxidant, a colorant, or a combination thereof.

11. The thermoplastic composition of any one of claims 1 to 10, wherein the composition comprises a recycle content of at least 40 wt%.

12. The thermoplastic composition of any one of claims 1 to 11, wherein the composition comprises: about 40 wt% to about 55 wt% of the resin component; about 10 wt% to about 20 wt% of the polyester carbonate copolymer; about 20 wt% to about 35 wt% of the glass fiber component; and about 5 wt% to about 10 wt% of the at least one additive component.

13. An article comprising the thermoplastic composition of any one of claims 1 to 12.

14. The article of claim 13, wherein the article is a component of a consumer electronics application.

15. The article of claim 13, wherein the article is an internal or external component of a cell phone, a tablet, a computer, or a watch.

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