Articles and structures having a colorable electrostatic dissipative (ESD) polycarbonate blend

Abstract

The present disclosure relates to a polymer composition comprising from about 0.1 wt.% to about 99 wt.% of a polycarbonate copolymer, homopolymer, or blends thereof; from about 0.1 wt.% to about 70 wt.% of a crystalline polyester; from about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and from about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor, wherein the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition. When measured according to ASTM D257, the polymer composition may exhibit a surface resistance of less than 1 x 10 9 ohms.

Description

Technical Field

[0001] The present disclosure relates to electrostatic dissipative polycarbonate blends, particularly colorable electrostatic dissipative polycarbonate blends. Background Art

[0002] Electrostatic discharge can be harmful to electronic components, leading to malfunctions, reduced reliability, increased costs, and potential component failures in the deployed devices. Polymer materials are generally good insulators but can become conductive or electrostatic dissipative upon addition of conductive fillers such as metal fillers, non-conductive fillers coated with a metal coating or conductive non-metallic fillers, and carbon-based fillers such as carbon nanotubes, carbon fibers, and carbon black. The addition of such materials creates a network of interconnected particles within the polymer matrix, allowing charge to conduct through the insulating polymer. Electrostatic dissipative (ESD) and antistatic materials are widely used in various fields such as semiconductors, consumer electronics, and industrial construction to prevent electrostatic buildup. These two types are defined by their surface resistance (SR), with the former being between 1×10 6 to 1×10 9 ohms, and the latter being 1×10 10 to 1×10 12 ohms. Typical ESD materials are generally non-colorable because they are limited by the natural black or dark color of the conductive carbon fillers. In contrast, those compounds doped with conventional inherently dissipative polymers (IDPs) (to achieve electrostatic performance) cannot achieve a surface resistivity as low as 1×10 9 ohms - despite their apparent lack of color. There remains a need in the art for materials that have a sufficiently low surface resistance (at least as low as 1×10 9 ohms) while also maintaining a colorable appearance. Summary of the Invention

[0003] Aspects of the present disclosure relate to a polymer composition comprising from about 1 wt.% to about 99 wt.% of a polycarbonate copolymer resin; from about 1 wt.% to about 70 wt.% of a crystalline polyester resin; from about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and from about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor, wherein the polymer composition exhibits a surface resistance of less than 1×10 9 ohms when measured according to ASTM D257, and wherein the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

[0004] In still other aspects, the present disclosure relates to a method of forming a composition comprising a polycarbonate copolymer, a crystalline polyester, an inherently dissipative polymer additive, and a transesterification inhibitor.

[0005] In some aspects, the present disclosure relates to methods of forming articles, the methods including the step of molding an article from a polymer composition as described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects and, together with the description, serve to explain the principles of the disclosure.

[0007] Figure 1 Table 5 showing the formulations and properties of C-1, C-2, and EX-2 is presented.

[0008] Figure 2 Table 6 showing the formulations and characteristics of C-3, EX-2, EX-3, EX-4, EX-5, EX-6, and EX-7 is presented.

[0009] Figure 3 Table 7 showing the formulations and properties of EX-8, EX-9, and EX-10 is presented.

[0010] Figure 4A An image of a molded plate containing sample EX-2 is shown.

[0011] Figure 4B An image of a molded plate containing sample C-3, which is a conventional conductive carbon black filled polycarbonate, is shown. DETAILED DESCRIPTION

[0012] Given the complexity and sensitivity of microelectronic devices, controlling electrostatic discharge is becoming increasingly challenging. Even at low voltages, such electrostatic discharge can severely damage sensitive devices. Electrostatic dissipative (ESD) and antistatic materials are widely used in various fields such as semiconductors, consumer electronics, and industrial construction to prevent the accumulation of static electricity. These two types are defined by their surface resistance (SR), the former being between 1×10 6 to 1×10 9 ohms, and the latter being 1×10 10 to 1×10 12 ohms. Thus, by using various different electrostatic dissipative (ESD) materials, the accumulation of static charges on plastics during manufacturing or use can be avoided.

[0013] However, incorporating static dissipative materials (antistatic agents) into various different substrates or polymer resin matrices has its own limitations. Polymers generally require high temperature processing, which can damage or destroy the antistatic agent, thus rendering its ESD properties ineffective. Additionally, many higher molecular weight ESD reagents are immiscible with certain substrates or matrix polymers used. The use of antistatic agents can also only provide temporary ESD properties to the compositions used. Performance and effectiveness are also limited by environmental conditions such as humidity. Conventional ESD materials also include conductive fillers such as carbon fibers, conductive carbon black, graphite, graphene, and carbon nanotubes, which generally also impart a dark color to the composition. Thus, typical ESD materials are not easily colorable because the color space can be limited by the natural black color of the conductive carbon fillers. Additionally, although compounds doped with conventional inherently dissipative polymers (IDP) do not darken due to additives, they generally cannot achieve a surface resistance value as low as 1×10 9 ohms. However, the formulations of the present disclosure achieve both ESD and a broad coloring potential while also maintaining desired electrical, impact, and processing properties.

[0014] The present disclosure provides a composition of a colorable static dissipative (ESD) compound, which comprises an inherently dissipative polymer (IDP)-doped polyetherimide (PEI) and a crystalline polymer such as polybutylene terephthalate (PBT) or poly(1,4-cyclohexylene dimethylene 1,4-cyclohexanedicarboxylate) (PCCD). The composition can provide a low surface resistance (SR) of at least as low as 1×10 9 ohms, making it sufficiently colorable and suitable for ESD applications. Impact, heat, and flow properties are also desirable for manufacturing.

[0015] In one aspect, the disclosed composition comprises from about 1 wt.% to about 99 wt.% of a polycarbonate copolymer resin; from about 1 wt.% to about 70 wt.% of a crystalline polyester resin; from about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and from about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor. When measured according to ASTM D257, the polymer composition can exhibit a surface resistance of less than 1x 10 9 ohms. Additionally, the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

[0016] 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 specific reagents - unless otherwise specified, as these 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.

[0017] The present disclosure encompasses various combinations of elements of the present disclosure, e.g., combinations of elements from dependent claims that depend on the same independent claim.

[0018] Furthermore, it should be understood that, unless otherwise explicitly stated, no method recited herein is intended to be construed as requiring that its steps be performed in a particular order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or where no other indication is given in the claims or specification that the steps are limited to a particular order, no order is intended to be inferred in any respect. This applies to any possible non-explicit basis for interpretation, including: logical issues regarding step arrangement or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0019] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and / or materials related to the citation of these publications.

[0020] Definitions

[0021] It should also 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 claims, the term "comprising" can include embodiments "consisting of" and "consisting essentially of". Unless otherwise defined, 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 pertains. In this specification and the appended claims, a number of terms will be referred to that are defined herein.

[0022] As used in the specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a polycarbonate" includes mixtures of two or more polycarbonate polymers.

[0023] As used herein, the term "combination" includes blends, mixtures, alloys, reaction products, and the like.

[0024] Ranges may be expressed herein as from a value (the first value) to another value (the second value). When such a range is expressed, the range includes in some aspects one or both of the first and second values. Similarly, when a value is expressed as an approximation by use of the antecedent "about", it will be understood that the specific value constitutes another aspect. It will also be understood that each endpoint of each range is significant both in relation to the other endpoint and independently of the other endpoint. It should also be understood that a plurality of values are disclosed herein, and that each value is also disclosed herein as "about" that specific value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It should also be understood that each unit between two specific units has also been disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0025] As used herein, the terms "about" and "at or about" mean that the quantity or value can be the specified value, approximately the specified value, or approximately equal to the specified value. When used herein, it should generally be understood that it is a ±10% variation of the indicated nominal value, unless otherwise specified or deduced. This term is intended to convey that similar values contribute to equivalent results or effects recited in the claims. That is, it should be understood that quantities, dimensions, 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, measurement errors, etc., and other factors known to those skilled in the art. Generally, a quantity, dimension, formulation, parameter, or other quantity or characteristic is "about" or "approximate", whether or not expressly so stated. It should be understood that in the case where "about" is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless otherwise specifically stated.

[0026] As used herein, the term "optional" or "optionally" means that the subsequent described event or circumstance may or may not occur, and the description includes the case where the event or circumstance occurs and the case where it does not occur. For example, the phrase "optional additive" means that the additive may or may not be included, and the description includes polymer compositions that include and do not include additional additives.

[0027] In one aspect, "substantially free of" may mean less than 0.5 wt.% or less than about 0.5 wt.% present in a given composition or component. In another aspect, substantially free of may be less than 0.1 wt.% or less than about 0.1 wt.%. In another aspect, substantially free of may be less than 0.01 wt.% or less than about 0.01 wt.%. In yet another aspect, substantially free of may be less than 100 parts per million (ppm), or less than about 100 ppm. In yet another aspect, substantially free of or free of may further mean an amount below the detectable level, if present. Substantially free of or free of may further refer to a component that has not been added or incorporated into the composition.

[0028] Components for preparing the compositions of the present disclosure and the compositions themselves for the methods disclosed herein are disclosed. These and other materials are disclosed herein, and it should be understood that when combinations, subsets, interactions, groupings, etc. of these materials are disclosed, and specific mention of each individual and collective combination and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a specific compound is disclosed and discussed, and various modifications that can be made to a variety of molecules including that compound are discussed, then each combination and permutation of that compound and possible modifications are specifically contemplated, unless there is an express contrary statement. Thus, if a class of molecules A, B, and C is disclosed and a class of molecules D, E, and F is disclosed and an example of a combined molecule A-D is disclosed, then each of these is individually and collectively contemplated, meaning that combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered to be disclosed even if each is not individually recited. Similarly, any subset or combination of these is also disclosed. Thus, for example, subgroups A-E, B-F, and C-E are considered to be disclosed. This concept applies to all aspects of this application, including but not limited to the steps in the methods of preparing and using the compositions of the present disclosure. Thus, if there are multiple additional steps that can be performed, it should be understood that each of these additional steps can be performed in any specific aspect or combination of aspects of the methods of the present disclosure.

[0029] References in the specification and the appended claims to the weight parts of a specific element or component in a composition or article represent the weight relationship between that element or component and any other element or component in the composition or article as expressed in weight parts. Thus, in a compound containing 2 weight parts of component X and 5 weight parts of component Y, X and Y are present in a weight ratio of 2:5, and are present in this ratio regardless of whether there are additional components in the compound.

[0030] Unless specifically stated to the contrary, the weight percentage of a component is based on the total weight of the formulation or composition containing that component.

[0031] As used herein, the terms "weight percentage", "wt%", and "wt.%" which may be used interchangeably, represent the weight percentage of a given component based on the total weight of the composition, unless otherwise specified. That is, unless otherwise specified, all wt% values are based on the total weight of the composition. It should be understood that the sum of the wt% values of all components in the disclosed composition or formulation equals 100.

[0032] Unless otherwise stated to the contrary herein, all test standards are the latest effective standards at the time of filing of this application.

[0033] The various materials disclosed herein are commercially available and / or their preparation methods are known to those skilled in the art.

[0034] It should be understood that the compositions disclosed herein have certain functions. Certain structural requirements for performing the disclosed functions are disclosed herein, and it should be understood that there are various structures that can perform the same functions associated with the disclosed structures, and these structures will generally achieve the same results.

[0035] Polymer resin

[0036] On the one hand, the polymer composition may comprise a polymer resin. In various aspects, the polymer base resin may include a thermoplastic resin or a thermosetting resin. The thermoplastic resin may include polypropylene, polyethylene, ethylene copolymers, polyamides, polycarbonates, polyesters, polyoxymethylene (POM), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycyclohexylenedimethylene terephthalate (PCT), liquid crystal polymer (LCP), polyphenylene sulfide (PPS), polyphenylene ether (PPE), polyphenylene ether-polystyrene blend, polystyrene, high impact modified polystyrene, acrylonitrile-butadiene-styrene (ABS) terpolymer, acrylic polymers, polyetherimide (PEI), polyurethane, polyetheretherketone (PEEK), polylactic acid (PLA)-based polymers, polyethersulfone (PES), and combinations thereof. The thermoplastic resin may also include thermoplastic elastomers such as polyamide and polyester-based elastomers. The base substrate may also include blends of the above resins and / or other types of combinations. In various aspects, the polymer base resin may also include a thermosetting polymer. Suitable thermosetting resins may include phenolic resins, urea resins, melamine-formaldehyde resins, urea-formaldehyde latex, xylene resins, diallyl phthalate resins, epoxy resins, aniline resins, furan resins, polyurethanes, or combinations thereof.

[0037] In a specific aspect, the polymer composition comprises a polycarbonate, specifically a polycarbonate copolymer, a polycarbonate homopolymer, or a combination thereof. As used herein, "polycarbonate" refers to an oligomer or polymer that includes residues of one or more dihydroxy compounds (e.g., dihydroxy aromatic compounds) linked by carbonate linkages; it also includes homopolycarbonates, copolycarbonates, and (co)polyester carbonates. The terms "residue" and "structural unit" used with respect to the composition of the polymer are synonymous throughout the specification. As used herein, the terms "BisA", "BPA", or "bisphenol A", which may be used interchangeably, refer to a compound having the structure represented by formula (1):

[0038]

[0039] BisA may also be referred to by the name 4,4'-(propane-2,2-diyl)diphenol; p,p'-isopropylidenediphenol; or 2,2-bis(4-hydroxyphenyl)propane. BisA has CAS# 80-05-7.

[0040] Combinations of polycarbonates with other thermoplastic polymers may be used, such as homopolycarbonates, copolycarbonates, and polycarbonate copolymers in combination with polyesters. Useful polyesters include, for example, poly(alkylene dicarboxylates), liquid crystal polyesters, and polyester copolymers. When blended, the polyesters described herein may generally be fully miscible with the polycarbonate.

[0041] In a further example, the polycarbonate of the polymeric base resin may include a branched polycarbonate. Exemplary branching agents may include, but are not limited to, 1,1,1-tris(4-hydroxyphenyl)ethane (THPE). As another example, the branched polycarbonate resin may be terminated with a suitable terminating agent such as, for example, p-cyanophenol (referred to as HBN).

[0042] The polymeric resin may include a polycarbonate copolymer comprising units derived from BPA, or a mixture of one or more polycarbonate copolymers comprising units derived from BPA. In a specific example, the polymeric resin may include a polycarbonate copolymer having units derived from BPA and a poly(aliphatic ester)-polycarbonate copolymer derived from sebacic acid.

[0043] According to various aspects, the polycarbonate may comprise high-flow PC or low-flow PC, or a combination thereof. High-flow PC may be defined as a polycarbonate having a melt flow index (MFI) greater than 10 g / 10 minutes at 300 °C / 1.2 kg. Low-flow PC may be defined as a PC having an MFI less than 10 g / 10 minutes at 300 °C / 1.2 kg when tested according to ASTM D1238.

[0044] In some aspects, the polycarbonate copolymer component includes a polyester-polycarbonate copolymer. As further described herein, the polyester has a repeating unit of formula (A):

[0045]

[0046] wherein T is a residue derived from terephthalic acid or a chemically equivalent form thereof, and D is a residue polymerically derived from ethylene glycol, butylene glycol, specifically 1,4-butanediol, or a chemically equivalent form thereof.

[0047] In a specific aspect, the polyester unit is derived from the reaction of isophthalic acid, terephthalic acid, and resorcinol (also referred to as ITR resin). The polyester unit has the following structure (B):

[0048]

[0049] Where x corresponds to the molar ratio of isophthalate groups, y corresponds to the molar ratio of resorcinol, and z corresponds to the molar ratio of terephthalate groups; x, y, and z add up to 100% of the polyester units. Based on the number of moles in the polymer, the concentration of the polyester (ITR) resin can be at least 5%. In a further aspect, the polyester and polycarbonate are used in a molar ratio of about 5:95 to about 40:60 or more specifically about 5:95 to about 35:65 - depending on the desired properties. The weight average molecular weight of the polyester-polycarbonate can be from about 1,500 to about 100,000, or more specifically from about 2,000 to about 40,000. The polyester-polycarbonate polymer can be a copolymer, especially a block copolymer.

[0050] Specifically, the polyester units of the polyester-polycarbonate can be derived from the reaction of isophthalic acid and terephthalic acid (or their derivatives) with resorcinol, bisphenol A, or a combination containing one or more of these, where the molar ratio of isophthalate (isophthalate group) units to terephthalate (terephthalate group) units is from 91:9 to 2:98, specifically from 85:15 to 3:97, more specifically from 80:20 to 5:95, still more specifically from 70:30 to 10:90. In the case where the polycarbonate contains units derived from resorcinol and / or bisphenol A, the molar ratio of resorcinol carbonate units to bisphenol A carbonate units is from 0:100 to 99:1, and the molar ratio of the mixed isophthalate-terephthalate polyester units to the polycarbonate units in the polyester-polycarbonate can be from 1:99 to 99:1, specifically from 5:95 to 90:10, more specifically from 10:90 to 80:20. When using a blend of polyester-polycarbonate and polycarbonate, the ratio of polycarbonate to polyester-polycarbonate in the blend can be from 1:99 to 99:1, specifically from 10:90 to 90:10.

[0051] In a specific aspect, the polycarbonate copolymer may include a resorcinol-based aryl polyester or a resorcinol-based polyester carbonate polymer. ITR (isophthalate terephthalate resorcinol) resorcinol-based aryl polyesters and "resorcinol-based polyaryl esters" and "resorcinol-based polyarylesters" all mean copolymers containing a resorcinol moiety and resorcinol-based ester linkages and possibly other linkages (such as resorcinol-based polycarbonate linkages). These terms mean to include both polyesters and polyester carbonates containing only ester bonds in the presence of resorcinol-based polycarbonate linkages. Thus, the polyester-polycarbonate copolymer may include carbonate repeat structural units of bisphenol A and ester repeat structural units, which may be any copolymer of BPA polycarbonate and isophthalic acid resorcinol (ITR) (C) and as in (D).

[0052]

[0053] These copolycarbonates can be synthesized by those skilled in the art or can be obtained commercially, such as SABIC LEXAN TM SLX resin. LEXAN TM The SLX resin is an ITR-polycarbonate copolymer with a molecular weight of 20,000 - 30,000 and a refractive index of about 1.59 - 1.603.

[0054] As an example, the resorcinol-based polyaryl ester may include carbonate linkages (e.g., between the resorcinol moiety and the bisphenol A moiety) and ester linkages (e.g., between the resorcinol moiety and the isophthalic acid moiety). In an aspect of the present disclosure, the composition comprises ITR-BPAPC.

[0055] In some cases, the resorcinol-based polyarylester resin may include at least about 40 mol% of the moiety derived from resorcinol. The resorcinol moiety may be introduced as resorcinol or a functionalized resorcinol and as a reaction product of an aromatic dicarboxylic acid or an aromatic dicarboxylic acid derivative suitable for forming an aryl ester linkage with resorcinol. Suitable dicarboxylic acid derivatives include, for example, carboxylic acid halides, carboxylic acid esters, and carboxylates.

[0056] The resorcinol-based polyarylate may further comprise carbonate linkages derived from the reaction of a bisphenol with a carbonate-forming species such as phosgene, such that the resorcinol-based polyarylate becomes a polyester carbonate copolymer. In another embodiment of the present invention, the resorcinol polyarylate carbonate copolymer will comprise the reaction product of isophthalic acid and terephthalic acid, resorcinol, and optionally bisphenol A and phosgene. In one aspect, the resorcinol polyester carbonate copolymer will be prepared in a manner that minimizes the number of bisphenol dicarboxylate linkages, for example by pre-reacting resorcinol with a dicarboxylic acid to form an aryl polyester block, and then reacting the aryl polyester block with a bisphenol and a carbonate moiety to form the polycarbonate portion of the copolymer. Examples of polymers containing resorcinol esters can be found in U.S. Pat. Nos. 6,861,482, 6,559,270, 6,265,522, 6,294,647, 6,291,589, and 5,916,997.

[0057] In other examples, the polycarbonate copolymer may include a polycarbonate-dimethylbisphenol cyclohexane copolymer (DMBPC) that includes at least 50 mol% of dimethylbisphenol cyclohexane monomers. DMBPC has the formula (E):

[0058]

[0059] where x and y represent the molar ratios of dimethylbisphenol cyclohexane monomers and polycarbonate monomers, respectively. Thus, when x is 50, y is also 50, and the copolymer comprises 50 mol% of dimethylbisphenol cyclohexane monomers and 50 mol% of polycarbonate monomers. In some aspects, x is from 20 to 100.

[0060] In a further aspect, the polyester-polycarbonate copolymer comprises repeating units of formula (A) above, where D is a divalent radical derived from a dihydroxy compound and can be, for example, a C 2-10 alkylene radical, a C 6-20 cycloaliphatic radical, a C 6-20 aromatic radical, or a polyoxyalkylene radical, where the alkylene contains 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and T is a divalent radical derived from a dicarboxylic acid and can be, for example, a C 2-10 alkylene radical, a C 6-20 cycloaliphatic radical, an alkylaromatic radical, or a C 6-20 aromatic radical. 6-20

[0061] In one aspect, D is a C 2-6 alkylene radical. In another aspect, D is derived from an aromatic dihydroxy compound of formula (F):

[0062] ​

[0063] where each R f is independently a halogen atom, C 1-10 hydrocarbyl or C 1-10 halogen-substituted hydrocarbyl, and n is from 0 to 4. The halogen is usually bromine. Examples of compounds represented by formula (7) include resorcinol, 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 or the like; catechol; hydroquinone; substituted hydroquinones 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-tetra-tert-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone or the like; or combinations comprising at least one of the foregoing compounds.

[0064] Examples of aromatic dicarboxylic acids useful for preparing polyesters include isophthalic acid or terephthalic acid, 1,2-bis(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bibenzoic acid, and mixtures comprising at least one of the foregoing acids. Acids containing fused rings may also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acid. Specific dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, cyclohexanedicarboxylic acid, or mixtures thereof. Specific dicarboxylic acids include mixtures of isophthalic acid and terephthalic acid, where the weight ratio of terephthalic acid to isophthalic acid is from 91:1 to 2:98. In another specific embodiment, D is C 2-6 alkylene radical, and T is p-phenylene, m-phenylene, naphthylene, a divalent alicyclic radical, or mixtures thereof. Such polyesters include poly(alkylene terephthalates).

[0065] The polysiloxane-polycarbonate copolymer can be a useful polycarbonate copolymer and can contain from 50 wt.% to 99 wt.% of carbonate units and from 1 wt.% to 50 wt.% of siloxane units. Within this range, the polyorganosiloxane-polycarbonate copolymer can contain from 70 wt.% to 98 wt.%, more specifically from 75 wt.% to 97 wt.% of carbonate units and from 2 wt.% to 30 wt.%, more specifically from 3 wt.% to 25 wt.% of siloxane units.

[0066] On the one hand, the polysiloxane-polycarbonate copolymer may contain 10 wt% or less, specifically 6 wt% or less, and more specifically 4 wt% or less of polysiloxane based on the total weight of the polysiloxane-polycarbonate copolymer, and may generally be optically transparent and be commercially available from SABIC under the name EXL-T. On the other hand, the polysiloxane-polycarbonate copolymer may contain 10 wt% or more, specifically 12 wt% or more, and more specifically 14 wt% or more of polysiloxane copolymer based on the total weight of the polysiloxane-polycarbonate copolymer, and is generally optically opaque and is commercially available from SABIC under the trade name EXL-P.

[0067] The weight-average molecular weight of the polyorganosiloxane-polycarbonate may be from 2,000 Daltons to 100,000 Daltons, specifically from 5,000 to 50,000 Daltons, measured by gel permeation chromatography using a crosslinked styrene-divinylbenzene column at a sample concentration of 1 mg / mL and calibrated with polycarbonate standards.

[0068] The polyorganosiloxane-polycarbonate may have a melt volume flow rate measured at 300 degrees Celsius (°C) / 1.2 kilograms (kg) of 1 to 50 cubic centimeters per 10 minutes (cm 3 / 10 min), specifically 2 to 30 cm 3 / 10 min. Mixtures of polyorganosiloxane-polycarbonates with different flow properties may be used to achieve the overall desired flow properties.

[0069] Non-limiting examples of the polysiloxane-polycarbonate copolymer may include various copolymers available from SABIC. On the one hand, the polysiloxane-polycarbonate copolymer may contain a polysiloxane content of 6 weight percent based on the total weight of the polysiloxane-polycarbonate copolymer. In various aspects, by gel permeation chromatography using bisphenol A polycarbonate absolute molecular weight standards, the weight-average molecular weight (Mw) of the 6 weight percent polysiloxane block copolymer may be from about 23,000 to 24,000 Daltons. In certain aspects, the melt volume flow rate (MVR) of the 6 weight percent siloxane polysiloxane-polycarbonate copolymer at 300 °C / 1.2 kg may be about 10 cm 3 / 10 min (see C9030T, a copolymer with 6 wt% polysiloxane content, available as "transparent" EXL C9030T resin polymer from SABIC). In another example, the polysiloxane - polycarbonate block may contain 20 wt% polysiloxane based on the total weight of the polysiloxane block copolymer. For example, a suitable polysiloxane - polycarbonate copolymer may be a bisphenol A polysiloxane - polycarbonate copolymer capped with p - cumylphenol (PCP) and having a 20% polysiloxane content (see C9030P, commercially available as "opaque" EXL C9030P from SABIC). In various aspects, when tested by gel permeation chromatography (GPC) on a cross - linked styrene - divinylbenzene column according to polycarbonate standards and calibrated relative to a polycarbonate reference (using a UV - VIS detector set at 264 nanometers (nm) on a 1 milligram / milliliter (mg / ml) sample eluting at a flow rate of about 1.0 ml / minute), the weight - average molecular weight of the 20% polysiloxane block copolymer may be from about 29,900 daltons to about 31,000 daltons. Additionally, the melt volume rate (MVR) of the 20% polysiloxane block copolymer at 300 °C / 1.2 kg may be 7 cm 3 / 10 min and may exhibit siloxane domains sized in the range of about 5 microns to about 20 microns (micrometers, μm).

[0070] The composition may comprise from about 0.1 wt.% to about 99 wt.% of the polycarbonate copolymer. The PC copolymer component present in the polymer composition may be in the range of at least about 45 wt.% to about 85 wt.%. In a further example, the composition may comprise from about 10 wt.% to about 90 wt.% of the polycarbonate copolymer, or from about 10 wt.% to about 80 wt.% of the polycarbonate copolymer, or from about 20 wt.% to about 80 wt.% of the polycarbonate copolymer, or from about 25 wt.% to about 80 wt.% of the polycarbonate copolymer, or from about 30 wt.% to about 80 wt.% of the polycarbonate copolymer, or from about 40 wt.% to about 80 wt.% of the polycarbonate copolymer, or from about 40 wt.% to about 75 wt.% of the polycarbonate copolymer, or from about 45 wt.% to about 80 wt.% of the polycarbonate copolymer. In certain aspects, at least 45 wt.% may allow the composition to reach a high deflection temperature of at least 150 °C, or at least about 150 °C, which may be beneficial for the optimal application performance of the thermoplastic composition. For optimal performance within the thermoplastic composition, 50 - 55 wt.% or about 50 - 55 wt.% is preferred.

[0071] In various aspects, the disclosed compositions can include at least one crystalline polyester. Crystallization or semi-crystallization of a polymer can describe a polymer in which the molecular chains are organized or more closely packed. Thus, such a highly organized molecular structure can provide a more defined melting point. These polymers are anisotropic when flowing, so they exhibit greater shrinkage across the flow than along the flow, which can sometimes lead to certain dimensional instability. There can be different degrees of crystallinity between different materials, and there can also be variations within the same material. Crystallinity can affect many properties of the polymer. Molecular weight and branching can affect crystallinity.

[0072] The at least one crystalline polyester includes polybutylene terephthalate (PBT), polycyclohexanedimethylene terephthalate (PCT), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polycyclohexylenedimethylene terephthalate glycol (PCTG), polycyclohexylene dimethylene terephthalate acid (PCTA), copolymers thereof, or combinations thereof. In a specific aspect, the at least one crystalline polyester includes polybutylene terephthalate (PBT).

[0073] Certain aspects of the composition include from about 1 wt.% to about 99 wt.% of the at least one crystalline polyester, from 50 wt.% to about 97 wt.% of a thermoplastic resin, or from about 40 wt.% to about 97 wt.% of a polymer base resin, or from about 55 wt.% to about 97 wt.% of a polymer base resin, or from about 60 wt.% to about 97 wt.% of a polymer base resin, or from about 70 wt.% to about 97 wt.% of a polymer base resin, or from about 40 wt.% to about 95 wt.% of a polymer base resin, or from about 55 wt.% to about 95 wt.% of a polymer base resin, or from about 60 wt.% to about 95 wt.% of a polymer base resin, or from about 75 wt.% to about 97 wt.% of a polymer base resin.

[0074] In various aspects of the present disclosure, the thermoplastic resin can include a crystalline polyester. For example, the thermoplastic resin can include a polyalkylene ester (polyester), such as a polyalkylene terephthalate polymer.

[0075] As provided herein, the polyester has repeating units of the above formula (A). Chemically equivalent forms of the diacid include dialkyl esters such as dimethyl esters, diaryl esters, acid anhydrides, salts, acyl chlorides, acyl bromides, etc. Chemically equivalent forms of ethylene glycol and butanediol include esters such as dialkyl esters, diaryl esters, etc. In addition to units derived from terephthalic acid or its chemically equivalent forms and ethylene glycol or butanediol (specifically 1,4-butanediol) or its chemically equivalent forms, other T and / or D units may be present in the polyester provided that the type or amount of such units does not significantly and adversely affect the desired properties of the thermoplastic composition. The poly(alkylene arylate) may have a polyester structure according to formula (A), wherein T comprises a group derived from an aromatic dicarboxylate, an alicyclic dicarboxylic acid or a derivative thereof.

[0076] Examples of particularly useful T groups include, but are not limited to, 1,2-, 1,3- and 1,4-phenylene; 1,4- and 1,5-naphthylene; cis- or trans-1,4-cyclohexylene; and the like. Specifically, when T is 1,4-phenylene, the poly(alkylene arylate) is a poly(alkylene terephthalate). In addition, with respect to the poly(alkylene arylate), particularly useful alkylene Ds include, for example, ethylene, 1,4-butylene and bis-(alkylene-disubstituted cyclohexane), including cis- and / or trans-1,4-(cyclohexylene)dimethylene.

[0077] Examples of poly(alkylene terephthalates) include polyethylene terephthalate (PET), poly(1,4-butylene terephthalate) (PBT) and poly(propylene terephthalate) (PPT). Poly(alkylene naphthalates) such as polyethylene naphthalate (PEN) and poly(butylene naphthalate) (PBN) are also useful. A useful poly(cycloalkylene diol ester) is poly(cyclohexanedimethylene terephthalate) (PCT). Combinations comprising at least one of the foregoing polyesters may also be used.

[0078] Copolymers comprising alkylene terephthalate repeating ester units and other ester groups may also be useful. Useful ester units may include different alkylene terephthalate units, which may be present as separate units or as blocks of poly(alkylene terephthalate) in the polymer chain. Specific examples of such copolymers include poly(cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate), abbreviated as PETG, wherein the polymer comprises greater than or equal to 50 mol% of poly(ethylene terephthalate), abbreviated as PCTG, wherein the polymer comprises greater than 50 mol% of poly(1,4-cyclohexanedimethylene terephthalate). Poly(cycloalkylene diol esters) may also include poly(methylene cyclohexanedicarboxylate). Among them, a specific example is poly(1,4-cyclohexanedimethanol-1,4-cyclohexanedicarboxylate) (PCCD), having repeating units of formula (G):

[0079]

[0080] Among them, as described by formula (A), R 2 is 1,4-cyclohexanedimethylene derived from 1,4-cyclohexanedimethanol, and T is a cyclohexane ring derived from cyclohexanedicarboxylate or its chemically equivalent form, and may include cis isomers, trans isomers, or a combination containing at least one of the foregoing isomers.

[0081] On the other hand, the composition may further comprise poly(butylene terephthalate) or "PBT" resin. PBT can be obtained by polymerizing: a glycol component, wherein at least 70 mol%, preferably at least 80 mol% consists of tetramethylene glycol; and an acid or ester component, wherein at least 70 mol%, preferably at least 80 mol% consists of terephthalic acid and / or its polyester-forming derivatives. Commercial examples of PBT include those manufactured by SABIC TM and available under the trade names VALOX TM 315, VALOX TM 195, and VALOX TM 176, which have an inherent viscosity of 0.1 deciliter / gram (dl / g) to about 2.0 dl / g (or 0.1 dl / g to 2 dl / g) when measured in a 60:40 phenol / tetrachloroethane mixture or a similar solvent at 23 degrees Celsius (°C) to 30 °C. On the one hand, the PBT resin has an inherent viscosity of 0.1 dl / g to 1.4 dl / g (or about 0.1 dl / g to about 1.4 dl / g), specifically 0.4 dl / g to 1.4 dl / g (or about 0.4 dl / g to about 1.4 dl / g).

[0082] As described herein, the composition may comprise from about 0.1 wt.% to about 99 wt.% of a crystalline polyester. In further examples, the composition may comprise from about 0.1 wt.% to about 50 wt.% of a crystalline polyester, or from about 0.1 wt.% to about 30 wt.% of a crystalline polyester, or from about 0.1 wt.% to about 40 wt.% of a crystalline polyester, or from about 0.1 wt.% to about 25 wt.% of a crystalline polyester, or from about 0.1 wt.% to about 15 wt.% of a crystalline polyester, or from about 1 wt.% to about 15 wt.% of a crystalline polyester, or from about 1 wt.% to about 20 wt.% of a crystalline polyester, or from about 0.5 wt.% to about 12 wt.% of a crystalline polyester. The polymer composition may comprise from about 0.1 wt.% to about 70 wt.% of a crystalline polyester.

[0083] Inherently dissipative polymer

[0084] In various aspects, the disclosed polymer compositions can include an inherently dissipative polymer (IDP). An inherently dissipative polymer can refer to a polymer resin having electrostatic dissipative (ESD) properties.

[0085] IDPs generally include modified polymers. In certain aspects, the IDP can include a thermoplastic elastomer or a modified thermoplastic elastomer. Such materials are generally described as polymers having hard and / or crystalline segments and / or blocks and soft and / or elastic segments and / or blocks in their backbone structure. These can be referred to as multiblock copolymers.

[0086] The IDPs disclosed herein can be ion-doped. Conventionally, the IDP can be sodium-ion doped. The IDPs of the present disclosure can be doped with phosphorus ions.

[0087] In some embodiments, the inherently dissipative polymer includes thermoplastic polyurethane (TPU), polyolefin polyether copolymer, thermoplastic polyester elastomer (COPE), polyether block amide elastomer (COPA or PEBA), or a combination thereof. Examples of suitable copolymers include polyolefin-polyether copolymers.

[0088] As an example, the polymer composition can include an IDP that includes an ion-doped nylon (or polyamide)-based multiblock copolymer, such as the commercially available Pelectron TM AS. Due to its properties, common nylon-based IDPs are harmful to PC, resulting in degradation. However, the specific combination of the components of the present disclosure can overcome this possibility of degradation. The processing temperature is desirably kept as low as possible to prevent the IDP from reacting with the PC and then losing surface conductivity. The unique composition enables low-temperature processing. Thus, for extrusion, compounding, or injection molding, especially for extrusion and injection molding, the processing temperature can be kept below 240 °C.

[0089] As a further example, the polymer composition can include an IDP that includes a polymer masterbatch based on a polymer resin, such as the commercially available avanDISS TM 378.

[0090] In certain aspects, the type of IDP selected can depend on the type of polycarbonate. For blending with a polycarbonate copolymer, Pelectron TM AS is a suitable IDP, while AvanDISS TM is suitable for polycarbonate copolymer or polycarbonate homopolymer compositions.

[0091] The surface resistance of the IDP can be from about E+6 to E+8 ohms (e.g., 1×10 6 ohms to 9×10 8in the order of ohms). The volume resistivity of the IDP can be from about E+4 to E+7 ohm·cm (e.g., 1×10 4 ohms to 9×10 7 ohms). As an example, the IDP can have a surface resistivity of about 1×10 7 ohms when tested on a plaque sample of 68 mm x 68 mm x 3 mm according to ASTM D257.

[0092] In some aspects, the polymer composition can comprise from about 0.1 wt.% to about 50 wt.% of the IDP. In further aspects, the composition can comprise from about 10 wt.% to about 50 wt.% of the IDP, or from about 15 wt.% to about 50 wt.% of the IDP, or from about 50 wt.% to about 70 wt.% of the IDP, or from about 18 wt.% to about 40 wt.% of the IDP, or from about 15 wt.% to about 45 wt.% of the IDP, or from about 12 wt.% to about 35 wt.% of the IDP, from about 12 wt.% to about 40 wt.% of the IDP, or from about 12 wt.% to about 50 wt.% of the IDP, or from about 12 wt.% to about 50 wt.% of the IDP.

[0093] Transesterification inhibitor

[0094] The polymer composition can comprise one or more transesterification inhibitors. The transesterification inhibitor can prevent the transesterification reaction of the polymer, thus inhibiting the polymerization reaction. It is also well known that the presence of a transesterification inhibitor can inhibit the polymerization reaction. U.S. Patent No. 4,069,278 teaches that in the polycondensation of ethylene glycol and dimethyl terephthalate catalyzed by calcium acetate and antimony oxide, no phosphorus-containing stabilizer (catalyst inhibitor) is added at any time.

[0095] Suitable transesterification inhibitors are well known in the art and can be selected from phosphorus-containing stabilizer inhibitors such as pentaerythritol diphosphite (GE Specialty Chemicals, Parkersburg, W.Va., Ultranox TM626), phosphoric acid and polyphosphoric acid. Other examples are zinc diisopropyl dithiophosphate, tris(2,4-di-tert-butylphenyl) phosphite, tris(monononylphenyl) phosphite, and mixtures thereof. Further transesterification inhibitors include sodium dihydrogen phosphate, potassium acetate, trimethyl phosphate, and phenylphosphonic acid. Also included are orthophosphoric acids represented by the formula xH2O·yP2O5 and satisfying x / y ≥ 3, polyphosphoric acids called diphosphoric acid, triphosphoric acid, tetraphosphoric acid, and pentaphosphoric acid according to the degree of condensation and satisfying 2 < x / y > 1, and mixtures thereof. Also included are metaphosphoric acids represented by the formula xH2O·yP2O5 and satisfying x / y = 1, especially trimetaphosphoric acid and tetrametaphosphoric acid, and superphosphoric acids having a network structure and having a part of the phosphorus pentoxide structure and satisfying 1 > x / y > 0 (these can be collectively referred to as "metaphosphoric acid-based compounds"). Also included are acid salts and esters of these phosphoric acids. Among them, cyclic sodium metaphosphate, ultra-region sodium metaphosphate, and diheptylphosphoric acid DHPA are advantageously used. As a specific example, the transesterification inhibitor may include a mixture of mono- and di-stearyl acid phosphate (commercially available as AX71).

[0096] The transesterification inhibitor may be present in an amount of about 0.001 wt.% to about 10 wt.% based on the total weight of the polymer composition.

[0097] White pigment

[0098] In addition to the polycarbonate copolymer, crystalline polyester, IDP, and transesterification inhibitor, the polymer composition of the present disclosure may further comprise a white pigment. The white pigment can impart opacity or a bright opaque appearance to the polymer resin composition. In a further aspect, the white pigment can impart a white or off-white color to the polymer resin composition. In addition, these pigments tend to have high reflectivity for both near-infrared (NIR) and visible light. As used herein, reflectivity can refer to the ability to scatter light from the surface of a material without absorbing light of a given wavelength.

[0099] Suitable white pigments may include titanium dioxide, zinc sulfide (ZnS), tin oxide, aluminum oxide (AlO3), zinc oxide (ZnO), calcium sulfate, barium sulfate (BaSO4), calcium carbonate (e.g., chalk), magnesium carbonate, antimony oxide (Sb2O3), white lead (basic lead carbonate, 2PbCO3·Pb(OH)2), lithopone (a combination of barium sulfate and zinc sulfide), sodium silicate, aluminum silicate, silicon dioxide (SiO2, i.e., silica), mica, clay, talc, metal-doped forms of the foregoing materials, and combinations comprising at least one of the foregoing materials. More specifically, inorganic white pigments are selected from rutile or anatase titanium dioxide, zinc sulfide, and coated forms thereof such as silanized titanium dioxide. Combinations of different types of white pigments may be used. In a specific aspect, the white pigment may include titanium dioxide, antimony oxide, zinc oxide, white lead, or lithopone. In some aspects of the present disclosure, talc may be used as a white pigment. Talc can be a suitable white pigment where the material has a color coordinate value high enough to impart whiteness to the material. In one example, talc with a color coordinate *L value (corresponding to the whiteness of a given material) greater than 80 will be a suitable white pigment as described herein.

[0100] The average particle size of the white pigment may be from 0.01 to 10 micrometers (μm), specifically 0.05 μm to 1 μm, and more specifically 0.1 μm to 0.6 μm. The amount of the white pigment present may be from about 0.1 wt.% to about 50 wt.%. As an example, the composition may comprise titanium dioxide in an amount between 0.1 wt.% and 50 wt.%. In a further example, the composition may comprise titanium dioxide in an amount between 0.1 wt.% and 20 wt.%.

[0101] Optical agent

[0102] In a further aspect of the present disclosure, the polymer composition may comprise an optical agent. The optical agent may include an optical brightening agent. Examples of optical brightening agents include optical brightening agents (OBA), fluorescent brightening agents (FBA), fluorescent whitening agents (FWA) or the like, or a combination comprising at least one of the foregoing optical brightening agents. As used herein, an optical brightening agent refers to a dye that absorbs light in the ultraviolet and violet regions of the electromagnetic spectrum (typically from about 340 to about 370 nm) and re-emits light in the blue region (typically from about 420 to about 470 nm). These additives are commonly used to enhance the color appearance of the polymer composition, producing a perceived "whitening" effect. Depending on the perceived whitening effect, a given material may appear less yellow by increasing the total amount of blue light reflected. Exemplary optical brightening agents are triazine-stilbene (di-, tetra- or hexa-sulfonated), coumarin, imidazoline, oxadiazole, triazole, benz oxazoline, biphenylstilbene or the like, or a combination comprising at least one of the foregoing optical brightening agents. In a specific aspect of the present disclosure, the optical agent may include, but is not limited to, 4,4'-bis(2-benz oxazolyl)stilbene (commercially available as Eastman Eastobrite TM OB-1) or 2,5-bis(5-tert-butyl-2-benz oxazolyl)thiophene (commercially available as Tinopal TM OB) or a combination thereof.

[0103] In certain aspects, the composition comprises from about 0.001 wt.% to about 10 wt.% of an optical brightening agent. In a further aspect, the composition comprises from about 0.01 wt.% to about 5 wt.% of an optical brightening agent, or from about 0.01 wt.% to about 1 wt.% of an optical brightening agent.

[0104] Additives

[0105] The disclosed thermoplastic composition may comprise one or more additives conventionally used in the manufacture of molded thermoplastic parts, provided that the optional additives do not adversely affect the desired properties of the resulting composition. Mixtures of optional additives may also be used. Such additives may be mixed at an appropriate time during the mixing of the components used to form the composite mixture. Exemplary additives may include ultraviolet agents, ultraviolet stabilizers, heat stabilizers, antistatic agents, antimicrobial agents, anti-drip agents, radiation stabilizers, pigments, dyes, fibers, fillers, plasticizers, fibers, flame retardants, antioxidants, lubricants, wood, glass and metal and combinations thereof.

[0106] The thermoplastic compositions disclosed herein may include one or more additional fillers. Fillers may be selected to impart additional impact strength and / or provide additional properties that may be based on the final selected properties of the polymer composition. In some aspects, the filler(s) may include inorganic materials, which may include clay, titanium oxide, asbestos fibers, silicates, and silica powder, boron powder, calcium carbonate, talc, kaolin, sulfides, barium compounds, metals, and metal oxides, wollastonite, glass spheres, glass fibers, flake fillers, fiber fillers, natural fillers, and reinforcing agents, and reinforcing organic fiber fillers.

[0107] Suitable fillers or reinforcing agents may include, for example, mica, clay, feldspar, quartz, quartzite, perlite, tripoli, diatomaceous earth, aluminum silicate (mullite), synthetic calcium silicate, fused silica, fumed silica, sand, boron nitride powder, boron silicate powder, calcium sulfate, calcium carbonate (such as chalk, limestone, marble, and synthetic precipitated calcium carbonate), talc (including fibrous, modular, acicular, and lamellar talc), wollastonite, hollow or solid glass spheres, silicate spheres, hollow microspheres, aluminosilicates or (armospheres), kaolin, silicon carbide, alumina, boron carbide, whiskers of iron, nickel, or copper, continuous and chopped carbon fibers or glass fibers, molybdenum sulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, barite, TiO2, alumina, magnesia, granular or fibrous aluminum, bronze, zinc, copper, or nickel, glass flakes, flake silicon carbide, flake aluminum diboride, flake aluminum, steel flakes, natural fillers such as wood flour, fibrous cellulose, cotton, sisal, jute, starch, lignin, ground nut shells, or rice husks, reinforcing organic fibrous fillers such as poly(ether ketone), polyimide, polybenz azole, poly(phenylene sulfide), polyester, polyethylene, aromatic polyamide, aromatic polyimide, polyetherimide, polytetrafluoroethylene, and poly(vinyl alcohol), and combinations including at least one of the foregoing fillers or reinforcing agents. The fillers and reinforcing agents may be coated with a layer of metallic material to promote electrical conductivity, or surface treated, for example, with silanes, to improve adhesion and dispersibility in the polymer matrix. The fillers may generally be used in an amount of 1 to 200 parts by weight based on 100 parts by weight of the total composition.

[0108] In some aspects, the thermoplastic composition may include a synergist. In various examples, the filler may act as a flame retardant synergist. When added to a flame retardant composition, the synergist promotes an improvement in flame retardant properties as compared to a comparative composition containing all the same components in the same amounts except for the synergist. Examples of mineral fillers that can act as synergists are mica, talc, calcium carbonate, dolomite, wollastonite, barium sulfate, silica, kaolin, feldspar, barite, or the like, or combinations including at least one of the foregoing mineral fillers. Metal synergists such as antimony oxide can also be used with the flame retardant. In one example, the synergist may include magnesium hydroxide and phosphoric acid. The mineral filler may have an average particle size of from about 0.1 to about 20 μm, specifically from about 0.5 to about 10 μm, and more specifically from about 1 to about 3 μm.

[0109] The thermoplastic composition may include an antioxidant. The antioxidant may include a primary antioxidant or a secondary antioxidant. For example, the antioxidant may include organic phosphites such as tris(nonylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, distearylpentaerythritol diphosphite, or the like; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]methane, or the like; butylated reaction products of p-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylene-bisphenols; benzyl compounds; esters of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with mono- or polyhydric alcohols; esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with mono- or polyhydric alcohols; esters of thioalkyl or thioaryl compounds such as distearyl thiodipropionate, dilauryl thiodipropionate, bis(tridecyl) thiodipropionate, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], or the like; amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, or combinations including at least one of the foregoing antioxidants. The antioxidant can generally be used in an amount of from 0.01 to 0.5 parts by weight based on 100 parts by weight of the total composition excluding any fillers.

[0110] In various aspects, the thermoplastic composition may include a mold release agent. Exemplary mold release agents may include, for example, metal stearates, stearyl stearate, pentaerythritol tetrastearate, beeswax, montan wax, paraffin wax, or the like, or combinations including at least one of the foregoing mold release agents. The mold release agent is generally used in an amount of from about 0.1 to about 1.0 parts by weight based on 100 parts by weight of the total composition excluding any fillers.

[0111] On the one hand, the thermoplastic composition may include a heat stabilizer. As an example, the heat stabilizer may include, for example, organic phosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, tris-(mixed mono- and di-nonylphenyl) phosphite or the like; phosphonates such as dimethyl phenylphosphonate or the like, phosphates such as trimethyl phosphate or the like, or a combination comprising at least one of the foregoing heat stabilizers. The heat stabilizer can generally be used in an amount of 0.01 to 0.5 parts by weight based on 100 parts by weight of the total composition excluding any fillers.

[0112] In a further aspect, a light stabilizer may be present in the thermoplastic composition. Exemplary light stabilizers may include, for example, benzotriazoles such as 2-(2-hydroxy-5-methylphenyl) benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2-hydroxy-4-n-octyloxybenzophenone or the like, or a combination comprising at least one of the foregoing light stabilizers. The light stabilizer can generally be used in an amount of about 0.1 to about 1.0 parts by weight based on 100 parts by weight of the total composition excluding any fillers.

[0113] The thermoplastic composition may also contain a plasticizer. For example, the plasticizer may include phthalates such as dioctyl-4,5-epoxy-hexahydrophthalate, tris-(octyloxycarbonylethyl) isocyanurate, glyceryl tristearate, epoxidized soybean oil or the like, or a combination comprising at least one of the foregoing plasticizers. The plasticizer is generally used in an amount of about 0.5 to about 3.0 parts by weight based on 100 parts by weight of the total composition excluding any fillers.

[0114] In a further aspect, the disclosed composition may contain an antistatic agent. These antistatic agents may include, for example, glycerol monostearate, sodium stearylsulfonate, sodium dodecylbenzenesulfonate or the like, or a combination of the foregoing antistatic agents. On the one hand, carbon fibers, carbon nanofibers, carbon nanotubes, carbon black or any combination of the foregoing can be used in a polymer resin containing a chemical antistatic agent to render the composition electrostatic dissipative.

[0115] An ultraviolet (UV) absorber may also be present in the disclosed thermoplastic composition. Exemplary UV absorbers may include, for example, hydroxybenzophenone; hydroxybenzotriazole; hydroxybenzotriazine; cyanoacrylate; oxanilide; benz oxazinone; 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB TM 5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB TM531); 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine-2-yl]-5-(octyloxy)-phenol (CYASORB TM 1164); 2,2'-(1,4-phenylene)bis(4H-3,1-benzo Oxazine-4-one) (CYASORB TM UV-3638); 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL TM 3030); 2,2'-(1,4-phenylene)bis(4H-3,1-benzo oxazine-4-one); 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane; nano-sized inorganic materials such as titanium oxide, cerium oxide and zinc oxide, all with a particle size of less than 100 nanometers; or the like, or a combination comprising at least one of the foregoing UV absorbers. The UV absorber is generally used in an amount of 0.01 to 3.0 parts by weight based on 100 parts by weight of the total composition excluding any filler.

[0116] The thermoplastic composition may further include a lubricant. As an example, the lubricant may include, for example, a fatty acid ester such as an alkyl stearyl ester, such as methyl stearate or the like; a mixture of methyl stearate with a hydrophilic and hydrophobic surfactant, including polyethylene glycol polymers, polypropylene glycol polymers, and copolymers thereof, such as methyl stearate and polyethylene glycol-polypropylene glycol copolymers in a suitable solvent; or a combination comprising at least one of the foregoing lubricants. The lubricant may generally be used in an amount of about 0.1 to about 5 parts by weight based on 100 parts by weight of the total composition excluding any filler.

[0117] Anti-drip agents may also be used in the composition, such as fibril-forming or non-fibril-forming fluoropolymers such as polytetrafluoroethylene (PTFE). The anti-drip agent may be encapsulated by a rigid copolymer such as styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is referred to as TSAN. In one example, the TSAN may contain 50 wt.% PTFE and 50 wt.% SAN based on the total weight of the encapsulated fluoropolymer. The SAN may contain, for example, 75 wt.% styrene and 25 wt.% acrylonitrile based on the total weight of the copolymer. Anti-drip agents such as TSAN may be used in an amount of 0.1 to 10 parts by weight based on 100 parts by weight of the total composition excluding any filler.

[0118] As an example, the disclosed composition can include an impact modifier. The impact modifier can be a chemically reactive impact modifier. By definition, a chemically reactive impact modifier can have at least one reactive group such that when the impact modifier is added to the polymer composition, the impact properties of the composition (represented by the IZOD impact value) are improved. In some examples, the chemically reactive impact modifier can be an ethylene copolymer having a reactive functional group selected from, but not limited to, acid anhydride, carboxyl, hydroxyl, and epoxy groups.

[0119] In a further aspect of the present disclosure, the composition can include a rubbery impact modifier. A rubbery impact modifier can be a polymeric material that is capable of substantially recovering its shape and size after the removal of a force at room temperature. However, the rubbery impact modifier should generally have a glass transition temperature of less than 0 °C. In certain aspects, the glass transition temperature (T g ) can be lower than -5 °C, -10 °C, -15 °C, where a T g lower than -30 °C generally provides better performance. Representative rubbery impact modifiers can include, for example, functionalized polyolefin ethylene-acrylate terpolymers such as ethylene-acrylate-maleic anhydride (MAH) or glycidyl methacrylate (GMA). The functionalized rubbery polymer can optionally contain repeating units in its backbone that are derived from monomers containing an acid anhydride group such as maleic anhydride. In another case, the functionalized rubbery polymer can contain an acid anhydride moiety grafted onto the polymer in a post-polymerization step.

[0120] In one example, the composition can include a core-shell copolymer impact modifier having a core comprising poly(butyl acrylate) of about 80 wt.% and a shell comprising poly(methyl methacrylate) of about 20 wt.%. In another example, the impact modifier can include an acrylic impact modifier such as an ethylene-ethyl acrylate copolymer having an ethyl acrylate content of less than 20 wt.% (such as EXL 3330 supplied by SABIC). The composition can contain about 5 wt.% of the ethylene-ethyl acrylate copolymer.

[0121] In various aspects, the compositions can be prepared according to a variety of methods. The compositions of the present disclosure can be blended, compounded, or otherwise combined with the foregoing ingredients by a variety of methods that involve intimately mixing the materials with any other additives desired in the formulation. Due to the availability of melt blending equipment in commercial polymer processing facilities, melt processing methods can be used. In various further aspects, the equipment used in such melt processing methods can include, but is not limited to, co-rotating and counter-rotating extruders, single screw extruders, co-kneaders, disc-pack processors, and various other types of extrusion equipment. In a further aspect, the extruder is a twin screw extruder. In various further aspects, the compositions can be processed in an extruder at a temperature of about 180 °C to about 350 °C, specifically 250 °C to 300 °C.

[0122] Properties and Articles

[0123] The disclosed combination of IDP, polycarbonate (PC) or its copolymer (ITR-BPAPC, SLX), and crystalline polymer provides desired ESD properties while maintaining a wide color space. The disclosed compositions also achieve balanced performance in terms of electrical, aesthetic, impact, and processing through the combined advantages of crystalline polymers and unique amorphous PC or PC copolymers.

[0124] In certain aspects, the compositions can exhibit electrostatic dissipative properties. For example, in some aspects, when measured according to ASTM D257, the compositions can exhibit a surface resistance of less than 1×10 9 ohms.

[0125] As provided herein, the compositions of the present disclosure are colorable. Colorability can describe the ease of coloring of a polymer composition. That is, the color of the polymer composition can be sufficiently "light" to accept dyes, pigments, or other color treatments / additives that impart a desired hue to the composition. Conventional dissipative materials typically include dark-colored dissipative additives such as carbon fiber or carbon black. Therefore, the color space of conventional ESD materials can be limited. The disclosed compositions can mitigate these limitations because they achieve a surface resistance of less than 1×10 9The surface resistance of Ohm is also colorable. The values disclosed herein have certain values with respect to certain colorimetric coordinates L*, a*, b*. The "L* value" describes the light-dark property. If the L* value is 0, the object is black. If the L* value is 100, the object is white. The L* value is always positive. A composition having an L* value far from the extreme values (0 and 100) has a more natural color, which can be the color selected for a specific application or which can make the composition easier to color. An L* value far from 0 and close to 100 results in a composition having a far wider "color space". The "color space" is the range of L* that can be achieved using optional colorants, pigments, and / or dyes. L* can be measured using ASTM 2244 and a 10° observer; the International Commission on Illumination (CIE) Standard Illuminant D65 illuminant; reflection including the specular component included (SCI); and a large aperture). When measured in reflection mode in a 10° observer using a spectrophotometer with D65 illumination, the polymer composition can exhibit an L* color value of at least about 50 or at least about 80 or at least about 90.

[0126] Accordingly, these compositions are candidates for consumer electronics / semiconductor / construction applications, and are capable of achieving key capabilities in ESD products and having a customized color. In addition, these compositions show the potential to replace ESD materials filled with carbon fiber, conductive carbon black, graphite, graphene, carbon nanotubes, etc. in the market.

[0127] In various aspects, the present disclosure relates to articles that include the compositions herein. The compositions can be molded into useful shaped articles by various means, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming to form articles. The compositions can be used to manufacture articles that require materials having high modulus, good flow, good impact strength, thermal conductivity, and reflectivity.

[0128] The advantageous properties of the compositions disclosed herein enable them to be suitable for a variety of uses. The shaped articles can include, but are not limited to, personal computers, notebooks and portable computers, mobile phone antennas and other such communication devices, medical applications, radio frequency identification RFID applications, automotive applications, etc. In various further aspects, the articles can be suitable as housings for computers and business machines, such as housings for high-end laptop personal computers, monitors, robots, handheld electronic device housings (such as housings for smart phones, tablets, music devices or flash brackets), electrical connectors, light-emitting diode LED heat sinks, and components of lighting fixtures, wearable devices, ornaments, household appliances, etc.

[0129] In a further aspect, non-limiting examples of fields where the thermoplastic composition can be used can include electrical, electromechanical, radio frequency (RF) technology, telecommunications, automotive, aerospace, medical, sensors, military, and security. In a still further aspect, the thermoplastic composition can also be present in overlapping fields, such as in electromechanical systems that integrate mechanical and electrical properties, which can be used, for example, in automotive or medical engineering.

[0130] In a further aspect, suitable articles can be electronic devices, automotive devices, telecommunications devices, medical devices, security devices, or electromechanical devices. In a still further aspect, the articles can be selected from computer devices, electromagnetic interference devices, printed circuits, Wi-Fi devices, Bluetooth devices, GPS devices, cellular antenna devices, smart phone devices, automotive devices, medical devices, sensor devices, security devices, shielding devices, RF antenna devices, LED devices, and RFID devices. In a still further aspect, the articles can be selected from computer devices, sensor devices, security devices, RF antenna devices, LED devices, and RFID devices.

[0131] On the other hand, the molded article can be used to manufacture devices in the automotive field. In a still further aspect, non-limiting examples of such devices in the automotive field where the disclosed blended thermoplastic composition can be used inside the vehicle include adaptive cruise control, headlight sensors, windshield wiper sensors, and door / window switches. In a further aspect, non-limiting examples of devices in the automotive field where the disclosed blended thermoplastic composition can be used outside the vehicle include pressure and flow sensors for engine management, air conditioning, crash detection, and external lighting fixtures.

[0132] In a further aspect, the obtained disclosed composition can be used to provide any desired shaped, formed, or molded article. For example, the disclosed composition can be molded into useful shaped articles by various means such as injection molding, extrusion, rotational molding, blow molding, and thermoforming. As mentioned above, the disclosed composition is particularly suitable for manufacturing electronic components and devices. Thus, according to some aspects, the disclosed composition can be used to form articles such as printed circuit board carriers, burn in test sockets, flexible brackets for hard disk drives, and the like.

[0133] Aspect

[0134] Aspect 1A. A polymer composition comprising: about 0.1 wt.% to about 99 wt.% of a polycarbonate copolymer, homopolymer, or blends thereof; about 0.1 wt.% to about 70 wt.% of a crystalline polyester; about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor, wherein when measured according to ASTM D257, the polymer composition exhibits a surface resistance of less than 1 × 10 9 ohms, and wherein the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

[0135] Aspect 1B. A polymer composition consisting of: about 0.1 wt.% to about 99 wt.% of a polycarbonate copolymer, homopolymer, or blends thereof; about 0.1 wt.% to about 70 wt.% of a crystalline polyester; about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor, wherein when measured according to ASTM D257, the polymer composition exhibits a surface resistance of less than 1 × 10 9 ohms, and wherein the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

[0136] Aspect 1C. A polymer composition consisting essentially of: about 0.1 wt.% to about 99 wt.% of a polycarbonate copolymer, homopolymer, or blends thereof; about 0.1 wt.% to about 70 wt.% of a crystalline polyester; about 0.1 wt.% to about 50 wt.% of an inherently dissipative polymer; and about 0.001 wt.% to about 10 wt.% of a transesterification inhibitor, wherein when measured according to ASTM D257, the polymer composition exhibits a surface resistance of less than 1 × 10 9 ohms, and wherein the combined weight percentage values of all components do not exceed about 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

[0137] Aspect 2. The polymer composition according to any one of Aspects 1A - 1C, wherein the polycarbonate copolymer comprises ITR - BPAPC, BPAPC, or a combination thereof.

[0138] Aspect 3. The polymer composition according to any one of Aspects 1A - 2, wherein the polyester comprises polybutylene terephthalate, polyethylene terephthalate, or 1,4 - cyclohexanedimethylene - 1,4 - cyclohexanedicarboxylate, or a combination thereof.

[0139] Aspect 4. A polymer composition according to any one of Aspects 1A - 3, wherein the inherently dissipative polymer comprises an ion - doped thermoplastic polyurethane (TPU) - based multiblock copolymer.

[0140] Aspect 5. A polymer composition according to any one of Aspects 1A - 4, wherein the inherently dissipative polymer comprises an ion - doped nylon - based multiblock copolymer.

[0141] Aspect 6. A polymer composition according to any one of Aspects 1A - 5, wherein when tested on a 68 mm x 68 mm x 3 mm plaque sample according to ASTM D257, the inherently dissipative polymer has a surface resistance of about 1×10 7 ohms.

[0142] Aspect 7. A polymer composition according to any one of Aspects 1A - 6, wherein the transesterification inhibitor comprises zinc monophosphate, a mixture of mono - and di - stearyl phosphates, or an alkyl acid phosphate.

[0143] Aspect 8. A polymer composition according to any one of Aspects 1A - 8, wherein when measured according to ASTM D257, the polymer composition exhibits a surface resistance of 1×10 6 to 1×10 9 ohms.

[0144] Aspect 9. A polymer composition according to any one of Aspects 1A - 8, wherein when measured in reflection mode in a 10° observer on a spectrophotometer with D65 illumination, the polymer composition exhibits an L* color value of at least about 50.

[0145] Aspect 10. A polymer composition according to any one of Aspects 1A - 9, wherein when measured in reflection mode in a 10° observer on a spectrophotometer with D65 illumination, the polymer composition exhibits an L* color value of at least about 80.

[0146] Aspect 11. A polymer composition according to any one of Aspects 1A - 10, wherein the polymer composition does not contain or is substantially free of carbon fibers, conductive carbon black, graphite, graphene, carbon nanotubes, or carbon nanostructures.

[0147] Aspect 12. A polymer composition according to any one of Aspects 1A - 11, wherein the polymer composition further comprises a polycarbonate - siloxane copolymer.

[0148] Aspect 13. A polymer composition according to any one of Aspects 1A - 11, wherein the polymer composition further comprises an impact modifier.

[0149] Aspect 14. A polymer composition according to any one of Aspects 1A - 13, wherein the polymer composition exhibits a heat distortion temperature of at least 90 °C when tested according to ASTM D648 at 45 MPa and a sample thickness of 3.2 mm.

[0150] Aspect 15. A polymer composition according to any one of Aspects 1A - 14, wherein the composition further comprises an optical brightening agent.

[0151] Aspect 16. The polymer composition of Aspect 15, wherein the additives include pigments, dyes, fillers, plasticizers, fibers, flame retardants, antioxidants, lubricants, wood, glass, metal, ultraviolet agents, antistatic agents, antimicrobial agents, or combinations thereof.

[0152] Examples

[0153] The detailed aspects of the present disclosure are disclosed herein; it should be understood that the disclosed aspects are merely examples of the present disclosure that may be implemented in various forms. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a basis for teaching those skilled in the art to use the present disclosure. The following specific examples will enable the present disclosure to be better understood. However, it is given only as a guide and does not imply any limitation.

[0154] The following examples are provided to illustrate the compositions, methods, and properties of the present disclosure. These examples are merely illustrative and are not intended to limit the present disclosure to the materials, conditions, or method parameters set forth herein.

[0155] General Materials and Methods

[0156] The compositions set forth in the following examples were prepared from the components shown in Table 1.

[0157] Table 1. Components of the Composition

[0158]

[0159] The compositions set forth in the following examples were prepared from the components shown in Table 1.

[0160] The formulations were prepared by extruding the pre - blended components using a twin - screw extruder. The polymer base resins (polycarbonate and polyester), IDP, inhibitor, and additives were pre - mixed and fed through the main feed port. The extrudate was cooled in a water bath before pelletizing. Using Toshiba TMThe TEM-37BS Twin Screw Extruder co-rotating twin screw extruder composites the components between 240 °C and 250 °C. The compounding and molding conditions used are shown in Tables 2 and 3. The processing temperature is maintained as much as possible because IDP has a high probability of reacting with polycarbonate and causing degradation and loss of final surface conductivity. Specific component combinations overcome this technical obstacle, such as enabling low-temperature processing in the present disclosure.

[0161] Table 2. Compounding Conditions for Colored ESD Polycarbonate Grades

[0162] Output (kg / hr) Screw (RPM) Vacuum (bar) Torque (%) Barrel Temperature ℃ Mold Temperature ℃ Set Conditions 40 400 -0.08 56 240 250

[0163] Table 3. Injection Molding Conditions for Colored ESD Polycarbonate Grades

[0164] Molding Parameters Unit Value Pre-drying Time Hour 6 Pre-drying Temperature ℃ 70 Hopper Temperature ℃ 70 Zone 1 Temperature ℃ 220 Zone 2 Temperature ℃ 220 Zone 3 Temperature ℃ 220 Nozzle Temperature ℃ 220 Mold Temperature ℃ 50

[0165] Molded samples are tested according to the standards shown in Table 4.

[0166] Table 4. Test Standards

[0167] Heat Distortion Temperature, HDT ASTM D 648, 0.45MPa, 3.2mm Notched Izod Impact (NII) ASTM D256, Room Temperature Surface Resistance (SR) ASTM D257 Melt Volume Flow Rate (MVR) ISO1133, 2.16kg

[0168] Optical properties such as color and reflectance are measured in the reflectance mode in a 10° observer on a ColorEye TM 7000A under D65 illumination. Evaluation is carried out according to the International Commission on Illumination (CIE) - providing the values of the colorimetric coordinates L*, a*, b*. The coordinates correspond to different color attributes: a* represents red and green; b* represents yellow and blue; and L* represents whiteness. The L* value ranges from 0 to 100. A lower L* value corresponds to the darkness of the material, while an L* value greater than 70 corresponds to the material appearing nearly white to the naked eye.

[0169] According to ASTM D256, a notched Izod impact ("NII") test is performed on molded samples (bars) of 63.5 mm x 12.7 mm x 3.2 mm at 25 °C. The data unit is J / m.

[0170] According to ASTM D4812, an unnotched Izod impact ("UNII") test is performed on molded samples (bars) of 63.5 mm x 12.7 mm x 3.2 mm at 25 °C. The data unit is J / m.

[0171] According to ISO 1133, the melt volume rate (MVR) is measured at 220 °C and 2.16 kg.

[0172] The heat deflection temperature was determined in accordance with ASTM D 648 at 0.45 megapascals (MPa) using a 3.2 mm thick specimen (127 mm x 12.7 mm) with a flatwise specimen orientation. The data are provided in °C.

[0173] Comparative samples C-1 and C-2 were prepared to evaluate the performance of formulations with and without the transesterification inhibitor. The comparative samples did not contain the polycarbonate copolymer or the polyester PBT 315. Table 5 (shown Figure 1 in) presents these formulations and the properties observed (surface resistance and L*).

[0174] The combination of nylon-based IDP and pure PC (C-1 and C-2 in Table 5) did not reduce the surface resistance to below 1 x 10 10 ohms, whether or not a transesterification inhibitor was added additionally. For EX-1, the ITR-BPAPC copolymer SLX and PBT were used as building blocks, and the surface resistance was reduced to 1 x 10 9 ohms, meeting the ESD requirements. SLX has good chemical resistance, so it can remain intact under the attack of nylon-based IDP, and PBT, as a crystalline polymer, is also not affected by nylon. In addition, PBT flows faster than amorphous PC and brings the IDP closer to the surface of the molded part, which is crucial for the formation of the conductive network.

[0175] The formulations in Table 5 were prepared by small-scale screw mixing to prevent any thermal degradation. For more general manufacturing purposes, further samples were prepared using a screw of conventional size. Their formulations (recipes) and their corresponding properties are presented in Table 6 ( Figure 2 ).

[0176] EX-2 reproduced the results of EX-1, showing a surface resistance as low as E+9 ohms. The HDT and notched Izod impact (NII) values also remained at a high level. Compared with the SLX / PBT of EX-1, EX-5 did not maintain 1 x 10 9The surface resistance of Ohm's. For other crystalline polymers blended with SLX, PCCD in EX-4 achieved a low surface resistance, but not EX-3 with PET as the polyester polymer base resin. EX-4 including IDP / SLX / PCCD also maintained a high HDT and NII. For blends of PC homopolymer with PET (EX-6) or PCCD (EX-7), granulation failed because the extruded strands did not maintain their shape. Without being bound by any specific theory, this can be attributed to the degradation of the PC homopolymer, while SLX (ITR-BPAPC copolymer) exhibits good chemical resistance. Compared with the control sample C-3 (commercial grade name DD000), it can be easily found that the formulations we claim (EX-2 to EX-5) all have much higher toughness measured by the notched Izod impact. Regarding the processing freedom, the conventional carbon black filled PC (C-3) cannot be processed below 300 °C, while EX-2 to EX-5 in Table 5.2 can all be injection molded at 220 °C.

[0177] Further IDP was also studied. AvanDISS produced by Avanzare TM 378 is not a nylon-based polymer and is conventionally considered not to be as chemically aggressive to PC as Pelectron TM AS. Table 7 (shown in Figure 3 it) presents three blends of avanDISS TM 378 / SLX or PC homopolymer / PBT, which exhibit a surface resistance as low as 1×10 9 Ohm and fairly thermal / mechanical properties.

[0178] The optical properties of the samples were also evaluated by naked-eye visual inspection and by a spectrophotometer. Another important feature of this formulation is that the appearance of all the listed blends is nearly white. As Figure 4A shown, the molded plates formed from the PC copolymer / PBT / IDP blend (EX-2) are white or light in color, enabling further coloring. In Figure 4B it, the conventional ESD material (C-3) appears completely black and has no potential for coloring. The L* values shown in Tables 5 and 6 also quantitatively indicate the coloring potential. The L* values of EX-1 and EX-2 are 90.6 and 82.5 respectively. This means a high potential for further coloring. For the control sample C-3 (carbon black filled PC), the observed L* value is 26. This black or dark color inhibits any further color space.

[0179] The patentable scope of the present disclosure is defined by the claims and may include other examples that would be contemplated by those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that have insubstantial differences from the literal language of the claims.

Claims

1. A polymer composition comprising: 45 wt.% to 85 wt.% of a polycarbonate copolymer, homopolymer, or blends thereof; 1 wt.% to 30 wt.% of a crystalline polyester; 12 wt.% to 35 wt.% of an inherently dissipative polymer comprising an ion-doped thermoplastic polyurethane (TPU)-based multiblock copolymer or an ion-doped nylon-based multiblock copolymer; and 0.001 wt.% to 10 wt.% of a transesterification inhibitor, wherein the composition comprises less than 0.5 wt.% of carbon fiber, conductive carbon black, graphite, graphene, carbon nanotubes, or carbon nanostructures, wherein the polymer composition exhibits a surface resistance of less than 1×10 9 ohms when measured according to ASTM D257, and wherein the combined weight percentage values of all components do not exceed 100 wt.%, and all weight percentage values are based on the total weight of the polymer composition.

2. The polymer composition according to claim 1, wherein the polycarbonate copolymer comprises ITR-BPAPC, BPAPC, or a combination thereof.

3. The polymer composition according to claim 1, wherein the polyester comprises polybutylene terephthalate, polyethylene terephthalate, or 1,4-cyclohexanedimethylene-1,4-cyclohexanedicarboxylate, or a combination thereof.

4. The polymer composition according to claim 1, wherein the inherently dissipative polymer has a surface resistance of 1×10 7 ohms when tested on a 68 mm x 68 mm x 3 mm plaque sample in accordance with ASTM D257.

5. The polymer composition according to claim 1, wherein the transesterification inhibitor comprises zinc monophosphate, a mixture of mono- and di-stearyl phosphates, or an alkyl acid phosphate.

6. The polymer composition according to any one of claims 1-5, wherein the polymer composition exhibits a surface resistance of 1×10 6 to 1×10 9 ohms when measured according to ASTM D257.

7. The polymer composition according to any one of claims 1-5, wherein the polymer composition exhibits an L* color value of at least 50 when measured in reflection mode using a spectrophotometer with D65 illumination and a 10° observer.

8. The polymer composition according to any one of claims 1-5, wherein the polymer composition exhibits an L* color value of at least 80 when measured in reflection mode using a spectrophotometer with D65 illumination and a 10° observer.

9. The polymer composition according to any one of claims 1-5, wherein the polymer composition further comprises a polycarbonate-siloxane copolymer.

10. The polymer composition according to any one of claims 1-5, wherein the polymer composition further comprises an impact modifier.

11. The polymer composition according to any one of claims 1-5, wherein the polymer composition exhibits a heat distortion temperature of at least 90 °C when tested according to ASTM D648 with a sample thickness of 0.45 Mpa and 3.2 mm.

12. The polymer composition according to any one of claims 1-5, wherein the composition further comprises an optical brightening agent.

13. The polymer composition according to claim 5, wherein the composition further comprises additives, the additives comprising pigments, dyes, fillers, plasticizers, fibers, flame retardants, antioxidants, lubricants, wood, glass, metals, ultraviolet agents, antistatic agents, antimicrobials, or a combination thereof.

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