Chemically resistant ultrasound weldable

Abstract

An ultrasonically weldable component comprising improved weld strength and chemical resistance, comprising a thermoplastic composition comprising a poly (carbonate-siloxane) composition comprising: based on the total weight of the thermoplastic composition, at least a portion of the thermoplastic composition comprising at least a portion of the thermoplastic composition, and at least a portion of the thermoplastic composition comprising at least a portion of the thermoplastic composition, and at least a portion of the thermoplastic composition comprising at least a portion of the thermoplastic composition; a poly (carbonate-siloxane) containing from 30 to 70 wt% siloxane repeat units, or a poly (carbonate-siloxane) containing from 30 to 70 wt% siloxane repeat units and a poly (carbonate-siloxane) containing from 2 to less than 30 wt% siloxane repeat units, optionally a polycarbonate, present in an amount effective to provide less than 6 wt% siloxane repeat units, or a poly (carbonate-siloxane) containing from 30 to 70 wt% siloxane repeat units and a poly (carbonate-siloxane) containing from 2 to less than 30 wt% siloxane repeat units, and optionally an additive composition, wherein the siloxane domain of a molded sample of the thermoplastic composition has an average diameter of 70 nm or less as measured using an atomic force microscope.

Description

Background Art

[0001] The present disclosure relates to ultrasonically weldable components, and in particular to chemically resistant ultrasonically weldable components, methods of making, and articles thereof.

[0002] Polycarbonates are useful in making articles and assemblies for a wide range of applications, from automotive parts to electronic appliances. Due to their widespread use, particularly in healthcare and electronics, it is desirable to provide polycarbonates that are ultrasonically weldable.

[0003] Therefore, there remains a need in the art for ultrasonically weldable thermoplastic compositions. It would be a further advantage if the thermoplastic composition was also chemically resistant. Summary of the invention

[0004] The above and other deficiencies in the art are met by an ultrasonically weldable part comprising a thermoplastic composition comprising: a poly(carbonate-siloxane) composition comprising: a poly(carbonate-siloxane) comprising from 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide less than 6 wt% of siloxane repeating units, or a poly(carbonate-siloxane) comprising from 30 to 70 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing from 2 wt% to less than 30 wt% of siloxane repeating units, optionally, a polycarbonate, and optionally an additive composition, wherein the siloxane domains of a molded sample of the thermoplastic composition have an average diameter of 70 nm or less as measured using atomic force microscopy.

[0005] In another aspect, a method for forming an ultrasonically weldable part comprises molding, extruding, or shaping the above-described thermoplastic composition to form an ultrasonically weldable part.

[0006] In yet another aspect, an ultrasonically welded article includes the ultrasonically weldable component described above.

[0007] In yet another aspect, a method for forming the ultrasonically welded article described above includes welding the ultrasonically weldable component described above to another thermoplastic component to provide an ultrasonically welded article.

[0008] The above described and other features are exemplified by the following figures, detailed description, examples, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following is a brief description of the drawings, in which like elements are similarly numbered, and which are illustrative of various aspects described herein.

[0010] Figure 1-2 It is shown that the surfaces of the molded samples of Comparative Examples 1, 5 and 6 and Example 8 are Figure 1 ) and 5μm( Figure 2 ) under atomic force microscopy (AFM) photograph. DETAILED DESCRIPTION

[0011] Ultrasonic welding is one of the most popular assembly techniques in the world. It is particularly useful in healthcare applications because it prevents the introduction of contaminants or degradation sources into the weld, thereby ensuring the biocompatibility of medical devices, for example. Ultrasonic components can be used to connect thermoplastic components and are achieved by converting high-frequency electrical energy into high-frequency mechanical motion. Ultrasonic plastic welding usually works by converting high-frequency (25-40kHz) ultrasonic energy into low-amplitude (1-25μm) mechanical vibrations. This mechanical motion, together with the applied force, generates frictional heat (i.e., "joining interface") where the two thermoplastic parts meet. When the thermoplastic material melts, it flows and wets the joining interface. The diffusion and entanglement of the polymer chains of the thermoplastic on the welding area lead to the formation of welding after cooling.

[0012] Conventional compositions comprising a combination of polycarbonate and poly(carbonate-siloxane) have 30-70 wt% siloxane repeating units based on the weight of the poly(carbonate-siloxane) and have good chemical resistance but do not provide ultrasonically welded articles with good weld strength. Although poly(carbonate-siloxane)s containing lower wt% siloxane repeating units have been used to prepare ultrasonically welded articles when an impact modifier is present, the articles have poor chemical resistance.

[0013] Under the conditions for preparing ultrasonically welded parts, poly(carbonate-siloxane) tends to form domains with very high siloxane content ("siloxane domains") and other domains lacking siloxane content in the part. The presence of unevenly dispersed siloxane domains can lead to cosmetic defects in ultrasonically welded parts. AFM can be used to study the surface morphology of ultrasonically weldable parts. In particular, it allows the size and uniformity of siloxane domains to be determined. The inventors have found a correlation between the size of siloxane domains and the weld strength of ultrasonically welded articles prepared from ultrasonically weldable parts with good weld strength (e.g., at least 25 MPa). Those articles containing good strength are prepared from ultrasonically weldable parts containing siloxane domains, the siloxane domains having an average size of 70 nanometers and less (nm) as measured by AFM, which are well dispersed (i.e., uniform) throughout the molded part and its articles.

[0014] Ultrasonic weldable parts are prepared from thermoplastic compositions comprising a particular poly(carbonate-siloxane) composition comprising one or more poly(carbonate-siloxanes) and optionally a polycarbonate different from the one or more poly(carbonate-siloxanes). Thermoplastic compositions are discussed in more detail below.

[0015] As used herein, "polycarbonate" refers to a polymer comprising repeating structural carbonate units of formula (1):

[0016]

[0017] Among them, R 1 At least 60% of the total number of groups contain aromatic moieties, and the remainder are aliphatic, alicyclic, or aromatic. 1 It is C 6-30 An aromatic group, ie, containing at least one aromatic moiety. 1 Can be derived from the formula HO-R 1 -OH, especially an aromatic dihydroxy compound of formula (2):

[0018] HO-A 1 –Y 1 –A 2 –OH(2)

[0019] Among them, A 1 and A 2 Each is a monocyclic divalent aromatic group, and Y 1 is a single bond or includes A 1 With A 2 In one aspect, one atom separates A 1 With A 2 Preferably, each R 1 It can be derived from bisphenols of formula (3):

[0020]

[0021] Among them, R a and R b are independently halogen, C 1-12 Alkoxy, or C 1-12 alkyl, and p and q are each independently an integer from 0 to 4. It should be understood that when p or q is less than 4, the valence of each carbon of the ring is filled with hydrogen. a is a bridging group connecting two hydroxy-substituted aromatic groups, wherein the bridging group and the hydroxy substituent of each C6 arylene group are arranged ortho, meta, or para (preferably para) to each other on the C6 arylene group. a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or C 1-60 Organic groups. The organic bridging group may be cyclic or acyclic, aromatic or non-aromatic, and may further contain heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorus. 1-60The organic group is such that the C6 arylene groups attached thereto are each attached to a common alkylidene carbon or to a C 1-60 In one aspect, p and q are each 1, and R a and R b Each is C 1-3 An alkyl group, preferably a methyl group, is disposed meta to the hydroxy group on each arylene group.

[0022] In one aspect, X a It is C 3-18 Cycloalkylidene, formula -C(R c )(R d )-C 1-25 Alkylene, where R c and R d are independently hydrogen, C 1-12 Alkyl, C 1-12 Cycloalkyl, C 7-12 Aralkyl, C 1-12 Heteroalkyl, or cyclic C 7-12 heteroarylalkyl, or having the formula -C(=R e )-, where R e It is a two-price C 1-12 Hydrocarbyl. These types of groups include methylene, cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, as well as 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, 3,3-dimethyl-5-methylcyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene.

[0023] On the other hand, X a It is C 1-18 Alkylene, C 3-18 Cycloalkylene, fused C 6-18 Cycloalkylene, or formula -J 1 –G–J 2 – a group, where J 1 and J 2 Is the same or different C 1-6 Alkylene, and G is C 3-12 Cycloalkylidene or C 6-16 Arylene.

[0024] For example, X a It can be a substituted C of formula (4) 3-18 Cycloalkylidene:

[0025]

[0026] Among them, R r , R p , R q , and R tare independently hydrogen, halogen, oxygen, or C 1-12 Hydrocarbyl; Q is a direct bond, carbon, or divalent oxygen, sulfur, or -N(Z)-, where Z is hydrogen, halogen, hydroxyl, C 1-12 Alkyl, C 1-12 Alkoxy, C 6-12 Aryl, or C 1-12 acyl; r is 0 to 2, t is 1 or 2, q is 0 or 1, and k is ≥ 0 to 3, provided that R r , R p , R q , and R t At least two of the fused rings together are fused alicyclic, aromatic, or heteroaromatic rings. It should be understood that when the fused rings are aromatic, the ring shown in formula (4) will have unsaturated carbon-carbon bonds, wherein the ring is fused. When k is 1 and q is 0, the ring shown in formula (4) contains 4 carbon atoms, when k is 2, the ring shown in formula (4) contains 5 carbon atoms, and when k is 3, the ring contains 6 carbon atoms. In one aspect, two adjacent groups (e.g., R q and R t together) form an aromatic group, and on the other hand, R q and R t together form an aromatic group and R r and R p Together they form a second aromatic group. q and R t When they form an aromatic group, R p It may be a double-bonded oxygen atom, ie, a ketone, or Q may be -N(Z)-, where Z is phenyl.

[0027] Where X a Bisphenols which are cycloalkylidene groups of formula (4) can be used to prepare polycarbonates comprising phthalidone carbonate units of formula (1a):

[0028]

[0029] Among them, R a , R b , p and q are as in formula (3), R 3 Each is independently C 1-6 alkyl, j is 0 to 4, and R 4 It is hydrogen, C 1-6 Alkyl, or substituted or unsubstituted phenyl, for example with up to 5 C 1-6 Alkyl substituted phenyl. For example, the phthalide carbonate unit has formula (1b):

[0030]

[0031] Among them, R5 is hydrogen, optionally replaced by up to five C 1-6 Alkyl or C 1-4 In one aspect, in formula (1b), R 5 is hydrogen, methyl, or phenyl, preferably phenyl. Carbonate units (1b) wherein R 5 The phenyl group may be derived from 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimide (also known as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one, or N-phenylphenolphthalein bisphenol ("PPPBP")).

[0032] Other bisphenol carbonate repeating units of this type are isatin carbonate units of formula (1c) and (1d):

[0033]

[0034] Among them, R a and R b are independently halogen, C 1-12 Alkoxy, or C 1-12 alkyl, p and q are each independently 0 to 4, and R i It is C 1-12 Alkyl, optionally with 1 to 5 C 1-10 alkyl-substituted phenyl, or optionally substituted with 1 to 5 C 1-10 In one aspect, R a and R b are each methyl, p and q are each independently 0 or 1, and R i It is C 1-4 Alkyl or phenyl.

[0035] Other examples of bisphenol carbonate units derived from bisphenol (3) wherein X a is substituted or unsubstituted C 3-18 Cycloalkylidene, including cyclohexylidene-bridged bisphenols of formula (1e):

[0036]

[0037] Among them, R a and R b Each is independently C 1-12 Alkyl, R g It is C 1-12 alkyl, p and q are each independently 0 to 4, and t is 0 to 10. In one specific aspect, each R a and R b In one aspect, at least one of R a and R b Each is independently C1-4 Alkyl, R g It is C 1-4 alkyl, p and q are each 0 or 1, and t is 0 to 5. In another specific aspect, R a , R b and R g Each is methyl, p and q are each 0 or 1, and t is 0 or 3, preferably 0. In yet another aspect, p and q are each 0, each R g is methyl, and t is 3, such that X a It is 3,3-dimethyl-5-methylcyclohexylidene.

[0038] Examples of other bisphenol carbonate units derived from bisphenol (3) wherein X a is substituted or unsubstituted C 3-18 Cycloalkylidene groups, including adamantyl units of formula (1f) and fluorenyl units of formula (1g)

[0039]

[0040] Among them, R a and R b Each is independently C 1-12 alkyl, and p and q are each independently 1 to 4. In one specific aspect, each R a and R b In one aspect, at least one of R a and R b Each is independently C 1-3 alkyl, and p and q are each 0 or 1; preferably, R a , R b Each is a methyl group, p and q are each 0 or 1, and when p and q are 1, the methyl group is arranged at the meta position of the cycloalkylidene bridging group. The carbonate containing units (1a) to (1g) can be used to produce a polycarbonate having a high glass transition temperature (Tg) and a high heat deformation temperature.

[0041] Other useful formulas HO-R 1 The dihydroxy compounds containing -OH include aromatic dihydroxy compounds of formula (6):

[0042]

[0043] Among them, each R h are independently halogen atoms, C 1-10 Hydrocarbon such as C 1-10 Alkyl, halogen substituted C 1-10 Alkyl, C 6-10 Aryl or halogen substituted C 6-10Aryl, and n is 0 to 4. Halogen is typically bromine.

[0044] Some illustrative examples of specific dihydroxy compounds include the following: 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)isobutylene, 1,1-bis(4-hydroxyphenyl)cyclopentane, Dodecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, α,α'-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-tert-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2 -bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 4,4'-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycol bis(4-hydroxyphenyl) ether, bis(4-hydroxyphenyl) ether, bis(4-hydroxyphenyl) sulfide, bis(4-hydroxyphenyl) sulfoxide, bis(4-hydroxyphenyl) sulfone, 9,9-bis(4-hydroxyphenyl) fluoride, 2,7-dihydroxypyrene, 6,6' -dihydroxy-3,3,3',3'-tetramethylspiro(bis)indane ("spirobiindane bisphenol"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenothiophene, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole, 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, etc.; 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, etc., or combinations thereof.

[0045] Specific examples of the bisphenol compound of formula (3) include 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (hereinafter "bisphenol A" or "BPA"), 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-2-methylphenyl)propane, 1,1-bis(4-hydroxy-tert-butylphenyl)propane, 3,3-bis(4-hydroxyphenyl)phthalimide, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimide (PPPBP), and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). Combinations may also be used. In one specific aspect, the polycarbonate is a linear homopolymer derived from bisphenol A, wherein each A in formula (3) 1 and A 2 is p-phenylene and Y 1 It is isopropylidene.

[0046] The polycarbonate may have an intrinsic viscosity of 0.3 to 1.5 deciliters per gram (dl / gm), preferably 0.45 to 1.0 dl / gm, as measured in chloroform at 25°C. The polycarbonate may have a weight average molecular weight (Mw) of 10,000 to 200,000 g / mol, preferably 20,000 to 100,000 g / mol, as measured by gel permeation chromatography (GPC) using a crosslinked styrene-divinylbenzene column and polystyrene standards, and calculated for the polycarbonate. The GPC sample was prepared at a concentration of 1 mg / ml and eluted at a flow rate of 1.5 ml / min.

[0047] One or more linear homopolycarbonates may be present. For example, the linear homopolycarbonate may include a bisphenol A homopolycarbonate comprising a weight average molecular weight of 15,000 to 25,000 g / mol, 17,000 to 23,000 g / mol, or 18,000 to 22,000 g / mol, a bisphenol A homopolycarbonate comprising a weight average molecular weight of 26,000 to 40,000 g / mol, or 26,000 to 35,000 g / mol, or a combination thereof, each measured by GPC according to a polystyrene standard and calculated for polycarbonate. The weight ratio of the linear homopolycarbonate relative to each other is 10:1 to 1:10, or 5:1 to 1:5, or 3:1 to 1:3, or 2:1 to 1:2, or 1:1.

[0048] When present, the one or more linear homopolycarbonates may be present in an amount of 1 to 99 weight percent, based on the total weight of the thermoplastic composition.

[0049] "Polycarbonate" includes homopolycarbonates (wherein each R 1 are the same), in carbonates containing different R 1 Partial copolymers ("copolycarbonates"), as well as copolymers comprising carbonate units and other types of polymer units such as ester units or siloxane units.

[0050] The polycarbonate may be an aromatic poly(ester-carbonate). In addition to the repeating carbonate units of formula (1), such polycarbonate further comprises repeating ester units of formula (3):

[0051]

[0052] Wherein, J is a divalent group derived from an aromatic dihydroxy compound (including its reactive derivatives), such as a bisphenol of formula (2), for example, bisphenol A; and T is a divalent group derived from an aromatic dicarboxylic acid (including its reactive derivatives), preferably isophthalic acid or terephthalic acid, wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. Copolyesters containing a combination of different T or J groups can be used. The polyester unit can be branched or linear.

[0053] In one aspect, J is derived from a bisphenol of formula (2), for example, bisphenol A. In another aspect, J is derived from an aromatic dihydroxy compound, for example, resorcinol. A portion of the group J, for example up to 20 mole % (mol %), may be a C containing a linear, branched or cyclic (including polycyclic) structure. 2-30 Alkylene, for example ethylene, n-propylene, isopropylene, 1,4-butylene, 1,4-cyclohexylene or 1,4-methylenecyclohexane. Preferably, all J groups are aromatic.

[0054] Aromatic dicarboxylic acids that can be used to prepare polyester units include isophthalic acid or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-dibenzoic acid, or combinations thereof. Acids containing fused rings may also be present, such as 1,4-, 1,5-, or 2,6-naphthalene dicarboxylic acids. Specific dicarboxylic acids include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acids, or combinations thereof. Specific dicarboxylic acids include a combination of isophthalic acid and terephthalic acid, wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. A portion of the group T, for example up to 20 mol%, may be aliphatic, for example derived from 1,4-cyclohexane dicarboxylic acid. Preferably, all T groups are aromatic.

[0055] The molar ratio of ester units to carbonate units in the polycarbonate can vary widely, for example 1:99 to 99:1, preferably 10:90 to 90:10, more preferably 25:75 to 75:25, or 2:98 to 15:85, depending on the desired properties of the final composition.

[0056] Specific poly(ester-carbonates) are those comprising bisphenol A carbonate units and isophthalate / terephthalate-bisphenol A ester units, i.e., poly(bisphenol A carbonate)-co-(bisphenol A-phthalate-ester) of formula (4a):

[0057]

[0058] Wherein, x and y represent the weight percentage of bisphenol A carbonate units and isophthalate / terephthalate-bisphenol A ester units, respectively. Typically, the units are present as blocks. In one aspect, the weight ratio of carbonate units x to ester units y in the polycarbonate is 1:99 to 50:50, or 5:95 to 25:75, or 10:90 to 45:55. Copolymers of formula (5) comprising 35-45 wt% carbonate units and 55-65 wt% ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45 are generally referred to as poly(carbonate-ester) (PCE). Copolymers comprising 15-25 wt% carbonate units and 75-85 wt% ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate from 98:2 to 88:12, are generally referred to as poly(phthalate-carbonate) (PPC).

[0059] In another aspect, the high heat poly(ester-carbonate) is a poly(carbonate-co-monoacrylate) of formula (4b) comprising aromatic carbonate units (1) and repeating monoacrylate units

[0060]

[0061] Among them, R 1 As defined in formula (1), and each R h are independently halogen atoms, C 1-10 Hydrocarbon such as C 1-10 Alkyl groups, halogen-substituted C 1-10 Alkyl group, C 6-10 Aryl group, or halogen substituted C 6-10 aryl group, and n is 0-4. Preferably, each R h Independently C 1-4 alkyl, and n is 0-3, 0-1, or 0. The molar ratio of carbonate units x to ester units z can be 99:1 to 1:99, or 98:2 to 2:98, or 90:10 to 10:90. In aspects, the molar ratio of x:z is 50:50 to 99:1, or 1:99 to 50:50.

[0062] In one aspect, the high heat poly(ester-carbonate) comprises aromatic ester units and monoacrylate units derived from the reaction of a combination of isophthalic acid and terephthalic acid (or reactive derivatives thereof) with resorcinol (or reactive derivatives thereof) to provide isophthalate / terephthalate-resorcinol ("ITR" ester units). The ITR ester units may be present in the high heat poly(ester-carbonate) in an amount greater than or equal to 95 mol%, preferably greater than or equal to 99 mol%, and more preferably greater than or equal to 99.5 mol%, based on the total moles of ester units in the polycarbonate. A preferred high heat poly(ester-carbonate) comprises bisphenol A carbonate units, and ITR ester units derived from terephthalic acid, isophthalic acid, and resorcinol, i.e., a poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) of formula (c):

[0063]

[0064] Wherein, the molar ratio of x:z is 98:2 to 2:98, or 90:10 to 10:90. In aspect, the molar ratio of x:z is 50:50 to 99:1, or 1:99 to 50:50. Based on the total moles of ester units in the copolymer, the ITR ester units can be present in the poly(bisphenol A carbonate-co-isophthalate-terephthalate-resorcinol ester) in an amount greater than or equal to 95 mol%, preferably greater than or equal to 99 mol%, and more preferably greater than or equal to 99.5 mol%. Based on the total moles of units in the copolymer, other carbonate units, other ester units, or combinations thereof can be present in a total amount of 1 to 20 mol%, such as monoaryl carbonate units of formula (5) and bisphenol ester units of formula (3a):

[0065]

[0066] Among them, in the above formula, R h Each is independently C 1-10 Hydrocarbyl, n is 0-4, R a and R b Each is independently C 1-12 alkyl, p and q are each independently an integer of 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or a compound of the formula -C(R c )(R d )-C 1-13 Alkylene, where R c and R d are independently hydrogen or C 1-12 Alkyl, or -C(=R e )-, where R e It is a two-price C 1-12 The bisphenol ester unit may be a bisphenol A phthalate unit of formula (3b):

[0067]

[0068] In one aspect, poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) (4c) comprises 1-90 mol% of bisphenol A carbonate units, 10-99 mol% of isophthalic acid-terephthalic acid-resorcinol ester units, and alternatively 1-60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate units, or combinations thereof. In another aspect, poly(bisphenol A carbonate-co-isophthalate / terephthalic acid-resorcinol ester) (6) comprises 10-20 mol% of bisphenol A carbonate units, 20-98 mol% of isophthalic acid-terephthalic acid-resorcinol ester units, and alternatively 1-60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate units, or combinations thereof.

[0069] The high heat poly(ester-carbonate) may have an Mw of 2,000-100,000 g / mol, preferably 3,000-75,000 g / mol, more preferably 4,000-50,000 g / mol, more preferably 5,000-35,000 g / mol, and still more preferably 17,000-30,000 g / mol. Molecular weight determinations were performed using GPC using a crosslinked styrene-divinylbenzene column at a sample concentration of 1 mg / ml, based on polystyrene standards, and calculated for polycarbonate. The sample was eluted with dichloromethane as the eluent at a flow rate of 1.0 ml / min.

[0070] The poly(carbonate-siloxane) composition of the thermoplastic composition includes one or more poly(carbonate siloxanes). The polysiloxane blocks include repeating diorganosiloxane units as in formula (10):

[0071]

[0072] Where each R is independently C 1-13 A monovalent organic group. For example, R can be C 1-13 Alkyl, C 1-13 Alkoxy, C 2-13 Alkenyl, C 2-13 Alkenyloxy, C 3-6 Cycloalkyl, C 3-6 Cycloalkoxy, C 6-14 Aryl, C 6-10 Aryloxy, C 7-13 Arylalkylene, C 7-13 Arylalkylalkenyloxy, C 7-13 Alkyl arylene, or C 7-13 Alkyl aryleneoxy. The above groups can be completely or partially halogenated with fluorine, chlorine, bromine, or iodine, or a combination thereof. In one aspect, when a transparent poly(carbonate-siloxane) is desired, R is not substituted with a halogen. Combinations of the foregoing R groups can be used in the same copolymer.

[0073] The value of E in formula (10) can vary widely, depending on the type and relative amount of each component in the thermoplastic composition, the desired performance of the composition, and similar considerations. Typically, E has an average value of 2 to 1,000, preferably 2 to 500, 2 to 200, or 2 to 125, 5 to 80, or 10 to 70. In one aspect, E has an average value of 10 to 80 or 10 to 40, and on the other hand, E has an average value of 40 to 80, or 40 to 70. When E has a lower value, such as less than 40, it is desirable to use a relatively large amount of poly (carbonate-siloxane) copolymers. On the contrary, when E has a higher value, such as greater than 40, a relatively low amount of poly (carbonate-siloxane) copolymers can be used. A combination of the first and second (or more) poly (carbonate-siloxane) copolymers can be used, wherein the average value of the E of the first copolymer is less than the average value of the E of the second copolymer.

[0074] In one aspect, the polysiloxane block has formula (11):

[0075]

[0076] wherein E and R are as defined in formula (10); each R may be the same or different and is as defined above; and Ar may be the same or different and is substituted or unsubstituted C 6-30 Arylene, wherein the bond is directly attached to the aromatic moiety. The Ar group in formula (11) can be derived from C 6-30 Dihydroxyarylene compounds, for example, dihydroxyarylene compounds of formula (3) or (6). The dihydroxyarylene compounds are 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxyphenyl)cyclohexane, bis(4-hydroxyphenyl sulfide), and 1,1-bis(4-hydroxy-tert-butylphenyl)propane.

[0077] In another aspect, the polysiloxane block has formula (13):

[0078]

[0079] Where R and E are as described above, and each R 5 Independently divalent C 1-30 In one specific aspect, the polysiloxane block is of formula (14):

[0080]

[0081] Wherein, R and E are as defined above. 6 It is a two-price C 2-8 Each M in formula (14) may be the same or different and may be halogen, cyano, nitro, C 1-8 Alkylthio, C 1-8 Alkyl, C 1-8 Alkoxy, C 2-8 Alkenyl, C 2-8 Alkenyloxy, C 3-8 Cycloalkyl, C 3-8 Cycloalkoxy, C 6-10 Aryl, C 6-10 Aryloxy, C 7-12 Aralkyl, C 7-12 Aralkyloxy, C 7-12 Alkyl, or C 7-12 Alkaryloxy, wherein each n is independently 0, 1, 2, 3 or 4.

[0082] In one aspect, M is bromo or chloro, alkyl such as methyl, ethyl, or propyl, alkoxy such as methoxy, ethoxy, or propoxy, or aryl such as phenyl, chlorophenyl, or tolyl; R 6 is dimethylene, trimethylene or tetramethylene; and R is C 1-8 In one aspect, R is methyl, M is methoxy, n is 1, and R is 1. 6 It is a two-price C 1-3 Aliphatic group. The specific polysiloxane block is the following formula:

[0083]

[0084] or a combination thereof, wherein E has an average value of 2 to 200, 2 to 125, 5 to 125, 5 to 100, 5 to 50, 20 to 80, or 5 to 20.

[0085] The blocks of formula (14) can be derived from the corresponding dihydroxy polysiloxanes, which in turn can be prepared to effect a platinum-catalyzed addition between siloxane hydrides and aliphatically unsaturated monohydric phenols such as eugenol, 2-alkylphenols, 4-allyl-2-methylphenol, 4-allyl-2-phenylphenol, 4-allyl-2-bromophenol, 4-allyl-2-tert-butoxyphenol, 4-phenyl-2-phenylphenol, 2-methyl-4-propylphenol, 2-allyl-4,6-dimethylphenol, 2-allyl-4-bromo-6-methylphenol, 2-allyl-6-methoxy-4-methylphenol, and 2-allyl-4,6-dimethylphenol. Poly(carbonate-siloxane) copolymers can then be made, for example, by the synthetic procedure of Hoover's European Patent Application Publication No. 0524731A1, page 5, Preparation 2.

[0086] The transparent poly(carbonate-siloxane) copolymer comprises carbonate units (1) derived from bisphenol A, and repeating siloxane units (14a), (14b), (14c), or a combination thereof (preferably Formula 14a), wherein E has an average value of 4 to 50, 4 to 15, preferably 5 to 15, more preferably 6 to 15, and even more preferably 7 to 10. The transparent copolymer can be made using one or both of the tubular reactor methods described in U.S. Patent Application No. 2004 / 0039145A1, or the poly(carbonate-siloxane) copolymer can be synthesized using the method described in U.S. Patent No. 6,723,864.

[0087] The poly(carbonate-siloxane) composition of the thermoplastic composition includes one or more poly(carbonate siloxanes). The poly(carbonate-siloxane) composition includes a poly(carbonate-siloxane) comprising 30 to 70 wt% siloxane repeating units, based on the weight of the poly(carbonate-siloxane). Within this range, the poly(carbonate-siloxane) can have 35 to 70 wt%, or 35 to 65 wt%, or 35-55 wt%, or 35-45 wt% siloxane repeating units.

[0088] The poly(carbonate-siloxane) composition can include one or more poly(carbonate-siloxanes) containing 30 to 70 wt% siloxane repeating units. When the poly(carbonate-siloxane) composition is limited to one or more poly(carbonate-siloxanes) containing 30 to 70 wt% siloxane repeating units and does not include one or more auxiliary poly(carbonate-siloxane) copolymers containing 2 to less than 30 wt% siloxane repeating units, then based on the weight of the thermoplastic composition, one or more poly(carbonate-siloxanes) containing 30 to 70 wt% siloxane repeating units are present in an amount effective to provide less than 6 wt%, or 2 to less than 6 wt% siloxane repeating units. In this regard, polycarbonate is present. Polycarbonate includes linear homopolycarbonate, poly(phthalate-carbonate), or a combination thereof. In some aspects, the polycarbonate is a linear homopolycarbonate. In some aspects, the polycarbonate is a combination of a linear homopolycarbonate and a poly(phthalate-carbonate).

[0089] In some aspects, the poly(carbonate-siloxane) composition comprises a combination of one or more poly(carbonate-siloxanes) containing 30 to 70 wt % siloxane repeating units and one or more auxiliary poly(carbonate-siloxanes) containing 2 wt % to less than 30 wt % siloxane repeating units.

[0090] The auxiliary poly(carbonate-siloxane) can have 10 to less than 30 wt% siloxane repeating units based on the total weight of the poly(carbonate-siloxane). Within this range, the poly(carbonate-siloxane) copolymer can have 15 to 25 wt% siloxane repeating units.

[0091] The auxiliary poly(carbonate-siloxane) can have 2 to less than 10 wt% siloxane repeating units based on the total weight of the poly(carbonate-siloxane). Within this range, the poly(carbonate-siloxane) can have 4 to less than 10 wt% siloxane repeating units.

[0092] The auxiliary poly(carbonate siloxane) may include one or more poly(carbonate-siloxane) copolymers comprising 10 wt% to less than 30 wt% siloxane repeating units and one or more poly(carbonate-siloxane) copolymers comprising 2 wt% to less than 10 wt% siloxane repeating units.

[0093] When the poly(carbonate siloxane) composition includes an auxiliary poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units, the poly(carbonate-siloxane) containing 30 to 70 wt% of siloxane repeating units can be present in an amount effective to provide up to 6 wt%, or 0.5-6 wt%, of siloxane repeating units, based on the total weight of the thermoplastic composition, and the poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units can be present in an amount effective to provide up to 6 wt%, or 0.5-6 wt%. The poly(carbonate-siloxane) containing 30 to 70 wt% of siloxane repeating units and the auxiliary poly(carbonate-siloxane) together can be present in an amount effective to provide up to 10 wt%, or 2-10 wt%, of siloxane repeating units, based on the total weight of the thermoplastic composition.

[0094] When the poly(carbonate siloxane) composition comprises one or more poly(carbonate-siloxane) copolymers containing 10 to less than 30 weight percent siloxane repeating units and one or more poly(carbonate-siloxane) copolymers containing 30 to 70 weight percent siloxane repeating units, the poly(carbonate-siloxane) copolymers containing 10 to less than 30 weight percent siloxane repeating units can be present in an amount effective to provide up to 6 weight percent, 0.5 to 6 weight percent, 0.5 to 5 weight percent, 0.5 to 4 weight percent, %, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units, and one or more poly(carbonate-siloxane)s containing 30 wt% to 70 wt% of siloxane repeating units can be present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units, each based on the total weight of the composition.

[0095] When the poly(carbonate siloxane) composition comprises one or more poly(carbonate-siloxane) copolymers containing 2 to less than 10 weight percent of siloxane repeating units and one or more poly(carbonate-siloxane)s containing 30 to 70 weight percent of siloxane repeating units, the poly(carbonate-siloxane) copolymers containing 2 to less than 10 weight percent of siloxane repeating units can be present in an amount effective to provide up to 6 weight percent, 0.5-6 weight percent, 0.5-5 weight percent, 0.5-4 weight percent, 1-6 weight percent, 1-5 weight percent, or % siloxane repeating units, and one or more poly(carbonate-siloxane)s containing 30 wt% to 70 wt% siloxane repeating units can be present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 0.5-3 wt%, or 0.5-2 wt%, 1-6 wt%, 1-5 wt%, 1-4 wt%, 1-3 wt%, or 1-2 wt% siloxane repeating units, each based on the total weight of the composition.

[0096] In one aspect, blends are used, especially blends of bisphenol A homopolycarbonate and poly(carbonate-siloxane) block copolymers of bisphenol A blocks and eugenol-terminated polydimethylsiloxane blocks of the formula:

[0097]

[0098] wherein x is 1 to 200, preferably 5 to 85, preferably 10 to 70, preferably 15 to 65, and more preferably 40 to 60; x is 1 to 500, or 10 to 200, and z is 1 to 1000, or 10 to 800. In one aspect, x is 1 to 200, y is 1 to 90 and z is 1 to 600, and in another aspect, x is 30 to 50, y is 10 to 30 and z is 45 to 600. The polysiloxane blocks may be randomly distributed or controlled distributed in the polycarbonate blocks.

[0099] The poly(carbonate-siloxane) can have a weight average molecular weight of 2,000 to 100,000 g / mol, preferably 5,000 to 50,000 g / mol, as measured by gel permeation chromatography using a crosslinked styrene-divinylbenzene column with a sample concentration of 1 mg / ml and calibrated for polystyrene and calculated for polycarbonate.

[0100] The poly(carbonate-siloxane) can have a melt volume flow rate of 1 to 50 cubic centimeters per 10 minutes (cc / 10 min), preferably 2 to 30 cc / 10 min, measured at 300°C / 1.2 kg. Combinations of poly(carbonate-siloxane)s having different flow properties can be used to achieve the overall desired flow properties.

[0101] Thermoplastic compositions can include various additives that are usually incorporated into this type of polymer composition, provided that the additive is selected to not significantly adversely affect the desired properties of the thermoplastic composition, especially chemical resistance and ultrasonic weldability (e.g., weld strength). During the period of mixing the components for forming the composition, such additives can be mixed at the appropriate time. Additives include fillers, reinforcing agents, antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV) light stabilizers, plasticizers, lubricants, mold release agents, antistatic agents, colorants such as titanium dioxide, carbon black and organic dyes, surface effect additives, radiation stabilizers, flame retardants and anti-dripping agents. Typically, additives are used in a known effective amount. For example, based on the gross weight of the thermoplastic composition, the total amount of additives (except any impact modifier, filler or reinforcing agent) can be 0.01 to 10wt%.

[0102] Thermoplastic compositions may include flame retardants. Useful flame retardants include organic compounds including phosphorus, bromine, chlorine or fluorine. For regulatory reasons, non-brominated and non-chlorinated phosphorus-containing flame retardants may be preferred in certain applications, for example, organic phosphates and organic compounds comprising phosphorus-nitrogen bonds. Therefore, thermoplastic compositions may be substantially free of halogen. As used herein, the phrase "substantially free of halogen" is defined by IEC 61249-2-21 or UL 746H. According to the International Electrochemical Commission, Restriction Use of Halogen (IEC 61249-2-21), the composition should include chlorine and bromine each 900ppm (ppm) or less, and also include a total bromine, chlorine and fluorine content of less than 1500ppm. According to UL 746H, the composition should include 900ppm or less of each of chlorine, bromine and fluorine and 1500ppm or less of total chlorine, bromine and fluorine content. Bromine, chlorine and fluorine content (in ppm) can be calculated by the composition or measured by elemental analysis techniques.

[0103] Inorganic flame retardants such as C 2-16Salts of alkyl sulfonates such as potassium perfluorobutanesulfonate (Rimar salt), potassium perfluorooctanesulfonate and tetraethylammonium perfluorohexanesulfonate, salts of aromatic sulfonates such as sodium benzenesulfonate, sodium toluenesulfonate (NATS), etc., salts of aromatic sulfone sulfonates such as potassium diphenylsulfonesulfonate (KSS), etc.; salts formed by reaction, for example, alkali metal or alkaline earth metal (e.g., lithium, sodium, potassium, magnesium, calcium and barium salts) and inorganic acid complex salts, for example, oxygen-containing anions (e.g., alkali metal and alkaline earth metal salts of carbonate, such as Na2CO3, K2CO3, MgCO3, CaCO3, and BaCO3, or fluorine-containing anion complexes such as Li3AlF6, BaSiF6, KBF4, K3AlF6, KAlF4, K2SiF6, or Na3AlF6, etc.). Rimar salts, KSS and NATS, alone or in combination with other flame retardants, are particularly useful. Rimar salts and KSS and NATS, alone or in combination with other flame retardants, are particularly useful. The perfluoroalkyl sulfonate may be present in an amount of 0.30 to 1.00 wt%, preferably 0.40 to 0.80 wt%, and more preferably 0.45 to 0.70 wt%, based on the total weight of the composition. The aromatic sulfonate may be present in an amount of 0.01 wt% to 0.1 wt%, preferably 0.02 wt% to 0.06 wt%, and more preferably 0.03 wt% to 0.05 wt% in the final thermoplastic composition. An exemplary amount of the aromatic sulfone sulfonate may be 0.01 wt% to 0.6 wt%, preferably 0.1 wt% to 0.4 wt%, and more preferably 0.25 wt% to 0.35 wt%, based on the total weight of the thermoplastic composition.

[0104] Halogenated materials can also be used as flame retardants, such as halogenated compounds and polymers of formula (20):

[0105]

[0106] Wherein, R is an alkylene, alkylidene, or alicyclic bond (e.g., methylene, ethylene, propylene, isopropylene, isopropylidene, butylene, isobutylene, pentylene, cyclohexylene, cyclopentylidene, etc.), selected from bonds of oxygen ether, carbonyl, amine, sulfur-containing bonds (e.g., thioether, sulfoxide, or sulfone), phosphorus-containing bonds, etc., or R may also be composed of two or more alkylene or alkylidene bonds connected by groups such as aromatic, amino, ether, carbonyl, thioether, sulfoxide, sulfone, phosphorus-containing bonds, etc.; Ar and Ar' may be X, ... each X is the same or different and is a monovalent hydrocarbon group, such as an alkyl group (e.g., methyl, ethyl, propyl, isopropyl, butyl, decyl, etc.), an aryl group (e.g., phenyl, naphthyl, biphenyl, xylyl, tolyl, etc.), an arylalkylene group (e.g., benzyl, vinylphenyl, etc.), an alicyclic group (e.g., cyclopentyl, cyclohexyl, etc.), and a monovalent hydrocarbon group containing an inert substituent; the letter d represents a maximum of 1 to the same number of replaceable hydrogens as the number substituted on the aromatic ring containing Ar or Ar'. The letter e represents an integer from 0 to a maximum value equal to the number of replaceable hydrogens on R; the letters a, b and c represent integers including 0, provided that when b is not 0, neither a nor c can be 0, or either a or c but not both can be 0, or when b is 0, the aromatic group is attached by a direct carbon-carbon bond; the hydroxyl and Y substituents, Ar and Ar' on the aromatic group can vary in the ortho, meta or para position of the aromatic ring, and the groups can be in any possible geometric relationship to each other.

[0107] Included within the scope of the above formula are the following representative bisphenols: 2,2-bis-(3,5-dichlorophenyl)-propane; bis-(2-chlorophenyl)-methane; bis-(2,6-dibromophenyl)-methane; 1,1-bis-(4-iodophenyl)-ethane; 1,2-bis-(2,6-dichlorophenyl)-ethane; 1,1-bis-(2-chloro-4-iodophenyl)-ethane; 1,1-bis-(2-chloro-4-methylphenyl)-ethane; 1,1-bis-(3,5-dichlorophenyl)-ethane; 2,2-bis-(3-phenyl-4-bromophenyl)-ethane ; 2,6-bis-(4,6-dichloronaphthyl)-propane; 2,2-bis-(2,6-dichlorophenyl)-pentane; 2,2-bis-(3,5-dibromophenyl)-hexane; bis-(4-chlorophenyl)-phenyl-methane; bis-(3,5-dichlorophenyl)-cyclohexylmethane; bis-(3-nitro-4-bromophenyl)-methane; bis-(4-hydroxy-2,6-dichloro-3-methoxyphenyl)-methane; and 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane; 2,2-bis-(3-bromo-4-hydroxyphenyl)-propane. Also included in the above structural formula are: 1,3-dichlorobenzene, 1,4-dibromobenzene, 1,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'-dibromobiphenyl, and 2,4'-dichlorobiphenyl and decabromodiphenyl ether.

[0108] Oligomeric and polymeric halogenated aromatic compounds are also useful, such as copolycarbonates of bisphenol A and tetrabromobisphenol A with carbonate precursors (eg, phosgene). Metal synergists, such as antimony oxide, may also be used with the flame retardants.

[0109] The flame retardant may include an organic phosphorus compound. In an organic phosphorus compound having at least one organic aromatic group, the aromatic group may be a substituted or unsubstituted C 3-30 Group, the C 3-30 The group contains one or more monocyclic or polycyclic aromatic moieties (which may optionally contain up to three heteroatoms (N, O, P, S, or Si)) and optionally further contains one or more non-aromatic moieties, such as alkyl, alkenyl, alkynyl, or cycloalkyl. The aromatic portion of the aromatic group may be directly bonded to the phosphorus-containing group, or bonded via another portion (e.g., an alkylene group). The aromatic portion of the aromatic group may be directly bonded to the phosphorus-containing group, or bonded via another portion (e.g., an alkylene group). In one aspect, the aromatic group is the same as the aromatic group of the polycarbonate backbone, such as a bisphenol group (e.g., bisphenol A), a monoarylene group (e.g., 1,3-phenylene or 1,4-phenylene), or a combination comprising at least one of the foregoing.

[0110] The phosphorus-containing group can be a phosphate (P(=O)(OR)3), a phosphite (P(OR)3), a phosphonate (RP(=O)(OR)2), a phosphinate (R2P(=O)(OR)), a phosphine oxide (R3P(=O)), or a phosphine (R3P), wherein each R in the aforementioned phosphorus-containing group can be the same or different, provided that at least one R is an aromatic group. Combinations of different phosphorus-containing groups can be used. The aromatic group can be directly or indirectly bonded to the phosphorus, or bonded to the oxygen of the phosphorus-containing group (i.e., ester).

[0111] In one aspect, the aromatic organophosphorus compound is a monomeric phosphate. Representative monomeric aromatic phosphates have the formula (GO) 3P=O, wherein each G is independently an alkyl, cycloalkyl, aryl, alkylarylene, or arylalkylene group containing up to 30 carbon atoms, with the condition that at least one G is an aromatic group. Two G groups can be linked together to provide a cyclic group. In some aspects, G corresponds to a monomer for forming a polycarbonate, for example, resorcinol. Exemplary phosphates include phenyl didodecyl phosphate, phenyl di(neopentyl) phosphate, phenyl di(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, di(2-ethylhexyl) p-tolyl phosphate, tricresyl phosphate, di(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, didodecyl p-tolyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl di(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, etc. Specific aromatic phosphates are those in which each G is aromatic, for example, triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, etc.

[0112] Difunctional or polyfunctional aromatic organophosphorus compounds are also useful, for example, compounds of the formula:

[0113]

[0114] Among them, each G 1 Independently C 1-30 Hydrocarbon; each G 2 Independently for C 1-30 Hydrocarbyl or alkoxy; X a is as defined in formula (3) or formula (4); each X is independently bromine or chloride; m is 0 to 4, and n is 1 to 30. In one specific aspect, X a It is a single bond, methylene, isopropylidene or 3,3,5-trimethylcyclohexylidene.

[0115] Specific aromatic organophosphorus compounds include acid esters of formula (9):

[0116]

[0117] Among them, each R 16 Independently C 1-8 Alkyl, C 5-6 Cycloalkyl, C 6-20 Aryl, or C 7-12 Arylalkylene, each optionally substituted by C 1-12 Alkyl, specifically C 1-4 alkyl substituted, and X is a mononuclear or polynuclear aromatic C 6-30 Partial or linear or branched C 2-30 aliphatic groups which may be OH-substituted and may contain up to 8 ether bonds, provided that at least one R 16 or X is an aromatic group; each n is independently 0 or 1; and q is from 0.5 to 30. In some aspects, each R 16 Independently C 1-4 Alkyl, naphthyl, phenyl (C 1-4 ) alkylene, optionally C 1-4 Alkyl substituted aryl group; each X is a mononuclear or polynuclear aromatic C 6-30 part, each n is 1; and q is from 0.5 to 30. In some aspects, each R 16 is aromatic, such as phenyl; each X is a mononuclear or polynuclear aromatic C 6-30 moieties, including moieties derived from formula (2); n is 1; and q is from 0.8 to 15. In other aspects, each R 16 is phenyl; X is tolyl, xylyl, propylphenyl, or butylphenyl, one of the following divalent groups

[0118]

[0119] or a combination comprising one or more of the foregoing; n is 1; and q is 1 to 5, or 1 to 2. In some aspects, at least one R 16 Or X corresponds to the monomer used to form the polycarbonate, for example, bisphenol A, resorcinol, etc. Aromatic organophosphorus compounds of this type include bis(diphenyl)phosphate of hydroquinone, resorcinol bis(diphenyl phosphate) (RDP), and bisphenol A bis(diphenyl)phosphate (BPADP), as well as their oligomeric and polymeric counterparts.

[0120] The organophosphorus flame retardant containing a phosphorus-nitrogen bond can be a phosphazene, a phosphazene chloride, a phosphorus ester amide, a phosphoric acid amide, a phosphonic acid amide, a phosphinate amide, or a tris(aziridinyl)phosphine oxide. These flame retardant additives are commercially available. In one aspect, the organophosphorus flame retardant containing a phosphorus-nitrogen bond is a phosphazene or a cyclic phosphazene of the formula:

[0121]

[0122] wherein w1 is 3 to 10,000; w2 is 3 to 25, or 3 to 7; and each R w Independently C 1-12 An alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkylene group. In the above groups, at least one hydrogen atom in these groups may be substituted by a group containing N, S, O, or F atoms, or an amino group. For example, each R w It may be a substituted or unsubstituted phenoxy, amino, or polyoxyalkylene group. w There may further be a crosslink to another phosphazene group. Exemplary crosslinks include bisphenol groups, such as bisphenol A groups. Examples include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, and the like. In one aspect, the phosphazene has a structure represented by the formula:

[0123]

[0124] Commercially available phenoxyphosphazenes containing the above structure are LY202 manufactured and sold by Lanyin Chemical Co., Ltd, FP-110 manufactured and sold by Fushimi Pharmaceutical Co., Ltd, and SPB-100 manufactured and sold by Otsuka Chemical Co., Ltd.

[0125] When present, phosphorus-containing flame retardants are generally present in an amount effective to provide up to 2 weight percent phosphorus, based on the total weight of the thermoplastic composition.

[0126] Anti-drip agents, such as fibril-forming or non-fibril-forming fluoropolymers such as polytetrafluoroethylene (PTFE), may also be used in the composition. The anti-drip agent may be encapsulated by a rigid copolymer, such as a styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is referred to as TSAN. TSAN contains 50 wt% PTFE and 50 wt% SAN, based on the total weight of the encapsulated fluoropolymer. SAN may contain, for example, 75 wt% styrene and 25 wt% acrylonitrile, based on the total weight of the copolymer. The anti-drip agent may be used in an amount of 0.1-5 wt%, or 0.1-1.0 wt%, based on the total weight of the thermoplastic composition.

[0127] Thermoplastic compositions can be manufactured by various methods. The components are first optionally blended with fillers in a high-speed mixer. Other low shear methods, including but not limited to manual mixing, can also achieve this blending. The blend is then fed to the throat of a twin-screw extruder through a hopper. Alternatively, at least one component can be incorporated into the composition by directly feeding the extruder through a side stuffer at the throat or downstream. Additives can also be mixed with the desired polymer into a masterbatch and fed to the extruder. The extruder is usually operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched and granulated in a water bath. As required, the pellets prepared in this way can be a quarter inch long or less. Such pellets can be used for subsequent molding, shaping, or forming.

[0128] The transparent composition can be produced by operating a method for making a thermoplastic composition. An example of such a method for producing a transparent thermoplastic composition is described in US Patent Application No. 2003 / 0032725.

[0129] Also provided are ultrasonically weldable shaped, formed, or molded thermoplastic parts comprising the thermoplastic composition.The thermoplastic composition can be molded into useful shaped parts by a variety of methods, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming.

[0130] Ultrasonic welded articles can be prepared using an ultrasonic welding device and parts made of a thermoplastic composition. The ultrasonically weldable shaped, formed or molded thermoplastic parts to be connected together using ultrasonic welding can be placed one above the other on a support surface (i.e., a "clamp"). A titanium or aluminum-plated part (i.e., a "horn") is brought into contact with the upper thermoplastic part. Pressure is applied to the horn, thereby clamping the thermoplastic parts together against the fixture. The horn is then vertically vibrated at 15kHz or 30kHz per second for a predetermined time ("welding time"). Mechanical vibrations are transmitted to the joint contact surface through the thermoplastic part to generate frictional heat. When the temperature at the joint interface reaches the melting point, the thermoplastic composition melts and flows, and the vibration stops, causing the thermoplastic composition to begin to cool. The clamping force is maintained for a predetermined time (i.e., a "hold time") to allow the thermoplastic parts to melt when the molten thermoplastic cools and solidifies. Once the molten thermoplastic has solidified, the clamping force is removed and the horn is retracted. The now joined thermoplastic components are removed from the fixture as one component (ie, an ultrasonically welded article).

[0131] Advantageously, ultrasonic welding avoids the use of solvents, adhesives, and mechanical fasteners. Ultrasonic welded assemblies can be used in applications such as automotive applications, medical applications, electrical and electronic applications, and consumer applications. Ultrasonic welding of thermoplastics is a joining technique particularly suitable for medical applications. It prevents the introduction of contaminants or sources of degradation into the weld, thereby producing a medical device that is essentially free of contaminants and allows very fast and highly repeatable production cycles. Non-limiting examples of medical devices include syringes, blood filter housings, blood bags, solution bags, intravenous connectors, dialyzers, catheters, medical storage trays, medical instruments, medical tubing, pacemakers, defibrillators, cannulas, implantable prostheses, cardiac assist devices, heart valves, vascular grafts, extracorporeal devices, artificial organs, pacemaker leads, defibrillator leads, blood pumps, balloon pumps, AV shunts, membranes for cell encapsulation, wound dressings, artificial joints, orthopedic implants, Petri dishes, face shields, respirators, sensors, and autoclavable articles (e.g., medical or scientific equipment or food processing equipment, any of which can be trays, pans, syringes, containers, etc.).

[0132] Ultrasonic welding can also join complex components, for example, to provide ultrasonically welded articles for electronic applications. Non-limiting examples include computer and business machine housings (such as housings for monitors), handheld electronic device housings (such as housings for cellular phones), and electrical connectors.

[0133] The present disclosure is further illustrated by the following examples, which are non-limiting.

[0134] Example

[0135] The following components were used in the examples. Unless otherwise specifically stated, the amount of each component is in wt % based on the total weight of the composition.

[0136] The materials shown in Table 1 were used.

[0137] Table 1

[0138]

[0139]

[0140] The test samples were prepared as described below and the following test methods were used.

[0141] The typical compounding procedure is described as follows: Various formulations were prepared by direct dry blending of the raw materials and homogenized with a paint shaker prior to compounding. These formulations were compounded on a 25 mm Werner Pfleiderer ZSK co-rotating twin screw extruder. Typical extrusion profiles are listed in Table 2.

[0142] Table 2

[0143]

[0144]

[0145] These formulations were molded into welded test cups on an Arburg 520S molding machine with a closing force of 130 T. The molding conditions for Examples 1-5 are listed in Table 3.

[0146] Table 3

[0147]

[0148] Ultrasonic welding is performed on a BRANSON X2000 ultrasonic welding machine. The BRANSON X2000 includes a transducer with an amplitude of 20kHz and a fixed horn of 2.3 times. A black amplifier (black booster) (factor 2.5X) is used, which produces a maximum amplitude of 115μm. During the ultrasonic welding process, two components are connected together. These two components are called energy directors and energy absorbers. The energy director is mainly a triangle (90°) that transfers energy to the tip, resulting in heat accumulation in a small contact area. This area melts and flows through the energy absorber to form a weld.

[0149] The tensile strength was determined at room temperature on a welded test cup of a LLOYD LR30K tensile testing machine with a 10 KN load cell. The tensile strength was measured on the welded cup at a constant speed of 10 mm / min using a special tool fitted in the cup. To calculate the strength value in MPa, the area (mm 2 ) and breaking force (N). Calculated as follows: Strength (MPa) = force at failure (N) divided by the area of ​​the weld cup (mm 2 ).

[0150] Atomic force microscopy (AFM) experiments were performed using a Dimension FastScan AFM system (Dimension FastScan, Bruker, Santa Barbara, USA). The software Nanoscope Analysis 9.4 from Bruker was used as a computer interface for operation, and Nanoscope Analysis 2.0 from Bruker was used to analyze the AFM measurements. All AFM measurements were performed under ambient conditions. For rubber distribution characterization, the AFM tapping mode in FastScan mode was used at a frequency of 4 Hz, using a FastScan mode AFM tip (model FastScan-A, k: 18 N / m, f: 1400 kHz).

[0151] By using a full factorial design of experiments (DoE), the direction of the equipment settings is defined to obtain the highest possible weld strength. Three settings, amplitude, weld force and deceleration, are used as variables in this study. The outputs are weld strength and cycle time. Table 4 summarizes the weld test machines used for the DOE study.

[0152] Table 4

[0153]

[0154] Examples 1-10

[0155] The compositions and properties of the following comparative examples and examples are shown in Table 5. Comparative examples are indicated by asterisks.

[0156] Table 5

[0157]

[0158]

[0159] The ultrasonic welding performance of molded samples of the thermoplastic compositions of Table 5 was evaluated. Comparative Examples 1-2 were not easily welded with an ultrasonic welder, while Examples 3-10 were welded with optimized settings. Consistent with this observation, the contour plots of Comparative Examples 1-2 from the DoE study (data not shown) were a darker shade of blue, indicating that the weld strength was lower, ranging up to 15 MPa. Example 3 and Comparative Examples 9 and 10 had a mix of light blue (weld strength 10-25 MPa) and green (weld strength greater than 25 MPa) on the contour plots (data not shown). The contour plots of Examples 4, 7 and 8 and Comparative Examples 5-6 were completely green, indicating that the weld strength was greater than 25 MPa (data not shown).

[0160] In addition to good weld strength, ultrasonically welded articles should also have good chemical resistance as determined according to ASTM D-543. Specifically, good chemical resistance can be demonstrated by the retention (expressed in %) of yield / break tensile stress and break tensile elongation. Chemical resistance was evaluated on 3.2 mm ASTM tensile test bars at 23 ° C after exposure to chemical agents. Specifically, the ASTM tensile bars are bent to a specific strain level (e.g., 0.5% or 1% in a test fixture), and the bars are kept constantly exposed to strain and chemical agents for a specified test period. The bars can be wrapped so that they remain saturated when in contact with the strained area. After a predetermined amount of time, the retention (expressed in %) of the yield / break tensile stress and break tensile elongation is measured. The yield stress retention should be greater than 90%, and the elongation at break retention should be 80 to 139%.

[0161] As previously discussed, it is known that when the poly(carbonate siloxane) containing 30-70 wt% of siloxane repeating units is not present, the wt% poly(carbonate siloxane) containing less than 30 wt% of siloxane repeating units, including PC-Si-1 (6 wt%) and PC-Si-2 (20 wt%), has insufficient chemical resistance. Specifically, the yield stress retention is 80-89%, or greater than 90%, and the elongation at break retention is 65-79%, or outside the range of 80% to 139%. Therefore, when tested, the thermoplastic compositions of Table 5 (in which the poly(carbonate siloxane) containing 30 wt%-70 wt% of siloxane repeating units is not present) are expected to have insufficient chemical resistance and are therefore comparative examples (see Comparative Examples 5-6 and 9-10).

[0162] It is expected that there will be some vibration loss due to the viscous behavior of the rubber. However, the weldability of the compositions of Table 5 is not necessarily related to the total siloxane content of the composition. For example, Comparative Examples 1-2, which contain 6 wt% of siloxane repeating units, are not weldable, while Comparative Examples 9-10, which contain a higher siloxane content than Comparative Examples 1-2 (i.e., 7 wt%), are weldable, as are Examples 3-4, which contain a lower siloxane content than 6 wt% (i.e., 4.44 wt%).

[0163] Instead of the total siloxane content of the total thermoplastic composition determining the ultrasonic weldability of the thermoplastic composition, the examples show that the specific poly(carbonate-siloxane) copolymers present and the contribution of the siloxane content of each respective poly(carbonate-siloxane) copolymer affect ultrasonic weldability. When the 40 wt% poly(carbonate-siloxane) is the only poly(carbonate-siloxane) present in the thermoplastic composition, the calculated wt% of siloxane repeating units should be less than 6 wt% (compare Example 3 with Comparative Examples 1-2). When the 40 wt% poly(carbonate-siloxane) is combined with another poly(carbonate siloxane), the siloxane content of the composition can exceed 6 wt% (see Examples 7-8). In addition, in Examples 7-8 at 7 wt% siloxane content, the contribution to the siloxane content from the poly(carbonate-siloxane) (PC-Si-3) containing 40 wt% siloxane can be greater (Example 8) or less than (Example 7) the contribution to the siloxane content from the poly(carbonate-siloxane) (PC-Si-1) containing 6 wt% siloxane. Specifically, in Example 7, the total siloxane content is 7 wt%, of which 2.08 wt% is from PC-Si-3 and 4.92 wt% is from PC-Si-1. In Example 8, the total siloxane content is also 7 wt%, of which 4 wt% is from PC-Si-3 and 3 wt% is from PC-Si-1.

[0164] Comparative Examples 1, 5 and 6 and Example 8 were selected for morphological measurements. For morphological analysis, a cross section of each sample was prepared using a microtome, and then a planar cross section was prepared at -120°C using a microtome device (LEICA EMUC7) to obtain a planar cross-sectional surface suitable for AFM measurement without further surface treatment. The samples were prepared using a diamond knife (Diatome) mounted in a stainless steel holder.

[0165] Comparative Examples 1, 5 and 6 and Example 8 selected for morphological measurements each have different combinations of total siloxane content and type of poly(carbonate-siloxane). Figures 11-12 show morphological comparisons at 2 μm and 5 μm, respectively. Comparative Example 1, which includes 15% of a poly(carbonate siloxane) containing 40 wt% siloxane repeating units, shows large siloxane domains with irregular shapes. Comparative Example 5, which includes a poly(carbonate siloxane) containing 20 wt% siloxane repeating units, has a siloxane domain smaller than Comparative Example 1. Comparative Example 6 includes a mixture of a poly(carbonate siloxane) containing 20 wt% and a poly(carbonate siloxane) containing 6 wt%. The siloxane domains of Comparative Example 6 are more uniform than those of Comparative Examples 1 and 5. Example 8 includes a mixture of a poly(carbonate siloxane) containing 40 wt% siloxane repeating units and a poly(carbonate siloxane) containing 6 wt% siloxane repeating units. The siloxane domains of Example 8 are more uniform than those of Comparative Examples 1 and 5-6.

[0166] The present invention further encompasses the following aspects.

[0167] Aspect 1. An ultrasonically weldable part comprising a thermoplastic composition, an optional polycarbonate, and an optional additive composition, the thermoplastic composition comprising a poly(carbonate-siloxane) composition comprising a poly(carbonate-siloxane) containing 30 to 70 wt% siloxane repeating units present in an amount effective to provide less than 6 wt% siloxane repeating units, or a poly(carbonate-siloxane) containing 30 to 70 wt% siloxane repeating units and a poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% siloxane repeating units, based on the total weight of the thermoplastic composition, wherein the siloxane domains of a molded sample of the thermoplastic composition have an average diameter of 70 nm or less as measured using atomic force microscopy.

[0168] Aspect 1a. The ultrasonically weldable component of Aspect 1, comprising a thermoplastic composition comprising a poly(carbonate-siloxane) containing 30 to 70 wt% of siloxane repeating units present in an amount effective to provide less than 6 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units.

[0169] Aspect 2. The ultrasonically weldable component of Aspect 1, comprising a % retention of yield stress greater than 90%, and a % retention of elongation at break of 80 to 139%, each measured according to ASTM D543 using a 3.2 mm thick ASTM bar at 0.5% strain or at 1% strain at 23°C after exposure to a cleaning agent for 24 hours.

[0170] Aspect 3. The ultrasonically weldable component of Aspect 1 or Aspect 2, wherein the poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units comprises a poly(carbonate-siloxane) containing 2 to less than 10 wt% of siloxane repeating units, a poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units, or a combination thereof.

[0171] Aspect 3a. The ultrasonically weldable component of Aspect 1 or Aspect 2, wherein the poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units includes a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units, each based on the total weight of the composition.

[0172] Aspect 3b. The ultrasonically weldable component of Aspect 1 or Aspect 2, wherein the poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units comprises a poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units. %, 0.5-4 wt%, 0.5-3 wt%, or 0.5-2 wt%, 1-6 wt%, 1-5 wt%, 1-4 wt%, 1-3 wt%, or 1-2 wt% of siloxane repeating units, each based on the total weight of the composition.

[0173] Aspect 3c. The ultrasonically weldable component of aspect 1 or aspect 2, wherein the poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units comprises a poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units and a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units, wherein the poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units and the poly(carbonate-siloxane) containing 2 to less than 10 wt% of siloxane repeating units are effective to provide up to 6 wt%, 0.5 -6 wt%, 0.5-5 wt%, 0.5-4 wt%, 1-6 wt%, 1-5 wt%, or 1-4 wt% of siloxane repeating units, and the poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units is present in an amount effective to provide up to 6 wt%, 0.5-6 wt%, 0.5-5 wt%, 0.5-4 wt%, 0.5-3 wt%, or 0.5-2 wt%, 1-6 wt%, 1-5 wt%, 1-4 wt%, 1-3 wt%, or 1-2 wt% of siloxane repeating units, each based on the total weight of the composition.

[0174] Aspect 4. The ultrasonically weldable component of any of the above aspects, wherein the polycarbonate is present and comprises a linear homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof.

[0175] Aspect 5. The ultrasonically weldable component of any of the above aspects, wherein the polycarbonate is present and comprises a linear homopolycarbonate, or a linear homopolycarbonate and a poly(phthalate-carbonate).

[0176] Aspect 6. The ultrasonically weldable part of any of the above aspects, wherein the poly(carbonate-siloxane) composition is present in an amount effective to provide 2 wt% to less than 10 wt% of siloxane repeating units based on the total weight of the thermoplastic composition.

[0177] Aspect 6. The ultrasonically weldable part of any of the above aspects, wherein the polycarbonate is present and comprises a linear homopolycarbonate having a molecular weight of 15,000 to 25,000 g / mole, preferably 19,000 to 23,000 g / mole, a linear homopolycarbonate having a molecular weight of 25,000 to 35,000 g / mole, preferably 28,000 to 33,000 g / mole, or a combination thereof, each measured by gel permeation chromatography according to polystyrene standards and calculated for the polycarbonate.

[0178] Aspect 7. An ultrasonically weldable part according to any of the above aspects, wherein the thermoplastic composition comprises a polycarbonate comprising a linear homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; a poly(carbonate-siloxane) composition, wherein the poly(carbonate-siloxane) composition is a poly(carbonate-siloxane) containing 30-70 wt% siloxane repeating units present in an amount effective to provide less than 6 wt% siloxane repeating units, based on the total weight of the composition; and an optional additive composition.

[0179] Aspect 8. An ultrasonically weldable part according to any of the above aspects, wherein the thermoplastic composition comprises a polycarbonate, the polycarbonate comprising a linear homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; and a poly(carbonate-siloxane) composition, wherein the poly(carbonate-siloxane) composition is a poly(carbonate-siloxane) containing 30-70 wt % siloxane repeating units present in an amount effective to provide less than 6 wt % siloxane repeating units based on the total weight of the thermoplastic composition; and an optional additive composition.

[0180] Aspect 9. An ultrasonically weldable part according to any of the above aspects, wherein the thermoplastic composition comprises a polycarbonate comprising a linear homopolycarbonate, or a linear homopolycarbonate and a poly(phthalate-carbonate); and a poly(carbonate-siloxane) composition, wherein the poly(carbonate-siloxane) composition is a poly(carbonate-siloxane) containing 30 wt % to 70 wt % of siloxane repeating units effective to provide 2 wt % to 10 wt % of siloxane repeating units to the total thermoplastic composition; and optionally an additive composition.

[0181] Aspect 10. The ultrasonically weldable part of any of the above aspects, wherein the thermoplastic composition comprises a poly(carbonate-siloxane) containing 30 wt% to 70 wt% siloxane repeating units, and a poly(carbonate-siloxane) containing 10 wt% to less than 30 wt% siloxane repeating units, a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% siloxane repeating units, or a combination thereof, and an optional additive composition, wherein the poly(carbonate-siloxane) together is present in an amount effective to provide 2 to 10 wt% siloxane repeating units to the total thermoplastic composition.

[0182] Aspect 10a. The ultrasonically weldable part of any of the above aspects, wherein the poly(carbonate-siloxane) composition comprises a poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide 0.5 to 3 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units present in an amount effective to provide 1 to 6 wt% of siloxane repeating units.

[0183] Aspect 10a-1. The ultrasonically weldable part of any of the above aspects, wherein the poly(carbonate-siloxane) composition comprises a poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide 1.5 to 2.5 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units present in an amount effective to provide 4 to 6 wt% of siloxane repeating units.

[0184] Aspect 10b. The ultrasonically weldable part of any of the above aspects, wherein the poly(carbonate-siloxane) composition comprises a poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide 1 to 6 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units present in an amount effective to provide 1 to 5 wt% of siloxane repeating units.

[0185] Aspect 10b-1. An ultrasonically weldable component according to any of the above aspects, wherein the poly(carbonate-siloxane) composition comprises a poly(carbonate-siloxane) containing 30 wt% to 70 wt% of siloxane repeating units present in an amount effective to provide 4 to 6 wt% of siloxane repeating units, and a poly(carbonate-siloxane) containing 2 wt% to less than 10 wt% of siloxane repeating units present in an amount effective to provide 2 to 4 wt% of siloxane repeating units.

[0186] Aspect 11. The ultrasonically weldable component of any of the above aspects, wherein the additive composition comprises a flow modifier, a filler, a reinforcing agent, an antioxidant, a thermal stabilizer, a light stabilizer, an ultraviolet light stabilizer, a UV absorbing additive, a plasticizer, a lubricant, a mold release agent, an antistatic agent, an antifog agent, an antimicrobial agent, a colorant, a surface effect additive, a radiation stabilizer, a flame retardant, an anti-drip agent, or a combination thereof.

[0187] Aspect 12. A method for forming an ultrasonically weldable part, comprising molding, extruding or shaping the thermoplastic composition of any of the preceding aspects to form an ultrasonically weldable part.

[0188] Aspect 13. An ultrasonically welded article comprising the ultrasonically weldable component of any one of aspects 1-11.

[0189] Aspect 14. A method for forming an ultrasonically welded article, comprising ultrasonically welding the ultrasonically weldable component of any of Aspects 1-11 to another thermoplastic component to provide an ultrasonically welded article.

[0190] Aspect 15. The method of aspect 13, wherein the plastic component is the ultrasonically weldable component of any one of aspects 1 to 11.

[0191] Alternatively, the compositions, methods and articles may comprise, consist of or consist essentially of any suitable material, step or component disclosed herein. The compositions, methods and articles may additionally or alternatively be formulated so as to be free of or essentially free of any material (or substance), step, or component that is otherwise not necessary for achieving the function or purpose of the compositions, methods and articles.

[0192] All ranges disclosed herein include endpoints, and the endpoints can be combined independently of each other (e.g., "up to 25wt%, or more specifically, 5wt% to 20wt%" includes endpoints and all intermediate values ​​of the "5wt% to 25wt%" range, etc.). "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not indicate any order, quantity, or importance, but are used to distinguish one element from another. Unless otherwise indicated herein or clearly contradicted by the context, the terms "one", "a kind of" and "the" do not indicate a limit to quantity, but are interpreted to cover the singular and plural. Unless otherwise explicitly stated, "or" means "and / or". Throughout the specification, reference to "some embodiments", "embodiments", etc. means that the specific elements described in conjunction with the embodiments are included in at least one embodiment described herein, and may or may not exist in other embodiments. In addition, it should be understood that the described elements can be combined in various embodiments in any suitable manner. "Their combination" is open and includes any combination, which contains at least one of the listed components or properties, optionally together with unlisted similar or equivalent components or properties.

[0193] Unless specified to the contrary herein, all test standards are the most current standards in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0194] Unless otherwise defined, technical and scientific terms used herein have the same meanings as those generally understood by those of ordinary skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in a combined reference, the term from this application takes precedence over the conflicting term from the combined reference.

[0195] Compounds are described using standard nomenclature. For example, any position not substituted by any indicator group is understood to have its valency filled by a bond or hydrogen atom as indicated. A dash ("-") not between two letters or symbols is used to indicate the point of attachment of a substituent. For example, -CHO is connected through the carbon of a carbonyl group.

[0196] The term "alkyl" refers to a branched or straight chain, unsaturated aliphatic hydrocarbon group, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, sec-pentyl, and n-hexyl and sec-hexyl. "Alkenyl" refers to a straight or branched monovalent hydrocarbon group containing at least one carbon-carbon double bond (for example, vinyl (-HC=CH2)). "Alkoxy" refers to an alkyl group connected via oxygen (i.e., alkyl-O-), such as methoxy, ethoxy and sec-butoxy. "Alkylene" refers to a straight or branched, saturated, divalent aliphatic hydrocarbon group (for example, methylene (-CH2-) or propylene (-(CH2)3-)). "Cycloalkylene" refers to a divalent cyclic alkylene group, -C n H 2n-x , wherein x is the number of hydrogens replaced by cyclization. "Cycloalkenyl" means a monovalent group comprising one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbon group containing a specified number of carbon atoms, such as phenyl, cycloheptatrienone, indanyl or naphthyl. "Arylene" refers to a divalent aryl group. "Alkylidenearylene" refers to an arylidene group substituted by an alkyl group. "Arylalkylene" refers to an alkylene group substituted by an aryl group (e.g., benzyl). The prefix "halo" refers to a group or compound comprising one or more of fluorine, chlorine, bromine or iodine substituents. There may be a combination of different halogen groups (e.g., bromine and fluorine) or only chlorine groups. The prefix "hetero" refers to a compound or group comprising at least one ring member of a heteroatom (e.g., 1, 2 or 3 heteroatoms), wherein the heteroatoms are each independently N, O, S, Si or P. "Substituted" means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents, each of which may be independently C 1-9 Alkoxy, C 1-9 Haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 Alkylsulfonyl (-S(=O)2-alkyl), C 6-12 Arylsulfonyl (-S(=O)2-aryl) thiol (-SH), thiocyanate (-SCN), tosyl (CH3C6H4SO2-), C 3-12 Cycloalkyl, C 2-12 Alkenyl, C 5-12 Cycloalkenyl, C 6-12 Aryl, C 7-13 Arylalkylene, C4-12 Heterocycloalkyl, and C 3-12 A heteroaryl group replaces a hydrogen provided that the normal valence of the substituted atom is not exceeded. The number of carbon atoms indicated in the group does not include any substituents. For example, -CH2CH2CN is a C2 alkyl group substituted with a nitrile.

[0197] Although specific embodiments have been described, the applicant or other persons skilled in the art may conceive of alternatives, modifications, variations, improvements, and substantial equivalents that are not currently foreseeable or may not be foreseeable. Therefore, the appended claims as filed and as they may be amended are intended to cover all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. An ultrasonically weldable component comprising a thermoplastic composition, the thermoplastic composition comprising: A poly(carbonate-siloxane) composition comprising: a poly(carbonate-siloxane) containing 30 to 70 weight percent siloxane repeating units present in an amount effective to provide less than 6 weight percent siloxane repeating units, based on the total weight of the thermoplastic composition, or poly(carbonate-siloxane) containing 30 to 70 wt% of siloxane repeating units and poly(carbonate-siloxane) containing 2 wt% to less than 30 wt% of siloxane repeating units, Optional polycarbonate, and Optional additive composition, in, The silicone domains of the molded sample of the thermoplastic composition have an average diameter of 70 nm or less as measured using atomic force microscopy.

2. The ultrasonically weldable component according to claim 1, comprising: The % retention of yield stress is greater than 90%, and % retention of elongation at break ranges from 80% to 139%, Each is measured according to ASTM D543, using a 3.2 mm thick ASTM bar, at 0-1% strain, at 23°C, after 24 h exposure to the cleaning agent.

3. An ultrasonically weldable component according to claim 1 or claim 2, wherein: The poly(carbonate-siloxane) containing 2 wt % to less than 30 wt % of siloxane repeating units comprises: Poly(carbonate-siloxane) containing 2 to less than 10 wt% of siloxane repeating units, Poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units, or a combination thereof.

4. An ultrasonically weldable component according to any one of the preceding claims, wherein: The polycarbonate is present and includes a linear homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof.

5. An ultrasonically weldable component according to any one of the preceding claims, wherein: The polycarbonate is present and comprises: Linear homopolycarbonate, or Linear homopolycarbonates and poly(phthalate-carbonates).

6. An ultrasonically weldable component according to any one of the preceding claims, wherein: The poly(carbonate-siloxane) composition is present in an amount effective to provide 2 to less than 10 weight percent of siloxane repeating units, based on the total weight of the composition.

7. An ultrasonically weldable component according to any one of the preceding claims, wherein: The polycarbonate is present and comprises: A linear homopolycarbonate comprising a weight average molecular weight of 15,000 to 25,000 g / mol, preferably 19,000 to 23,000 g / mol, A linear homopolycarbonate comprising a weight average molecular weight of 25,000 to 35,000 g / mol, preferably 28,000 to 33,000 g / mol, or a combination thereof, each measured by gel permeation chromatography against polystyrene standards and calculated for polycarbonate.

8. An ultrasonically weldable component according to any one of the preceding claims, wherein: The thermoplastic composition comprises: Polycarbonates, including linear homopolycarbonates, poly(phthalate-carbonates), or combinations thereof, A poly(carbonate-siloxane) composition, wherein the poly(carbonate-siloxane) composition is a poly(carbonate-siloxane) containing 30-70 wt% siloxane repeating units present in an amount effective to provide less than 6 wt% siloxane repeating units, based on the total weight of the thermoplastic composition, and Optional Additive Compositions.

9. The ultrasonically weldable component according to any one of claims 1 to 7, wherein: The thermoplastic composition comprises: Polycarbonate, comprising: Linear homopolycarbonate, or Linear homopolycarbonates and poly(phthalate-carbonates), and A poly(carbonate-siloxane) composition, wherein the poly(carbonate-siloxane) composition is a poly(carbonate-siloxane) containing 30-70 wt% siloxane repeating units present in an amount effective to provide less than 6 wt% siloxane repeating units, based on the total weight of the thermoplastic composition, and Optional Additive Compositions.

10. The ultrasonically weldable component according to any one of claims 1 to 7, wherein: The thermoplastic composition comprises: a poly(carbonate-siloxane) containing 30 to 70 wt% of siloxane repeating units, and Poly(carbonate-siloxane) containing 10 to less than 30 wt% of siloxane repeating units, Poly(carbonate-siloxane) containing 2 to less than 10 wt% of siloxane repeating units, or a combination thereof, and Optional additive composition, Therein, the poly(carbonate-siloxane)s together are present in an amount effective to provide 2 to 10 weight percent of siloxane repeating units to the total thermoplastic composition.

11. An ultrasonically weldable component according to any one of the preceding claims, wherein: The additive composition comprises a flow modifier, a filler, a reinforcing agent, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, a UV absorbing additive, a plasticizer, a lubricant, a mold release agent, an antistatic agent, an antifog agent, an antimicrobial agent, a colorant, a surface effect additive, a radiation stabilizer, a flame retardant, an anti-drip agent, or a combination thereof.

12. A method for forming an ultrasonically weldable component as claimed in any one of claims 1 to 11, comprising moulding, extruding or shaping the thermoplastic composition as claimed in any one of the preceding claims to form the ultrasonically weldable component.

13. An ultrasonically welded article comprising the ultrasonically weldable component according to any one of claims 1 to 11.

14. A method for forming an ultrasonically welded article, comprising ultrasonically welding an ultrasonically weldable component according to any one of claims 1 to 11 to another thermoplastic component to provide the ultrasonically welded article.

15. The method according to claim 14, wherein: The thermoplastic component is an ultrasonically weldable component according to any one of claims 1-11.

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