Thermoplastic compositions, methods of making same, and articles made therefrom

Abstract

A thermoplastic composition comprises specific amounts of a post consumer recovered polycarbonate; a polycarbonate composition comprising a polycarbonate-siloxane copolymer, a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate comprising recurring units derived from a bulky bisphenol group, a polycarbonate-siloxane copolymer, a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate comprising recurring units derived from bulky bisphenol groups; and optionally, one or more linear homopolycarbonates having a specific melt flow rate. The composition may provide a desired combination of properties and may be particularly useful in a variety of articles, including consumer electronics.

Description

[0001] Citations of Related Applications

[0002] This application claims priority to and the benefit of European patent application No. 22192155.4 filed on August 25, 2022, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to polycarbonate compositions, methods of making the same, and articles comprising the same. Background Art

[0004] Polycarbonates (PC) are used on a large scale in a variety of applications, including, for example, electronics, mobility, industry, infrastructure, and healthcare, due to their good mechanical, electrical, and flame retardant properties and wide color space. Products with a smaller carbon footprint are becoming more desirable. Post-consumer recycling (PCR) can enable the reuse of plastic materials by recovering them from final products on the market and converting them into raw materials for new products. However, PCR-based materials generally exhibit inferior mechanical properties compared to corresponding virgin materials, for example, due to additional thermal history or degradation that may occur during the recycling process. In addition, some PCR materials may have colors, which may result in a narrow color space that can be used for the final product.

[0005] Therefore, there remains a continuing need for compositions comprising recycled materials which exhibit comparable mechanical properties, flame retardant performance and color space relative to virgin materials. It would be particularly advantageous to provide compositions having a high PCR content. Summary of the invention

[0006] One aspect of the present disclosure is a thermoplastic composition comprising: 30 to 95 weight percent of post-consumer recycle polycarbonate; and 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; and wherein when the composition comprises a polycarbonate-siloxane copolymer, a branched polycarbonate, or a copolycarbonate containing phthalimidine (phthalimidine) carbonate repeating units, the composition further comprises 5 to 65 weight percent of a linear polycarbonate homopolymer comprising at least two of the following: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238, a polycarbonate having a melt flow rate of 100 to 200 g / 10 min as measured according to ASTM D1238, a polycarbonate having a melt flow rate of 100 to 200 g / 10 min as measured according to ASTM D1238, a polycarbonate having a melt flow rate of 100 to 200 g / 10 min as measured according to ASTM D1238, a polycarbonate having a melt flow rate of 100 to 200 g / 10 min as measured according to ASTM D1238 The invention relates to a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, and an ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, wherein the weight percentage of each component is based on the total weight of the composition.

[0007] Another aspect of the present disclosure is a method for preparing a composition comprising melt mixing the components of the composition.

[0008] Another aspect is an article comprising the composition.

[0009] The above described and other features are exemplified by the following detailed description. DETAILED DESCRIPTION

[0010] The present inventors have discovered that compositions comprising a combination of specific amounts of post-consumer recycled polycarbonate, a polycarbonate component (eg, virgin polycarbonate), and a linear polycarbonate having a specific melt flow rate can provide a desired combination of properties.

[0011] Therefore, one aspect of the present disclosure is a thermoplastic composition. Thermoplastic composition comprises post-consumer recycled polycarbonate. As used in this article, the term "post-consumer recycled polycarbonate" refers to polycarbonate that has previously been used in end-use parts, articles, or assemblies and has been collected or recovered after use by an end user or consumer. Therefore, for example, it should be understood that the term refers to a polycarbonate material that would otherwise be thrown away as waste, but is collected and recovered (recovered) as a material input, replacing new virgin materials for recycling or manufacturing processes. The term includes such collected or recovered materials that have been further processed or processed to promote the reuse of the material. Therefore, for example, the term includes materials that have been reprocessed by a manufacturing process from collected or recovered materials and made into a product or made into a component for being incorporated into a product. The polycarbonate of this recovery can be further processed into the form of a ground material, sheet, or pellets.

[0012] Post-consumer recycled polycarbonate includes polycarbonate. As used herein, "polycarbonate" refers to a homopolymer or copolymer having a repeating structural carbonate unit of formula (1):

[0013]

[0014] Among them, R 1 At least 60% of the total number of radicals are aromatic, or each R 1 Contains at least one C 6-30 Preferably, each R 1 It may be derived from a dihydroxy compound, such as an aromatic dihydroxy compound of formula (2) or a bisphenol of formula (3).

[0015]

[0016] In formula (2), each R h is independently a halogen atom, such as bromine; C 1-10 Hydrocarbon groups, such as C 1-10 Alkyl; Halogen substituted C 1-10 Alkyl; C 6-10 Aryl or halogen substituted C 6-10 aryl, and n is 0 to 4.

[0017] In formula (3), 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, such that when p or q is less than 4, the valence of each carbon of the ring is filled by hydrogen. In one aspect, p and q are each 0, or p and q are each 1, and R a and Rb Each is C 1-3 An alkyl group, preferably a methyl group, is disposed meta to the hydroxyl group on each arylene group. 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, for example, a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or C 1-18 An organic group, which may be cyclic or acyclic, aromatic or non-aromatic, and may further contain heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorus. For example, X a Can be substituted or unsubstituted 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 Heteroaralkyl; or -C(=R e )-, wherein R e It is a two-price C 1-12 Hydrocarbon.

[0018] Examples of the bisphenol compound include 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, 1,2-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-Bis(4-hydroxyphenyl)cyclododecane, 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 phenyl)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)fluorene, 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-dihydroxyphenoxathin, 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.;

[0019] Specific dihydroxy compounds include resorcinol, 2,2-bis(4-hydroxyphenyl)propane ("bisphenol A" or "BPA"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimide (also known as N-phenylphenolphthalein bisphenol, "PPPBP", or 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one), 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (isophorone bisphenol).

[0020] In one aspect, the post-consumer recycled polycarbonate can have a phenolic end group content greater than 5 mole percent, preferably from 10 to 35 mole percent.

[0021] In one aspect, the post-consumer recycled polycarbonate comprises a homopolycarbonate, such as bisphenol A homopolycarbonate. The post-consumer recycled polycarbonate may contain residual amounts of one or more additives present in the polycarbonate composition prior to recycling.

[0022] In one aspect, the post-consumer recycled polycarbonate can have an L value greater than or equal to 85, preferably greater than or equal to 92, as determined according to ASTM D2244, a yellowness index less than or equal to 8, preferably less than or equal to 3.5, as determined according to ASTM E313, a transmittance greater than or equal to 70%, preferably greater than or equal to 82%, at a thickness of 3 mm as determined according to ASTM D1003, and a haze less than or equal to 10, preferably less than or equal to 6, at a thickness of 3 mm as determined according to ASTM D1003.

[0023] Based on the gross weight of the composition, the polycarbonate recycled after consumption can be present in the composition in an amount of 25 to 95 weight percents. Within this range, the polycarbonate recycled after consumption can be present in the composition in an amount of at least 30 weight percents, or at least 35 weight percents, or at least 40 weight percents, or at least 45 weight percents, or at least 50 weight percents. Also within this range, the polycarbonate recycled after consumption can be present in the composition in an amount of up to 95 weight percents, or up to 85 weight percents, or up to 80 weight percents, or up to 75 weight percents, or up to 70 weight percents. In one aspect, the polycarbonate recycled after consumption can be present in the composition in an amount of 45 to 90 weight percents, or 45 to 80 weight percents, or 50 to 75 weight percents, or 25 to 55 weight percents, or 30 to 50 weight percents. Any combination of the aforementioned upper and lower limits is also contemplated herein.

[0024] In addition to post-consumer recycled polycarbonate, the composition further comprises a polycarbonate component which is a polycarbonate-siloxane copolymer, a polycarbonate-ester, a branched polycarbonate, or a copolycarbonate containing phthalazolone carbonate repeating units, a polycarbonate copolymer. The above polycarbonate component is preferably a virgin material.

[0025] In one aspect, the polycarbonate component is a polycarbonate-siloxane copolymer. The polycarbonate-siloxane copolymer is preferably a virgin material, i.e., a material that has not yet been used in an end-use component, article, or assembly. The polycarbonate-siloxane copolymer comprises carbonate repeating units according to formula (1) and polysiloxane blocks comprising repeating diorganosiloxane units as in formula (4):

[0026]

[0027] 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 Arylalkyleneoxy, C 7-13 Alkyl arylene, or C 7-13 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.

[0028] The value of E in formula (4) 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 in another aspect, E has an average value of 40 to 80, or 40 to 70. When E has a lower value, for example, when 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, for example, when 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.

[0029] In one aspect, the polysiloxane block has formula (5):

[0030]

[0031] wherein E and R are as defined in formula (4); 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 (5) can be derived from C 6-30 Dihydroxyarylene compounds. 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.

[0032] In another aspect, the polysiloxane block has formula (6):

[0033]

[0034] Where R and E are as described above, and each R 5 Independently divalent C 1-30 An organic group, and wherein the polymerized polysiloxane unit is the reaction residue of its corresponding dihydroxy compound. In a specific aspect, the polysiloxane block is of formula (7):

[0035]

[0036] Wherein, R and E are as defined above. 6 It is a two-price C 2-8 Each M in formula (7) 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.

[0037] 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 groups. Specific polysiloxane blocks have the following formula:

[0038]

[0039] 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.

[0040] The blocks of formula (7) 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 prepared, for example, by the synthetic procedure of Hoover's European Patent Application Publication No. 0 524 731 A1, page 5, Preparation 2.

[0041] The poly(carbonate-siloxane) copolymer can contain 50 to 95 weight percent carbonate units and 5 to 50 weight percent siloxane units. Within this range, the poly(carbonate-siloxane) copolymer can contain 50 to 85 weight percent, more preferably 60 to 80 weight percent carbonate units and 15 to 50 weight percent, more preferably 20 to 40 weight percent siloxane units.

[0042] Suitable polycarbonate-siloxane copolymers may include, for example, those commercially available from SABIC under the trade name EXL.

[0043] In one aspect, the polycarbonate component may include a branched polycarbonate. Specifically, in one aspect, the polycarbonate component may be a branched polycarbonate comprising a unit as described above; based on the total moles of polycarbonate, a portion derived from a branching agent greater than or equal to 3 mol%; and an end-capping group derived from an end-capping agent with a pKa between 8.3 and 11. The branching agent may include trimellityl chloride, 1,1,1-tris(4-hydroxyphenyl)ethane or a combination of trimellityl chloride and 1,1,1-tris(4-hydroxyphenyl)ethane, and the end-capping agent is a phenol or a phenol containing a cyano group, an aliphatic group, an olefinic group, an aromatic group, a halogen, an ester group, an ether group, or a substituent of a combination thereof. In a specific aspect, the end-capping agent is phenol, p-tert-butylphenol, p-methoxyphenol, p-cyanophenol, p-cumylphenol, or a combination thereof. In one aspect, the end-capping agent is cyanophenol.

[0044] In one aspect, the polycarbonate component can include a copolycarbonate comprising repeating units derived from bisphenol A and bulky bisphenol carbonate units, i.e., derived from a bisphenol containing at least 18 carbon atoms, e.g., 18 to 60 carbon atoms or 20 to 40 carbon atoms. Exemplary bulky bisphenol carbonate units can include, for example, bulky bisphenol carbonate groups of formula (8) to (14):

[0045]

[0046] Among them, R c and R d Each independently is C 1-12 Alkyl, C 2-12 Alkenyl, C 3-8 Cycloalkyl, or C 1-12 Alkoxy, each R f is hydrogen or two R f Together they are carbonyl groups, each R 3 Independently C 1-6 Alkyl, R 4 It is hydrogen, C 1-6 alkyl, or optionally 1 to 5 C 1-6 Alkyl substituted phenyl, R 6 Independently C 1-3 Alkyl, or phenyl, preferably methyl, X a It is C 6-12 Polycyclic aromatic groups, C 3-18 Mono- or polycyclic alkylene, C 3-18 Mono- or polycycloalkylidene, -C(R f )(R g )-, where R f It is hydrogen, C 1-12 Alkyl, or C 6-12 Aryl, and R g It is C 6-10 Alkyl, C 6-8 Cycloalkyl, or C 6-12 Aryl, or -(Q a ) x -G-(Q b ) y - group, where Q a and Q b Each independently is C 1-3 Alkylene, G is C 3-10 Cycloalkylene, x is 0 or 1, and y is 0 or 1, and j, m and n are each independently 0 to 4. Combinations of high heat bisphenol groups may be used.

[0047] In one aspect, R c and R d Each independently is C 1-3 Alkyl, or C 1-3 Alkoxy, each R 6 is a methyl group, each R 3 Independently C 1-3 Alkyl, R 4 is methyl or phenyl, each R 6 Independently C 1-3Alkyl, or phenyl, preferably methyl, X a It is C 6-12 Polycyclic aromatic groups, C 3-18 Mono- or polycyclic alkylene, C 3-18 Mono- or polycycloalkylidene, -C(R f )(R g )-, where R f It is hydrogen, C 1-12 Alkyl, or C 6-12 Aryl, and R g It is C 6-10 Alkyl, C 6-8 Cycloalkyl, or C 6-12 Aryl, or -(Q 1 ) x -G-(Q 2 ) y - group, where Q 1 and Q 2 Each independently is C 1-3 Alkylene and G is C 3-10 Cycloalkylene, x is 0 or 1, and y is 0 or 1, and j, m and n are each independently 0 or 1.

[0048] Exemplary bulky bisphenol groups may include those of formulae (13a) and (14a) to (14k):

[0049]

[0050] Among them, R c and R d As defined in equations (8) to (14), each R 2 Independently for C 1-4 alkyl, m and n are each independently 0 to 4, each R 3 Independently for C 1-4 Alkyl or hydrogen, R 4 It is C 1-6 alkyl or optionally 1 to 5 C 1-6 alkyl-substituted phenyl, and g is 0 to 10. In a specific aspect, each bond of the bisphenol group is located between the linking group X a In one aspect, R c and R d Each independently is C 1-3 Alkyl or C 1-3 Alkoxy, each R 2 is methyl, x is 0 or 1, y is 1, and m and n are each independently 0 or 1.

[0051] The bulky bisphenol group preferably has the formula (13a-2) or (14a-2):

[0052]

[0053] Among them, R 4 is methyl or phenyl, each R 2 is methyl, and g is 1 to 4. Preferably, the bulky bisphenol group is derived from 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine (PPPBP) or from 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane (BP-TMC).

[0054]

[0055] In one aspect, such copolycarbonates may include copolycarbonates containing bisphenol A carbonate units and 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimide carbonate units (BPA-PPPBP copolymers, commercially available from SABIC under the trade names XHT and CXT), copolymers containing bisphenol A carbonate units and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane carbonate units (BPA-DMBPC copolymers, commercially available from SABIC under the trade name DMC), and copolymers containing bisphenol A carbonate units and isophorone bisphenol carbonate units (e.g., commercially available from Bayer under the trade name APEC). In one aspect, the polycarbonate component may include a BPA-PPPBP copolymer.

[0056] In one aspect, the composition can include a polycarbonate-ester, for example, a poly(aromatic ester-carbonate) comprising bisphenol A carbonate units and bisphenol A isophthalate-bisphenol A terephthalate units, also commonly referred to as poly(carbonate-ester) (PCE) or poly(phthalate-carbonate) (PPC), depending on the relative ratio of carbonate units to ester units. Another specific poly(ester-carbonate) includes resorcinol isophthalate and resorcinol terephthalate units and bisphenol A carbonate units, such as those commercially available from SABIC under the trade name LEXAN SLX.

[0057] For example, in one specific aspect, in addition to recurring carbonate units of formula (1), the polyester-carbonate comprises recurring ester units of formula (15):

[0058]

[0059] Wherein, J is a divalent group derived from an aromatic dihydroxy compound (including its reactive derivatives), such as a bisphenol of formula (3), 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.

[0060] In one aspect, J is derived from a bisphenol of formula (3), 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 percent (mol%), can be a C having 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.

[0061] 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 a combination 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 a combination 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.

[0062] 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.

[0063] Specific poly(ester-carbonates) are those comprising bisphenol A carbonate units and bisphenol A isophthalate / bisphenol A terephthalate units, i.e., poly(bisphenol A carbonate)-co-(bisphenol A-phthalate-ester) of formula (15a):

[0064]

[0065] Wherein, x and y represent the weight percentage of bisphenol A carbonate units and bisphenol A isophthalate / bisphenol A terephthalate 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 (15) comprising 35-45wt% carbonate units and 55-65wt% ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45, are commonly referred to as poly(carbonate-ester) (PCE). Copolymers comprising 15-25wt% carbonate units and 75-85wt% ester units. Where the ester units have a molar ratio of isophthalate to terephthalate of 98:2 to 88:12, they are generally referred to as poly(phthalate-carbonate) (PPC).

[0066] In another aspect, the high heat poly(ester-carbonate) is a poly(carbonate-co-monoarylate ester) of formula (15b) comprising aromatic carbonate units (1) and repeating monoarylate ester units

[0067]

[0068] 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, halogen substituted C 1-10 Alkyl, C 6-10 Aryl or halogen substituted C 6-10 aryl, 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 one aspect, the molar ratio of x:z is 50:50 to 99:1, or 1:99 to 50:50.

[0069] In one aspect, the high heat poly(ester-carbonate) comprises aromatic ester units and monoarylated ester 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 resorcinol isophthalate / resorcinol terephthalate ("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 even 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-resorcinol isophthalate / resorcinol terephthalate) of formula (15c):

[0070]

[0071] Wherein, the molar ratio of x:z is 98:2 to 2:98, or 90:10 to 10:90. In one 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 may be present in the poly(bisphenol A carbonate-co-resorcinol isophthalate-resorcinol terephthalate) 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 may be present in a total amount of 1 to 20 mol%, such as monoaryl carbonate units of formula (16) and bisphenol ester units of formula (17):

[0072]

[0073] Among them, in the above formula, R h Each independently is 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 -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 )-, wherein Re It is a two-price C 1-12 The bisphenol ester unit may be a bisphenol A phthalate unit of formula (17b):

[0074]

[0075] In one aspect, poly(bisphenol A carbonate-co-resorcinol isophthalate / resorcinol terephthalate) (15c) comprises 1-90 mol% of bisphenol A carbonate units, 10-99 mol% of resorcinol isophthalate-resorcinol terephthalate units, and optionally 1-60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate units, or combinations thereof. In another aspect, the poly(bisphenol A carbonate-co-resorcinol isophthalate / resorcinol terephthalate) comprises 10-20 mol% of bisphenol A carbonate units, 20-98 mol% of resorcinol isophthalate-resorcinol terephthalate units, and optionally 1-60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate units, or combinations thereof.

[0076] The high heat poly(ester-carbonate) may have a weight average molecular weight (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 and calibrated with bisphenol A homopolycarbonate standards. The sample was eluted with dichloromethane as the eluent at a flow rate of 1.0 ml / min.

[0077] Based on the gross weight of the composition, the polycarbonate component (that is, polycarbonate-siloxane copolymer, polycarbonate-ester, branched polycarbonate or copolycarbonate containing bulky bisphenol groups) can be present in the composition in an amount of 5 to 70 weight percents. Within this scope, the polycarbonate component can be present in the composition in an amount of at least 9 weight percents, or at least 10 weight percents, or at least 15 weight percents, or at least 25 weight percents, or at least 40 weight percents, or at least 50 weight percents. Also within this scope, the polycarbonate component can be present in the composition in an amount of at most 65 weight percents, or at most 60 weight percents, or at most 55 weight percents, or at most 50 weight percents. In one aspect, the polycarbonate component can be present in an amount of 5 to 35 weight percents, or 10 to 25 weight percents, or 10 to 30 weight percents, or 35 to 55 weight percents. The combination of any aforementioned upper and lower limits is also contemplated.

[0078] When the composition comprises a polycarbonate-siloxane copolymer, a branched polycarbonate, or a copolycarbonate containing a bulky bisphenol carbonate repeating unit, the composition further comprises a linear polycarbonate, preferably a linear homopolycarbonate. When present in the composition together with a polycarbonate-siloxane copolymer, a branched polycarbonate, or a copolycarbonate containing a phthalimide carbonate repeating unit, the linear polycarbonate is a combination of at least two polycarbonates having a specific melt flow rate. For example, the linear polycarbonate homopolymer comprises at least two of the following: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min or 20 to 50 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min or 5 to 10 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238, and an ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238. The at least two linear polycarbonate homopolymers are preferably selected from the above different flow rate categories. For example, the composition does not include two linear polycarbonate homopolymers that are both high flow (ie, both within the range of greater than 20 to 54 g / 10 min).

[0079] When the composition includes polyester-carbonate, one or more of the aforementioned linear polycarbonate components may or may not be present. When included with polyester-carbonate, a single linear homopolycarbonate or a combination of two or more may be used. The linear polycarbonate may be as described above.

[0080] Linear polycarbonate can also be characterized according to its molecular weight, which is in the range of 10,000 to 100,000 g / mol. For example, high flow polycarbonate can have a weight average molecular weight of less than 25,000 g / mol. Low flow polycarbonate can have a weight average molecular weight of 25,000 to 35,000 g / mol. Ultra-low flow polycarbonate can have a weight average molecular weight greater than 35,000 g / mol. Molecular weight can be determined using gel permeation chromatography (GPC) relative to linear bisphenol A polycarbonate standards.

[0081] When present, the linear polycarbonate is preferably a native polycarbonate.

[0082] The linear polycarbonate may be as described above, for example comprising repeating units according to formula (1).An exemplary linear homopolymer comprising bisphenol A carbonate units (BPA-PC) is commercially available from SABIC under the trade name LEXAN.

[0083] When present, the composition can include the linear polycarbonate homopolymer in an amount of 5 to 65 weight percent, based on the gross weight of the composition. Within this range, the composition can include the polycarbonate in an amount of at least 10 weight percent, or at least 12 weight percent, or at least 15 weight percent. Also within this range, the composition can include the polycarbonate in an amount of up to 45 weight percent, or up to 40 weight percent, or up to 35 weight percent, or up to 30 weight percent, or up to 25 weight percent, or up to 20 weight percent.

[0084] In one aspect, the composition can include 25 to 90 weight percent of post-consumer recycled polycarbonate; 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a branched polycarbonate, or a copolycarbonate containing repeating units derived from bulky bisphenol groups; and 5 to 65 weight percent of a linear polycarbonate homopolymer comprising at least two of the following: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238; and an ultra-low flow polycarbonate having a melt flow rate of 10 to 20 g / 10 min as measured according to ASTM D1238. D1238 has a melt flow rate of less than 5 g / 10 min measured at 300°C and 1.2 kg.

[0085] Various combinations of the above linear homopolycarbonates having different melt flow rates are contemplated herein. For example, the linear polycarbonate homopolymer may comprise a high flow polycarbonate and a low flow polycarbonate, a low flow polycarbonate and an ultra-low flow polycarbonate, or a low flow polycarbonate and an ultra-high flow polycarbonate.

[0086] In one aspect, the composition can include 5 to 35 weight percent high flow polycarbonate and 4 to 10 weight percent low flow polycarbonate. In one aspect, the composition can include 1 to 10 weight percent low flow polycarbonate and 8 to 15 weight percent ultra low flow polycarbonate. In one aspect, the composition can include 8 to 22 weight percent low flow polycarbonate and 20 to 35 weight percent ultra high flow polycarbonate.

[0087] In one aspect, when the composition comprises a polycarbonate-siloxane copolymer, the linear polycarbonate homopolymer may comprise a high-flow polycarbonate and a low-flow polycarbonate or a low-flow polycarbonate and an ultra-low-flow polycarbonate. In one aspect, when the composition comprises a copolycarbonate containing repeating units derived from a bulky bisphenol group (e.g., a phthalazine group), the linear polycarbonate homopolymer may comprise a low-flow polycarbonate and an ultra-high-flow polycarbonate. In one aspect, when the composition comprises a branched polycarbonate, the linear polycarbonate homopolymer may comprise a high-flow polycarbonate and a low-flow polycarbonate.

[0088] In a specific aspect, the composition can include 45 to 90 weight percent post-consumer recycled polycarbonate; 5 to 35 weight percent polycarbonate-siloxane copolymer and 5 to 40 weight percent linear polycarbonate homopolymer, wherein the linear polycarbonate homopolymer includes a high flow polycarbonate and a low flow polycarbonate or includes a low flow polycarbonate and an ultra-low flow polycarbonate.

[0089] In another specific aspect, the composition can comprise 25 to 55 weight percent post-consumer recycled polycarbonate, 10 to 25 weight percent copolycarbonate containing phthalazolone carbonate repeating units, and 30 to 55 weight percent linear polycarbonate homopolymers including low flow polycarbonate and ultra high flow polycarbonate.

[0090] In another specific aspect, the composition can comprise 40 to 60 weight percent post-consumer recycled polycarbonate, 10 to 30 weight percent branched polycarbonate containing cyanophenol end groups, and 10 to 30 weight percent linear polycarbonate homopolymers comprising low flow polycarbonate and high flow polycarbonate.

[0091] In another specific aspect, the composition can include 20 to 60 weight percent post-consumer recycled polycarbonate, 35 to 55 weight percent polycarbonate-ester, and optionally 15 to 35 weight percent high flow polycarbonate.

[0092] Thermoplastic compositions may optionally further include various additives that are usually incorporated into polycarbonate compositions, provided that the additives are selected to not significantly adversely affect the desired properties of the polycarbonate compositions, especially the color of the compositions. During the mixing of the components for forming the compositions, such additives may be mixed at suitable mixing times. The additives may include, for example, impact modifiers, 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. Combinations of additives may be used, such as stabilizers (for example, heat stabilizers), flame retardants and color packages. Typically, additives may be used in amounts known to be effective. For example, the total amount of additives (except any impact modifiers, fillers or reinforcing agents) may be 0.001 to 10.0wt%, or 0.01 to 5wt%, each based on the gross weight of the polymer in the composition.

[0093] In one aspect, the composition may optionally further comprise a flame retardant. Useful flame retardants may include organic compounds that include phosphorus, bromine, or chlorine. 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 that include phosphorus-nitrogen bonds.

[0094] Flame retardant aromatic phosphates include triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tricresyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, and 2-ethylhexyl diphenyl phosphate. Di- or polyfunctional aromatic phosphorus-containing compounds are also useful, such as resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl) phosphate of hydroquinone, and bis(diphenyl) phosphate of bisphenol A, and their oligomeric and polymeric counterparts, respectively.

[0095] Flame retardant compounds containing phosphorus-nitrogen bonds include phosphazenes, phosphazene chlorides, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl)phosphine oxides. These flame retardant additives are commercially available. In one aspect, the organophosphorus flame retardant containing a phosphorus-nitrogen bond is a phosphazene or cyclophosphazene of the formula:

[0096]

[0097] 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 group, an alkenyl group, an alkoxy group, an aryl group, an aryloxy group, or a polyoxyalkylene group. In the above groups, at least one hydrogen atom in these groups may be substituted by a group having 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:

[0098]

[0099] Commercially available phenoxyphosphazenes having 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.

[0100] Halogenated materials can also be used as flame retardants, such as 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 and 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3-bromo-4-hydroxyphenyl)-propane. Other halogenated materials include 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, and oligomeric and polymeric halogenated aromatic compounds such as copolycarbonates of bisphenol A and tetrabromobisphenol A with carbonate precursors (e.g., phosgene). Metal synergists such as antimony oxide can also be used with flame retardants.

[0101] Alternatively, the thermoplastic composition can be substantially free of chlorine and bromine. "Substantially free of chlorine and bromine" is defined as having a bromine or chlorine content of less than or equal to 100 parts per million (ppm), less than or equal to 75 ppm, or less than or equal to 50 ppm by weight, based on the total weight of the composition.

[0102] Inorganic flame retardants such as C 1-16 Salts of alkyl sulfonates, such as potassium perfluorobutanesulfonate (Rimar salt), potassium perfluorooctanesulfonate, tetraethylammonium perfluorohexanesulfonate, and potassium diphenylsulfonesulfonate; salts such as Na2CO3, K2CO3, MgCO3, CaCO3 and BaCO3, or fluoride anion complexes such as Li3AlF6, BaSiF6, KBF4, K3AlF6, KAlF4, K2SiF6 or Na3AlF6.

[0103] When present, the flame retardant can be included in the composition in an amount of 0.01 to 10 weight percent. Within this range, the flame retardant can be present in an amount of 0.1 to 10 weight percent, or 1 to 10 weight percent, or 1 to 8 weight percent, or 2 to 6 weight percent, or 3 to 5 weight percent, each based on the gross weight of the composition.

[0104] The heat stabilizer additive may include an organic phosphite (e.g., triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, tris-(mixed mono- and dinonylphenyl) phosphite, etc.), a phosphonate (e.g., dimethylphenylphosphonate, etc.), a phosphate (e.g., trimethyl phosphate, etc.), or a combination thereof. The heat stabilizer may be tris(2,4-di-tert-butylphenyl) phosphate available as IRGAPHOS 168. The heat stabilizer is typically used in an amount of 0.01 to 5 wt % based on the total weight of the polymer in the composition.

[0105] Light stabilizers or ultraviolet (UV) absorbing additives, also known as UV stabilizers, may also be used. Light stabilizer additives include benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2-hydroxy-4-n-octyloxybenzophenone, or combinations thereof.

[0106] UV absorbing additives include hydroxybenzophenones; hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones; aryl salicylates; monoesters of diphenols, such as resorcinol monobenzoate; 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB 5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB 531); 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine-2-yl]-5-(octyloxy)-phenol (CYASORB 1164); 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (CYASORB UV-3638); poly[(6-morpholino-s-triazine-2,4-diyl)[2,2,6,6-tetramethyl-4-piperidinyl]imino]-hexamethylene[(2,2,6,6-tetramethyl-4-piperidinyl)imino], 2-hydroxy-4-octyloxybenzophenone (UVINUL TM 3008), 6-tert-butyl-2-(5-chloro-2H-benzotriazol-2-yl)-4-methylphenyl (UVINUL TM 3026), 2,4-di-tert-butyl-6-(5-chloro-2H-benzotriazol-2-yl)-phenol (UVINUL TM3027), 2-(2H-benzotriazol-2-yl)-4,6-di-tert-amylphenol (UVINUL3028), 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (UVINUL3029), 1,3-bis[(2'cyano-3',3'-diphenylacryloyl)oxy]-2,2-bis-{[(2'-cyano-3',3'-diphenylacryloyl)oxy]methyl}-propane (UVINUL UL3030), 2-(2H-benzotriazole-2-yl)-4-methylphenol (UVINUL3033), 2-(2H-benzotriazole-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (UVINUL3034), ethyl-2-cyano-3,3-diphenylacrylate (UVINUL3035), (2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (UVINUL3039), N,N'-dimethyl Acyl-N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)hexamethylenediamine (UVINUL4050H), bis-(2,2,6,6-tetramethyl-4-piperidinyl)-sebacate (UVINUL4077H), bis-(1,2,2,6,6-pentamethyl-4-piperidinyl)-sebacate + methyl-(1,2,2,6,6-pentamethyl-4-piperidinyl)-sebacate (UVINUL4092H), 1,3-bis[(2 -cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL3030), 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one), 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane, TINUVIN 234; nano-sized inorganic materials such as titanium oxide, cerium oxide and zinc oxide, each having a particle size of less than or equal to 100 nanometers; and the like, or a combination thereof. The UV absorber may be used in an amount of 0.01 to 1 parts by weight based on 100 parts by weight of the polycarbonate and the impact modifier. UV absorbers that may be particularly suitable for use in the polycarbonate compositions disclosed herein include 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (e.g., CYASORB TM5411, commercially available from Cytec Industries, Inc., Woodland Park, New Jersey) and 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (e.g., CYASORB UV-3638, commercially available from Cytec Industries, Inc., Woodland Park, New Jersey), or a combination thereof. The UV stabilizer may be present in an amount of 0.01 to 1 wt%, preferably 0.1 to 0.5 wt%, and more preferably 0.15 to 0.4 wt%, based on the total weight of the polycarbonate composition.

[0107] Plasticizers, lubricants, or mold release agents may also be used. There is considerable overlap among these types of materials, which include, for example, phthalates such as dioctyl-4,5-epoxy-hexahydrophthalate; tris-(octyloxycarbonylethyl) isocyanurate; tristearin; di- or polyfunctional aromatic phosphates such as resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl) phosphate of hydroquinone, and bis(diphenyl) phosphate of bisphenol A; poly-α-olefins; epoxidized soybean oil; silicones, including silicone oils; esters, for example, fatty acid esters such as alkyl stearyl esters, for example, methyl stearate, stearyl stearate, pentaerythritol tetrastearate, and the like; methyl stearate in combination with a hydrophilic and hydrophobic nonionic surfactant comprising a polyethylene glycol polymer, a polypropylene glycol polymer, a poly(ethylene glycol-co-propylene glycol) copolymer, or a combination thereof, for example, methyl stearate and a polyethylene glycol-polypropylene glycol copolymer in a suitable solvent; waxes such as beeswax, montan wax, paraffin wax, and the like.

[0108] Thermoplastic compositions can optionally minimize or exclude various components not specifically provided herein. For example, the composition can exclude polymers other than post-consumer recycled polycarbonates, polycarbonate-siloxane copolymers, polycarbonate-esters, branched polycarbonates, copolycarbonates containing carbonate repeating units derived from bulky bisphenol groups, and linear polycarbonate homopolymers. In one aspect, the composition can include less than 1 weight percent, or less than 0.5 weight percent, or less than 0.1 weight percent, or less than 0.01 weight percent of laser direct structuring additives. In one aspect, the composition can exclude laser direct structuring additives.

[0109] A method for preparing a composition of the present disclosure is also provided. Thermoplastic compositions can be prepared by various methods. For example, powdered polycarbonate and other optional components can be optionally blended with any filler in a high-speed mixer or by manual mixing. The blend is then fed to the throat of a twin-screw extruder through a hopper. Alternatively, at least one component can be fed directly to the extruder through a side filler at the throat or downstream, or incorporated into the composition by being mixed into a masterbatch with the desired polymer 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 can be immediately quenched and granulated in a water bath. As required, the pellets so prepared can be a quarter inch long or less. Such pellets can be used for subsequent molding, shaping, or forming.

[0110] Also provided are shaped, formed, cast, or molded articles comprising polycarbonate compositions. The polycarbonate compositions can be molded into useful shaped articles by a variety of methods, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming. The articles can be molded articles, thermoformed articles, extruded films, extruded sheets, honeycomb structures, one or more layers of multilayer articles, substrates for coating articles, and substrates for metallized articles. Exemplary articles can include computer and business machine housings such as housings for monitors, handheld electronic device housings such as housings for mobile phones, electrical connectors, and components of lighting equipment, ornaments, household appliances, roofs, greenhouses, solariums, swimming pool enclosures, electronic device housings, and signs, etc. In addition, the polycarbonate compositions can be used in such applications as automotive panels and decorations.Examples of suitable articles are shown by, but are not limited to, the following: aircraft, automobile, truck, military vehicle (including automotive, aircraft and marine vehicles), scooter and motorcycle exterior and interior components, including panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, instrument panels, grilles, reflector housings, pillar trim, cladding, body side moldings, wheel covers, visors, door handles, spoilers, window frames, headlight bezels, headlights, taillights, taillight housings, taillight bezels, license plate housings, vehicle Headers and dash panels; housings, casings, panels, and components for outdoor vehicles and devices; housings for electrical and telecommunications equipment; outdoor furniture; aircraft components; boat and marine equipment, including trim, casings, and casings; outboard motor casings; depth sounder casings; personal watercraft; jet skis; pools; sprays; hot tubs; steps; step coverings; architectural and construction applications such as glazing, roofing, windows, flooring, decorative window treatments or treatments; treated glass covers for pictures, paintings, posters, and similar display items; wall panels and doors; countertops; protected graphics; interior Exterior and interior signage; cases, housings, panels, and components for automated teller machines (ATMs); computers; desktop computers; portable computers; laptop computers; handheld computer housings; monitors; printers; keyboards; fax machines; copiers; telephones; phone frames; mobile phones; radio transmitters; radio receivers; cases, housings, panels, and components for lawn and garden tractors, mowers, and tools (including lawn and garden tools); window and door trim; sporting equipment and toys; cases, housings, panels, and components for snowmobiles; recreational vehicle panels and components; playground equipment; shoelaces; articles made from plastic-wood combinations; golf course markings; utility pit covers; lamps; lighting fixtures; network interface device housings; transformer housings; air conditioner housings; cladding or seating for public transportation; cladding or seating for trains, subways, or buses; instrument housings; antenna housings; cladding for satellite dishes; coated helmets and personal protective equipment; coated synthetic or natural textiles; coated painted articles; coated dyed articles; coated fluorescent articles; coated foam articles; and similar applications.

[0111] The compositions of the present disclosure can be particularly useful for articles for consumer electronic applications. For example, the article can be a component of a consumer electronic device, such as a game console, a game controller, a portable game device, a cellular phone, a television, a personal computer, a tablet computer, a laptop computer, a personal digital assistant, a portable media player, a digital camera, a portable music player, an appliance, a power tool, a robot, a toy, a greeting card, a home entertainment system, a speaker, or a sound bar. In one aspect, the article can be an electronic housing for an adapter, a mobile phone, a smart phone, a GPS device, a laptop computer, a tablet computer, an e-reader, a copier, or a solar device.

[0112] The present disclosure is further illustrated by the following examples, which are non-limiting.

[0113] Example

[0114] The materials used in the following examples are described in Table 1.

[0115] Table 1

[0116]

[0117]

[0118]

[0119] The compositions of the following examples were prepared by blending the components together and extruding on a 25- or 37-mm twin screw extruder. The compositions were then injection molded. The temperature profiles for the compounding and injection molding conditions are summarized in Tables 2 and 3, respectively.

[0120] Table 2

[0121] PCE PPPBP-PC parameter unit Screw S-3-1B Screw 2 - lobes Screw 2-protrusion Mixing machine type \ W&P ZSK26Mc W&P ZSK25 ZSK25 Feed (zone 0) temperature \ 50 45 40 Zone 1 Temperature ℃ 100 200 200 Zone 2 Temperature ℃ 265 250 250 Zone 3 Temperature ℃ 265 270 270 Zone 4 Temperature ℃ 265 290 310 Zone 5 Temperature ℃ 265 290 310 Zone 6 Temperature ℃ 265 290 310 Zone 7 Temperature ℃ 265 290 310 Zone 8 Temperature ℃ 265 310 Zone 9 Temperature ℃ 265 310 Zone 10 Temperature ℃ 265 Zone 11 Temperature ℃ 265 Die temperature ℃ 265 290 310

[0122] Table 3

[0123] PCE PPPBP-PC Molding parameters unit value value value Pre-drying time Hour 4 2-4 4 Pre-drying temperature ℃ 120 120 120 Hopper temperature ℃ 50 45 40 Zone 1 Temperature ℃ 290 280 290 Zone 2 Temperature ℃ 300 290 300 Zone 3 Temperature ℃ 300 300 310 Nozzle temperature ℃ 300 295 305 Mold temperature ℃ 90 90 105

[0124] Physical measurements were made using the tests and test methods described below.

[0125] Tensile properties are measured on standard tensile bars according to ASTM D638 or ISO 527 at a test speed of 50 mm / min.

[0126] The bending properties were measured according to ASTM D790 at a test speed of 2.54 mm / min or ISO 178 standard at a test speed of 2 mm / min.

[0127] Notched Izod impact strength (INI) was measured at different temperatures (including temperatures of 23°C, -20°C, or -30°C) under a load of 5 lbf according to ASTM D256. All ASTM INI measurements were performed on 3.2 mm thick sample plates. For the tests at -20°C and -30°C, the test samples were placed in a freezer for more than 4 hours and then taken out for testing at room temperature within 5 seconds.

[0128] The heat distortion temperature (HDT) is determined according to ASTM D648 at a load of 1.82 MPa, according to ISO 75 / Af at a load of 1.8 MPa, or according to ISO 75 / Bf at a load of 0.45 MPa.

[0129] Light transmittance and haze were characterized according to ASTM D1003 using color chips having a thickness of 2.54 mm.

[0130] The flammability test is conducted in accordance with the procedures of Underwriter's Laboratory Bulletin 94 entitled "Tests for the Flammability of Plastic Materials for Parts in Devices and Appliances" (ISBN 0-7629-0082-2), Fifth Edition, October 29, 1996, incorporating revisions up to and including December 12, 2003. Multiple ratings can be applied based on the burning rate, extinguishing time, ability to resist dripping, and whether the drippings burn. According to the procedure, the material can be classified as UL94 HB, V-0, V-1, V-2, 5VA or 5VB. The test samples are aged at 23°C, 50% RH for more than 2 days or at 70°C for 168 hours before testing. Specifically, in the UL 94 50W (20mm) vertical burning flame test, a set of five burning rods are tested. For each rod, a flame is applied to the rod, then removed, and the time required for the rod to self-extinguish (first afterflame time, t1) is recorded. The flame is then reapplied and removed, and the time required for the rod to self-extinguish (second afterflame time, t2) and the flame afterglow time (afterglow time, t3) are recorded. To achieve a rating of V-0, the afterflame times t1 and t2 of each individual sample must be less than or equal to 10 seconds; and the total afterflame time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 50 seconds; and the second afterflame time plus the afterglow time (t2+t3) of each individual sample must be less than or equal to 30 seconds; and no sample can burn or smolder to the holding fixture; and the cotton indicator cannot be ignited by burning particles or drippings. To achieve a V-1 rating, the afterflame times t1 and t2 of each individual sample must be less than or equal to 30 seconds; and the total afterflame time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 250 seconds; and the second afterflame time plus the afterglow time (t2+t3) of each individual sample must be less than or equal to 60 seconds; and no specimen can burn or smolder to the holding fixture; and the cotton indicator cannot be ignited by burning particles or drippings. To achieve a V-2 rating, the afterflame times t1 and t2 of each individual sample must be less than or equal to 30 seconds; and the total afterflame time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 250 seconds; and the second afterflame time plus the afterglow time (t2+t3) of each individual sample must be less than or equal to 60 seconds; and no specimen can burn or smolder to the holding fixture; but the cotton indicator can be ignited by burning particles or drippings. To achieve an HB rating, in a horizontal burn test, the material must not have a burning rate exceeding 40 mm / min over a 75 mm span for samples having a thickness between 3 and 13 mm, or 75 mm / min over a 75 mm span for samples having a thickness less than 3.0 mm.If the material ceases to burn before the 100mm reference mark, an HB rating is also achieved.

[0131] The carbon footprint of each composition was characterized according to the Intergovernmental Panel on Climate Change (IPCC) methodology (IPCC 2013 GWP100a V1.03).

[0132] The compositions and test results are shown in Table 4. In Table 4, the amount of each component is provided in weight percent based on the total weight of the composition.

[0133] Table 4

[0134]

[0135]

[0136] Table 5

[0137]

[0138]

[0139] As shown in Tables 4 and 5, despite the inclusion of high levels of post-consumer recycled polycarbonate in the compositions of Ex. 1-Ex. 10, these examples exhibit comparable mechanical properties and flame retardancy relative to the comparative examples including only virgin materials. Thus, the compositions according to the present disclosure can significantly reduce the carbon footprint compared to the comparative examples, thereby contributing to sustainability. Thus, significant improvements are provided by the compositions according to the present disclosure.

[0140] The present disclosure further encompasses the following aspects.

[0141] Aspect 1: A thermoplastic composition comprising: 30 to 95 weight percent of post-consumer recycled polycarbonate; and 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; and wherein when the composition comprises a polycarbonate-siloxane copolymer, a branched polycarbonate, or a copolycarbonate containing phthalazine carbonate repeating units, the composition further comprises 5 to 65 weight percent of a linear polycarbonate homopolymer comprising at least two of the following: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min as measured at 300° C. and 1.2 kg as measured according to ASTM D1238; a low flow polycarbonate having a melt flow rate of greater than 10 to 25 g / 10 min as measured according to ASTM D1238; D1238 at 300 ° C and 1.2 kg measured at 5 to 19 g / 10 min; and ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min measured at 300 ° C and 1.2 kg according to ASTM D1238; wherein the weight percentage of each component is based on the total weight of the composition.

[0142] Aspect 2: The thermoplastic composition according to aspect 1, wherein the post-consumer recycled polycarbonate comprises bisphenol A polycarbonate, preferably, wherein the post-consumer recycled polycarbonate has an L value greater than or equal to 85, preferably greater than or equal to 92, as measured according to ASTM D2244, a yellowness index less than or equal to 8, preferably less than or equal to 3.5, as measured according to ASTM E313, a transmittance greater than or equal to 70%, preferably greater than or equal to 82%, at a thickness of 3 mm as measured according to ASTM D 1003, and a haze less than or equal to 10, preferably less than or equal to 6, at a thickness of 3 mm as measured according to ASTM D 1003.

[0143] Aspect 3: A thermoplastic composition according to aspect 1 or 2, comprising 25 to 90 weight percent of post-consumer recycled polycarbonate; 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a branched polycarbonate, or a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; and 5 to 65 weight percent of a linear polycarbonate homopolymer comprising at least two of the following: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min as measured at 300°C and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min as measured at 300°C and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min as measured at 300°C and 1.2 kg according to ASTM D1238; and an ultra-low flow polycarbonate having a melt flow rate of 100 g / 10 min as measured at 300°C and 1.2 kg according to ASTM D1238. D1238 has a melt flow rate of less than 5 g / 10 min measured at 300°C and 1.2 kg.

[0144] Aspect 4: The thermoplastic composition according to any one of aspects 1 to 3, comprising a polycarbonate copolymer, wherein the polycarbonate-siloxane comprises 5 to 50 weight percent, or 15 to 50 weight percent, or 20 to 40 weight percent siloxane content based on the weight of the polycarbonate-siloxane copolymer.

[0145] Aspect 5: A thermoplastic composition according to any one of aspects 1 to 3, comprising a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups, preferably a copolycarbonate containing phthalimide carbonate repeating units, more preferably, wherein the copolycarbonate is a bisphenol A carbonate-2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimide carbonate copolymer.

[0146] Aspect 6: The thermoplastic composition according to any one of aspects 1 to 3, comprising a branched polycarbonate, preferably wherein the branched polycarbonate is a branched polycarbonate homopolymer comprising cyanophenol end groups.

[0147] Aspect 7: A thermoplastic composition according to any one of Aspects 1 to 6, wherein the linear polycarbonate homopolymer comprises a high-flow polycarbonate and a low-flow polycarbonate, or a low-flow polycarbonate and an ultra-low-flow polycarbonate, or a low-flow polycarbonate and an ultra-high-flow polycarbonate; preferably, wherein the composition comprises a polycarbonate-siloxane copolymer, and the linear polycarbonate homopolymer comprises a high-flow polycarbonate and a low-flow polycarbonate, or a low-flow polycarbonate and an ultra-low-flow polycarbonate; or wherein the composition comprises a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups, and the linear polycarbonate homopolymer comprises a low-flow polycarbonate and an ultra-high-flow polycarbonate; or wherein the composition comprises a branched polycarbonate, and the linear polycarbonate homopolymer comprises a high-flow polycarbonate and a low-flow polycarbonate.

[0148] Aspect 8: A thermoplastic composition according to any one of Aspects 1 to 3, comprising 45 to 90 weight percent of post-consumer recycled polycarbonate, 5 to 35 weight percent of a polycarbonate-siloxane copolymer, and 5 to 40 weight percent of a linear polycarbonate homopolymer, which comprises a high flow polycarbonate and a low flow polycarbonate; or a low flow polycarbonate and an ultra-low flow polycarbonate.

[0149] Aspect 9: A thermoplastic composition according to any one of Aspects 1 to 3, comprising 25 to 55 weight percent of post-consumer recycled polycarbonate, 10 to 25 weight percent of a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups, and 3 to 55 weight percent of a linear polycarbonate homopolymer comprising a low flow polycarbonate and an ultra-high flow polycarbonate.

[0150] Aspect 10: The thermoplastic composition according to any one of aspects 1 to 3, comprising 40 to 60 weight percent of post-consumer recycled polycarbonate, 10 to 30 weight percent of a branched polycarbonate comprising cyanophenol end groups, and 10 to 30 weight percent of a linear polycarbonate homopolymer comprising a low flow polycarbonate and a high flow polycarbonate.

[0151] Aspect 11: The thermoplastic composition according to aspect 1 or 2, comprising a polycarbonate-ester, preferably, wherein the polycarbonate-ester comprises resorcinol isophthalate repeating units and resorcinol terephthalate repeating units and bisphenol A carbonate repeating units.

[0152] Aspect 12: The thermoplastic composition according to aspect 11, comprising 20 to 60 weight percent of post-consumer recycled polycarbonate, 35 to 55 weight percent of polycarbonate-ester, and optionally 15 to 35 weight percent of high flow polycarbonate.

[0153] Aspect 13: The thermoplastic composition according to any one of aspects 1 to 12, further comprising 0.01 to 10 weight percent of a flame retardant.

[0154] Aspect 14: A method for preparing the composition according to any one of aspects 1 to 13, the method comprising melt mixing the components of the composition.

[0155] Aspect 15: An article comprising the composition according to any one of aspects 1 to 13, preferably, wherein the article is a consumer electronic component.

[0156] 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 species), step, or component that is otherwise not necessary to achieve the function or purpose of the compositions, methods and articles.

[0157] All ranges disclosed herein include endpoints, and endpoints can be combined independently of each other. "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not represent any order, quantity, or importance, but are used to distinguish one element from another. Unless otherwise specified herein or clearly contradictory to the context, the terms "one" and "a kind of" and "the" do not represent the limitation of quantity, but are interpreted as covering the singular and plural. Unless otherwise clearly stated, "or" means "and / or". Throughout the specification, mentioning "an aspect" means that the specific elements described in conjunction with the aspect are included in at least one aspect described herein, and may or may not be present in other aspects. The term "their combination" as used in this article includes one or more listed elements, and is open, allowing one or more unnamed similar elements to exist. In addition, it should be understood that the described elements can be combined in any suitable manner in various aspects.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] As used in this article, the term "alkyl", whether used alone or as a prefix, suffix or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight chain, cyclic, bicyclic, branched, saturated or unsaturated. It can also contain a combination of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated and unsaturated hydrocarbon parts. However, when the alkyl residue is described as substituted, it can optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Therefore, when specifically described as substituted, the alkyl residue can also include one or more carbonyls, amino, hydroxyl, etc., or it can include heteroatoms in the main chain of the alkyl residue. The term "alkyl" refers to a branched or straight chain, saturated 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 radical having at least one carbon-carbon double bond (e.g., vinyl (-HC=CH2)). "Alkoxy" refers to an alkyl radical attached via an oxygen (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butoxy. "Alkylene" refers to a straight or branched, saturated, divalent aliphatic hydrocarbon radical (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). "Cycloalkylene" refers to a divalent cyclic alkylene radical, -C n H 2n-x , wherein x is the number of hydrogens replaced by cyclization. "Cycloalkenyl" refers to a monovalent group having 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. "Alkylarylene" refers to an arylene substituted by an alkyl group. "Arylalkylene" refers to an alkylene 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 atoms (e.g., bromine and fluorine) or only chlorine atoms. 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 to replace hydrogen, each of which can be independently C 1-9 Alkoxy, C1-9 Haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 Alkylsulfonyl (-S(=O)2-alkyl), C 6-12 Arylsulfonyl (-S(=O)2-aryl), mercapto (-SH), thiocyanato (-SCN), tosyl (CH3C6H4SO2-), C 3-12 Cycloalkyl, C 2-12 Alkenyl, C 5-12 Cycloalkenyl, C 6-12 Aryl, C 7-13 Arylalkylene, C 4-12 Heterocycloalkyl and C 3-12 Heteroaryl, 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 substituted with a nitrile.

[0162] Although specific embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are not currently foreseeable or may not be foreseeable may occur to the applicant or other persons skilled in the art. 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. A thermoplastic composition comprising: 30 to 95 weight percent post-consumer recycled polycarbonate; and 5 to 70 weight percent of the following: Polycarbonate-siloxane copolymer, or Polycarbonate-ester, or Branched polycarbonate, or a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; and in, When the composition comprises the polycarbonate-siloxane copolymer, the branched polycarbonate, or the copolycarbonate containing phthalimide carbonate repeating units, the composition further comprises: 5 to 65 weight percent of a linear polycarbonate homopolymer comprising at least two of the following: An ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; A high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; A low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; and An ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min as measured at 300° C. and 1.2 kg according to ASTM D1238; The weight percentage of each component is based on the total weight of the composition.

2. The thermoplastic composition according to claim 1, wherein The post-consumer recycled polycarbonate comprises bisphenol A polycarbonate, preferably, wherein the post-consumer recycled polycarbonate has: An L value greater than or equal to 85, preferably greater than or equal to 92, as determined according to ASTM D2244; A yellowness index less than or equal to 8, preferably less than or equal to 3.5, measured according to ASTM E313; A transmittance greater than or equal to 70%, preferably greater than or equal to 82%, at a thickness of 3 mm, measured according to ASTM D 1003; and A haze of less than or equal to 10, preferably less than or equal to 6 at a thickness of 3 mm, measured according to ASTM D 1003.

3. The thermoplastic composition according to claim 1 or 2, comprising: 25 to 90 weight percent of said post-consumer recycled polycarbonate; 5 to 70 weight percent of the following: The polycarbonate-siloxane copolymer, or The branched polycarbonate, or The copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; and 5 to 65 weight percent of the linear polycarbonate homopolymer comprising at least two of the following: An ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; A high-flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; A low-flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238; and An ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min measured at 300° C. and 1.2 kg according to ASTM D1238.

4. The thermoplastic composition according to any one of claims 1 to 3, comprising a polycarbonate copolymer, wherein: The polycarbonate-siloxane comprises 5 to 50 weight percent, or 15 to 50 weight percent, or 20 to 40 weight percent, or 25 to 50 weight percent siloxane content, based on the weight of the polycarbonate-siloxane copolymer.

5. Thermoplastic composition according to any one of claims 1 to 3, comprising the copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups, preferably a copolycarbonate containing phthalidone carbonate repeating units, more preferably, wherein, The copolycarbonate is a bisphenol A carbonate-2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimide carbonate copolymer.

6. The thermoplastic composition according to any one of claims 1 to 3, comprising the branched polycarbonate, preferably, wherein: The branched polycarbonate is a branched polycarbonate homopolymer containing cyanophenol end groups.

7. The thermoplastic composition according to any one of claims 1 to 6, wherein The linear polycarbonate homopolymer comprises: The high-flow polycarbonate and the low-flow polycarbonate, or The low flow polycarbonate and the ultra-low flow polycarbonate, or The low-flow polycarbonate and the ultra-high-flow polycarbonate; Preferably, wherein the composition comprises the polycarbonate-siloxane copolymer, and the linear polycarbonate homopolymer comprises the high-flow polycarbonate and the low-flow polycarbonate or comprises the low-flow polycarbonate and the ultra-low-flow polycarbonate; or wherein the composition comprises the copolycarbonate comprising carbonate repeating units derived from bulky bisphenol groups, and the linear polycarbonate homopolymer comprises the low flow polycarbonate and the ultra-high flow polycarbonate; or The composition comprises the branched polycarbonate, and the linear polycarbonate homopolymer comprises the high-flow polycarbonate and the low-flow polycarbonate.

8. The thermoplastic composition according to any one of claims 1 to 3, comprising: 45 to 90 weight percent of said post-consumer recycled polycarbonate; 5 to 35 weight percent of the polycarbonate-siloxane copolymer, and 5 to 40 weight percent of a linear polycarbonate homopolymer, the linear polycarbonate homopolymer comprising: The high-flow polycarbonate and the low-flow polycarbonate; or The low flow polycarbonate and the ultra low flow polycarbonate.

9. The thermoplastic composition according to any one of claims 1 to 3, comprising: 25 to 55 weight percent of said post-consumer recycled polycarbonate; 10 to 25 weight percent of said copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups, and 30 to 55 weight percent of a linear polycarbonate homopolymer comprising the low flow polycarbonate and the ultra high flow polycarbonate.

10. The thermoplastic composition according to any one of claims 1 to 3, comprising: 40 to 60 weight percent of said post-consumer recycled polycarbonate; 10 to 30 weight percent of said branched polycarbonate containing cyanophenol end groups, and 10 to 30 weight percent of a linear polycarbonate homopolymer comprising the low flow polycarbonate and the high flow polycarbonate.

11. The thermoplastic composition according to claim 1 or 2, comprising the polycarbonate-ester, preferably, wherein: The polycarbonate-ester comprises resorcinol isophthalate repeating units and resorcinol terephthalate repeating units and bisphenol A carbonate repeating units.

12. The thermoplastic composition according to claim 11, comprising: 20 to 60 weight percent of said post-consumer recycled polycarbonate; 35 to 55 weight percent of said polycarbonate-ester; and Optionally, 15 to 35 weight percent of the high flow polycarbonate.

13. The thermoplastic composition according to any one of claims 1 to 12, further comprising: 0.01 to 10 weight percent of a flame retardant.

14. A process for preparing the composition of any one of claims 1 to 13, the process comprising melt mixing the components of the composition.

15. A product comprising the composition according to any one of claims 1 to 13, preferably, wherein: The article is a consumer electronic component.

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