Flame retardant polycarbonate formulations

Abstract

Disclosed is a polycarbonate composition which does not contain an alkali metal salt of a perfluoroalkane sulfonate and has a high level of flame retardancy and excellent physical properties. Methods of making such compositions are disclosed. Disclosed are structures prepared from the disclosed compositions. The composition comprises: a) at least one polycarbonate polymer; b) an impact modifier comprising a silicone core; and c) a phosphazene-based flame retardant. The composition may include a polyarylate, or at least a portion of the at least one polycarbonate is a high temperature polycarbonate. The composition may include one or more carbon-based particles, metal particles, or metal oxide particles. The composition may include a post consumer recovered polycarbonate.

Description

Technical Field

[0001] Disclosed are polycarbonate compositions that exhibit high levels of flame retardancy and excellent physical properties without requiring the presence of an alkali metal salt of a perfluoroalkane sulfonate. Disclosed are polycarbonate compositions containing high post-consumer recycled content that exhibit excellent flame retardant properties. Disclosed are methods of making such compositions. Disclosed are structures prepared from the disclosed compositions. Background Art

[0002] Polycarbonate and copolymers containing carbonate units are used in various molded structures. Polycarbonate and copolymers containing carbonate units form rigid molded structures. Molded structures can be used for a variety of purposes, including housings for electronic devices, automotive parts, medical devices, household appliances, speakers, household items, etc. The flame retardancy of such structures is an important safety consideration. The market requires improved flame retardancy while maintaining the excellent performance of molded structures. Some polycarbonate formulations contain salts of carbonized salts, perfluoroalkyl sulfur compounds, or aromatic sulfur compounds to improve the flame retardancy of the composition, see U.S. Patent Publication 2020 / 0354569, which is incorporated herein by reference in its entirety for all purposes. Some regulatory agencies believe that such compounds are potentially harmful. It is necessary to recycle used polycarbonate or its copolymers. It is desirable to use recycled polycarbonate or its copolymers in molded products as long as the structure provides flame retardancy and maintains excellent performance. Recycled polycarbonate and its copolymers can be derived from post-consumer waste, such as water bottles, soda bottles, etc. Significant progress has been made in developing polycarbonate formulations containing post-consumer recycled polycarbonate, see WO2019 / 115506, which discloses a laminate containing a fiber base layer and a polycarbonate-based layer, wherein up to fifty percent of the polycarbonate may be post-consumer recycled polycarbonate. Many polycarbonate users want to use polycarbonates with higher post-consumer recycled content that do not contain compounds that regulators consider to be potentially harmful and require flame retardancy that achieves a UL V-0 rating while also having the excellent physical properties of virgin polycarbonate.

[0003] What is needed is a composition that is free of compounds considered to be potentially harmful by regulatory agencies, that may contain high levels of post-consumer recycled polycarbonate, and that forms a molded structure having desirable flame retardancy while maintaining the excellent properties of molded products containing polycarbonate, such as excellent tensile strength at yield, tensile strength at break, tensile elongation at yield, tensile elongation at break, and notched Izod impact strength, etc. What is also needed is a molding composition prepared from such a composition that exhibits improved flame retardancy, is free of compounds considered to be potentially harmful, and exhibits the excellent properties described above. Summary of the invention

[0004] A composition comprising the following ingredients is disclosed: a) one or more polycarbonate polymers; b) an impact modifier comprising a silicone core; and c) a phosphazene-based flame retardant. The composition may comprise a polyarylate, or at least a portion of the one or more polycarbonate polymers may be a high temperature polycarbonate. The disclosed composition may comprise about 90 wt% or more of one or more polycarbonate polymers. The one or more polycarbonate polymers may comprise about 0-95 wt% of a linear polycarbonate. The one or more polycarbonates may comprise at least one of: a polycarbonate having a low melt flow rate; a polycarbonate having a medium melt flow rate; and a polycarbonate having a high melt flow rate. The low melt flow rate may be about 0.1-5 g / 10 min. The medium melt flow rate may be about 5-15 g / 10 min. The high melt flow rate may be greater than about 15 g / 10 min. The melt flow rate may be measured according to ASTM D1238. A portion of the one or more polycarbonate polymers may be post-consumer recycled polymers. The composition may include a mixture of virgin polycarbonate and post-consumer recycled polycarbonate. According to ASTM D1238, the melt flow rate of post-consumer recycled polycarbonate and / or virgin polycarbonate may be about 1-30 g / 10 min. One or more polycarbonate polymers may include about 50-90 wt% of high temperature polycarbonate. High temperature polycarbonate may have a glass transition temperature of about 150°C or higher, as determined by differential scanning calorimetry according to ASTM test method D 746-52T. The polyarylate may have a molecular weight of about 10,000-150,000 amu (atomic mass unit). The composition may include about 3.0 wt% or less of an impact modifier based on the weight of the composition. The impact modifier may contain about 20-70 wt% of a silicone core component based on the weight of the composition. The composition may include about 5.0 wt% or less of a phosphazene-based flame retardant based on the weight of the composition. The composition may not contain a carbonizing salt including a perfluoroalkyl sulphur compound. The composition may contain a carbonizing salt consisting of an aromatic sulphur compound which does not contain a halogen atom (eg fluorine).

[0005] The composition may include an anti-drip agent. The composition may include one or more non-halogenated flame retardants. The composition may include one or more antioxidants. The composition may include one or more UV absorbers. The composition may include one or more release agents. The composition may include one or more colorants. The composition may include one or more carbon-based particles, one or more metals, or one or more metal oxides. The composition may include about 0.1-0.9wt% of an anti-drip agent based on the weight of the composition. The composition may include about 0.1-1wt% of a release agent based on the weight of the composition. The composition may include about 0.05 to 0.5wt% of an antioxidant based on the weight of the composition. The composition may include about 0.1-0.3wt% of a UV stabilizer based on the weight of the composition. The composition may include about 0.02-10wt% of one or more carbon-based particles, metals, or metal oxides. The composition may include one or more carbonized salts, wherein the carbonized salt does not contain any halogen atoms. The one or more carbonized salts may include one or more sulfonates. The carbonized salts include one or more aromatic sulfonates. The carbonized salts may include one or more alkali metal salts and alkaline earth metal salts. The one or more carbonizing salts may be present in an amount of about 0.01-1.0 wt % of the one or more carbonizing salts, based on the weight of the composition.

[0006] The composition may include: about 60-98wt% of at least one polycarbonate polymer; about 0.1-5.0wt% of an impact modifier containing a silicone core; about 1.0-5.0wt% of a phosphazene-based flame retardant; about 0-60wt% of a polyarylate; 0-1.0wt% of an anti-drip agent; 0-1.0wt% of a mold release agent; 0-0.5wt% of an antioxidant; 0-0.5wt% of a UV stabilizer; and 0-10wt% of a colorant; wherein 0-90% of the at least one polycarbonate polymer is a high temperature polycarbonate; and the wt% is based on the weight of the composition. The composition may include about 60-98 wt % of at least one polycarbonate polymer; about 0.1-5 wt % of one or more impact modifiers comprising a silicone core, about 0.01-2 wt % of one or more anti-drip agents, about 0.02-10 wt % of one or more carbon-based particles, metals or metal oxides, and about 0.02-0.2 wt % of one or more buffering compounds (e.g., alkali metal phosphates), wherein the wt % is based on the total weight of the composition.

[0007] Disclosed are articles made from the compositions disclosed herein.

[0008] A method is disclosed, comprising: a) contacting and mixing the ingredients of any of the compositions disclosed herein at a temperature of about 250° C. or higher for about 10 seconds or longer, b) filling a mold with the mixed composition of a), and c) forming the composition in the mold into a solid article, and d) removing the formed article from the mold. The contact mixing can be performed in an extruder and the formed mixture can be moved from the extruder to the mold.

[0009] Compositions and structures prepared from such disclosed compositions may contain high post-consumer recycled content. The composition may not contain halogen-containing carbonizing salts, such as salts of perfluoroalkyl sulfide compounds. Articles prepared from the composition may achieve UL94 V0@1.0mm flame retardancy. Articles prepared from the composition may achieve UL94 V0@1.0mm flame retardancy after immersion in water. Articles prepared from the composition may achieve UL94 V0@1.5mm flame retardancy. Articles prepared from the composition may achieve UL94 V0@1.5mm flame retardancy after immersion in water. Articles prepared from the composition may maintain ductile strength at -20°C or -30°C, as determined by notched Izod testing. Articles prepared from the composition can maintain their ductile impact strength even after exposure to high temperature and humidity (85°C / 85% RH) for 500 hours. According to ASTM D648, an article prepared from the composition may exhibit a heat distortion temperature at 1.8 MPa higher than 110° C., 120° C. or 125° C. The article may be used in automobiles, trains, buses, and recreational vehicles. DETAILED DESCRIPTION

[0010] While the present disclosure has been described in conjunction with certain embodiments, it should be understood that the present disclosure is not limited to the disclosed embodiments, and is intended to cover various modifications and equivalent arrangements included within the purview of the appended claims, the scope of which is to be given the broadest interpretation so as to encompass all such modifications and equivalent structures permitted by law.

[0011] As used herein, one or more means that at least one or more of the listed components can be used as disclosed. As used herein, a hydrocarbyl group refers to a group containing one or more carbon atom backbones and hydrogen atoms, which may optionally contain one or more heteroatoms. When a hydrocarbyl group contains heteroatoms, the heteroatoms may form one or more functional groups known to those skilled in the art. The hydrocarbyl group may contain any combination of alicyclic, aliphatic, aromatic or such segments. The aliphatic segment may be straight chain or branched. The aliphatic and alicyclic segments may contain one or more double bonds and / or triple bonds. The hydrocarbyl group includes alkyl, alkenyl, alkynyl, aryl, cycloalkyl, cycloalkenyl, alkaryl and aralkyl groups. The alicyclic group may contain both cyclic and non-cyclic parts. Hydrocarbylene means a hydrocarbyl group or any described subset having more than one valence state, such as alkylene, alkenylene, alkynylene, arylene, cycloalkylene, cycloalkenylene, alkarylene and aralkylene. As used herein, valence refers to a covalent bond between a hydrocarbyl or hydrocarbylene group and another group such as a group or atom containing a carbonyl, oxygen, nitrogen or sulfur, or a base compound mentioned. Unless otherwise indicated, wt% or weight parts as used herein refer to or are based on the weight of the composition. Tg is the temperature or temperature range at which a sudden change in the physical properties of a polymeric material, including, for example, mechanical strength, occurs. Tg can be determined by differential scanning calorimetry (DSC) according to ASTM test method D 746-52T. Post-industrial as used herein refers to a source of materials generated during the manufacture of goods or products. "Post-consumer" as used herein refers to a source of materials generated after the final consumer uses the consumer goods or products made of the material.

[0012] A composition is disclosed comprising: a) at least one polycarbonate polymer; b) an impact modifier comprising a silicone core; and c) a phosphazene-based flame retardant. The composition may comprise one or more post-consumer recycled polycarbonates, accounting for 95% of the weight of the composition. The disclosed composition may contain virgin polycarbonate. Virgin polycarbonate is a polycarbonate that has not been used in any composition before. The composition may not contain halogen-containing carbonizing salts, such as salts of perfluoroalkyl sulfur compounds. The composition may comprise one or more carbon-based particles, one or more metals, or one or more metal oxides. The composition may comprise polyarylates, or at least a portion of the one or more polycarbonate polymers may be high temperature polycarbonates. The composition may contain halogen-free carbonizing salts, such as aromatic sulfur compounds. The composition may contain one or more non-halogenated flame retardants, one or more antioxidants, one or more UV absorbers, one or more mold release agents, and / or one or more colorants.

[0013] As used herein, polycarbonate means a polymer containing carbonate units. Such polymers can be homopolymers consisting essentially of carbonate monomer units or copolymers containing one or more other monomer units (comonomer units) and carbonate units. Such copolymers can be block copolymers containing blocks of two or more different monomer units, or can be random copolymers in which different monomer units are randomly distributed on the polymer backbone. If the intended use requires, additional monomer units may include any monomer units that do not have a negative impact on the inherent properties of polycarbonate (such as heat resistance, impact resistance, moldability, flexural modulus, flexural strength, flexural strength, haze and transparency). Exemplary comonomer units include ester units, polysiloxane units, etc. As disclosed herein, the amount of carbonate monomer units in the copolycarbonate is selected so that the resulting polymer retains the desired properties of polycarbonate. Copolycarbonate can include carbonate monomer units greater than 50mol%, carbonate monomer units of about 75mol% or more, carbonate monomer units of about 80mol% or more, or carbonate monomer units of about 85mol% or more. Copolycarbonate can comprise about 99mol% or carbonate monomer units still less, about 97mol% or carbonate monomer units still less or about 95mol% or carbonate monomer units still less.Copolycarbonate can comprise about 1mol% or more comonomer units, about 3mol% or more comonomer units or about 5mol% or more comonomer units.Copolycarbonate can comprise comonomer units, about 25mol% or less comonomer units, about 20mol% or less comonomer units or about 15mol% or less comonomer units that are less than 50mol%.Polycarbonate unit can comprise aromatic unit in the main chain of polymer. The production of polycarbonates is achieved, for example, by reacting diphenols with carbonic acid halides (preferably phosgene) and / or with aromatic dicarboxylic acid dihalides (preferably benzene dicarboxylic acid dihalides) by the phase boundary process, optionally using chain terminators (e.g. monophenols) and optionally using trifunctional branching agents or branching agents with a functionality greater than 3 (e.g. trisphenols or tetraphenols). The diphenols that can be used to produce aromatic polycarbonates and / or aromatic polyester carbonates may correspond to formula I

[0014]

[0015] wherein A represents a single bond to which further aromatic rings, optionally containing heteroatoms, may be condensed, 1-5 Alkylene, C 2-5 Alkylidene, C 5-6 Cycloalkylidene, -O-, -SO-, -CO-, -S-, -SO 2 - or C 6-12 Arylene, or a group of formula II or III:

[0016]

[0017] wherein B is independently at each occurrence hydrogen, C 1-12 alkyl (preferably methyl) or halogen (preferably chlorine and / or bromine); x is in each case independently of one another 0, 1 or 2; and p is 0 or 1; R c and R d are independent of each other, and for each X 1 is individually selectable and is hydrogen or C 1 -C 6 alkyl, preferably hydrogen, methyl or ethyl; and X 1 represents carbon; and m represents an integer of 4-7, preferably 4 or 5, with the condition that R c and R d At least one X 1 The alkyl group on the atom.

[0018] Exemplary diphenols are hydroquinone, resorcinol, dihydroxybiphenyl, bis(hydroxyphenyl)-C 1-5 Alkanes, bis(hydroxyphenyl)-C 5-6 Cycloalkanes, bis(hydroxy-phenyl) ethers, bis(hydroxyphenyl) sulfoxides, bis(hydroxyphenyl) ketones, bis(hydroxy-phenyl) sulfones and 4,4″-bis(hydroxyphenyl) diisopropylbenzene, and derivatives thereof having a brominated and / or chlorinated nucleus. Particularly preferred diphenols are 4,4′-dihydroxybiphenyl, bisphenol A, 2,4-bis(4-hydroxyphenyl)-2-methyl-butane, 1,1-bis(4-hydroxyphenyl)-cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane, 4,4-dihydroxydiphenyl sulfide and 4,4-dihydroxydiphenyl sulfone, and dibrominated and tetrabrominated or chlorinated derivatives thereof, such as 2,2-bis(3-chloro-4- 2,2-bis-(4-hydroxyphenyl)propane (bisphenol A) is particularly preferred. The diphenols can be used alone or in any mixture. The diphenols are known from the literature or can be obtained by methods known from the literature. In addition to bisphenol A homopolycarbonates, exemplary polycarbonates include copolycarbonates of bisphenol A having up to 15 mol % of other disclosed diphenols, such as 2,2-bis(3,5-dibromo-4-hydroxyphenyl)-propane, relative to the molar sum of the diphenols.

[0019] Exemplary chain terminators for producing polycarbonate include phenolic compounds, including phenol, p-chlorophenol, p-tert-butylphenol, 4-(1,3-dimethyl-butyl)-phenol, and 2,4,6-tribromophenol; long-chain alkylphenols, such as monoalkylphenols or dialkylphenols containing a total of 8 to 20 carbon atoms in their alkyl substituents, exemplified by 3,5-di-tert-butylphenol, p-isooctylphenol, p-tert-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)-phenol, and 4-(3,5-dimethylheptyl)-phenol. The amount of chain terminator used may be about 0.1 mol% or more, based on the molar sum of the diphenols used in each case. The amount of chain terminator used may be about 10 mol% or less, based on the molar sum of the diphenols used.

[0020] The polycarbonate can be branched, for example, by incorporating about 0.05-2.0 mol % of a trifunctional compound or a compound having a functionality higher than 3, such as those containing four or more phenolic groups, relative to the total amount of diphenols used. Branched polycarbonates used in the disclosed compositions can be prepared by known techniques, for example, several methods are disclosed in USP 3,028,365, 4,529,791 and 4,677,162 (which patents are hereby incorporated by reference in their entirety). Exemplary branching agents include tri- or polyfunctional carboxylic acid chlorides such as trimesic acid trichloride, cyanuric acid trichloride, 3,3'-,4,4'-benzophenonetetracarboxylic acid tetrachloride, 1,4,5,8-naphthalene-tetracarboxylic acid tetrachloride or pyromellitic acid tetrachloride in an amount of about 0.01-1.0 mol % (relative to the dicarboxylic acid dichloride used), or tri- or polyfunctional phenols such as phloroglucinol, 4,6-dimethyl-2,4,6-tris(4-hydroxyphenyl)-2-heptene, 4,4-dimethyl-2,4,6-tris(4-hydroxyphenyl)heptane, 1,3,5-tris(4-hydroxyphenyl)-benzene, 1 , 1,1-tris(4-hydroxyphenyl)ethane, tris(4-hydroxyphenyl)-phenyl-methane, 2,2-bis[4,4-bis(4-hydroxyphenyl)cyclohexyl]-propane, 2,4-bis[1-(4-hydroxyphenyl)-1-methyl-ethyl]phenol, tetrakis(4-hydroxyphenyl)-methane, 2,6-bis(2-hydroxy-5-methyl-benzyl)-4-methyl-phenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane or tetrakis(4-[1-(4-hydroxyphenyl)-1-methylethyl]-phenoxy)-methane, which is about 0.01-1.0 mol% relative to the amount of diphenol used. Phenolic branching agents can be placed in the reaction vessel together with the diphenol. Acidic chloride branching agents can be introduced together with the acidic chloride.

[0021] Copolycarbonates can be prepared by known methods. For example, polydiorganosiloxanes containing hydroxyaryloxy end groups of about 1-25 parts by weight, about 2.5-25 parts by weight (relative to the total amount of diphenol to be used) can also be used. These are known (see USP 3,419,634), or can be produced by methods known in the literature. Ester-forming monomers can be used in the preparation of polymers containing polycarbonates. Exemplary ester-forming monomers include dicarboxylic acid halides and hydroxycarboxylic acids. Aromatic dicarboxylic acid dihalides used to produce aromatic polyester carbonates can be dichlorides of isophthalic acid, terephthalic acid, diphenyl ether-4,4'-dicarboxylic acid and naphthalene-2,6-dicarboxylic acid. A mixture of dichlorides of isophthalic acid and terephthalic acid in a ratio of about 1:20-20:1 can be used. Phosgene, such as phosgene, can be used together as a difunctional acid derivative in the production process of polyester carbonates. Aromatic polyester carbonates may also contain incorporated hydroxycarboxylic acids. The polyester carbonates may be linear and / or branched. Branching agents have been disclosed above.

[0022] In addition to monophenols, exemplary chain terminators include chlorocarboxylates, and acid chlorides of aromatic monocarboxylic acids, which may optionally be C 1-22 Alkyl or halogen atom substitution, and may also include aliphatic C 2-22 Monocarboxylic acid chlorides. The amount of chain terminator may be about 0.1 to 10 mol % relative to the moles of diphenol (in the case of phenolic chain terminators) and relative to the moles of dicarboxylic acid dichloride (in the case of monocarboxylic acid chloride chain terminators).

[0023] Polycarbonate or the copolymer containing carbonate unit can be derived from recycled materials, such as post-consumer recycled materials. Composition can contain up to 95% recycled polycarbonate by composition weight, such as post-consumer recycled materials, about 90% or less by composition weight, or about 80% or less by weight. Composition can contain about 30wt% or more, about 50% or more, about 75wt% or more, or about 90wt% or more recycled polycarbonate based on the weight of composition. Raw materials as used herein refer to materials that have not been used before. Recycled materials can be linear, branched or their mixtures. Recycled materials can be branched. Recycled materials can be in the form of flakes. Recycled materials can be recycled from bottles or other structures, wherein the structures used are shredded into flake forms. Recycled materials can be formed into other structures, such as pellets. Using recycled materials in the form of flakes is the most effective way to utilize the material. The recycled polycarbonate or the copolymer containing carbonate units may contain, for example, 0.1 to 1.0 wt % or 0.1 to 0.25 wt % (based on the recycled polycarbonate or the copolymer containing carbonate units) of impurities such as polyester.

[0024] Composition can contain virgin polycarbonate or the multipolymer containing carbonate unit, and its amount is about 5wt% or more, about 10wt% or more, about 20wt% or more, about 30wt% or more or about 40wt% or more based on composition. Composition can contain virgin polycarbonate or the multipolymer containing carbonate unit, and its amount is about 98wt% or less, about 95wt% or less, about 65wt% or less, about 45wt% or less, about 35wt% or less or about 25wt% or less based on composition.

[0025] One or more polymers containing carbonate monomer units can include polycarbonate, copolycarbonate or a blend of polycarbonate and copolycarbonate. Polycarbonate and / or copolycarbonate can show a weight average molecular weight sufficient to provide the desired performance for the articles prepared by polycarbonate and / or copolycarbonate. The weight average molecular weight of polycarbonate and / or copolycarbonate can be about 5,000amu or larger, about 15,000amu or larger or about 20,000amu or larger. The weight average molecular weight of polycarbonate and / or copolycarbonate can be about 40,000amu or less, about 35,000amu or less or about 30,000amu or less. Unless otherwise indicated, the "molecular weight" of polycarbonates and / or copolycarbonates herein refers to the weight average molecular weight (Mw) determined by gel permeation chromatography (GPC) using a laser scattering technique using bisphenol A polycarbonate standards and is given in units of grams per mole (g / mole), also known as atomic mass units (amu).

[0026] The polycarbonate and / or copolymer used to prepare the disclosed composition may have a melt flow rate that provides the desired processing properties. A mixture of polycarbonate and / or a copolymer containing carbonate units with different melt flow rates can be used to provide a composite melt flow rate to enhance the processing of the disclosed composition. A mixture of polycarbonate and / or a copolymer containing carbonate units with different melt flow rates may include: a polycarbonate and / or a copolymer containing carbonate units with a low melt flow rate, a polycarbonate and / or a copolymer containing carbonate units with a medium melt flow rate, and a polycarbonate and / or a copolymer containing carbonate units with a high melt flow rate. The melt flow rate is determined by measuring the grams of material through a capillary with a diameter of 25.4 mm measured according to ASTM D1238 over a period of 10 minutes at 300°C and a load of 1.2 kg. The melt flow rate of the disclosed composition may be about 1 g / 10 min or more, about 3 g / 10 min or more, about 5 g / 10 min or more, 10 g / 10 min or more, or about 15 g / 10 min or more. The melt flow rate of the disclosed composition may be about 70 g / 10 min or less, about 30 g / 10 min or less, about 28 g / 10 min or less, about 22 g / 10 min or less, about 20 g / 10 min or less, or about 10 g / 10 min or less. The melt flow rate of the disclosed composition may be about 3 g / 10 min-30 g / 10 min. The test protocol is based on ASTM D1238. The capillary diameter of the plastometer is 9.5504 mm and the hole die size is 2.095 mm. The low melt flow rate may be about 0.1-5 g / 10 min; the medium melt flow rate may be about 5-15 g / 10 min; and the high melt flow rate may be greater than about 15 g / 10 min. The composition may include: one or more polycarbonates with a low melt flow rate; one or more polycarbonates with a medium melt flow rate; and one or more polycarbonates with a high melt flow rate. The low melt flow rate may be about 0.1-5 g / 10 min. The medium melt flow rate may be about 5-15 g / 10 min. The high melt flow rate may be greater than 15 g / 10 min.

[0027] The amount of polycarbonate in the composition can make the composition reach the performance described. The composition can contain polycarbonate or a copolymer containing carbonate units in an amount of about 35wt% or more, about 50wt% or more, about 60wt% or more, about 70wt% or more, about 80wt% or more, about 90wt% or more, or about 95wt% or more based on the weight of the composition. The composition can contain virgin polycarbonate or a copolymer containing carbonate units in an amount of about 98wt% or less, about 95wt% or less, about 93wt% or less, about 65wt% or less, about 60wt% or less, about 55wt% or less, or about 50wt% or less based on the weight of the composition.

[0028] The composition may contain one or more resins with a high Tg. Any resin that exhibits a high Tg and can be blended with a polycarbonate, where the blend provides the desired properties as disclosed herein, can be used. In this context, the high Tg can be about 150°C or higher, about 160°C or higher, or about 190°C or higher. The high Tg resin can be one or more high Tg polycarbonates, one or more polyarylates, and the like.

[0029] Polyarylate is a copolymer of aromatic dicarboxylic acid and bisphenol. Exemplary aromatic esters are isophthalic acid, terephthalic acid. Exemplary bisphenols include bisphenol A and bisphenol F. The Tg of polyarylate can be about 180°C or higher or about 200°C or higher. The weight average molecular weight of polyarylate can be about 10,000amu or greater, about 50,000amu or greater, or about 100,000amu or greater. The weight average molecular weight of polyarylate can be about 150,000amu or less, about 120,000amu or less, or about 100,000amu or less. Polyarylate can be present in the composition in an amount sufficient to provide the desired properties of the composition. Polyarylate can be present in the composition in an amount of about 0wt% or more, about 10wt% or more, or about 30wt% or more based on the weight of the composition. The polyarylate can be present in the composition in an amount of about 60 wt %, about 50 wt % or less, about 40 wt % or less, about 30 wt % or less, about 20 wt % or less, or about 10 wt % or less, based on the weight of the composition.

[0030] The high temperature polycarbonate can be any polycarbonate with a certain Tg, which can improve the performance of the composition and the articles prepared from the composition. The Tg of the high temperature polycarbonate can be about 150°C or higher, about 170°C or higher, or about 190°C or higher. The high temperature polycarbonate can be present in the composition in an amount sufficient to provide the desired properties of the composition. The high temperature polycarbonate can be present in the composition in an amount of about 0wt% or more, about 10wt% or more, or about 50wt% or more based on the weight of the composition. The high temperature polycarbonate can be present in the composition in an amount of about 90wt% or less, about 60wt% or less, about 50wt% or less, or about 10wt% or less based on the weight of the composition.

[0031] The composition may contain one or more silicon compounds having a branched structure and an organic functional group. Any silicon compound having a branched structure and an organic functional group may be used to enhance the flame retardant properties of the composition. An organosilicon compound having a branched main chain and containing an organic functional group may be represented by the following general formula:

[0032]

[0033] Where R 1 , R 2 and R 3 represents an organic functional group on the main chain, X represents a terminal functional group, and n, m and 1 represent the number of moles of a single unit, wherein the organic functional group includes an aromatic group or an aromatic group, and a hydrocarbon group (excluding an aromatic group) can be used as the organic silicon compound.

[0034] The organosilicon compound may contain siloxane units (R 3-0 SiO 2-0.5 ) at least 20 mol% of T units (RSiO 1.5 ) and / or Q unit (SiO 2.0 ), wherein R represents an organic functional group. At least 20mol% of the organic functional groups contained in the organosilicon compound can be aromatic groups. The aromatic groups present can be phenyl, biphenyl, naphthalene or their derivatives, or can be phenyl. The side chains other than the phenyl group can be hydrocarbon groups having no more than 4 carbon atoms, or can be methyl groups. The terminal groups can be one or more of methyl, phenyl and / or hydroxyl groups. The weight average molecular weight of the organosilicon compound can be about 3,000amu or greater or about 5,000amu or greater. The weight average molecular weight of the organosilicon compound can be about 500,000amu or less or about 270,000 or less. Based on the weight of the composition, the amount of the organosilicon compound can be about 0.01wt% or more or about 0.5wt% or more. Based on the weight of the composition, the amount of the organosilicon compound can be about 3wt% or less or about 1.5wt% or less.

[0035] The composition may also include a fluorinated anti-drip agent. Anti-drip means that in the event of a fire, the tendency of the composition to form burning drips is reduced. Fluorinated polyolefins known in the art as anti-drip agents can be used in the composition. The anti-drip agent can be a fluoropolymer that forms fibers, which form a fibril structure in a composition containing polycarbonate. The fluoropolymers that form fibers include polytetrafluoroethylene, tetrafluoroethylene-type copolymers (such as tetrafluoroethylene / hexafluoropropylene copolymers, etc.), partially fluorinated polymers shown in U.S. Patent No. 4,379,910 (the relevant part is incorporated herein by reference), polycarbonates made from fluorinated diphenols, etc. Polytetrafluoroethylene having a molecular weight of at least 1,000,000, a secondary particle size of at least 100 μm and the ability to form fibrils can be used. Exemplary fluorinated polyolefins are described in EP-A 0 640 655. They are marketed by DuPont under the trade name 30N is sold. The amount of the anti-drip agent can be any amount that enhances the flame retardant properties of the composition. The amount of the anti-drip agent can be about 0 wt% or more, about 0.01 wt% or more, or about 0.1 wt% or more, based on the weight of the composition. The amount of the organosilicon compound can be about 1.0 wt% or less, about 0.9 wt% or less, or about 0.5 wt% or less, based on the weight of the composition.

[0036] The disclosed compositions may contain one or more carbon-based particles, metals or metalloid oxides. Any carbon-based particles, metals or metal oxides that can improve the V0@1.5 mm flame retardancy rating can be used. Exemplary metal or metalloid oxides include Group 3 or Group 4 metal or metalloid oxides. Exemplary metal or metalloid oxides include TiO 2 、MgO、SiO 2 , Fe 2 O 3 、Al 2 O 3 etc. Exemplary metal or metalloid oxides include TiO 2 , MgO and SiO 2 The one or more metal or metalloid oxides may be a mixture of metal and / or metalloid oxides, for example, containing MgO and SiO 2of talc. One or more carbon-based particles can be any particulate carbon material capable of improving the flame retardancy of the composition disclosed herein. Exemplary carbon-based particles can be carbon black or carbon nanotubes. One or more carbon compounds, metals or metalloid oxides can be present in an amount sufficient to enhance the flame retardancy of the composition. One or more carbon-based particles, metals or metalloid oxides can be present in an amount sufficient to provide a flame retardant rating of V0@1.5mm. One or more carbon-based particles, metals or metalloid oxides can be present in an amount of 0wt% or more, about 0.2wt% or more, about 0.3wt% or more, or about 0.5wt% or more based on the weight of the composition. One or more carbon-based particles, metals or metal oxides can be present in an amount of about 10wt% or less, about 5wt% or less, about 3wt% or less, or about 2wt% or less based on the weight of the composition. One or more carbon-based particles, metals or metal oxides can be present in a particle form. One or more carbon-based particles, metals or metal oxides can be nanoparticles. The particle size can be any particle size capable of improving the flame retardant rating of the composition. The particle size may be about 0.2 μm or more or about 0.35 μm or more. The particle size may be about 2.0 μm or less or about 1.0 μm or less. The particle size may be measured using the laser diffraction technique described in ISO 13322. The particle size measured is the average diameter. The compositions disclosed herein may contain a buffer system. The buffer system described herein may be a proton-providing (i.e., H + or hydronium ion), accepting protons (i.e., H + or hydronium ions) or any combination of the two. A buffer system can contain a weak acid and a conjugate base. A buffer system can resist changes in pH after the addition of alkaline or acidic components. A buffer system can be based on the total number of protons (i.e., H + or hydronium ion), hydroxyl (i.e. hydroxide or OH -) or both. The buffer system may include one or more monoprotic, diprotic, triprotic or polyprotic buffer compounds. Based on the total weight of the composition, the buffer system can stabilize the polycarbonate in proportion to the total amount of the buffer system present. The buffer system described herein includes one or more buffers having acidic and alkaline functions, so that the pH of the composition can reach about neutral. The buffer system may include one or more buffer compounds, two or more buffer compounds, three or more buffer compounds, or multiple buffer compounds. The buffer system may contain a single compound. The buffer system may contain a pair of compounds. The buffer system may include an inorganic compound, an organic compound, or both. The buffer system may include a counterion. The concentration of the buffer system (i.e., wt% of the total composition) is sufficient to promote the improvement of the molecular weight stability of the polycarbonate. The buffer system may include a buffer compound, which is an inorganic compound or an organic compound, which balances the pH of the composition, thereby achieving optimal copolymerization and compounding. The inorganic compound may include a compound that does not contain saturated carbon (i.e., does not contain a CH bond). The inorganic compound may contain a carbon atom that does not contain a hydrogen bond. The organic compound may include a compound that contains saturated carbon (i.e., contains a CH bond). The buffer compound may include acetate, sulfonate, phosphate, ammonia, formates or any combination thereof. The buffer system may include aromatic or aliphatic buffer compounds. The buffer system may include a buffer compound pair of a weak acid and a conjugate base. The buffer compound may be selected based on an approximately neutral pKa. The buffer compound may control the pH of the water to approximately neutral. The buffer system may include a Good buffer.The organic compound may include 2-(N-morpholino)ethanesulfonic acid (MES), 2-[bis(2-hydroxyethyl)amino]-2-(hydroxymethyl)propane-1,3-diol (bis-tris-methane), 2-[(2-amino-2-oxoethyl)-(carboxymethyl)amino]acetic acid (ADA), N-(2-acetylamino)-2-aminoethanesulfonic acid (ACES), piperazine-N,N'-bis(2-ethanesulfonic acid) (PIPES), 2-hydroxy-3-morpholinopropanesulfonic acid (MOPSO), 1,3-bis(tris(hydroxymethyl)methylamino)propane (bis-6-tris-propane), NN-bis(2 1,3-dihydroxy-2-(hydroxymethyl)propan-2-yl]amino]ethanesulfonic acid (TES), 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid (HEPES), 3-(N,N-bis[2-hydroxyethyl]amino)-2-hydroxypropanesulfonic acid (DIPSO), 4-(N-morpholino)butanesulfonic acid (MOBS), 3-[[1,3-dihydroxy-2-(hydroxymethyl)propan-2-yl]amino]-2-hydroxypropane-1-sulfonic acid (TAPSO), 4-(2-hydroxyethyl)piperazine-1-(2 -hydroxypropanesulfonic acid) (HEPPSO), POPSO, 3-[4-(2-hydroxyethyl)piperazine-1-yl]propane-1-sulfonic acid (EPPS or HEPPS), N-(2-hydroxy-1,1-bis(hydroxymethyl)ethyl)glycine (Tricine), glycylglycine (Gly-Gly), 2-(bis(2-hydroxyethyl)amino)acetic acid (Bicine), N-(2-hydroxyethyl)piperazine-N′-(4-butanesulfonic acid) (HEPBS), [tris(hydroxymethyl)ethylamino]propanesulfonic acid (TAPS), 2-amino-2-methyl-1,3-propanedisulfonic acid (TAPS), The inorganic compound includes metal phosphate, metal sulfonate, metal acetate, metal format, etc.

[0037] The buffer system may include one or more alkali metal phosphates. Any alkali metal phosphate that can enhance the thermal stability of the composition can be used. The alkali metal phosphate can be a sodium metal phosphate or a potassium metal phosphate. Exemplary alkali metal phosphates can be one or more of distearyl pentaerythritol diphosphate, monohydrogen phosphate or dihydrogen phosphate, and monohydrogen phosphate, dihydrogen phosphate or trihydrogen phosphate compounds. Exemplary alkali metal phosphates can be one or more of monohydrogen phosphate, dihydrogen phosphate or trihydrogen phosphate compounds. The alkali metal phosphate can be sodium dihydrogen phosphate. The alkali metal phosphate can be used in any amount that improves the thermal stability of the composition. Based on the weight of the composition, the alkali metal phosphate can be used in any amount of about 0.01wt% or more, about 0.02wt% or more, or about 0.03wt% or more. Based on the weight of the composition, the alkali metal phosphate can be used in any amount of about 1.0wt% or less, about 0.2wt% or less, or about 0.1wt% or less.

[0038] The composition may contain one or more non-halogenated flame retardants commonly used in polycarbonate compositions. Non-halogenated means that there are no halogen atoms in the flame retardant. Using a non-halogenated flame retardant means that the composition containing the non-halogenated flame retardant will not release halogens during combustion. The flame retardant can be any flame retardant known for use in polycarbonate-based compositions that provides flame retardant properties and does not negatively affect the impact, heat resistance, flexural modulus, flexural strength, haze and transparency of the composition. The amount of the flame retardant used can be sufficient to meet the flame retardancy requirements of the end use and is used in an amount that does not adversely affect the performance of the article prepared from the composition. Exemplary flame retardants include phosphorus-containing compounds, such as oligomeric phosphates, poly (block-phosphonooxy-esters) and / or poly (block-phosphonooxy-carbonates), see USP 7,645,850 (incorporated herein in its entirety). Exemplary oligomeric phosphates include bisphenol-A bis (diphenyl phosphate) (BAPP). Exemplary additional flame retardants include 1,3-phenyltetrakis(2,6-dimethylphenyl)ester (Daihachi PX-200).

[0039] The one or more non-halogenated flame retardants may be one or more phosphazenes. Any one or more phosphazenes that enhance flame retardancy may be used. The phosphazene may contain more than one phosphazene unit. Phosphazene is an organic compound having a –P=N- structure. The phosphazene may be a linear structure containing one or more phosphazene units or a cyclic structure containing one or more phosphazene units. The phosphorus atom on the phosphazene structure may be bonded with one or more hydrocarbyloxy structures. The hydrocarbyloxy group may be an alkoxy group, an aryloxy group, an alkyl-substituted aryloxy group, an alkoxy-substituted aryloxy group, or a halogen-substituted aryloxy group. The hydrocarbyloxy group may be an aryloxy group or an alkyl-substituted aryloxy group. The hydrocarbyloxy group may be a phenoxyoxy group or an alkyl-substituted phenoxy group. The alkyl group may be C 1-10 Alkyl, C 1-3Alkyl or methyl or ethyl. The cyclic phosphazene compound may contain 1 or more phosphazene units, and may also contain 3 or more phosphazene units. The cyclic phosphazene compound may contain 25 or less phosphazene units, 10 or less phosphazene units, or 5 or less phosphazene units. The linear phosphazene compound may contain 1 or more phosphazene units, 3 or more phosphazene units, 5 or more phosphazene units, or 6 or more phosphazene units. The linear phosphazene compound may contain 10,000 or less phosphazene units, 1,000 or less phosphazene units, 100 or less phosphazene units, or 25 or less phosphazene units. Exemplary cyclic phosphazenes include phenoxycyclotriphosphazenes, octaphenoxycyclotetraphosphazenes, and decaphenoxycyclopentaphosphazenes. Cyclic phosphazenes can be obtained by reacting ammonium chloride with phosphorus pentachloride at 120 to 130°C to obtain a mixture containing cyclic and linear chlorophosphazenes, extracting cyclic chlorophosphazenes such as hexachlorocyclotriphosphazenes, octachlorocyclotetraphosphazenes, and decachlorocyclopentaphosphazenes, and then replacing them with phenoxy groups. Exemplary linear phosphazenes include compounds obtained by the following method: ring-opening polymerization of the hexachlorocyclotriphosphazene obtained by the above method at 220-250°C, and then replacing the chain dichlorophosphazenes with a degree of polymerization of 3-10,000 (or as described above) obtained therefrom with phenoxy groups. The phosphazene compound can be cross-linked. The phosphazene compound can be cross-linked by bisphenol compounds such as 4,4'-diphenylene groups, such as 4,4'-sulfonyldiphenylene (bisphenol S residue), 2,2-(4,4'-diphenylene), isopropylidene groups, 4,4'-oxydiphenylene groups, 4,4'-thiodiphenylene groups, and the like. The cross-linked phenoxyphosphazene compound generally has a phenylene content of 50-99.9 wt % or 70-90 wt %. The cross-linked phenoxyphosphazene compound may not contain any free hydroxyl groups in the molecule.

[0040] Based on the weight of the composition, one or more flame retardants may be present in an amount of about 0.1wt% or more, about 1wt% or more, about 2wt% or more, or about 5wt% or more. Based on the weight of the composition, one or more flame retardants may be present in an amount of about 10wt% or less, about 5wt% or less, about 4wt% or less, or about 2wt% or less. Based on the weight of the composition comprising polycarbonate and / or a copolymer containing carbonate units, one or more phosphazene flame retardants may be present in an amount of about 0.1wt% or more, about 1wt% or more, about 2wt% or more, or about 5wt% or more. Based on the weight of the composition, one or more flame retardants may be present in an amount of about 10wt% or less, about 5wt% or less, about 4wt% or less, or about 2wt% or less.

[0041] The composition may contain one or more organic metal salts used as carbonizing salts. Carbonizing salts are any compounds that help maintain the original shape of plastic products by forming char from the compound. The char forms a shell of non-flammable material, reducing the melting and dripping of the compound in which the carbonizing salt is located. Any organic metal salt that can be used as a carbonizing salt can be used, provided that the carbonizing salt does not contain halogens, such as fluorine. The one or more organic metal salts can be one or more salts of aromatic sulfur compounds. The one or more organic metal salts can be one or more salts of aromatic sulfonates. The one or more salts of aromatic sulfur compounds can include one or more salts of alkali metals, alkaline earth metals, or both. The one or more salts of aromatic sulfur compounds can include potassium salts, sodium salts, magnesium salts, calcium salts, or any combination thereof. The one or more salts of aromatic sulfur compounds can include one or more sodium salts or potassium salts. The one or more salts of aromatic sulfur compounds can be sulfonates. The sulfur-containing salt can include one or more carbon-containing groups. The number of carbon atoms in the sulfur-containing salt can be about 15 or less, about 13 or less, about 7 or less, or about 5 or less. The number of carbon atoms in the sulfur-containing salt can be 1 or more, 2 or more, 3 or more, or 4 or more. The carbon-containing group can be acyclic or aromatic. The sulfur-containing salt can include or be substantially composed of one or more sodium p-toluenesulfonate or potassium diphenylsulfonesulfonate. The organic metal salt of the aromatic sulfur compound can exist in a certain amount to improve the flame retardancy of the composition. The organic metal salt can exist in an amount of about 0.01wt% or more or about 0.05wt% or more or about 0.1wt% or more of the composition. The organic metal salt can exist in an amount of about 2.0wt% or less, about 1.0wt% or less, about 0.5wt% or less, about 0.4wt% or less or about 0.25wt% or less of the composition.

[0042] The disclosed composition contains one or more antioxidants. Antioxidants can be introduced into the composition from the ingredients used (e.g., impact modifiers or polymers recycled after consumption). Antioxidants can be added to the composition separately. Antioxidants can be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonates, aromatic hydroxybenzyl compounds, triazine compounds, benzyl phosphonates, acylaminophenols, esters and amides of propionic acid, ascorbic acid, or amine antioxidants. Antioxidants can be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonates, aromatic hydroxybenzyl compounds, triazine compounds, benzyl phosphonates, acylaminophenols, esters and amides of propionic acid, ascorbic acid, or amino antioxidants that do not contain sulfur-containing groups.

[0043] Phenol-based antioxidants include 2,6-di-tert-butyl-4-methylphenol; 2,6-diphenyl-4-methoxyphenol; 2,2′-methylenebis(6-tert-butyl-4-methylphenol); 2,2′-methylenebis(6-tert-butyl-4-methylphenol); 2,2′-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol]; 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2′-methylenebis(4-methyl-6-cyclohexylphenol); 2,2′-methylenebis(4-methyl-6-nonylphenol); 1,1, 3-Tris(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)-4-n-dodecylmercaptobutane; ethylene glycol bis[3,3-bis(3-tert-butyl-4-hydroxyphenyl)butyrate]; 1,1-bis(3,5-dimethyl-2-hydroxyphenyl)-3-(n-dodecylthio)butane; 4,4′-thiobis(6-tert-butyl-3-methylphenol); 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene; 2,2-bis(3,5-di-tert-butyl Hydroquinone and alkylated hydroquinone antioxidants include 2,6-di-tert-butyl-4-methoxyphenol, 2,5-di-tert-butylhydroquinone, 2,5-di-tert-amylhydroquinone, 2,6-diphenyl-4-octadecyloxyphenol, 2,6-di-tert-butylhydroquinone, 2,6-di-tert-butyl-4-hydroxyphenyl propionate ... Antioxidants based on tocopherol include α-tocopherol, β-tocopherol, γ-tocopherol, δ-tocopherol and mixtures thereof (vitamin E). Antioxidants based on O- and N-benzyl compounds include, for example, 3,5,3′,5′-tetra-tert-butyl-4,4′-dihydroxydibenzyl ether and tris(3,5-di-tert-butyl-4-hydroxybenzyl)amine.Alkylene bisphenol-based antioxidants include 2,2'-methylenebis(6-tert-butyl-4-methylphenol), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), 2,2'-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol], 2,2'-methylenebis(4-methyl-6-cyclohexylphenol), 2,2'-methylenebis(6-nonyl-4-methylphenol), 2 , 2'-methylenebis(4,6-di-tert-butylphenol), 2,2'-ethylenebis(4,6-di-tert-butylphenol), 2,2'-ethylenebis(6-tert-butyl-4-isobutylphenol), 2,2'-methylenebis[6-(α-methylbenzyl)-4-nonylphenol], 2,2'-methylenebis[6-(α,α-dimethylbenzyl)-4-nonylphenol], 4,4'-methylenebis(2, 6-di-tert-butylphenol), 4,4′-methylenebis(6-tert-butyl-2-methylphenol), 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, 2,6-bis(3-tert-butyl-5-methyl-2-hydroxybenzyl)-4-methylphenol, 1,1,3-tri(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, ethylene glycol bis[3,3-bis(3′-tert-butyl- The antioxidants based on hydroxybenzylated malonate include dioctadecyl-2,2-bis(3,5-di-tert-butyl-2-hydroxybenzyl)malonate, dioctadecyl-2-(3-tert-butyl-4-hydroxy-5-methylbenzyl)malonate, bis[4-(1,1,3,3-tetramethylbutyl)phenyl]-2,2-bis(3,5-di-tert-butyl-4-hydroxybenzyl)malonate. Aromatic hydroxybenzyl-based antioxidants include 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, 1,4-bis(3,5-di-tert-butyl-4-hydroxybenzyl)-2,3,5,6-tetramethylbenzene, and 2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)phenol.The antioxidants based on triazine compounds include 2,4-bis(octylmercapto)-6-(3,5-di-tert-butyl-4-hydroxyanilino)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyanilino)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyphenoxy)-1,3,5-triazine, 2,4,6-tris-(3,5-di-tert-butyl- isocyanurate, 2,4,6-tris(3,5-di-tert-butyl-4-hydroxyphenylethyl)-1,3,5-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)-hexahydro-1,3,5-triazine and 1,3,5-tris(3,5-dicyclohexyl-4-hydroxybenzyl) isocyanurate. Benzylphosphonate-based antioxidants include dimethyl-2,5-di-tert-butyl-4-hydroxybenzylphosphonate, diethyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-5-tert-butyl-4-hydroxy-3-methylbenzylphosphonate, and the calcium salt of 3,5-di-tert-butyl-4-hydroxybenzylphosphonic acid monoethyl ester. Amidophenol-based antioxidants include, for example, 4-hydroxylauroylanilide, 4-hydroxystearylanilide, and octyl N-(3,5-di-tert-butyl-4-hydroxyphenyl)carbamate. Exemplary antioxidants include esters of D-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctyl alcohol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propylene glycol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxamide, 3-thioundecanol, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctyl alcohol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propylene glycol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N′-bis ... 3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5.5]-undecane.Exemplary antioxidants include esters of β-(3,5-dicyclohexyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, octanol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propylene glycol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxamide, 3-thioundecanol, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of 3,5-di-tert-butyl-4-hydroxyphenylacetic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, octanol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propylene glycol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N′-bis(hydroxyethyl)oxamide, 3-thioundecanol, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid, such as N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hexamethylene diamide, N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)trimethylene diamide, N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazide, N,N′-bis[2-(3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionyloxy)ethyl]oxalamide (. XL-1, provided by Uniroyal). An exemplary antioxidant is ascorbic acid (vitamin C). Amino antioxidants include N,N′-diisopropyl-p-phenylenediamine, N,N′-di-sec-butyl-p-phenylenediamine, N,N′-bis(1,4-dimethylpentyl)-p-phenylenediamine, N,N′-bis(1-ethyl-3-methylpentyl)-p-phenylenediamine, N,N′-bis(1-methylheptyl)-p-phenylenediamine, N,N′-dicyclohexyl-p-phenylenediamine, N,N′-diphenyl-p-phenylenediamine, N,N′-bis(2-naphthyl)-p-phenylenediamine, N-isopropyl-N′-phenyl-p-phenylenediamine, N-(1,3-dimethylbutyl)-N′-phenyl-p-phenylenediamine, N -(1-methylheptyl)-N'-phenyl-p-phenylenediamine, N-cyclohexyl-N'-phenyl-p-phenylenediamine, N,N'-dimethyl-N,N'-di-sec-butyl-p-phenylenediamine, diphenylamine, N-allyl diphenylamine, 4-isopropoxy diphenylamine, N-phenyl-1-naphthylamine, N-(4-tert-octylphenyl)-1-naphthylamine, N-phenyl-2-naphthylamine, octylated diphenylamine, p,p'-di-tert-octyl diphenylamine, 4-n-butylaminophenol, 4-butyrylaminophenol, 4-nonanoylaminophenol, 4-dodecanoylaminophenol, 4-octadecanoylaminophenol, diphenylamine (4-methoxyphenyl)amine, 2,6-di-tert-butyl-4-dimethylaminomethylphenol, 2,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, N,N,N',N'-tetramethyl-4,4'-diaminodiphenylethane, 1,2-bis[(2-methylphenyl)amino]ethane, 1,2-bis(phenylamino)propane, (o-tolyl)biguanide, bis[4-(1',3'-dimethylbutyl)phenyl]amine, tert-octylated N-phenyl-1-naphthylamine, mixtures of mono- and di-alkylated tert-butyl / tert-octyl diphenylamines, mono- and di-alkylated Mixtures of alkylated nonyldiphenylamines, mixtures of mono- and di-alkylated dodecyldiphenylamines, mixtures of mono- and di-alkylated isopropyl / isohexyldiphenylamines, mixtures of mono- and di-alkylated tert-butyldiphenylamines, N,N,N′,N′-tetraphenyl-1,4-diaminobut-2-ene, N,N-bis(2,2,6,6-tetramethylpiperidin-4-yl-hexamethylenediamine, bis(2,2,6,6-tetramethylpiperidin-4-yl) sebacate, 2,2,6,6-tetramethylpiperidin-4-one, 2,2,6,6-tetramethylpiperidin-4-ol.Phosphorus antioxidants include tetrakis(2,4-di-tert-butylphenyl)-4,4-biphenylene phosphite, tris(2,4-di-tert-butylphenyl)phosphite, 2,2'-methylenebis(4,6-di-tert-butylphenyl)octylphosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, di(nonylphenyl)pentaerythritol diphosphite, phenyl-bisphenol A-pentaerythritol diphosphite, distearyl pentaerythritol diphosphite, dioctyl pentaerythritol diphosphite, dilauryl pentaerythritol diphosphite. Phosphate, diphenyl pentaerythritol diphosphite, dicyclohexyl pentaerythritol diphosphite, bis(2,4,6-tri-tert-butylphenyl)pentaerythritol diphosphite, 2,2'-ethylenebis(4,6-di-tert-butylphenyl)fluorophosphite, triisodecyl phosphite, tri-dodecyl phosphite, phenyl isooctyl phosphite, phenyl isodecyl phosphite, phenyl dodecyl phosphite, diphenyl isooctyl phosphite, diphenyl isodecyl phosphite, diphenyl dodecyl phosphite, triphenyl phosphite, tri(mononylphenyl)phosphite and tri(dinonylphenyl)phosphite. The antioxidant may be octadecyl 3,5-di-(tert-)butyl-4-hydroxyhydrocinnamate, which may be commercially available from BASF as IRGANOX 1076.

[0044] Exemplary antioxidant additives include, for example, organic phosphites such as tris(nonylphenyl)phosphite, tris(2,4-di-tert-butylphenyl)phosphite (e.g., "IRGAFOS 168" or "I-168"), bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, distearylpentaerythritol diphosphite, and the like; alkylated monophenols or polyphenols; alkylation reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)methane, and the like; butylation reaction products of p-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; reactions of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with monohydric or polyhydric alcohols; Esters; esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid and monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl compounds, such as distearyl thiopropionate, dilauryl thiopropionate, ditridecyl thiodipropionate, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, etc.; amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid, etc., or a combination comprising at least one of the foregoing antioxidants.

[0045] The antioxidant may be one or more phenol and / or phosphorus-based antioxidants, such as phosphite-based antioxidants. The antioxidant may be at least one of tris(2,4-di-tert-butylphenyl)phosphite and octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate.

[0046] The antioxidant may be present in the composition and structures formed therefrom in any amount that retards oxidation of the polymer. Based on the weight of the disclosed composition, the antioxidant may be present in an amount of about 100 parts per million (0.01 wt%) or greater, about 200 parts per million (0.02 wt%) or greater, about 300 parts per million (0.03 wt%) or greater, about 500 parts per million (0.05 wt%) or greater, or about 1000 parts per million (0.1 wt%) or greater. Based on the weight of the disclosed composition, the antioxidant may be present in an amount of about 10,000 parts per million (1.0 wt%) or less, about 8,000 parts per million (0.8 wt%) or less, about 6,000 parts per million (0.6 wt%) or less, about 5,000 parts per million (0.5 wt%) or less, or about 2,000 parts per million (0.2 wt%) or less.

[0047] The composition may contain a release agent. Exemplary release agents include any release agent known in the art and combinations thereof. The release agent may be an internal release agent. The release agent may include one or more compatibilizers, such as those taught in U.S. Pat. No. 5,212,209A, which is incorporated herein by reference in its entirety for all purposes. Example classes of release agents include aliphatic carboxylic acids; esters of aliphatic carboxylic acids and alcohols; aliphatic hydrocarbon compounds having a number average molecular weight of 200 to 15,000; and polysiloxane-based silicone oils. Examples of aliphatic carboxylic acids include saturated or unsaturated aliphatic monovalent, divalent or trivalent carboxylic acids. Aliphatic carboxylic acids also include alicyclic carboxylic acids. The aliphatic carboxylic acid may be a C 6-36 The aliphatic carboxylic acid may be a monovalent or divalent carboxylic acid. 6-36Aliphatic saturated monovalent carboxylic acids. Specific examples of such aliphatic carboxylic acids include palmitic acid, stearic acid, caproic acid, capric acid, lauric acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, melissic acid, tetratriadecanoic acid, montanic acid, adipic acid and azelaic acid. Examples of aliphatic carboxylic acids in esters of aliphatic carboxylic acids and alcohols include the same aliphatic carboxylic acids as described above. Examples of alcohols include saturated or unsaturated, monohydric or polyhydric alcohols, which may have substituents, such as fluorine atoms or aromatic groups. The alcohol may be a monohydric or polyhydric saturated alcohol having a carbon number of no more than 30. The alcohol may be an aliphatic saturated monohydric alcohol and an aliphatic saturated polyhydric alcohol having a carbon number of no more than 30. The term "aliphatic" is used herein as a term that also includes alicyclic compounds. Specific examples of such alcohols include octanol, decyl alcohol, dodecanol, stearyl alcohol, behenyl alcohol, ethylene glycol, diethylene glycol, glycerol, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentyl glycol, ditrimethylolpropane and dipentaerythritol. Each of the above esters may be a pure product or a mixture of multiple compounds. Each of the aliphatic carboxylic acid and alcohol that are combined with each other to form an ester may be a single type, or two or more types thereof may be used in any proportion and in any combination. Specific examples of esters of aliphatic carboxylic acids and alcohols include beeswax (a mixture containing lauryl palmitate as a main component), stearyl stearate, behenyl behenate, stearyl behenate, glyceryl monopalmitate, glyceryl monostearate, glyceryl distearate, glyceryl tristearate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristearate and pentaerythritol tetrastearate. Examples of aliphatic hydrocarbons having a number average molecular weight of 200-15,000 include liquid paraffin, paraffin wax, microcrystalline wax, polyethylene wax, Fischer-Tropsch wax, and α-olefin oligomers having a carbon number of 3-12. Aliphatic hydrocarbons also include alicyclic hydrocarbons. Each of these hydrocarbons can be partially oxidized. Aliphatic hydrocarbons can be paraffin wax, polyethylene wax, and partially oxidized polyethylene wax is preferred. More preferred are paraffin wax and polyethylene wax. The number average molecular weight of aliphatic hydrocarbons must not exceed 5000. Examples of polysiloxane-based silicone oils include dimethyl silicone oil, methylphenyl silicone oil, diphenyl silicone oil, and fluorinated alkyl silicone oil. A single type of release agent may be included, or two or more types of release agents may be included in any combination of any proportion. Exemplary release agents include at least one of an aliphatic carboxylic acid or an ester of an aliphatic carboxylic acid with an alcohol. The release agent may be at least one of pentaerythritol tetrastearate, glycerol monostearate, and octyldodecyl stearate. The release agent may be pentaerythritol tetrastearate.

[0048] The amount of the release agent is not limited, and may be about 0 wt% or more, about 0.01 wt% or more, or about 0.1 wt% or more based on the weight of the composition. The amount of the release agent is not limited, and may be about 2 wt% or less, about 1 wt% or less, or about 0.5 wt% or less based on the weight of the composition. If the content of the release agent is below the lower limit of the range, the demolding effect may be insufficient, and on the other hand, if the content of the release agent exceeds the upper limit of the range, a decrease in hydrolysis resistance, mold contamination during injection molding, and the like may occur.

[0049] The composition may contain one or more impact modifiers. The terms impact modifier and rubber are used interchangeably. Various impact modifiers can be used in the disclosed composition; such as diene rubber, ethylene propylene rubber, ethylene propylene diene (EPDM) rubber, ethylene copolymer rubber, acrylate rubber, polyisoprene rubber, silicone rubber, silicone-acrylate rubber, polyurethane, thermoplastic elastomer, halogen-containing rubber, and mixtures thereof. Also suitable are interpolymers of rubber-forming monomers and other copolymerizable monomers. The rubber may be present in a sufficient amount in the formulated composition to provide the composition with the desired impact resistance. The desired impact resistance includes increased Izod impact strength, Charpy impact strength, Gardner impact strength, tensile strength, dart impact strength, etc.

[0050] The rubber may be a diene rubber such as polybutadiene, polyisoprene, polypentadiene, polychloroprene, etc. or a mixture of diene rubbers, i.e., any rubbery polymer of one or more conjugated 1,3-dienes such as 1,3-butadiene. Such rubbers include homopolymers of 1,3-butadiene and copolymers of 1,3-butadiene with one or more copolymerizable monomers such as vinylidene-substituted aromatic compounds (styrene). The diene rubber may be a homopolymer of 1,3-butadiene. Exemplary copolymers of 1,3-butadiene are blocks or tapered blocks of at least about 30 wt% 1,3-butadiene, about 50 wt%, about 70 wt% or about 90 wt% 1,3-butadiene and up to about 70 wt% of vinylidene-substituted aromatic monomers, up to about 50 wt%, up to about 30 wt% or up to about 10 wt% of vinylidene-substituted aromatic monomers, the weight being based on the weight of the 1,3-butadiene copolymer. The impact modifiers employed may be those polymers and copolymers that exhibit a secondary transition temperature, sometimes referred to as a glass transition temperature (Tg), for diene segments, of not greater than 0°C or not greater than -20°C, as determined using conventional techniques (e.g., ASTM test method D 746-52T). The average particle size of the rubber particles may be equal to or greater than about 0.05 μm (micrometer), equal to or greater than about 0.1 μm, and equal to or greater than about 0.5 μm. The average particle size diameter of the rubber particles may be equal to or less than about 10 μm, equal to or less than about 5 μm, or equal to or less than about 4 μm.

[0051] The impact modifier can be an impact modifier (MBS) based on butadiene or styrene-butadiene rubber and methyl methacrylate-styrene grafted with a core-shell structure, a silicone-acrylate rubber with a core-shell structure, a core-shell impact modifier based on acrylate rubber, etc. The core-shell impact modifier based on butadiene or styrene-butadiene rubber is an impact modifier based on butadiene or styrene-butadiene rubber grafted with methyl methacrylate or methyl methacrylate-styrene copolymer. The silicone acrylate rubber with a core-shell structure can be made of methacrylate alkyl esters and / or acrylate alkyl esters, a crosslinking agent and a grafting agent. Exemplary methacrylate alkyl esters and / or acrylate alkyl esters are C 1-5 - alkyl esters, such as methyl, ethyl, n-butyl, tert-butyl, n-propyl, n-hexyl, n-octyl, n-lauryl and 2-ethylhexyl esters; haloalkyl esters, preferably haloC 1-5 -alkyl esters, such as chloroethyl acrylate, and mixtures of these monomers. Particularly preferred is n-butyl acrylate. Monomers having more than one polymerizable double bond can be used as crosslinking agents for the polyalkyl (meth) acrylate rubber component of the silicone acrylate rubber. Examples of crosslinking monomers are esters of unsaturated monocarboxylic acids having 3 to 8 carbon atoms and unsaturated monohydric alcohols having 3 to 12 carbon atoms or saturated polyols having 2 to 4 OH- groups and 2 to 20 carbon atoms, such as ethylene glycol dimethacrylate, propylene glycol dimethacrylate, 1,3-butanediol dimethacrylate and 1,4-butanediol dimethacrylate. Such crosslinking agents can be used alone or as a mixture of at least two crosslinking agents. Exemplary grafting agents are allyl methacrylate, triallyl cyanurate, triallyl isocyanurate or mixtures thereof. Allyl methacrylate can also be used as a crosslinking agent. Such grafting agents can be used alone or as a mixture of at least two grafting agents. Based on the total weight of the polyalkyl (meth) acrylate rubber component of the silicone acrylate rubber, the crosslinking agent and the grafting agent can be present in an amount of about 0.1-20wt%. The core can be based on silicone rubber. The silicone core can account for about 20wt% or more, about 50wt% or more of the weight of the impact modifier. The silicone core can account for about 70wt% or less or about 40wt% or less of the weight of the impact modifier. The amount of the impact modifier (rubber) contained in the composition disclosed herein is about 0.5wt% or more, about 1.0wt% or more, about 2.0wt% or more or about 3.0wt% or more based on the weight of the composition. The amount of the impact modifier contained in the composition disclosed herein is about 8wt% or less, about 6wt% or less, about 5wt% or less, about 4wt% or less or about 3.0wt% or less based on the weight of the composition.

[0052] The composition disclosed herein may include a UV stabilizer (i.e., a UV stabilizer), which in yet another embodiment serves to stabilize the color of the composition. After adding the UV stabilizer, polycarbonate, impact modifiers, and other polymers present may absorb light energy in the UV and convert it into heat. UV absorbers can reduce the weathering effect of polymer compositions (e.g., compositions of polycarbonate and vinylidene-substituted aromatic compounds). UV stabilizers may include benzotriazole, hydroxyphenyl triazine, benzophenone, s-triazine, etc., or any combination thereof. Based on the weight of the composition, the UV stabilizer may be present in an amount of about 500ppm (0.05wt%) or more, about 1,000ppm (0.1wt%) or more, or about 1,500ppm (0.15wt%) or more. The UV stabilizer may be present in an amount of about 10,000 ppm (1.0 wt%) or less, about 8,000 ppm (0.8 wt%) or less, about 6,000 ppm (0.6 wt%) or less, or about 5,000 ppm (0.5 wt%) or less.

[0053] The disclosed composition may contain a colorant. The colorant may be any colorant that provides the desired color to the composition or the product prepared therefrom. The colorant may be a pigment or a dye. Exemplary pigments include carbon black, titanium dioxide, zinc sulfide, kaolin, etc. The colorant may be present in sufficient amounts to provide the desired color to the composition or the product prepared therefrom. The colorant may be present in an amount of about 0.01% or more, about 0.1wt% or more, or about 1wt% or more, based on the weight of the disclosed composition. The colorant may be present in an amount of about 10wt% or less, about 5wt% or less, about 1wt% or less, or about 0.5wt% or less of the disclosed composition. When the colorant is a pigment, the concentration may be at the higher end of the disclosed range, for example, 0.1-10.0% by weight of the composition. When the colorant is a dye, its amount may be at the lower end of the range, for example, 0.01%-0.5% by weight of the composition. Some pigments may also be particles as described herein.

[0054] If used, the filler can be a reinforcing filler, such as a fiber having a length-to-diameter ratio of about 4 or more. Based on the gross weight of the polymer composition, the amount of other fillers (e.g., non-reinforcing fillers, such as talc, clay, etc.) can be about 10wt% or less, about 4wt% or less, about 2wt% or less, or about 1wt% or less. Reinforcing fillers can be used to increase the strength of the polymer composition and / or reduce the linear thermal expansion coefficient of the composition. Reinforcing fillers can include glass fibers, carbon fibers, metal fibers, or any combination thereof. Exemplary fillers include talc, clay, wollastonite, mica, glass, or a mixture thereof. Reinforcing fillers include mineral fillers with a needle-like structure (i.e., a needle-like structure), such as wollastonite. The composition can optionally include a component that adsorbs volatile organic compounds. The component can be zeolite, activated carbon, bamboo, charcoal, or a combination thereof.

[0055] The disclosed compositions may contain one or more additives commonly used in compositions of this type. Exemplary additives include: zinc salts, colorants, reinforcing fibers, stabilizers, antistatic agents, silicone oils, flow enhancers, and the like. Exemplary anti-ignition additives may also include antimony oxides and metal salts of aromatic sulfurs, or mixtures thereof may be used. Compounds that stabilize the rubber-modified vinylidene-substituted aromatic copolymer compositions to prevent degradation caused by, but not limited to, heat, light, and oxygen, or mixtures thereof may be used. Some of these additives may adsorb volatile organic compounds, such as zeolites, activated carbon, bamboo charcoal, and the like.

[0056] Additives and / or fillers and / or adsorbents may be present in the formulated composition in an amount of about 0.01 wt% or more, about 0.1 wt% or more, about 1 wt% or more, about 2 wt% or more, or about 3 wt% or more, based on the weight of the composition. Additives and / or fillers may be present in an amount of about 40 wt% or less, about 30 wt% or less, about 20 wt% or less, about 15 wt% or less, about 10 wt% or less, about 5 wt% or less, based on the weight of the composition. Additives and adsorbents may be present independently in an amount of up to 5 wt%, and fillers may be present in an amount of up to about 40 wt%, based on the weight of the composition.

[0057] The disclosed compositions can be produced by mixing the individual components in a known manner and melt mixing and / or melt extruding them in conventional units such as internal kneaders, extruders and twin-screw extruders at temperatures of 200° C. to 300° C. The individual components can be mixed continuously and simultaneously in a known manner at temperatures of about 23° C. (room temperature) and above.

[0058] The disclosed compositions can be molded using methods known in the art.

[0059] The polycarbonate composition can be molded into useful shaped articles by various means, such as injection molding, overmolding, extrusion, rotational molding, blow molding and thermoforming to form various molded articles. Such articles may include thin-walled articles for consumer products (such as mobile phones, MP3 players, computers, laptops, cameras, video recorders, electronic tablets, handheld receivers, kitchen appliances, electrical housings, etc.), such as smart meter housings, etc.; electrical connectors, lighting equipment components, decorations, household appliances, roofs, greenhouses, sunrooms, swimming pool fences, light emitting diodes (LEDs) and light panels, extruded film and sheet products; electrical components, such as relays; and telecommunications components, such as components of base station terminals. The present disclosure also contemplates additional manufacturing operations for the articles, such as but not limited to molding, in-mold decoration, baking in a paint oven, lamination and / or thermoforming. The disclosed composition is heated to a temperature at which the composition flows, which temperature may be higher than the glass transition temperature of the polycarbonate in the composition. Such temperatures may be higher than 155°C, higher than 200°C or higher, 250°C or higher. Such temperatures may be 400°C or less, or 300°C or less. The mold may be heated to facilitate processing, such as to 60°C or more, 80°C or more, or 100°C or more.

[0060] The UL-94 vertical test (20mm vertical burning test) in the UL standard is a measurement method for measuring the flame retardancy index of unexpanded resins. The purpose of the test is to determine the resistance of plastic materials used for components in equipment and appliances to the spread of flames and luminescence. UL 94 is used to measure the burning rate and characteristics based on standard samples. The sample size is 12.7mm x 127mm with different thicknesses. When a rating is given, the thickness must be reported. The relevant ratings are: V-2, V-1, and V-0. "V-0" is the most commonly rated visible component where increased combustion protection is required. V-0 has the following requirements:

[0061] 1. None of the five samples burned for more than 10 seconds after each of two 10-second flame applications.

[0062] 2. The total burning time of ten 10 second flame applications (5 samples, 2 applications each) exceeds 50 seconds.

[0063] 3. None of the five samples will flame or emit light to the clamping jaws.

[0064] 4. None of the five samples dripped burning particles that would ignite dry cotton wool located 305 mm below the sample.

[0065] 5. None of the five samples glowed and burned for more than 30 seconds after the flame was removed for the second time.

[0066] The other ratings have a similar format. The most notable difference in the ratings is the time the sample is allowed to support flame combustion or luminous combustion. The flame application time is the same. Here is a brief summary of the required results for V-0, V-1, and V-2: V-0 combustion ceases within 10 seconds after two 10-second flames are applied to the test strip, and no flame dripping is allowed; V-1 combustion ceases within 60 seconds after two 10-second flames are applied to the test strip, and no flame dripping is allowed; and V-2 combustion ceases within 60 seconds after two 10-second flames are applied to the test strip, and flame dripping is allowed.

[0067] The test procedure is outlined here. A sample of specific dimensions is attached vertically to a fixture and flame contact is made for 10 seconds with a 20mm flame. Each of the five samples is clamped 300mm above a layer of dry cotton. A calibrated flame is applied to the bottom edge of the vertically supported test strip for 10 seconds and any afterflame time (t1) is recorded. When the flame stops, the flame is applied again for an additional 10 seconds and the afterflame time (t2) and afterglow time (t3) are recorded. If one sample fails, a second set of five samples can be tested. Further details can be obtained by contacting UL or by obtaining a copy of this and other UL standards by visiting the UL Standards website (located at http: / / ulstandardsinfonet.ul.com). The following table defines the specific criteria for V-0, V-1 and V-2 ratings.

[0068] surface

[0069]

[0070] Before the UL-94 vertical test (20mm vertical burning test), the samples can be immersed in water. The samples should be immersed in distilled or deionized water at 70±2℃ (158±4℉) for 7 days. The water should be completely changed every day for the first 5 days. After immersion, the samples that need to be tested for flammability need to be placed in air at a temperature of 23±2℃ (73±4℉) and a relative humidity of 50±10% for two weeks.

[0071] Implementation

[0072] 1. A composition comprising: a) one or more polycarbonate polymers; b) an impact modifier comprising a silicone core; and c) a phosphazene-based flame retardant.

[0073] 2. The composition of embodiment 1, wherein the composition comprises a polyarylate, or at least one of the one or more polycarbonates can be a high temperature polycarbonate.

[0074] 3. The composition of embodiment 1 or 2, wherein the composition may comprise about 90 wt% or more of the one or more polycarbonate polymers.

[0075] 4. The composition of any of the preceding embodiments, wherein the one or more polycarbonate polymers comprises about 0-95 wt% linear polycarbonate.

[0076] 5. The composition of any of the preceding embodiments, wherein the one or more polycarbonate polymers include at least one of: a polycarbonate with a low melt flow rate; a polycarbonate with a medium melt flow rate; and a polycarbonate with a high melt flow rate.

[0077] 6. A composition as described in embodiment 5, wherein the low melt flow rate is about 0.1-5 g / 10 min; the medium melt flow rate is about 5-15 g / 10 min; and the high melt flow rate is greater than about 15 g / 10 min, the melt flow rates are measured according to ASTM D1238.

[0078] 7. The composition of any of the preceding embodiments, wherein the one or more polycarbonate polymers comprises about 50-90 wt% of a high temperature polycarbonate.

[0079] 8. The composition of any of the preceding embodiments, wherein the one or more high temperature polycarbonates have a melt flow rate of about 3-30 g / 10 min as measured according to ASTM D1238.

[0080] 9. The composition of any of the preceding embodiments, wherein the one or more high temperature polycarbonates have a glass transition temperature of about 150° C. or greater as determined by differential scanning calorimetry according to ASTM Test Method D 746-52T.

[0081] 10. The composition of any of the preceding embodiments, wherein a portion of the one or more polycarbonate polymers is post-consumer recycled polymer.

[0082] 11. The composition of any of the preceding embodiments, wherein the composition comprises about 10-30 wt% of the polyarylate, based on the weight of the composition.

[0083] 12. The composition of any of the preceding embodiments, wherein the polyarylate has a molecular weight of about 10,000-150,000 amu.

[0084] 13. The composition of any of the preceding embodiments, wherein the composition comprises about 3.0 wt% or less of the impact modifier based on the weight of the composition.

[0085] 14. The composition of any one of the preceding embodiments, wherein the impact modifier contains about 20-70 wt% of the silicone core component based on the weight of the impact modifier.

[0086] 15. The composition of any one of the preceding embodiments, wherein the composition comprises about 5.0 wt% or less of a phosphazene-based flame retardant based on the weight of the composition.

[0087] 16. The composition of any one of the preceding embodiments, wherein the phosphazene-based flame retardant is a cyclic structure containing one or more phosphazene units.

[0088] 17. A composition as described in any of the preceding embodiments, wherein the phosphazene-based flame retardant comprises at least one of phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene, hexaphenoxy cyclotriphosphazene and decaphenoxy cyclopentaphosphazene

[0089] 18. The composition of any one of the preceding embodiments, wherein the phosphazene-based flame retardant comprises hexaphenoxycyclotriphosphazene.

[0090] 19. The composition of any one of the preceding embodiments, wherein the composition comprises an anti-drip agent.

[0091] 20. The composition of embodiment 19, wherein the composition comprises about 0.1-0.9 wt % of the anti-drip agent based on the weight of the composition.

[0092] 21. The composition of embodiment 19, wherein the anti-drip agent is a fibril-forming or non-fibril-forming fluorinated polyolefin.

[0093] 22. The composition of embodiment 19, wherein the anti-drip agent is polytetrafluoroethylene encapsulated in styrene acrylonitrile.

[0094] 23. The composition of any one of the preceding embodiments, wherein the composition comprises a release agent.

[0095] 24. The composition of embodiment 23, wherein the composition comprises about 0.1-1 wt % of the release agent based on the weight of the composition.

[0096] 25. The composition of embodiment 23 or 24, wherein the release agent is one or more of: an aliphatic carboxylic acid; an ester of an aliphatic carboxylic acid with an alcohol; an aliphatic hydrocarbon compound having a number average molecular weight of 200 to 15,000; and a polysiloxane-based silicone oil.

[0097] 26. The composition of embodiment 23 or 24, wherein the release agent is one or more of an aliphatic carboxylic acid or an ester of an aliphatic carboxylic acid and an alcohol.

[0098] 27. The composition of embodiment 23, wherein the mold release agent is one or more of pentaerythritol tetrastearate, glycerol monostearate, and octyldodecyl stearate.

[0099] 28. The composition of embodiment 23, wherein the mold release agent is pentaerythritol tetrastearate.

[0100] 29. The composition of any one of the preceding embodiments, wherein the composition comprises an antioxidant.

[0101] 30. The composition of embodiment 28, wherein the composition comprises about 0.05 to 0.5 wt % of the antioxidant based on the weight of the composition.

[0102] 31. A composition as described in embodiment 28, wherein the antioxidant is one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonates, aromatic hydroxybenzyl compounds, triazine compounds, benzyl phosphonates, acylaminophenols, esters and amides of propionic acid, ascorbic acid or amine-based antioxidants.

[0103] 32. The composition of embodiment 28, wherein the antioxidant is one or more of a phenol and a phosphorus-based antioxidant.

[0104] 33. The composition of embodiment 28, wherein the antioxidant comprises a phenol-based antioxidant and a phosphorus-based antioxidant.

[0105] 34. The composition of embodiment 28, wherein the antioxidant is at least one of tris(2,4-di-tert-butylphenyl)phosphite and octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate.

[0106] 35. The composition of any one of the preceding embodiments, wherein the composition comprises a UV stabilizer.

[0107] 36. The composition of embodiment 34, wherein the composition comprises about 0.1-0.3 wt % of the UV stabilizer based on the weight of the composition.

[0108] 37. The composition of embodiment 34, wherein the UV stabilizer is one or more of benzotriazole, hydroxyphenyltriazine, benzophenone and s-triazine, or any combination thereof.

[0109] 38. A composition as described in embodiment 34, wherein the UV stabilizer is at least one of 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol, 2,2'-methylenebis[6-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol] and 2-(2H-benzotriazol-2-yl)-4(1,1,3,3-tetramethylbutyl)phenol.

[0110] 39. A composition according to any one of the preceding claims, wherein the composition comprises:

[0111] about 60-98 wt % of at least one polycarbonate polymer;

[0112] about 0.1-5.0 wt % of an impact modifier comprising a silicone core;

[0113] About 1.0-5.0 wt% of a phosphazene-based flame retardant;

[0114] 0-60wt% of the polyarylate;

[0115] 0-1wt% of the anti-drip agent;

[0116] 0-1wt% of the release agent;

[0117] 0-0.5wt% of the antioxidant;

[0118] 0-0.5 wt% of said UV stabilizer; and

[0119] 0-10 wt% of a colorant;

[0120] about -10 wt % of one or more carbon-based particles, metals or metal oxides;

[0121] wherein 0-90% of the at least one polycarbonate polymer is a high temperature polycarbonate; and wherein the weight is based on the weight of the composition.

[0122] 40. A composition as described in any of the preceding embodiments, wherein the composition comprises:

[0123] About 60-93 wt% of one or more polycarbonate polymers; about 0.1-3.0 wt% of the impact modifier comprising a silicone core; about 1.0-5.0 wt% of the phosphazene-based flame retardant;

[0124] 0-30wt% of the polyarylate;

[0125] 0-0.9wt% of the anti-drip agent;

[0126] 0-0.6wt% of the release agent;

[0127] 0-0.3wt% of the antioxidant;

[0128] 0-0.5 wt% of said UV stabilizer; and

[0129] 0-10 wt% of a colorant;

[0130] wherein 0-90% of the one or more polycarbonate polymers are one or more of the high temperature polycarbonates; and wherein the weights are based on the weight of the composition.

[0131] 41. The composition of any one of the preceding embodiments, wherein the composition has a melt flow rate of about 3 to 30 at 300°C / 1.2kg.

[0132] 42. The composition of any of the preceding embodiments, wherein the composition produces an article having UL94 V-0@1.0 mm flame retardancy.

[0133] 43. The composition of any of the preceding embodiments, wherein the composition produces an article having UL94 V-0@1.0 mm flame retardancy after immersion in water.

[0134] 44. The composition of any of the preceding embodiments, wherein the composition produces an article having a heat distortion temperature greater than 110 degrees Celsius at 1.8 MPa according to ASTM D648.

[0135] 45. The composition of any of the preceding embodiments, wherein the composition produces an article having a heat distortion temperature greater than 120 degrees Celsius at 1.8 MPa according to ASTM D648.

[0136] 46. ​​The composition of any of the preceding embodiments, wherein the composition produces an article having a heat distortion temperature greater than 125 degrees Celsius at 1.8 MPa according to ASTM D648.

[0137] 47. The composition of any one of the preceding embodiments, wherein the composition is free of carbonizing salts.

[0138] 48. A composition according to any one of claims 1 to 46, containing a carbonizing salt, provided that the carbonizing salt does not contain halogens, such as fluorine.

[0139] 49. The composition of embodiment 487, wherein the carbonizing salt comprises one or more sulfonates.

[0140] 50. The composition of any of the preceding embodiments, wherein the one or more polycarbonate polymers comprises 30 wt% or more of one or more post-consumer recycled polycarbonates, and the composition comprises one or more carbon-based particles, metals, or metal oxides,

[0141] 51. A composition according to any one of the preceding embodiments, wherein the composition comprises one or more carbon-based particles, metals or metal oxides,

[0142] 52. The composition of embodiment 50 or 51, comprising 50 wt% or more of the one or more post-consumer recycled polycarbonates.

[0143] 53. The composition of any one of embodiments 50 to 52, comprising 75 wt% or more of the one or more post-consumer recycled polycarbonates.

[0144] 54. The composition of any of the preceding embodiments, comprising one or more buffering agents, such as alkali metal phosphates.

[0145] 55. The composition of any of the preceding embodiments, wherein the one or more carbonizing salts comprises one or more aromatic sulfonates.

[0146] 56. The composition of any of the preceding embodiments, wherein the one or more carbon-based particles, metals, or metal oxides are present in an amount of about 0.02-10 wt % based on the weight of the composition.

[0147] 57. A composition as described in any of the preceding embodiments, wherein the one or more buffering compounds (e.g., alkali metal phosphates) are present in an amount of about 0.02-0.2 wt%, wherein the wt% is based on the total weight of the composition.

[0148] 58. The composition of any of the preceding embodiments, wherein the one or more carbonizing salts are present in an amount of about 0.01-2 wt%, wherein the wt% is based on the total weight of the composition.

[0149] 59. The composition of any one of embodiments 50 to 58, wherein the composition comprises:

[0150] About 0.1-3 wt% of one or more impact modifiers containing a silicone core, d) about 0.01-2 wt% of one or more anti-drip agents, e) about 0.01-2 wt% of one or more carbonizing salts, f) about 0.02-10 wt% of one or more carbon-based particles, metals or metal oxides, and g) about 0.02-0.2 wt% of one or more buffering compounds (e.g., alkali metal phosphates), wherein the wt% are based on the total weight of the composition.

[0151] 60. A composition according to any one of the preceding embodiments, wherein the composition comprises:

[0152] c) about 1.5-3.0 wt % of the one or more impact modifiers containing a silicone core, d) about 0.01-2 wt % of one or more anti-drip agents, e) about 0.01-1.0 wt % of one or more carbonizing salts, f) about 0.03-5 wt % of one or more carbon-based particles, metals or metal oxides, and g) about 0.02-0.1 wt % of one or more buffering compounds (e.g., alkali metal phosphates), wherein the wt % are based on the total weight of the composition.

[0153] 61. A molded article prepared from the composition according to any one of the preceding embodiments.

[0154] 62. The article of embodiment 61, wherein the article achieves UL94 V-0@1.0 mm flame retardancy.

[0155] 63. The article of embodiment 61 or embodiment 62, wherein the article achieves UL94 V-0@1.0 mm flame retardancy after immersion in water.

[0156] 64. The article of embodiment 61, wherein the article achieves UL94 V-0@1.5mm flame retardancy.

[0157] 65. The article of embodiment 61, wherein the article achieves UL94 V-0@1.5 mm flame retardancy after immersion in water.

[0158] 66. The article of embodiment 61, wherein the article maintains ductile strength at -20°C as measured by notched Izod testing.

[0159] 67. The article of embodiment 61, wherein the article maintains ductile strength at -30°C as measured by notched Izod testing.

[0160] 68. An article as described in any of embodiments 61 to 63, wherein the article has a heat deformation temperature greater than 110 degrees Celsius at 1.8 MPa obtained according to ASTM D648.

[0161] 69. An article as described in any of embodiments 61 to 64, wherein the article has a heat deformation temperature greater than 120 degrees Celsius at 1.8 MPa obtained according to ASTM D648.

[0162] 70. An article as described in any of embodiments 61 to 64, wherein the article has a heat deformation temperature greater than 125 degrees Celsius at 1.8 MPa obtained according to ASTM D648.

[0163] 671. A method comprising: a) thoroughly mixing the ingredients of any one of embodiments 1 to 59 at a temperature of about 250°C or higher for about 10 seconds or longer, b) filling a mold with the mixed composition of a), and c) forming the composition in the mold into a solid article, and d) removing the formed article from the mold.

[0164] 72. A method according to embodiment 71, wherein the contact mixing is carried out in an extruder and the formed mixture is moved from the extruder to a die.

[0165] Illustrative Embodiments

[0166] The following examples are provided only to illustrate the present invention and are not intended to limit the scope thereof. Unless otherwise indicated, all parts and percentages are by weight.

[0167] Several samples were prepared according to the following procedure. The materials listed in the table above were mixed and pelletized on a twin screw extruder (Coperion ZSK-26) at a speed of ~400 rpm, an output of 80 kg / h, and an extrusion temperature of 290° C. The samples were molded into a size of 12.7 mm x 127 mm with a thickness of 1.0 mm.

[0168] The melt flow rate of the pellets predried at 120°C for 4 hours was determined as described above. The heat deformation temperature (HDT) was determined according to ASTM D648 at 1.8 mPa. The Notched Izod test was performed according to ASTM D256, which is a single-point test that measures the resistance of a material to a pendulum impact. It is defined as the kinetic energy required to initiate a fracture and continue the fracture until the specimen breaks. The compositions tested and the test results are summarized in Tables 1, 3, 4 and 5. Comparative examples are summarized in Table 2. The amounts of all ingredients in the table are wt%

[0169] Element

[0170] 1. An organosilicon-based graft copolymer containing more than 70 wt% of an organosilicon core component and a graft polymer component shell derived primarily from acrylate monomers.

[0171] 2. Silicone-based graft copolymers containing more than 20 wt% of a silicone core component and a graft polymer shell component derived primarily from acrylate monomers

[0172] 3. Butadiene / methyl methacrylate / styrene block copolymer

[0173] 4. Carbonized salt Perfluorobutanesulfonic acid potassium salt

[0174] 5. Hexaphenoxy cyclotriphosphazene

[0175] 6.PTFE (polytetrafluoroethylene) encapsulated in SAN (50% fluoropolymer)

[0176] 7-Pentaerythritol Tetrastearate

[0177] 8-Tris(2,4-di-tert-butylphenyl)phosphite

[0178] 9Benzotriazole UV absorber

[0179] 10 Octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate

[0180] 11 Sodium p-toluenesulfonate

[0181] 12 Carbon black

[0182] 13 Carbon Nanotubes

[0183] 14 Titanium dioxide

[0184] 15 Buffer Disodium dihydrogen phosphate MSP (NaH2PO4)

[0185]

[0186]

[0187]

[0188]

[0189]

[0190]

[0191]

[0192]

[0193] Examples U to Y demonstrate that adding 3% phosphazene to a PC composition can achieve a flame retardancy rating of V0@1.5mm. However, if the addition amount of phosphazene is less than 2.2%, the material can only achieve a flame retardancy rating of V1@1.5mm. Examples Z to AH show that by adding 0.4% carbon or carbon nanotubes to a material containing 2.1% phosphazene, the material can achieve a flame retardancy rating of V0@1.5mm. Examples AI and AJ show that adding 5% titanium dioxide to a material containing 2% phosphazene (whether or not containing MSP) can achieve a flame retardancy rating of V0@1.5mm. Examples AK to AM show that adding 3% silicone impact modifier and 0.4% carbon or 5% titanium dioxide to a material containing 2.1% or 2% phosphazene can achieve the same flame retardancy rating of V0@1.5mm. The percentage of silicone impact modifier is higher compared to U to AI.

[0194] In the examples that achieved a flame retardant rating of V0@1.5mm (AI to AN), materials AI, AJ, and AN containing 0.4% carbon nanotubes or 5% TiO2 had poor thermal stability, as indicated by a larger increase in MFR (>40%) after hot soak testing. To address the MFR increase observed in these materials, alternative solutions can be used. For example, using 0.4% carbon (rather than carbon nanotubes) in E13 can help correct the increase in MFR. In addition, adding 0.04% MSP to samples containing 5% TiO2 in AJ also helps to mitigate the increase in MFR. Materials AJ to AN- containing 3% silicone impact modifiers can maintain their ductile impact strength at -20°C, while AK to AN can even maintain their ductile impact strength as low as -30°C. In contrast, AG and AH containing 2% silicone impact modifiers may not be able to maintain their ductile impact strength at such low temperatures. Another advantage of the AK to AN materials containing 3% silicone impact modifier is that they maintain their ductile impact strength even after exposure to high temperature and humidity (85°C / 85% RH) for 500 hours. This is due to the higher content of silicone impact modifier compared to the samples containing only 2%.

[0195] The examples show that the compositions have good flame retardancy and excellent physical properties. The disclosed compositions do not contain alkali metal salts of perfluoroalkane sulfonates, which have been classified as substances of very high concern in Europe. The silicone-based impact modifiers maintain their flammability rating even when immersed in water. In addition, thermal properties will be improved by adding high Tg polycarbonate.

Claims

1. A composition comprising: a) at least one polycarbonate polymer; b) an impact modifier comprising a silicone core; and c) Phosphazene-based flame retardants.

2. The composition of claim 1, wherein the composition comprises i) about 10-30 wt% of a polyarylate having a glass transition temperature of about 180°C or greater, or the at least one polycarbonate comprises about 50-90 wt% of a high temperature polycarbonate having a glass transition temperature of about 150°C or greater, wherein the glass transition temperature is determined by differential scanning calorimetry according to ASTM test method D746-52; or ii) one or more carbon-based particles, metals or metal oxides.

3. The composition of any of the preceding claims, wherein the composition comprises a polyarylate, or at least a portion of the at least one polycarbonate is a high temperature polycarbonate having a glass transition temperature of about 150°C or greater as determined by differential scanning calorimetry according to ASTM test method D 746-52T.

4. The composition of any of the preceding claims, wherein the at least one polycarbonate polymer comprises from about 0 to about 95 wt% linear polycarbonate.

5. The composition according to any one of the preceding claims, wherein the at least one polycarbonate comprises at least one of: A polycarbonate having a low melt flow rate of about 0.1-5 g / 10 min; A polycarbonate having a medium melt flow rate of about 5-15 g / 10 min; and A polycarbonate having a high melt flow rate greater than about 15 g / 10 min, as measured according to ASTM D1238.

6. The composition of any of the preceding claims, wherein the at least one polycarbonate polymer comprises about 50-90 wt% high temperature polycarbonate.

7. The composition of any of the preceding claims, wherein the composition comprises about 0-60 wt% based on the weight of the composition of a high temperature polycarbonate having a glass transition temperature of about 150°C or higher or a polyarylate having a molecular weight of about 10,000-150,000 amu.

8. The composition of any one of the preceding claims, wherein the composition comprises about 5.0 wt% or less of the impact modifier based on the weight of the composition.

9. The composition of any one of the preceding claims, wherein the impact modifier contains about 20-70 wt% of the silicone core component based on the weight of the impact modifier.

10. The composition of any one of the preceding claims, wherein the composition comprises about 5.0 wt% or less of a phosphazene-based flame retardant based on the weight of the composition.

11. The composition according to any one of the preceding claims, wherein the composition is free of a halogen-based carbonizing salt, wherein the carbonizing salt is an organometallic salt of a perfluoroalkyl sulfide compound.

12. The composition of any of the preceding embodiments, wherein a portion of the at least one polycarbonate polymer is post-consumer recycled polymer.

13. A composition according to any one of the preceding claims, wherein the composition comprises: about 60-98 wt % of at least one polycarbonate polymer; about 0.1-5.0 wt % of an impact modifier comprising a silicone core; About 1.0-5.0 wt% of a phosphazene-based flame retardant; 0-60wt% of the polyarylate; 0-1wt% of the anti-drip agent; 0-1wt% of the release agent; 0-0.5wt% of the antioxidant; 0-0.5 wt% of said UV stabilizer; and 0-10 wt% of a colorant; wherein 0-90% of the at least one polycarbonate polymer is a high temperature polycarbonate; and wherein the weight is based on the weight of the composition.

14. The composition of any of the preceding claims, wherein the one or more polycarbonate polymers comprises 30 wt% or more of one or more post-consumer recycled polycarbonates and the composition comprises one or more carbon-based particles, metals, or metal oxides.

15. A composition according to any one of the preceding claims, wherein the composition comprises one or more carbon-based particles, metals or metal oxides.

16. The composition of claim 14 or 15, comprising 30 wt% or more of the one or more post-consumer recycled polycarbonates.

17. The composition of any one of claims 14 to 16, comprising 75 wt% or more of the one or more post-consumer recycled polycarbonates.

18. A composition according to any preceding claim comprising one or more buffering agents, such as alkali metal phosphates.

19. A composition according to any preceding claim comprising one or more carbonising salts.

20. The composition of any one of the preceding claims, wherein the one or more carbon-based particles, metals or metal oxides are present in an amount of about 0.01-10 wt% based on the weight of the composition.

21. A composition according to any one of the preceding claims, wherein the one or more buffer compounds (eg, alkali metal phosphates) are present in an amount of about 0.01-0.2 wt%, wherein the wt% is based on the total weight of the composition.

22. The composition of any one of the preceding claims, wherein the one or more carbonizing salts are present in an amount of about 0.01-2 wt%, wherein the wt% is based on the total weight of the composition.

23. A composition according to any one of the preceding claims, wherein the carbonising salt comprises one or more of sodium p-toluene sulfonate or potassium diphenyl sulfone sulfonate.

24. A molded article prepared from the composition of any preceding claim having UL94 V-0@1.0 mm flame retardancy and a heat distortion temperature greater than 110 degrees Celsius at 1.8 MPa according to ASTM D648.

25. A method wherein include: a) mixing the ingredients of any one of claims 1 to 23 at a temperature of about 250° C. or higher for about 10 seconds or longer; b) filling the mixed composition of a) into a mold; c) forming the composition in the mold into a solid article; and d) removing the formed article from the mold.

26. The method of claim 25, wherein the contact mixing is performed in an extruder and the resulting mixture is moved from the extruder to a die.

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