Polycarbonate compositions with improved combustion properties

Abstract

The present invention relates to a composition comprising, based on the total weight of the composition: (a) at least one poly (carbonate-siloxane-arylate) copolymer present in an amount of 5.0% to 55.0% by weight; (b) at least one brominated polycarbonate present in an amount of from 10.0 wt% to 45.0 wt%; (c) glass fibers present in an amount of from 12.0 wt% to 20.0 wt%; and (d) at least one polycarbonate polymer selected from the group consisting of a poly (carbonate-siloxane) copolymer or a polycarbonate homopolymer. The invention also relates to an article prepared from such a composition and to the use of such a composition.

Description

Technical Field

[0001] The present invention relates to a polycarbonate composition having improved flame retardant properties, and articles prepared from such polycarbonate compositions. The present invention also relates to the use of such polycarbonate compositions for improving the flame retardant properties of components used in mass transportation. Background Art

[0002] Although most thermoplastics are flammable, a major requirement for using such materials in interior components of mass transportation vehicles is to comply with the fire resistance / flame resistance requirements stipulated by different regulatory codes. For example, the European railway industry is governed by the EN45545-2 standard, which consists of three tests: heat release, smoke density, and flame spread. These define the material standards that need to be met for use in train interior components. The standard stipulates different risk and hazard levels that define the flame resistance standards that a material needs to meet for a given application. The risks are numbered from 1 (the strictest) to 26 (the least strict), with 1 associated with horizontal and vertical interior surfaces such as ceilings, walls, window frames, or display screens, and 26 associated with small electronic parts.

[0003] The hazard levels are associated with the design and operation of railway vehicles and are of three levels: HL1 (the least strict), HL2, and HL3 (the strictest). Specifically, to comply with EN45545-2 R1-HL2, a sample must have a heat release of ≤ (less than or equal to) 90.0 kW / m 2 , a Ds4 of ≤ (less than or equal to) 300.0, a VOF4 (reference smoke density) of ≤ (less than or equal to) 600.0, and a CFE (reference flame spread) of ≥ (greater than or equal to) 20.0 kW / m 2 . And to comply with EN45545-2 R1-HL3, a sample must have a heat release of ≤ 60.0 kW / m 2 , a Ds4 of ≤ 150.0, a VOF4 of ≤ 300.0, and a CFE of ≥ 20.0 kW / m 2 .

[0004] Due to certain inherent advantages, such as their mechanical properties, relatively low density, ease of processing, and ability to alter long-term stability, polycarbonate-based materials are attractive to the mass transportation industry for manufacturing interior components of trains and airplanes. Additionally, from a cost perspective, due to sustainability considerations such as reduced CO2 emissions provided by polycarbonates compared to competing materials such as aluminum or thermosetting materials, there is increasing interest in using polycarbonate-based materials in applications for interior components of mass transportation systems that need to meet strict combustion regulatory guidelines. Due to the challenge of enhancing flame retardant properties, the current use of polycarbonate-based materials is limited to a few specific applications where the regulations are relatively less strict or there are no regulatory requirements, such as armrests or lighting.

[0005] In the past, one possible way to improve the flame retardant / fire resistant properties of thermoplastic materials was to compound the polymer with flame retardant additives. However, the flame retardant additives need to be carefully selected and used in limited amounts because excessive use of such additives may affect polymer properties, such as rheological and mechanical properties, and thus affect the processing of such polymers.

[0006] An alternative way to improve the flame retardant properties of polycarbonates is to use polar functionalized polymers, such as polyetherimides. For example, industry practitioners have previously developed polyetherimide (PEI), polyphenylene oxide (PPO), which impart fire resistance / flame resistance to polycarbonate-based materials. However, due to their higher density, lower mechanical properties and significantly higher cost, such grades have processing-related drawbacks and may not be an ideal choice for price-sensitive and high-performance markets, such as the railway and aircraft industries.

[0007] Accordingly, an object of the present invention is to provide a polycarbonate-based composition having desired flame retardant properties and which can be used in bulk transportation applications. Another object of the present invention is to provide a composition that meets the requirements of EN45545-2 R1-HL2 and EN45545-2 R1-HL3 without the addition of additional flame retardants. Another object of the present invention is to provide an article prepared from such a polycarbonate-based composition that meets the flame retardant requirements of EN45545-2 R1-HL2 and / or EN45545-2 R1-HL3. Summary of the Invention

[0008] Accordingly, one or more objects of the present invention are achieved by a composition comprising, based on the total weight of the composition:

[0009] (a) 5.0 wt% to 55.0 wt% of at least one poly(carbonate-siloxane-arylate) copolymer;

[0010] (b) 10.0 wt% to 45.0 wt% of at least one brominated polycarbonate;

[0011] (c) 12.0 wt% to 20.0 wt% of glass fiber; and

[0012] (d) at least one polycarbonate polymer (PC1) selected from the following:

[0013] i. a poly(carbonate-siloxane) copolymer, which, if selected, is present in an amount of 10.0 wt% to 50.0 wt%;

[0014] ii. a polycarbonate homopolymer, which, if selected, is present in an amount of 5.0 wt% to 20.0 wt%; and

[0015] The combination of (iii.i) and (ii);

[0016] wherein at least one poly(carbonate-siloxane) copolymer does not contain repeating units derived from aromatic esters; and wherein the polycarbonate homopolymer does not contain bromine.

[0017] The sum of components (a)-(d) and any optional additives is 100% by weight. If present in the composition, the optional additives may be present in an amount of not more than 5.0% by weight, preferably not more than 2.5% by weight, preferably not more than 1.0% by weight, based on the total weight of the composition.

[0018] Preferably, based on the total weight of the composition:

[0019] ● The amount of poly(carbonate-siloxane-aromatic ester) copolymer present is from 10.0% to 45.0% by weight, preferably from 20.0% to 45.0% by weight, preferably from 20.0% to 40.0% by weight, preferably from 25.0% to 40.0% by weight, preferably from 30.0% to 40.0% by weight;

[0020] ● The amount of brominated polycarbonate present is from 20.0% to 40.0% by weight, preferably from 25.0% to 40.0% by weight, preferably from 25.0% to 35.0% by weight; and

[0021] ● The amount of glass fiber is 12.0% to 18.0% by weight of glass fiber.

[0022] Preferably, when the amount of poly(carbonate-siloxane-aromatic ester) copolymer is more than 30.0% by weight, the amount of brominated polycarbonate is at least 20.0% by weight, based on the total weight of the composition.

[0023] Preferably, based on the total weight of the composition:

[0024] ● The amount of poly(carbonate-siloxane) copolymer present is from 12.0% to 45.0% by weight, preferably from 12.0% to 25.0% by weight, preferably from 12.0% to 20.0% by weight; and / or

[0025] ● The amount of polycarbonate homopolymer present is from 5.0% to 18.0% by weight, preferably from 12.0% to 18.0% by weight.

[0026] The poly(carbonate-siloxane) copolymer does not contain repeating units derived from aromatic esters, thereby differentiating the poly(carbonate-siloxane) copolymer from the poly(carbonate-siloxane-aromatic ester) copolymer. The term "does not contain repeating units derived from aromatic esters" means that the poly(carbonate-siloxane) copolymer has 0.0% by weight of units derived from aromatic esters.

[0027] The polycarbonate homopolymer is bromine-free, thus differentiating this homopolymer from brominated polycarbonates. The term "bromine-free" means that the polycarbonate homopolymer contains 0.0 wt% of polymer units containing atomic bromine or bromine-based compounds.

[0028] Advantageously, the inventors have found that articles prepared from the compositions of the present invention exhibit excellent flame retardant properties and meet the standards of the EN45545-2 specification. Specifically, articles prepared from the compositions of the present invention meet the strict R1-HL2 and / or R1-HL3 EN45545-2 criteria when the article has a material thickness of at most 3 mm.

[0029] The composition contains less than 0.5 wt%, preferably less than 0.01 wt%, preferably 0.0 wt% of additional flame retardant compounds based on the total weight of the composition. Preferably, the additional flame retardant compounds are selected from organic phosphates / esters, polyetherimides (PEI), polyphenylene ethers (PPE), aromatic organophosphorus compounds having two or more phosphorus-containing groups, organic compounds containing phosphorus-nitrogen bonds, halogenated flame retardants, inorganic flame retardants, and combinations thereof.

[0030] The term "additional flame retardant compound" means a flame retardant compound different from any of poly(carbonate-siloxane-arylate) copolymer, poly(carbonate-siloxane) copolymer, brominated polycarbonate, and polycarbonate polymer (PC1), and glass fiber, which may or may not have certain flame retardant properties by itself.

[0031] The inventors have found that the compositions exhibit the R1-HL2 EN45545-2 ("HL2") and R1-HL3 EN45545-2 ("HL3") criteria even without the use of any additional flame retardant compounds.

[0032] For example, the composition has or is selected to have:

[0033] ● A smoke density (Ds4) after 4 minutes of less than or equal to 300.0, preferably less than or equal to 250.0, preferably less than or equal to 200.0, preferably less than or equal to 150.0, preferably less than or equal to 130.0, as measured on a 3 mm thick plate at 50.0 kW / m² according to ISO 5659-2; 2 ● A smoke density (VOF4) of less than or equal to 600.0, preferably less than or equal to 500.0, preferably less than or equal to 400.0, preferably less than or equal to 300.0, preferably less than or equal to 250.0, as measured on a 3.0 mm thick plate at 50.0 kW / m² according to ISO 5659-2;

[0034] ● 2 ​

[0035] ● Measured on 3 mm thick plates according to ISO 5660-1 at 50.0 kW / m 2 less than or equal to 90.0 kW / m 2 preferably less than or equal to or less than 80.0 kW / m 2 preferably less than or equal to or less than 60.0 kW / m 2 for the maximum average heat release rate (MAHRE); and

[0036] ● Measured according to ISO 5658-2, greater than or equal to 20.0 kW / m 2 preferably greater than or equal to 22.0 kW / m 2 preferably greater than or equal to 25.0 kW / m 2 for the critical heat flux at extinguishment (CFE).

[0037] In one aspect of the present invention, the composition complies with the R1-HL3 EN45545-2 ("HL3") criteria. Preferably, the composition has or is selected to have:

[0038] ● Measured according to ISO 5659-2 on 3 mm thick plates at 50.0 kW / m 2 less than or equal to 150.0, preferably less than or equal to 130.0, preferably less than or equal to 100.0 for the smoke density after 4 minutes (Ds4);

[0039] ● Measured according to ISO 5659-2 on 3.0 mm thick plates at 50.0 kW / m 2 less than or equal to 300.0, preferably less than or equal to 250.0, preferably less than or equal to 200.0, preferably less than or equal to 150.0, preferably less than or equal to 140.0 for the volume of flue gas (VOF4);

[0040] ● Measured on 3 mm thick plates according to ISO 5660-1 at 50.0 kW / m 2 less than or equal to 60.0 kW / m 2 preferably less than or equal to 50.0 kW / m 2 preferably less than or equal to 45.0 kW / m 2 preferably less than or equal to 40.0 kW / m 2 for the maximum average heat release rate (MAHRE); and

[0041] ● Measured according to ISO 5658-2, greater than or equal to 20.0 kW / m 2 preferably greater than or equal to 22.0 kW / m 2 preferably greater than or equal to 25.0 kW / m 2 for the critical heat flux at extinguishment (CFE).

[0042] The composition may have a smoke density (Ds4) of 55.0 to less than or equal to 300.0, preferably 60.0 to less than or equal to 250.0, preferably 60.0 to less than or equal to 200.0, preferably 55.0 to less than or equal to 200.0, preferably 60.0 to less than or equal to 100.0, measured according to ISO 5659-2 on a 3.0 mm thick plate at 50.0 kW / m 2 after 4 minutes.

[0043] The composition may have a smoke density (VOF4) of 55.0 to less than or equal to 600.0, preferably 80.0 to less than or equal to 550.0, preferably 100.0 to less than or equal to 500.0, preferably 100.0 to less than or equal to 500.0, preferably 100.0 to less than or equal to 300.0, preferably 100.0 to less than or equal to 250.0, measured according to ISO 5659-2 on a 3.0 mm thick plate at 50.0 kW / m 2 after 4 minutes.

[0044] The composition may have a maximum average heat release rate (MAHRE) of 25.0 to less than or equal to 90.0 kW / m, preferably 35.0 to less than or equal to or less than 80.0 kW / m, preferably 40.0 to less than or equal to or less than 60.0 kW / m, measured according to ISO 5660-1 on a 3 mm thick plate at 50 kW / m 2 2 preferably 35.0 to less than or equal to or less than 80.0 kW / m 2 preferably 40.0 to less than or equal to or less than 60.0 kW / m 2

[0045] The composition may have a critical heat flux at extinguishment (CFE) of greater than or equal to 20.0 kW / m 2 to at most 40.0 kW / m 2 preferably greater than or equal to 22.0 kW / m 2 to at most 35.0 kW / m 2 preferably greater than or equal to 25.0 kW / m 2 to at most 35.0 kW / m 2

[0046] Thus, in one aspect of the present invention, the present invention relates to an article comprising the composition of the present invention, preferably wherein the article is suitable for use in a bulk transportation system. Preferably, the article is at least one of a railway component, an aerospace component, or an automotive component. The article may comprise the composition of the present invention in an amount of at least 90.0 wt%, preferably at least 95.0 wt%, preferably at least 98.0 wt%, preferably at least 99.0 wt%, preferably 100 wt% based on the total weight of the article.

[0047] ​​​In another aspect of the present invention, the present invention relates to the use of the composition according to the present invention for improving the flame retardant properties of articles used in bulk transportation systems.

[0048] The polycarbonate polymer (PC1) can be a poly(carbonate-siloxane) copolymer

[0049] The polycarbonate polymer (PC1) can be a poly(carbonate-siloxane) copolymer. Thus, the composition can comprise, based on the total weight of the composition:

[0050] (a) 5.0% to 55.0% by weight of at least one poly(carbonate-siloxane-arylated ester) copolymer;

[0051] (b) 10.0% to 45.0% by weight of at least one brominated polycarbonate;

[0052] (c) 12.0% to 20.0% by weight of glass fiber; and

[0053] (d) at least one polycarbonate polymer (PC1) is a poly(carbonate-siloxane) copolymer, present in an amount of 10.0% to 50.0% by weight.

[0054] Preferably, when the polycarbonate polymer (PC1) is a poly(carbonate-siloxane) copolymer, the composition comprises 0.0% by weight of polycarbonate homopolymer.

[0055] Alternatively, the composition can comprise, based on the total weight of the composition:

[0056] (a) 10.0% to 45.0% by weight of at least one poly(carbonate-siloxane-arylated ester) copolymer;

[0057] (b) 25.0% to 40.0% by weight of at least one brominated polycarbonate;

[0058] (c) 12.0% to 20.0% by weight of glass fiber; and

[0059] (d) at least one polycarbonate polymer (PC1) is a poly(carbonate-siloxane) copolymer, present in an amount of 12.0% to 48.0% by weight, preferably 12.0% to 40.0% by weight, preferably 12.0% to 25.0% by weight, preferably 12.0% to 20.0% by weight.

[0060] The composition can comprise, based on the total weight of the composition:

[0061] (a) 30.0% to 45.0% by weight of at least one poly(carbonate-siloxane-arylated ester) copolymer;

[0062] (b) At least one brominated polycarbonate in an amount of 25.0% to 40.0% by weight;

[0063] (c) Glass fiber in an amount of 12.0% to 20.0% by weight; and

[0064] (d) At least one polycarbonate polymer (PC1) is a poly(carbonate - siloxane) copolymer, present in an amount of 12.0% to 48.0% by weight, preferably 12.0% to 40.0% by weight, preferably 12.0% to 25.0% by weight, preferably 12.0% to 20.0% by weight.

[0065] The composition may comprise, based on the total weight of the composition:

[0066] (a) At least one poly(carbonate - siloxane - aromatic ester) copolymer in an amount of 30.0% to 40.0% by weight;

[0067] (b) At least one brominated polycarbonate in an amount of 25.0% to 35.0% by weight;

[0068] (c) Glass fiber in an amount of 12.0% to 20.0% by weight; and

[0069] (d) At least one polycarbonate polymer (PC1) is a poly(carbonate - siloxane) copolymer, present in an amount of 12.0% to 48.0% by weight, preferably 12.0% to 40.0% by weight, preferably 12.0% to 25.0% by weight, preferably 12.0% to 20.0% by weight.

[0070] The polycarbonate polymer (PC1) can be a polycarbonate homopolymer

[0071] Alternatively, the composition may comprise, based on the total weight of the composition:

[0072] (a) At least one poly(carbonate - siloxane - aromatic ester) copolymer in an amount of 5.0% to 55.0% by weight;

[0073] (b) At least one brominated polycarbonate in an amount of 10.0% to 45.0% by weight;

[0074] (c) Glass fiber in an amount of 12.0% to 20.0% by weight; and

[0075] (d) At least one polycarbonate polymer (PC1) is a polycarbonate homopolymer, present in an amount of 5.0% to 20.0% by weight.

[0076] Preferably, when the polycarbonate polymer (PC1) is a polycarbonate homopolymer, the composition comprises 0.0% by weight of the poly(carbonate - siloxane) copolymer.

[0077] Preferably, based on the total weight of the composition:

[0078] ● The amount of the poly(carbonate-siloxane-arylated ester) copolymer is from 20.0 wt% to 45.0 wt%;

[0079] ● The amount of the brominated polycarbonate is from 25.0 wt% to 40.0 wt%;

[0080] ● The amount of glass fiber is 12.0 wt% to 18.0 wt% of glass fiber; and

[0081] ● The amount of the polycarbonate homopolymer is from 5.0 wt% to 18.0 wt%, preferably from 12.0 wt% to 18.0 wt%.

[0082] Preferably, based on the total weight of the composition:

[0083] ● The amount of the poly(carbonate-siloxane-arylated ester) copolymer is from 20.0 wt% to 45.0 wt%;

[0084] ● The amount of the brominated polycarbonate is from 25.0 wt% to 40.0 wt%;

[0085] ● The amount of glass fiber is 12.0 wt% to 18.0 wt% of glass fiber; and

[0086] ● The amount of the polycarbonate homopolymer is from 5.0 wt% to 18.0 wt%, preferably from 12.0 wt% to 18.0 wt%.

[0087] Preferably, when the polycarbonate polymer (PC1) is a polycarbonate homopolymer, the composition comprises 0.0 wt% of the poly(carbonate-siloxane) copolymer.

[0088] In one aspect of the present invention, the composition complies with the R1-HL3 EN45545-2 (“HL3”) criteria.

[0089] Preferably, based on the total weight of the composition:

[0090] ● The poly(carbonate-siloxane-arylated ester) copolymer is present in an amount of from 20.0 wt% to 40.0 wt%, preferably from 30.0 wt% to 40.0 wt%;

[0091] ● The brominated polycarbonate is present in an amount of from 20.0 wt% to 40.0 wt%, preferably from 25.0 wt% to 40.0 wt%, preferably from 30.0 wt% to 40.0 wt%;

[0092] ● The glass fiber is present in an amount of from 12.0 wt% to 18.0 wt%; and

[0093] ● The polycarbonate homopolymer is a linear polycarbonate homopolymer and is present in an amount of 12.0 wt% to 18.0 wt%;

[0094] Preferably, the composition has or is selected to have:

[0095] (i) A smoke density (Ds4) after 4 minutes of less than or equal to 150.0, measured according to ISO 5659-2 on a 3.0 mm thick plate at 50.0 kW / m 2 ;

[0096] (ii) A smoke density (VOF4) of less than or equal to 300.0, measured according to ISO 5659-2 on a 3.0 mm thick plate at 50.0 kW / m 2 ;

[0097] (iii) A maximum average heat release rate (MAHRE) of less than or equal to 60.0 kW / m 2 , measured according to ISO 5660-1 on a 3.0 mm thick plate at 50.0 kW / m 2 ; and

[0098] (iv) A critical heat flux at extinction (CFE) of greater than or equal to 20.0 kW / m 2 , measured according to ISO 5658-2.

[0099] Preferably, when the polycarbonate homopolymer is a linear polycarbonate homopolymer, the composition comprises 0.0 wt% of a poly(carbonate-siloxane) copolymer.

[0100] The polycarbonate polymer (PC1) can contain both a polycarbonate homopolymer and a poly(carbonate-siloxane) copolymer

[0101] Thus, the composition may comprise, based on the total weight of the composition:

[0102] (a) 5.0 wt% to 45.0 wt%, preferably 20.0 wt% to 45.0 wt% of at least one poly(carbonate-siloxane-arylate) copolymer;

[0103] (b) 10.0 wt% to 45.0 wt%, preferably 15.0 wt% to 40.0 wt% of at least one brominated polycarbonate;

[0104] (c) 12.0 wt% to 20.0 wt% of glass fiber; and

[0105] (d) At least one polycarbonate polymer (PC1) comprising:

[0106] ● A polycarbonate homopolymer, present in an amount of 5.0 wt% to 20.0 wt%, preferably 5.0 wt% to 15.0 wt%; and

[0107] ● The poly(carbonate-siloxane) copolymer is present in an amount of 10.0 wt% to 25.0 wt%, preferably 10.0 wt% to 20.0 wt%.

[0108] Poly(carbonate-siloxane-arylate) copolymer

[0109] The poly(carbonate-siloxane-aromatic ester) copolymer comprises repeating units of aromatic carbonate units, siloxane units and aromatic ester (aromaticized) units or consists of them. The poly(carbonate-siloxane-aromatic ester) copolymer may comprise 0.2 to 10.0 wt% of siloxane units, 50.0 to 99.6 wt% of aromatic ester units and 0.2 to 49.8 wt% of aromatic carbonate units based on the total weight of the poly(carbonate-siloxane-aromatic ester) copolymer.

[0110] Preferably, the poly(carbonate-siloxane-aromatic ester) copolymer comprises 0.25 wt% to 2.0 wt% of siloxane units, 60.0 to 94.75 wt% of aromatic ester units and 3.25 to 39.75 wt% of aromatic carbonate units, wherein the total weight percentage of the siloxane units, aromatic ester units and aromatic carbonate units is 100.0 wt% of the total weight of the poly(carbonate-siloxane-aromatic ester) copolymer.

[0111] Preferably, the poly(carbonate-siloxane-aromatic ester) copolymer has a silicon content of less than 3.0 wt%, preferably less than 1.5 wt%, more preferably 1.0 wt% based on the total weight of the poly(carbonate-siloxane-aromatic ester) copolymer. Preferably, the poly(carbonate-siloxane-aromatic ester) copolymer has a silicon content of more than 0.0 wt% and less than 3.0 wt%, preferably more than 0.0 and less than 1.5 wt%, more preferably 1.0 wt% based on the total weight of the poly(carbonate-siloxane-aromatic ester) copolymer.

[0112] The poly(carbonate-siloxane-aromatic ester) copolymer is present in an amount of 5.0 wt% to 55.0 wt%, preferably 10.0 wt% to 55.0 wt%, preferably 10.0 wt% to 45.0 wt%, preferably 20.0 wt% to 45.0 wt%, preferably 25.0 wt% to 45.0 wt%, preferably 30.0 wt% to 45.0 wt%, preferably 25.0 wt% to 40.0 wt%, preferably 30.0 wt% to 40.0 wt% based on the total weight of the composition.

[0113] Aromatic carbonate unit

[0114] The aromatic carbonate unit is a repeating unit of formula (1):

[0115]

[0116] wherein R 1 at least 60% of the total number of groups are aromatic, or each R 1 contains at least one C 6-30 aromatic group.

[0117] Specifically, each R 1 may be derived from an aromatic dihydroxy compound such as formula (2) or a dihydroxy compound of bisphenol of formula (3).

[0118]

[0119] In formula (2), each R h is independently a halogen atom, such as bromine, C 1-10 hydrocarbon group, such as C 1-10 alkyl group, halogen-substituted C 1-10 alkyl group, C 6-10 aryl group or halogen-substituted C 6-10 aryl group, and n is from 0 to 4.

[0120] In formula (3), R a and R b are each independently halogen, C 1-12 alkoxy group or C 1-12 alkyl group; and p and q are each independently an integer from 0 to 4, such that when p or q is less than 4, the valence of each carbon of the ring is filled with hydrogen.

[0121] Preferably, p and q are each 0, or p and q are each 1, and R a and R b are each C 1-3 alkyl group, especially methyl group, and are meta-positioned to the hydroxyl group on each arylene group. X a is a bridging group connecting two hydroxyl-substituted aryl groups, wherein the bridging group and the hydroxyl substituent of each C6 arylene group are ortho-positioned, meta-positioned or para-positioned (especially para-positioned) to each other on the C6 arylene group, and for example is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)- or C 1-18 organic group, which may be cyclic or acyclic, aromatic or non-aromatic and may also contain heteroatoms such as halogen, oxygen, nitrogen, sulfur, silicon or phosphorus.

[0122] For example, X a may be a substituted or unsubstituted C 3-18 cycloalkylene group; a C c alkylene group having the formula -C(R d )(R 1-25 )-, wherein R c and R d are each independently hydrogen, C 1-12 alkyl group, C 1-12Naphthenyl, C 7-12 Arylalkyl, C 1-12 Heteroalkyl or cyclic C 7-12 Heteroarylalkyl; or a group having the formula -C(=R e )-, where R e is a divalent C 1-12 hydrocarbon group.

[0123] Preferably, the aromatic carbonate units present in the poly(carbonate-siloxane-arylated ester) copolymer may comprise aromatic carbonate repeating units having the following formula:

[0124]

[0125] where R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 naphthenyl or C 1-12 alkoxy, p and q are each independently from 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c )(R d )-subalkyl having the formula -C(R 1-11 ), or a group having the formula -C(=R e )-, where R c and R d are each independently hydrogen or C 1-10 alkyl, where R e is a divalent C 1-10 hydrocarbon group, preferably X a is a C c )(R d )-subalkyl having the formula -C(R 1-11 ), where R c and R d are each independently C 1-6 alkyl.

[0126] Preferably, the aromatic carbonate units are selected from bisphenol A carbonate units, resorcinol carbonate units, and combinations thereof. Preferably, the aromatic carbonate units are derived from bisphenol A carbonate units and resorcinol carbonate units.

[0127] Arylate ester unit

[0128] The poly(carbonate-siloxane-arylated ester) copolymer further comprises arylated ester units, i.e., ester units based on aromatic dicarboxylic acid repeating ester units of formula (4):

[0129]

[0130] wherein D is a divalent group derived from a dihydroxy compound and may be a C 6-20 alicyclic group or a C 6-20 aromatic group; and T is a divalent C 6-20 arylene group. In one embodiment, D is derived from a dihydroxy aromatic compound of formula (2) or a bisphenol of formula (3), or a combination comprising at least one of the foregoing aromatic compounds.

[0131] The D and T groups are desirably substituted with hydrocarbon substituents such as alkyl, alkoxy or alkylene substituents to a minimal extent. In one embodiment, less than 5.0 mole %, preferably less than or equal to 2.0 mole %, and more preferably less than or equal to 1.0 mole % of the total moles of the D and T groups are substituted with hydrocarbon substituents such as alkyl, alkoxy or alkylene substituents.

[0132] Examples of the aromatic dicarboxylic acid from which the T group in the ester unit of formula (4) is derived include isophthalic acid or terephthalic acid, 1,2-bis(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bibenzoic acid, and combinations comprising at least one of the foregoing acids. Acids containing condensed rings such as 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid or 2,6-naphthalenedicarboxylic acid may also be present. Specific dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, cyclohexanedicarboxylic acid, or combinations thereof. Specific dicarboxylic acids comprise a combination of isophthalic acid and terephthalic acid, wherein the weight ratio of isophthalic acid to terephthalic acid is from 99:1 to 1:99.

[0133] Preferably, the arylate unit is derived from the reaction product of one equivalent of an isophthalic acid derivative and / or a terephthalic acid derivative. Accordingly, the arylate unit has the formula (5):

[0134]

[0135] wherein each R f is independently a halogen atom, such as bromine, a C 1-10 hydrocarbon group, such as a C 1-10 alkyl group, a halogen-substituted C 1-10 alkyl group, a C 6-10 aryl group or a halogen-substituted C 6-10 aryl group, and u is from 0 to 4, and'm' is greater than or equal to 4.0.

[0136] Preferably, 'm' is from 4.0 to 150.0, preferably from 4.0 to 100.0, preferably from 5.0 to 30.0, preferably from 5.0 to 25, preferably from 10.0 to 20.0. In another embodiment, 'm' is from 4.0 to 150.0, preferably from 10.0 to 100.0, preferably from 30.0 to 100.0, preferably from 50.0 to 100.0, preferably from 60.0 to 90.0.

[0137] Preferably, the molar ratio of isophthalate to terephthalate is from 0.25:1 to 9.0:1. Preferred arylated ester units are isophthalate-terephthalate-resorcinol ester units, isophthalate-terephthalate-bisphenol ester units or combinations comprising each of these, which may be referred to as poly(isophthalate-terephthalate-resorcinol) ester units, poly(isophthalate-terephthalate-bisphenol A) ester units and poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol A)] ester units, respectively.

[0138] Preferably, the aromatic carbonate units and the arylated ester units are present as a block of formula (6):

[0139]

[0140] wherein R f , u and m are as defined in formula (5), each R 1 is independently an arylene C 6-30 , and n is greater than or equal to one, for example from 1 to 50, especially from 3 to 25, and more especially from 5 to 20. Preferably, m is from 5 to 100 and n is from 3 to 50, or m is from 50 to 90 and n is from 5 to 20, and the molar ratio of isophthalate units to terephthalate units is from 80:20 to 20:80.

[0141] Preferred carbonate units are bisphenol A carbonate units, optionally together with resorcinol carbonate units, and the arylated units are poly(isophthalate-terephthalate-resorcinol) ester units, poly(isophthalate-terephthalate-bisphenol A) ester units and poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol A)] ester units.

[0142] Preferably, the aromatic carbonate and the arylated units are present as poly(isophthalate-terephthalate-resorcinol ester)-co-(resorcinol carbonate)-co-(bisphenol A carbonate) segments.

[0143] Preferred arylate units are isophthalate-terephthalate-resorcinol units, isophthalate-terephthalate-bisphenol units or combinations containing each of these. Alternatively, such arylate units may be referred to as poly(isophthalate-terephthalate-resorcinol) ester units, poly(isophthalate-terephthalate-bisphenol A) ester units and poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol A)] ester units, respectively.

[0144] Siloxane unit

[0145] The siloxane units of the poly(carbonate-siloxane-arylate) copolymer are present as polydiorganosiloxane (also referred to herein as "polysiloxane") blocks, containing repeating diorganosiloxane ("siloxane") units as in formula (7):

[0146]

[0147] where each 'R' is independently a C 1-13 monovalent organic group. For example, 'R' may independently be selected from C1-C 13 alkyl, C1-C 13 alkoxy, C2-C 13 alkenyl, C2-C 13 alkenyloxy, C3-C6 cycloalkyl, C3-C6 cycloalkoxy, C6-C 14 aryl, C6-C 10 aryloxy, C7-C 13 aralkyl, C7-C 13 aralkoxy, C7-C 13 alkaryl or C7-C 13 alkaryloxy. The foregoing groups may be fully or partially halogenated with fluorine, chlorine, bromine or iodine or combinations thereof. Preferably, in the case of a polysiloxane-polycarbonate where transparency is desired, 'R' is not substituted with halogen. Combinations of the foregoing 'R' groups may be used in the same copolymer.

[0148] The value of 'E' in formula (7) can vary widely, depending on the type and relative amount of each component in the copolymer and the composition containing the copolymer, the desired properties of the composition, and similar considerations. Generally speaking, E can have an average value of 2.0 to 1,000, preferably 2.0 to 500.0, preferably 2.0 to 200.0, preferably 2.0 to 100.0, preferably 5.0 to 60.0, preferably 5.0 to 50.0, preferably 5.0 to 20.0. Preferably, 'E' has an average value of 2.0 to 200.0, preferably 2.0 to 125.0, preferably 5.0 to 125.0, preferably 5.0 to 100.0, preferably 5.0 to 50.0, preferably 20.0 to 80.0, preferably 5.0 to 20.0.

[0149] Preferably, 'E' is from 5.0 to 25.0, preferably from 5.0 to 15.0, preferably from 30.0 to 80.0, preferably from 30.0 to 70.0.

[0150] Preferably, the siloxane block has formula (8):

[0151]

[0152] wherein 'E' is as defined in formula (7); each 'R' may be the same or different and is as defined above; and 'Ar' may be the same or different and is a substituted or unsubstituted C6-C 30 Arylene groups wherein the bond is directly to the aromatic moiety.

[0153] The 'Ar' group in formula (8) may be derived from a C6-C 30 Dihydroxyarylene compound. The dihydroxyarylene compound can be selected from: 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxyphenyl)cyclohexane, bis(4-hydroxyphenyl sulfide), and 1,1-bis(4-hydroxy-tert-butylphenyl)propane. Combinations comprising at least one of the foregoing dihydroxy compounds can also be used.

[0154] Preferably, the 'Ar' group is derived from resorcinol. Preferably, the Ar group is derived from bisphenol A.

[0155] Preferably, the polydiorganosiloxane block has formula (9):

[0156]

[0157] wherein 'R' and 'E' are as described in formula (7), and each R 5 is independently a divalent C1-C 30 organic group, and wherein the polymerized polysiloxane unit is the reaction residue of its corresponding dihydroxy compound.

[0158] Preferably, the polydiorganosiloxane block has the formula (10):

[0159]

[0160] wherein 'R' and 'E' are as defined above. The R in formula (10) 6 is a divalent C2-C8 aliphatic. Each M in formula (10) can be the same or different and can be halogen, cyano, nitro, C1-C8 alkylthio, C1-C8 alkyl, C1-C8 alkoxy, C2-C8 alkenyl, C2-C8 alkenoxy, C3-C8 cycloalkyl, C3-C5 cycloalkoxy, C6-C 10 aryl, C6-C 10 aryloxy, C7-C 12 aralkyl, C7-C 12 aralkoxy, C7-C 12 alkaryl or C7-C 12 alkaryloxy, wherein each n is independently 0, 1, 2, 3 or 4.

[0161] Preferably, the siloxane unit has the following formula:

[0162]

[0163] or a combination comprising at least one of the foregoing, wherein 'E' has an average value of from 2.0 to 200.0, preferably from 2.0 to 125.0, preferably from 5.0 to 125.0, preferably from 5.0 to 100.0, preferably from 5.0 to 50.0, preferably from 20.0 to 80.0, preferably from 5.0 to 20.0.

[0164] Preferably, the poly(carbonate-siloxane-arylated ester) copolymer comprises or consists of repeating units derived from the following: (i) an arylated ester unit, preferably wherein the arylated ester unit is an isophthalate-terephthalate-resorcinol (ITR) ester unit; (ii) an aromatic carbonate unit, preferably wherein the aromatic carbonate unit is selected from bisphenol A carbonate units, resorcinol carbonate units and combinations thereof; and (iii) a siloxane unit selected from the following formulae:

[0165]

[0166] and any combinations thereof, where 'E' has an average value of from 2.0 to 200.0, preferably from 2.0 to 125.0, preferably from 5.0 to 125.0, preferably from 5.0 to 100.0, preferably from 5.0 to 50.0, preferably from 20.0 to 80.0, preferably from 5.0 to 20.0.

[0167] Preferably, the poly(carbonate-siloxane-arylated ester) copolymer is represented by the following formula:

[0168]

[0169] where 'Ar' represents an aromatic structural moiety, preferably 'Ar' represents an aromatic structural moiety derived from bisphenol A, and 'R' represents a C 1-10 alkyl group, preferably 'R' is a methyl group. The poly(carbonate-siloxane) copolymer can be terminated with p-cumylphenol.

[0170] Preferably, the poly(carbonate-siloxane-arylated ester) copolymer is poly(bisphenol A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester)-co-polysiloxane.

[0171] Preferably, the poly(carbonate-siloxane-arylated ester) copolymer is poly(bisphenol A / resorcinol carbonate-isophthalate-resorcinol phthalate-dimethylsiloxane).

[0172] The poly(bisphenol A / resorcinol carbonate-isophthalate-resorcinol phthalate-dimethylsiloxane) copolymer can contain 5.0 to 20.0 mole percent (mol%) of bisphenol A carbonate repeat units, 5.0 to 20.0 mol% of resorcinol carbonate units, 75.0 to 90.0 mol% of resorcinol phthalate units, where the isophthalate:terephthalate ratio is from 1:0.5 to 0.5:1, and the balance of siloxane units, based on the total molar amount of repeat units in the poly(carbonate-siloxane-arylated ester) copolymer.

[0173] Polycarbonate polymer (PC1) - Poly(carbonate-siloxane) copolymer

[0174] The composition can contain a poly(carbonate-siloxane) copolymer, also known in the art as polyorganosiloxane-polycarbonate or poly(diorganosiloxane)-carbonate. The poly(carbonate-siloxane) copolymer does not contain arylated ester units, thereby differentiating the poly(carbonate-siloxane) copolymer from the poly(carbonate-siloxane-arylated ester) copolymer.

[0175] In one aspect of the invention, the polycarbonate polymer (PC1) is a poly(carbonate-siloxane) copolymer. Thus, when the polycarbonate polymer (PC1) is a poly(carbonate-siloxane) copolymer, the polycarbonate polymer (PC1) does not contain a polycarbonate homopolymer.

[0176] If present in the composition, the poly(carbonate-siloxane) copolymer may be present in an amount of 10.0 wt% to 50.0 wt%, preferably 12.0 wt% to 50.0 wt%, preferably 12.0 wt% to 48.0 wt%, preferably 12.0 wt% to 45.0 wt%, preferably 15.0 wt% to 45.0 wt%, preferably 15.0 wt% to 40.0 wt%, preferably 12.0 wt% to 25.0 wt%, preferably 12.0 wt% to 20.0 wt% based on the total weight of the composition. In one aspect of the invention, the composition comprises 0.0 wt% of the poly(carbonate-siloxane) copolymer.

[0177] More preferably, the amount of the poly(carbonate-siloxane) copolymer is 12.0 wt% to 48.0 wt%, preferably 12.0 wt% to 40.0 wt% based on the total weight of the composition.

[0178] The poly(carbonate-siloxane) copolymer comprises or consists of repeating units of aromatic carbonate units and siloxane units. The poly(carbonate-siloxane) copolymer may comprise 70.0 to 98.0 wt%, preferably 75.0 to 97.0 wt% of aromatic carbonate units based on the total weight of the poly(carbonate-siloxane) copolymer. The poly(carbonate-siloxane) copolymer may comprise 2.0 to 30.0 wt%, preferably 3.0 to 25.0 wt% of siloxane units based on the total weight of the poly(carbonate-siloxane) copolymer.

[0179] Preferably, the poly(carbonate-siloxane) copolymer has a silicon content of less than 3.0 wt%, preferably less than 1.5 wt%, preferably 1.0 wt% based on the total weight of the poly(carbonate-siloxane) copolymer.

[0180] Preferably, the poly(carbonate-siloxane) copolymer has a silicon content of more than 0.0 wt% and less than 3.0 wt%, preferably more than 0.0 and less than 1.5 wt%, preferably 1.0 wt% based on the total weight of the poly(carbonate-siloxane) copolymer.

[0181] The poly(carbonate-siloxane) copolymer may have an Mw of 2,000 to 100,000 g / mol, preferably 5,000 to 50,000 g / mol, preferably 25,000 to 40,000 g / mol. The molecular weight used herein is measured by gel permeation chromatography, using a cross-linked styrene-divinylbenzene column, at a sample concentration of 1 mg / mL and calibrated with polycarbonate standards. The poly(carbonate-siloxane) copolymer may have a polydispersity index of 2.0 to 3.0.

[0182] The repeating units derived from aromatic carbonate units and siloxane units can have the same chemical composition and formula as those constituting the poly(carbonate-siloxane-arylate) copolymer as described in the present invention.

[0183] Preferably, the poly(carbonate-siloxane) copolymer comprises or consists of repeating units derived from:

[0184] (i) aromatic carbonate units having the formula:

[0185]

[0186] wherein R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl or C 1-12 alkoxy, p and q are each independently 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c alkylene having the formula -C(R d )(R 1-11 ), or a group having the formula -C(=R e ), wherein R c and R d are each independently hydrogen or C 1-10 alkyl, wherein R e is a divalent C 1-10 hydrocarbyl, preferably wherein X a is a C c alkylene having the formula -C(R d )(R 1-11 ), wherein R c and R d are each independently C 1-6 alkyl, preferably wherein the aromatic carbonate unit is derived from bisphenol A carbonate; and

[0187] (ii) siloxane units selected from the formula:

[0188]

[0189] and any combination thereof, wherein 'E' has an average value of 2.0 to 200.0.

[0190] Preferably, the poly(carbonate-siloxane) copolymer comprises or consists of repeating units derived from bisphenol A (BPA) carbonate repeating units and dimethylsiloxane units.

[0191] For example, the poly(carbonate-siloxane) copolymer can be represented by formula (25), where 'x' is an integer from 1 to 100, or 5 to 85, or 10 to 70, or 15 to 65, or 40 to 60; 'y' is an integer from 10 to 30, and 'z' is an integer from 450 to 600.

[0192]

[0193] Polycarbonate polymer (PC1) - Polycarbonate homopolymer

[0194] In one aspect of the present invention, the polycarbonate polymer (PC1) is a polycarbonate homopolymer. Thus, when the polycarbonate polymer (PC1) is a polycarbonate homopolymer, the polycarbonate polymer (PC1) does not contain a poly(carbonate-siloxane) copolymer.

[0195] If present in the composition, the polycarbonate homopolymer can be present in an amount of 5.0 wt% to 20.0 wt%, preferably 5.0 wt% to 18.0 wt%, preferably 5.0 wt% to 15.0 wt%, preferably 10.0 wt% to 15.0 wt%, preferably 12.0 wt% to 18.0 wt%, preferably 12.0 wt% to 15.0 wt% based on the total weight of the composition.

[0196] Preferably, the amount of the polycarbonate homopolymer present is 10.0 wt% to 18.0 wt%, preferably 10.0 wt% to 15.0 wt% based on the total weight of the composition.

[0197] The polycarbonate homopolymer can be selected from a linear polycarbonate homopolymer or a branched polycarbonate homopolymer.

[0198] Preferably, the polycarbonate homopolymer is a linear polycarbonate homopolymer comprising or consisting of aromatic carbonate repeating units having the following formula:

[0199]

[0200] where R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl or C 1-12 alkoxy, 'p' and 'q' are each independently integers from 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c subalkyl having the formula -C(R d )(R 1-11 ), or a group having the formula -C(=R e )-, where Rc and R d each independently is hydrogen or a C 1-10 alkyl group, where R e is a divalent C 1-10 hydrocarbon group.

[0201] Preferably, X a is a C c subalkyl group having the formula -C(R d )(R 1-11 ), where R c and R d each independently is a C 1-6 alkyl group. Preferably, the linear polycarbonate homopolymer consists of repeating units derived from bisphenol A carbonate.

[0202] The polycarbonate homopolymer may have a weight average molecular weight (Mw) of 10,000 to 50,000 g / mol. The molecular weight used herein is measured by gel permeation chromatography, using a crosslinked styrene - divinylbenzene column, at a sample concentration of 1 mg / mL and calibrated with polycarbonate standards.

[0203] The branched polycarbonate homopolymer may comprise or consist of repeating units derived from aromatic carbonate units and units derived from a branching agent. The repeating aromatic carbonate units may have the following formula:

[0204]

[0205] where R a and R b each independently is a C 1-12 alkyl group, a C 1-12 alkenyl group, a C 3-8 cycloalkyl group or a C 1-12 alkoxy group, p and q each independently are 0 to 4, and X a is a bridging group between two arylene groups and is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c subalkyl group having the formula -C(R d )(R 1-11 ), or a group having the formula -C(=R e ), where R c and R d each independently is hydrogen or a C 1-10 alkyl group, where R e is a divalent C 1-10 hydrocarbon group.

[0206] The branching agent may include trimesoyl chloride, 1,1,1-tris(4-hydroxyphenyl)ethane, or a combination of trimesoyl chloride and 1,1,1-tris(4-hydroxyphenyl)ethane. The branching agent may be present in an amount greater than or equal to 0.2 mol% based on the total molar amount of the branched polycarbonate.

[0207] Brominated polycarbonate

[0208] The composition comprises a brominated polycarbonate. For example, the brominated polycarbonate may have the formula (2) and includes at least one R h being bromine, bromo-substituted C 1-10 alkyl or bromo-substituted C 6-10 aryl. Alternatively, the brominated polycarbonate having the formula (3) may include at least one R being bromine a or R b .

[0209] Preferably, the brominated polycarbonate comprises or consists of repeating units derived from (i) brominated aromatic carbonate repeating units derived from 2,2',6,6'-tetrabromo-4,4'-isopropylidenediphenol and (ii) aromatic carbonate repeating units derived from bisphenol A.

[0210] The bromine repeating units of the brominated polycarbonate may be present in an amount of at least 5.0% by weight, preferably 5.0 to 45.0% by weight, preferably 10.0 to 35.0% by weight, based on the total weight of the brominated polycarbonate.

[0211] The brominated polycarbonate may be present in an amount of 10.0% to 45.0% by weight, preferably 15.0% to 40.0% by weight, preferably 25.0% to 40.0% by weight, preferably 20.0% to 40.0% by weight, preferably 25.0% to 40.0% by weight, preferably 25.0% to 35.0% by weight, based on the total weight of the composition.

[0212] Glass fiber

[0213] The composition may comprise a variety of glass fibers. The glass fibers may be flat or round fibers. The flat glass fibers may have an elliptical cross-sectional area, while the round fibers have a circular cross-sectional area, where the cross-sectional area is measured perpendicular to the longitudinal axis of the fiber. The glass fibers may be made of "E glass", "A glass", "C glass", "D glass", "R glass", "S glass", and E glass derivatives without fluorine and / or boron. The glass fibers may have a diameter of 3 to 35 microns. The glass fibers may have a diameter of 3 to 25 microns, or 4 to 20 microns, or 8 to 15 microns. The glass fibers may comprise, for example, woven or non-woven fibers forming a reinforcing layer. The glass fibers may comprise chopped fibers. The chopped fibers may have a length of 0.5 millimeters (mm) to 2 centimeters (cm), or 1 mm to 1 cm. The glass fibers may be unbonded or bonded. An example of bonded glass fibers is T-120, which is commercially available from Nippon Electric Glass Co., Ltd.

[0214] The glass fibers may be present in an amount of 12.0 wt% to 20.0 wt%, preferably 12.0 wt% to 18.0 wt%, based on the total weight of the composition.

[0215] Additive

[0216] An additive component comprising one or more additives selected to impart desired properties may be used. The additive composition or individual additives may be mixed at a suitable time during mixing of the components to form the composition.

[0217] The additive component may include: antioxidants, impact modifiers, flow modifiers, fillers (such as granular polytetrafluoroethylene (PTFE), glass particles (such as different from fibers, such as spheres), carbon, minerals or metals), reinforcing agents (such as different from glass fibers), antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV) light stabilizers, UV absorption additives, plasticizers, lubricants, release agents (such as mold release agents), antistatic agents, antifogging agents, antimicrobial agents, colorants (such as dyes or pigments), surface effect additives, radiation stabilizers, additional flame retardants, anti-dripping agents (such as PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or combinations thereof.

[0218] The composition may include pigments, such as a combination of titanium dioxide, carbon black, and chromium titanate. Generally, the additives are used in well-known effective amounts.

[0219] For example, the total amount of the additive component (different from any impact modifier or filler) may be 0.0 to 5.0 wt%, preferably 0.001 to 2.0 wt%, preferably 0.01 to 1.0 wt%, based on the total weight of the composition.

[0220] Preparation method

[0221] The composition can be prepared by melt - mixing, for example, a poly(carbonate - siloxane - aromatic ester) copolymer, a brominated polycarbonate, glass fiber, and a polycarbonate polymer (PC1) in a batch mixer. The composition can also be prepared by extruding the components in a twin - screw extruder to form an extruded composition. The mixed or extruded composition is formed into a desired shape. The forming method is not limited and can include methods such as extrusion, molding, coating, lamination, and the like.

[0222] The present invention will now be further illustrated based on the following non - limiting examples. Examples

[0223] Purpose: Demonstrate the flame - retardant effect of the composition having a formulation prepared according to the present invention and compare such properties with a control formulation.

[0224] Materials: For the purposes of this example, the following materials were used:

[0225] Table 1

[0226]

[0227] Method for preparing samples: The composition used in the example was prepared by first extruding the components in a twin - screw extruder under the processing conditions described in Table 2A to form an extruded composition. Then, the extruded composition was dried and extruded into 400 - mm - wide sheets of different thicknesses using a Cincinnati extruder under the processing parameters described in Table 2B.

[0228] In this article, ℃ represents degrees Celsius, rpm represents revolutions per minute, kg / hr represents kilograms per hour, and m / min represents meters per minute.

[0229] Table 2A

[0230] Parameter Unit Value Unit Value Feed (zone 0) temperature ℃ 50 Zone 1 temperature ℃ - Zone 10 temperature ℃ - Zone 2 temperature ℃ 200 Zone 11 temperature ℃ - Zone 3 temperature ℃ 220 Zone 12 temperature ℃ - Zone 4 temperature ℃ 250 Die temperature ℃ 250 Zone 5 temperature ℃ 250 Screw speed rpm 450 Zone 6 temperature ℃ 250 Production rate kg / hr Maximum 35 Zone 7 temperature ℃ 250 Torque ％ - Zone 8 temperature ℃ 250 Vacuum 1 bar 0.7 Zone 9 temperature ℃ 250 Vacuum 2 bar

[0231] Table 2B

[0232]

[0233] Test standard:The flammability characterization of Examples 1 to 6 was carried out in accordance with EN45545-2 and included measurements of heat release (ISO 5660-1), smoke density (ISO 5659-2), and flame spread (ISO 5658-2). The requirements for passing the rating according to R1-HL2 and R1-HL3 are listed in Table 3. The R1-HL2 and R1-HL3 requirements were measured using samples with a thickness of 3.0 mm.

[0234] Table 3

[0235]

[0236] Various compositions were prepared by using a mixture design space via the design of experiments (DoE) method, and the combustion rating of the compositions was analyzed according to the EN45545-2 specification.

[0237] Results and conclusions: Table 4 provides the relative amounts of the components of the samples.

[0238] Table 4

[0239]

[0240] Table 5 provides the relative amounts of the components of the samples.

[0241] Table 5

[0242] <![CDATA[Heat release rate / kW / m 2 > Ds4 VOF4 CE4 The test complies with IE1 59.4 250 448 23.1 HL2 IE2 53.3 197 388 22.7 HL2 IE3 68.8 272 544 20.5 HL2 IE4 41.9 88 139 27.7 HL3 CE1 72.3 176 416 19.8 Failed CE2 100.5 359 794 18 Failed

[0243] As is clearly visible from the data provided in Table 5, the samples prepared according to the present invention passed the HL2 or HL3 flame retardancy test. Therefore, the articles prepared from these formulations can be used in mass transportation systems that require strict compliance with these test standards.

[0244] Furthermore, the present inventors found that even when the formulations used the same components but were blended in different proportions, the desired flame retardant properties could not be obtained. For example, the inventive sample IE3 and the comparative sample CE1 had the same components but different proportions. However, the IE3 sample passed the HL2 flame retardancy test, while the sample CE1 did not. This is unexpected because although the poly(carbonate-siloxane-arylate) copolymer used in the examples has a certain degree of flame retardant properties, it is clear that the desired flame retardant effect of the HL2 or HL3 criteria is achieved only when the ingredients are formulated in the proportions specified in the present invention, even without the addition of additional flame retardant additives.

Claims

1. A composition comprising, based on the total weight of the composition: (a) 5.0% to 55.0% by weight of at least one poly(carbonate-siloxane-arylated ester) copolymer; (b) 10.0% to 45.0% by weight of at least one brominated polycarbonate; (c) 12.0% to 20.0% by weight of glass fiber; and (d) at least one polycarbonate polymer (PC1) selected from the following: i. A poly(carbonate-siloxane) copolymer, which, if selected, is present in an amount of 10.0% to 50.0% by weight; ii. A polycarbonate homopolymer, which, if selected, is present in an amount of 5.0% to 20.0% by weight; and iii. A combination of i) and ii); wherein the at least one poly(carbonate-siloxane) copolymer does not contain repeating units derived from arylated esters; and wherein the polycarbonate homopolymer does not contain bromine.

2. The composition according to claim 1, wherein, based on the total weight of the composition: (a) The amount of poly(carbonate-siloxane-arylated ester) copolymer present is 10.0% to 45.0% by weight, preferably 20.0% to 45.0% by weight, preferably 25.0% to 40.0% by weight, preferably 30.0% to 40.0% by weight; (b) The amount of brominated polycarbonate present is 20.0% to 40.0% by weight, preferably 25.0% to 40.0% by weight, preferably 25.0% to 35.0% by weight; and (c) The amount of glass fiber present is 12.0% to 18.0% by weight of the glass fiber.

3. The composition according to any one of claims 1-2, wherein, based on the total weight of the composition: ● The amount of poly(carbonate-siloxane) copolymer present is 12.0% to 45.0% by weight, preferably 12.0% to 25.0% by weight, preferably 12.0% to 20.0% by weight; and / or ● The amount of polycarbonate homopolymer present is 5.0% to 18.0% by weight, preferably 12.0% to 18.0% by weight.

4. The composition according to any one of claims 1-3, wherein the poly(carbonate-siloxane-arylated ester) copolymer has a silicon content of less than 3.0% by weight, preferably less than 1.5% by weight, based on the total weight of the poly(carbonate-siloxane-arylated ester) copolymer, and preferably the silicon content is 1.0% by weight.

5. The composition according to any one of claims 1-4, wherein the polycarbonate polymer (PC1) is the polycarbonate homopolymer, and preferably the amount of polycarbonate homopolymer present is 10.0% to 18.0% by weight based on the total weight of the composition.

6. The composition according to claim 5, wherein the polycarbonate homopolymer is selected from linear polycarbonate homopolymers or branched polycarbonate homopolymers, and preferably the polycarbonate homopolymer is a linear polycarbonate homopolymer comprising or consisting of aromatic carbonate repeating units having the following formula: wherein R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl or C 1-12 alkoxy, p and q are each independently integers from 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c subalkyl having the formula -C(R d )(R 1-11 )-, or a group having the formula -C(=R e )-, wherein R c and R d are each independently hydrogen or C 1-10 alkyl, wherein R e is a divalent C 1-10 hydrocarbyl; preferably wherein X a is a C c subalkyl having the formula -C(R d )(R 1-11 ), wherein R c and R d are each independently C 1-6 alkyl; preferably wherein the linear polycarbonate homopolymer is composed of repeating units derived from bisphenol A carbonate.

7. The composition according to any one of claims 1 - 4, wherein the polycarbonate polymer (PC1) is the poly(carbonate - siloxane) copolymer, preferably the amount of the poly(carbonate - siloxane) copolymer present is 12.0 wt% to 48.0 wt%, preferably 12.0 wt% to 45.0 wt%, preferably 12.0 wt% to 40.0 wt% based on the total weight of the composition.

8. The composition according to claim 7, wherein the poly(carbonate - siloxane) copolymer comprises or consists of repeating units derived from the following: (i) an aromatic carbonate unit having the following formula: where R a and R b each independently is C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl or C 1-12 alkoxy, p and q each independently are integers from 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, a C c subalkyl having the formula -C(R d )(R 1-11 )-, or a group having the formula -C(=R e )-, wherein R c and R d each independently are hydrogen or C 1-10 alkyl, wherein R e is a divalent C 1-10 hydrocarbyl; preferably wherein X a is a C c subalkyl having the formula -C(R d )(R 1-11 )-, wherein R c and R d each independently are C 1-6 alkyl; preferably wherein the aromatic carbonate unit is derived from bisphenol A carbonate; and (ii) a siloxane unit selected from the following formula: and any combination thereof, wherein 'E' has an average value of 2.0 to 200.

0.

9. The composition according to any one of claims 1-8, wherein the poly(carbonate-siloxane-arylate) copolymer comprises or consists of repeating units derived from the following: (i) an aromatic ester unit, preferably wherein the aromatic ester unit is an isophthalate - terephthalate - resorcinol (ITR) ester unit; (ii) an aromatic carbonate unit, preferably wherein the aromatic carbonate unit is selected from bisphenol A carbonate units, resorcinol carbonate units, and combinations thereof; and (iii) a siloxane unit selected from the following formula: and any combination thereof, wherein 'E' has an average value of 2.0 to 200.

0.

10. The composition according to any one of claims 1 - 9, wherein the brominated polycarbonate comprises or consists of repeating units derived from (i) brominated aromatic carbonate repeating units derived from 2,2',6,6'-tetrabromo - 4,4'-isopropylidenediphenol and (ii) aromatic carbonate repeating units derived from bisphenol A.

11. The composition according to any one of claims 1 - 10, wherein the composition comprises less than 0.5 wt% of additional flame - retardant compounds based on the total weight of the composition, preferably wherein the additional flame - retardant compounds are selected from organic phosphates / esters, polyetherimide (PEI), polyphenylene ether (PPE), aromatic organophosphorus compounds having two or more phosphorus - containing groups, organic compounds containing phosphorus - nitrogen bonds, halogenated flame - retardants, inorganic flame - retardants, and combinations thereof.

12. The composition according to any one of claims 1 - 11, wherein the composition has or is selected to have: ● Smoke density (Ds4) after 4 minutes less than or equal to 300.0 measured according to ISO 5659-2 for 3.0 mm thick plates at 50.0 kW / m 2 ; ● Smoke density (VOF4) less than or equal to 600.0 measured on 3.0 mm thick plates according to ISO 5659-2 at 50.0 kW / m 2 ; ● The maximum average heat release rate (MAHRE) measured on 3.0 mm thick boards according to ISO 5660-1 is less than or equal to 90.0 kW / m 2 ; and 2 the maximum average heat release rate (MAHRE) of less than or equal to 90.0 kW / m ● Critical Heat Flux at Extinction (CFE) greater than or equal to 20.0 kW / m as determined in accordance with ISO 5658-2 2 ​ 13. The composition according to claim 1, wherein based on the total weight of the composition: ● the poly(carbonate - siloxane - aromatic ester) copolymer is present in an amount of 20.0 wt% to 40.0 wt%; ● the brominated polycarbonate is present in an amount of 20.0 wt% to 40.0 wt%; ● the glass fiber is present in an amount of 12.0 wt% to 18.0 wt%; and ● the polycarbonate homopolymer is a linear polycarbonate homopolymer and is present in an amount of 12.0 wt% to 18.0 wt%; preferably wherein the composition has or is selected to have: (i) The smoke density (Ds4) after 4 minutes less than or equal to 150.0 measured on a 3 mm thick plate according to ISO 5659-2 at 50.0 kW / m 2 ; (ii) Smoke density (VOF4) less than or equal to 300.0 measured on 3.0 mm thick plates at 50.0 kW / m according to ISO 5659-2 2 ; (iii) The maximum average heat release rate (MAHRE) measured on 3 mm thick boards according to ISO 5660-1 and less than or equal to 60.0 kW / m 2 ; and 2 of 50.0 kW / m (iv) Critical heat flux at extinction (CFE) greater than or equal to 20.0 kW / m as determined in accordance with ISO 5658-2 2 ​ 14. An article comprising the composition according to any one of claims 1 - 13, preferably wherein the article is suitable for use in a mass transportation system, preferably wherein the article is at least any one of a railway component, an aerospace component, or an automotive component.

15. Use of the composition according to any one of claims 1 - 13 for improving the flame retardant properties of articles used in bulk transportation systems.

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