Thermoplastic compositions and articles with metallic visual effects

Abstract

A composition includes specific amounts of a polycarbonate copolymer, a metal effect additive, and optionally a bisphenol A homopolycarbonate. The polycarbonate copolymer may be a copolycarbonate comprising a bisphenol A carbonate unit and a 2-phenyl-3, 3-bis (4-hydroxyphenyl) benzopyrrolone carbonate unit, a copolycarbonate comprising a bisphenol A carbonate unit and a bisphenol isophorone carbonate unit, or a copolycarbonate comprising a bisphenol A carbonate unit and a bisphenol isophorone carbonate unit, a polyester carbonate comprising resorcinol meta / terephthalate units and resorcinol carbonate units and bisphenol A carbonate units, a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units, a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units, and a polyester carbonate comprising bisphenol A carbonate units and bisphenol A carbonate units, a branched bisphenol A polycarbonate terminated with cyanophenol, or a combination thereof. The compositions exhibit a desired balance of metallic visual effects, chemical resistance, and mechanical properties.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 436,165, filed on December 30, 2022, the content of which is incorporated herein by reference in its entirety. Background of the Invention

[0003] For some automotive applications, such as hybrid / electric headlamp housings, door trim panels, and charging gun housings, painted metal components are increasingly being replaced by unpainted thermoplastic components with a metallic visual effect. Thermoplastic components exhibiting a metallic effect also need to provide a balance of mechanical properties, chemical resistance, and flame retardancy.

[0004] Accordingly, there is a need for thermoplastic compositions and articles that exhibit an improved balance of mechanical properties, chemical resistance, flame retardancy, and metallic visual effect. Summary of the Invention

[0005] One embodiment is a composition comprising, based on the total weight of the composition: 5 to 99.95 wt% of a polycarbonate copolymer selected from the group consisting of: a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units; a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units; a polyester carbonate comprising resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units; a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units; a cyanophenol-terminated branched bisphenol A polycarbonate; and combinations thereof; 0 to 90 wt% of bisphenol A homopolycarbonate; and 0.05 to 4 wt% of a metallic effect additive; wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 85 to 99.95 wt%.

[0006] Another embodiment is an article comprising the above composition.

[0007] These and other embodiments are described in detail below. Detailed Description

[0008] The inventors have determined that a performance balance of mechanical properties, chemical resistance, flame retardancy, and metallic visual effect is provided by a composition comprising a specific amount of a polycarbonate copolymer, a metallic effect additive, and optionally bisphenol A homopolycarbonate.

[0009] Thus, one embodiment is a composition comprising, based on the total weight of the composition: 5 to 99.95 wt% of a polycarbonate copolymer selected from the group consisting of: a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units; a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units; a polyester carbonate comprising resorcinol m / p-phthalate units, resorcinol carbonate units and bisphenol A carbonate units; a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units; a cyanophenol-terminated branched bisphenol A polycarbonate; and combinations thereof; 0 to 90 wt% of bisphenol A homopolycarbonate; and 0.05 to 4 wt% of a metallic effect additive; wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 85 to 99.95 wt%.

[0010] The composition comprises a polycarbonate copolymer selected from the group consisting of: a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units; a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units; a polyester carbonate comprising resorcinol m / p-phthalate units, resorcinol carbonate units and bisphenol A carbonate units; a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units; a cyanophenol-terminated branched bisphenol A polycarbonate; and combinations thereof.

[0011] In some embodiments, the polycarbonate copolymer comprises a copolycarbonate containing bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units. For brevity, this polycarbonate copolymer is referred to as BPA / PPPBP copolycarbonate. The bisphenol A carbonate unit has the following chemical structure:

[0012]

[0013] The 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate unit has the following chemical structure:

[0014]

[0015] Based on the total carbonate units in the BPA / PPPBP copolycarbonate, the BPA / PPPBP copolycarbonate comprises 10 to 90 mol% of bisphenol A carbonate units and 10 to 90 mol% of 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units. Within these ranges, the mole percentage of bisphenol A carbonate units can be 20 to 80 mol%, or 30 to 70 mol%, or 40 to 60 mol%. Also within these ranges, the mole percentage of 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units can be 20 to 80 mol%, or 30 to 70 mol%, or 40 to 60 mol%. In some embodiments, the sum of the mole percentage of bisphenol A carbonate units and the mole percentage of 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units is 95 to 100 mol%, or 97 to 100 mol%, or 99 to 100 mol%, or 100 mol%, all based on the total carbonate units in the BPA / PPPBP copolycarbonate.

[0016] The BPA / PPPBP copolycarbonate can be synthesized using a capping agent (also known as a chain terminator or chain stopper). A capping agent can be included during the polymerization of the BPA / PPPBP copolycarbonate to provide end groups, such as monocyclic phenols like phenol, 4-cyanophenol, and C 1-22 alkyl-substituted phenols such as 4-cumylphenol and 4-tert-butylphenol; monoethers of diols, such as 4-methoxyphenol; monoesters of diols, such as resorcinol monobenzoate; functionalized chlorides of aliphatic monocarboxylic acids, such as acryloyl chloride and methacryloyl chloride; and monochloroformates such as phenyl chloroformate, alkyl-substituted phenyl chloroformates, 4-cumylphenyl chloroformate, and tolyl chloroformate. Combinations of different capping groups can be used.

[0017] Based on gel permeation chromatography using bisphenol A polycarbonate standards, the BPA / PPPBP copolycarbonate can have a weight-average molecular weight of 10,000 to 100,000 grams per mole. Within the range of 10,000 to 100,000 grams per mole, the weight-average molecular weight of the BPA / PPPBP copolycarbonate can be 15,000 to 50,000 grams per mole, or 15,000 to 35,000 grams per mole, or 15,000 to 30,000 grams per mole, or 15,000 to 25,000 grams per mole.

[0018] The BPA / PPPBP copolycarbonate is commercially available, and methods for their synthesis are known.

[0019] In some embodiments, the polycarbonate copolymer comprises a copolycarbonate that includes bisphenol A carbonate units and bisphenol isophorone carbonate units. For the sake of brevity, this polycarbonate copolymer is referred to as BPA / BPI copolycarbonate. The bisphenol A carbonate units are described in the context of BPA / PPPBP copolycarbonate. The bisphenol isophorone carbonate units have the following chemical structure:

[0020]

[0021] Based on the total carbonate units in the BPA / BPI copolycarbonate, the BPA / BPI copolycarbonate comprises 10 to 90 mol% of bisphenol A carbonate units and 10 to 90 mol% of bisphenol isophorone carbonate units. Within these ranges, the mole percentage of bisphenol A carbonate units can be 20 to 80 mol%, or 30 to 70 mol%, or 40 to 60 mol%. Also within these ranges, the mole percentage of bisphenol isophorone carbonate units can be 20 to 80 mol%, or 30 to 70 mol%, or 40 to 60 mol%. In some embodiments, the sum of the mole percentage of bisphenol A carbonate units and the mole percentage of bisphenol isophorone carbonate units is 95 to 100 mol%, or 97 to 100 mol%, or 99 to 100 mol%, all based on the total carbonate units in the BPA / BPI copolycarbonate.

[0022] As described above in the context of BPA / PPPBP copolycarbonate, the BPA / BPI copolycarbonate can be synthesized using a capping agent.

[0023] Based on gel permeation chromatography using bisphenol A polycarbonate standards, the BPA / BPI copolycarbonate can have a weight average molecular weight of 10,000 to 100,000 grams per mole. Within the range of 10,000 to 100,000 grams per mole, the weight average molecular weight of the BPA / BPI copolycarbonate can be 15,000 to 50,000 grams per mole, or 15,000 to 35,000 grams per mole, or 15,000 to 30,000 grams per mole, or 15,000 to 25,000 grams per mole.

[0024] The BPA / BPI copolycarbonate is commercially available and the methods for their synthesis are known.

[0025] In some embodiments, the polycarbonate copolymer includes a polyester carbonate that includes resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units. The resorcinol meta / terephthalate units are resorcinol isophthalate units having the following structure:

[0026] or

[0027] A resorcinol terephthalate unit having the following structure:

[0028] or

[0029] A combination of resorcinol isophthalate units and resorcinol terephthalate units.

[0030] The resorcinol carbonate unit has the following structure:

[0031]

[0032] The bisphenol A carbonate unit has the structure shown above in the context of BPA / PPPBP copolycarbonate.

[0033] The poly(ester carbonate) comprising resorcinol iso / terephthalate units and resorcinol carbonate units and bisphenol A carbonate units may comprise from 5 to 35 mol% of resorcinol iso / terephthalate units, from 2 to 20 mol% of resorcinol carbonate units, and from 45 to 93 mol% of bisphenol A carbonate units, all based on the total moles of resorcinol iso / terephthalate units and resorcinol carbonate units and bisphenol A carbonate units. In the range of 5 to 35 mol%, the amount of resorcinol iso / terephthalate units may be from 10 to 30 mol%, or from 15 to 25 mol%. In the range of 2 to 20 mol%, the amount of resorcinol carbonate units may be from 3 to 15 mol%, or from 4 to 10 mol%. In the range of 45 to 93 mol%, the amount of bisphenol A carbonate units may be from 55 to 90 mol%, or from 65 to 85 mol%. In a very specific embodiment, the poly(ester carbonate) comprising resorcinol iso / terephthalate units and resorcinol carbonate units and bisphenol A carbonate units may comprise from 15 to 25 mol% of resorcinol iso / terephthalate units, from 4 to 10 mol% of resorcinol carbonate units, and from 65 to 85 mol% of bisphenol A carbonate units.

[0034] As described above in the context of BPA / PPPBP copolycarbonate, a poly(ester carbonate) comprising resorcinol iso / terephthalate units and resorcinol carbonate units and bisphenol A carbonate units can be synthesized using a capping agent.

[0035] Based on gel permeation chromatography using bisphenol A polycarbonate standards, a polyester carbonate comprising resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units can have a weight average molecular weight of 10,000 to 100,000 grams per mole. In the range of 10,000 to 100,000 grams per mole, the weight average molecular weight of the BPA / BPI copolycarbonate can be 15,000 to 50,000 grams per mole, or 15,000 to 35,000 grams per mole, or 15,000 to 30,000 grams per mole, or 15,000 to 25,000 grams per mole.

[0036] Polyester carbonates comprising resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units are commercially available, and methods for their synthesis are known.

[0037] In some embodiments, the polycarbonate copolymer comprises a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units. For brevity, this polycarbonate copolymer is referred to as BPA / sebacate polyester carbonate.

[0038] The sebacic acid-bisphenol A ester unit has the following chemical structure:

[0039]

[0040] The bisphenol A carbonate unit has the chemical structure described above in the context of bisphenol A homopolycarbonate.

[0041] Based on the total mole number of sebacic acid-bisphenol A ester units and bisphenol A carbonate units, the BPA / sebacate polyester carbonate can comprise sebacic acid-bisphenol A ester units in an amount of 3 to 20 mol% and bisphenol A carbonate units in an amount of 80 to 97 mol%. In the range of 3 to 20 mol%, the amount of sebacic acid-bisphenol A ester units can be 3 to 12 wt%, or 4 to 11 wt%. In the range of 80 to 97 mol%, the amount of bisphenol A carbonate units can be 88 to 97 wt%, or 89 to 96 wt%.

[0042] As described above in the context of BPA / PPPBP copolycarbonate, the BPA / sebacate polyester carbonate can be synthesized using a capping agent.

[0043] In some embodiments, based on gel permeation chromatography using bisphenol A polycarbonate standards, the BPA / sebacate polyester carbonate has a weight average molecular weight of 10,000 to 100,000 grams per mole. In the range of 10,000 to 100,000 grams per mole, the weight average molecular weight of the BPA / sebacate polyester carbonate can be 15,000 to 50,000 grams per mole, or 15,000 to 35,000 grams per mole. In some embodiments, the BPA / sebacate polyester carbonate has a melt flow rate of 10 to 50 grams / 10 minutes as determined according to ASTM D 1238-20 at 300 °C and a 1.2 kg load. Within this range, the melt flow rate can be 15 to 45 grams / 10 minutes.

[0044] The BPA / sebacate polyester carbonate is commercially available, and methods for their synthesis are known.

[0045] In some embodiments, the polycarbonate copolymer includes a polycarbonate-polysiloxane copolymer containing bisphenol A carbonate units and polysiloxane carbonate units. The bisphenol A carbonate units are defined above in the context of the BPA / PPPBP copolycarbonate. The polysiloxane carbonate units have the following general structure:

[0046]

[0047] wherein each occurrence of Ar is independently an unsubstituted or substituted C 6-30 arylene; each occurrence of R is independently a C 1-13 hydrocarbyl; and E is 5 to 100, or 10 to 75, or 40 to 60. As used herein, "substituted" means including at least one substituent such as a halogen (i.e., F, Cl, Br, I), hydroxyl, amino, thiol, carboxyl, amide, cyano, nitro, C 1-18 alkyl, C 1-18 alkoxy, C 6-18 aryl, C 6-18 aryloxy, C 7-18 alkaryl, or C 7-18 alkaryloxy. As used herein, the term "hydrocarbyl", whether used alone or as a prefix, suffix or fragment of another term, refers to a residue containing only carbon and hydrogen, unless it is specifically identified as a "substituted hydrocarbyl". Hydrocarbyl residues can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated or unsaturated. It can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated and unsaturated hydrocarbon moieties. When a hydrocarbyl residue is described as substituted, it can contain heteroatoms in addition to carbon and hydrogen.

[0048] In some embodiments, the polysiloxane carbonate units have the following structure:

[0049]

[0050] Wherein, each occurrence of M is independently a halogen, cyano, nitro, C 1-8 alkyl, C 1-8 alkoxy, C 1-8 alkylthio, C 2-8 alkenyl, C 2-8 alkenyloxy, C 6-10 aryl, C 6-10 aryloxy, C 7-12 aralkyl, C 7-12 aralkyloxy, C 7-12 alkaryl, or C 7-12 alkaryloxy; each occurrence of v is independently 0, 1, 2, 3, or 4; each occurrence of R 4 is independently a divalent C 2-8 aliphatic group; each occurrence of R 2 is independently a C 1-13 hydrocarbyl group; and E is as defined above.

[0051] In some embodiments, based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer comprises greater than 30 to 70 wt% of polysiloxane carbonate units and 30 to less than 70 wt% of bisphenol A carbonate units. Within these ranges, the polycarbonate-polysiloxane copolymer can comprise the polysiloxane carbonate units in an amount of 35 to 70 wt%, or 35 to 65 wt%, or 35 to 55 wt%, or 35 to 45 wt%. Also within these ranges, the polycarbonate-polysiloxane copolymer can comprise the bisphenol A carbonate units in an amount of 30 to 65 wt%, or 35 to 65 wt%, or 45 to 65 wt%, or 55 to 65 wt%.

[0052] In other embodiments, based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer comprises 2 to 30 wt% of polysiloxane carbonate units and 70 to 98 wt% of bisphenol A carbonate units. Within these ranges, the polycarbonate-polysiloxane copolymer can comprise the polysiloxane carbonate units in an amount of 3 to 20 wt%, or 4 to 10 wt%. Also within these ranges, the polycarbonate-polysiloxane copolymer can comprise the bisphenol A carbonate units in an amount of 80 to 97 wt%, or 90 to 96 wt%.

[0053] The polycarbonate-polysiloxane copolymer can be synthesized using a capping agent, as described above in the context of BPA / PPPBP copolycarbonates.

[0054] In some embodiments, based on gel permeation chromatography using bisphenol A polycarbonate standards, the polycarbonate-silicone copolymer has a weight average molecular weight of 10,000 to 100,000 grams per mole. Within the range of 10,000 to 100,000 grams per mole, the weight average molecular weight of the polycarbonate-silicone copolymer can be 15,000 to 50,000 grams per mole, or 15,000 to 35,000 grams per mole. In some embodiments, the polycarbonate-silicone copolymer has a melt flow rate of 10 to 50 grams per 10 minutes as determined according to ASTM D1238-20 at 300 °C and a 1.2 kilogram load. Within this range, the melt flow rate can be 15 to 45 grams per 10 minutes.

[0055] The polycarbonate-silicone copolymer is commercially available, and methods for their synthesis are known.

[0056] In some embodiments, the polycarbonate copolymer comprises a cyanophenol-capped branched bisphenol A polycarbonate. The carbonate repeating units of the cyanophenol-capped branched bisphenol A polycarbonate are derived from 90 to 99.5 mol% of bisphenol A, and 0.5 to 10 mol% of a branching agent comprising at least three hydroxyl groups, wherein the mole percentage values are based on the total moles of bisphenol A and the branching agent. Within these ranges, the mole percentage of bisphenol A can be 95 to 99, and the mole percentage of the branching agent can be 1 to 5 wt%. Suitable branching agents include trimesoyl chloride, 1,1,1-tris(4-hydroxyphenyl)ethane, and combinations of trimesoyl chloride and 1,1,1-tris(4-hydroxyphenyl)ethane. The molecular weight of the cyanophenol-capped branched bisphenol A polycarbonate is controlled by using cyanophenol as a capping agent.

[0057] The cyanophenol-capped branched bisphenol A polycarbonate can have a melt flow rate of 4 to 35 grams per 10 minutes, or 5 to 30 grams per 10 minutes, as determined according to ASTM D1238-20 at 300 °C and a 1.2 kilogram load.

[0058] The cyanophenol-capped branched bisphenol A polycarbonate is commercially available, and methods for their synthesis are known.

[0059] Based on the total weight of the composition, the composition comprises a polycarbonate copolymer in an amount of 5 to 99.95 wt%. Within this range, the amount of the polycarbonate copolymer can be 10 to 99.5 wt%, or 20 to 99.5 wt%, or 30 to 99.5 wt%, or 40 to 99.5 wt%, or 50 to 99.5 wt%, or 60 to 99.5 wt%, or 70 to 99.5 wt%, or 80 to 99.5 wt%, or 90 to 99.5 wt%, or 95 to 99.5 wt%, or 97 to 99.5 wt%, or 98 to 99.5 wt%.

[0060] The composition optionally comprises a bisphenol A homopolycarbonate. The bisphenol A homopolycarbonate is a polycarbonate in which, based on the total number of moles of carbonate units in the bisphenol A homopolycarbonate, at least 95 mol% of the carbonate units are bisphenol A carbonate units having the following structure:

[0061]

[0062] In some embodiments, based on the total number of moles of carbonate repeating units in the bisphenol A homopolycarbonate, the mole percentage of bisphenol A carbonate units is 95 to 100 mol%, or 97 to 100 mol%, or 99 to 100 mol%, or 100 mol%.

[0063] In some embodiments, the bisphenol A homopolycarbonate comprises up to 5 mol% of carbonate units in addition to the bisphenol A carbonate units described above. These other carbonate units can have the following structures:

[0064]

[0065] wherein, R 1 is a C2-C different from the residue of bisphenol A 30Hydrocarbyl (i.e., different from 2,2-bis(phenylene)isopropylidene). As used herein, the term "hydrocarbyl", whether used alone or as a prefix, suffix or fragment of another term, refers to a residue containing only carbon and hydrogen, unless it is specifically identified as a "substituted hydrocarbyl". Hydrocarbyl residues can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated or unsaturated. They can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated and unsaturated hydrocarbon moieties. When a hydrocarbyl residue is described as substituted, it can contain heteroatoms in addition to carbon and hydrogen. Examples of bisphenols from which R1 is derived include, for example, 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenothiazine, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole; resorcinol and substituted resorcinol compounds such as 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-tert-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, and 2,4,5,6-tetrabromoresorcinol; catechol; hydroquinone; substituted hydroquinones such as 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-tert-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-tert-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone, and combinations thereof. In some embodiments, the bisphenol A homopolycarbonate comprises carbonate units in addition to the bisphenol A carbonate units, present in an amount of 0 to 5 mol%, or 0 to 3 mol%, or 0 to 1 mol%, or zero mol%, all based on the total moles of carbonate repeating units in the bisphenol A homopolycarbonate.,

[0066] The bisphenol A homopolycarbonate can be synthesized using a capping agent, such as described above in the context of the BPA / PPPBP copolycarbonate.

[0067] Based on gel permeation chromatography using bisphenol A polycarbonate standards, the bisphenol A homopolycarbonate can have a weight average molecular weight of from 10,000 to 100,000 grams per mole. In the range of 10,000 to 100,000 grams per mole, the weight average molecular weight of the bisphenol A homopolycarbonate can be from from 15,000 to 50,000 grams per mole, or from 15,000 to 35,000 grams per mole.

[0068] The bisphenol A homopolycarbonate is commercially available and methods for their synthesis are known.

[0069] Based on the total weight of the composition, the composition comprises an amount of bisphenol A homopolycarbonate of from 0 to 90 wt%. Within this range, the amount of bisphenol A homopolycarbonate can be from 0 to 80 wt%, or from 0 to 70 wt%, or from 0 to 60 wt%, or from 0 to 50 wt%, or from 0 to 40 wt%, or from 0 to 30 wt%, or from 0 to 20 wt%, or from 0 to 15 wt%, or from 0 to 10 wt%, or from 0 to 5 wt%, or zero wt%. Also within this range, the amount of bisphenol A homopolycarbonate can be from 40 to 60 wt%, or from 40 to 50 wt%, or from 50 to 60 wt%, or from 75 to 85 wt%.

[0070] The composition comprises a metallic effect additive which provides a metallic appearance to the composition. Suitable metallic effect additives include metallic pigments, metal oxide-coated metallic pigments, flaky graphite pigments, flaky molybdenum disulfide pigments, pearlescent mica pigments, metal oxide-coated pearlescent mica pigments, and combinations thereof. In some embodiments, the metallic effect additive is in the form of flakes. These flakes can have a substantially planar structure. In some embodiments, exemplary flakes can be particles having a ratio of width to thickness (i.e., aspect ratio) of at least 2 and often in the range of 10 - 2,000, such as 3 - 400, or in some cases, 10 - 200, including 10 - 150. In some embodiments, the flake particles can have a thickness of 0.05 microns to 15 microns, such as 0.5 to 12 microns. In some embodiments, these flake particles have a maximum width of 10 to 55 microns, for example 10 to 30 microns. In some embodiments, as opposed to serrated edges, the flake particles can include rounded edges and a smooth planar surface. Flakes having angular edges and irregular surfaces are referred to as "corn flakes". On the other hand, flakes characterized by more rounded edges, smoother surfaces, and flatter surfaces are referred to as "silver coin flakes". In some embodiments, the metallic effect additive includes metallic aluminum. In some embodiments, the metallic effect additive has a number-based equivalent spherical diameter D50 of 5 to 50 microns or 8 to 30 microns, as determined by CTScan imaging and further described in the working examples below.

[0071] In some embodiments, the metallic effect additive has a major diameter in the range of 15 to 50 microns. In some embodiments, the metallic effect additive has a thickness of 2 to 15 microns, such as 4 to 10 microns. In some embodiments, the metallic effect additive has a sphericity greater than 0.6, such as 0.61 to 1, or 0.61 to 0.95, or 0.61 to 0.80, or 0.61 to 0.75. In certain aspects, the metallic effect additive can have a major diameter in the range of 23 to 27 microns, a thickness of 2 to 6 microns, a number-based equivalent spherical diameter D50 of 10 to 15 microns, and a sphericity of about 0.73 (e.g., 0.70 to 0.75). In another specific aspect, the metallic effect additive can have a major diameter of 30 to 35 microns, a thickness of 7 to 12 microns, a number-based equivalent spherical diameter D50 of 17 to 22 microns, and a sphericity of about 0.74 (e.g., 0.72 to 0.76). In another specific aspect, the metallic effect additive can have a major diameter of 15 to 20 microns, a thickness of 2 to 6 microns, a number-based equivalent spherical diameter D50 of 5 to 12 microns, and a sphericity of about 0.7 (e.g., 0.67 to 0.73). In yet another specific aspect, the metallic effect additive can have a major diameter of 44 to 48 microns, a thickness of 5 to 10 microns, a number-based equivalent spherical diameter D50 of 20 to 25 microns, and a sphericity of about 0.61 (e.g., 0.6 to 0.65).

[0072] In one aspect, the metallic effect additives of the present disclosure do not include an organic coating on the surface of the metallic effect additive. For example, an organic polymer coating is not present on the surface of the metallic effect additives of the present disclosure.

[0073] For the purpose of forming a composition by mixing the components of the composition (e.g., by mixing the components in a single-screw or twin-screw extruder), the metallic effect additive can be provided in the form of an additive masterbatch, which, based on the total weight of the additive masterbatch, contains 70 to 97 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns determined by CTScan imaging; and 3 to 30 wt% of polyethylene; wherein the sum of the weight percentages of the aluminum particles and the polyethylene is 95 to 100 wt%. Alternatively, the metallic effect additive can be provided in the form of an additive masterbatch, which, based on the total weight of the additive masterbatch, contains 50 to 90 wt% of bisphenol A homopolycarbonate, 7 to 48.5 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns determined by CTScan imaging, and 0.3 to 15 wt% of polyethylene, wherein the sum of the weight percentages of the bisphenol A homopolycarbonate, the aluminum particles, and the polyethylene is 95 to 100 wt%, or 97 to 100 wt%, or 99 to 100 wt%.

[0074] In a very specific embodiment of the composition, it comprises 95 to 99.9 wt% of a polycarbonate copolymer; wherein the polycarbonate copolymer comprises a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; 0 to 1 wt% of bisphenol A homopolycarbonate; and 0.1 to 0.5 wt% of a metal effect additive; wherein the metal effect additive comprises metallic aluminum; and wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 95 to 99.9 wt%. In the range of 95 to 99.9 wt%, the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate can be 96 to 99.5 wt%, or 97 to 99.5 wt%, or 98 to 99.5 wt%.

[0075] Based on the total weight of the composition, the composition comprises a metal effect additive in an amount of 0.05 to 4 wt%. In this range, the amount of the metal effect additive can be 0.1 to 2 wt%, or 0.1 to 1 wt%, or 0.1 to 0.5 wt%, or 0.1 to 0.3 wt%.

[0076] In some embodiments of the composition, it does not include a metal effect additive having an average particle size greater than or equal to 50 microns, or greater than or equal to 60 microns. In some embodiments of the composition, it does not include titanium dioxide.

[0077] In some embodiments of the composition, it comprises 0 to 0.005 wt% based on the total weight of the composition of an alkyl ketene dimer having the following structure

[0078]

[0079] wherein each occurrence of R is independently a C 12-24 alkyl group.

[0080] In some embodiments of the composition, it does not contain any alicyclic polyester resin that is a reaction product of an aliphatic C 2-12 diol or chemical equivalent with an aliphatic C 6-12 dicarboxylic acid or chemical equivalent, wherein the alicyclic polyester comprises at least 80 wt% of an alicyclic dicarboxylic acid or chemical equivalent and / or an alicyclic diol or chemical equivalent.

[0081] In some embodiments of the composition, based on the total weight of the composition, it comprises 0 to 0.05 wt% of a flame retardant. In some embodiments, no flame retardant is present in the composition.

[0082] In some embodiments of the composition, based on the total weight of the composition, it comprises 0 to 0.25 wt% of glass flakes. In some embodiments, no glass flakes are present in the composition.

[0083] The compositions described herein can provide a desired combination of properties. For example, the compositions described herein can exhibit a desired combination of mechanical properties, chemical resistance, and flame retardancy. In some embodiments, the composition can exhibit a tensile modulus of 2000 MPa or higher as determined at 23 °C using Type I specimens and a test speed of 50 mm / min according to ASTM D638-14. In some embodiments, the composition can exhibit a flexural modulus of 2000 MPa or greater as determined at 23 °C using a 50 mm span and a test speed of 1.27 mm / min according to ASTM D790-17. In some embodiments, the composition can exhibit a UL94 rating of V-0 at 0.6 mm thickness. In some embodiments, the composition can exhibit a pencil hardness rating of at least 4B, preferably at least 3B, more preferably at least 2B as determined according to ASTM D3363-22 using a 1 kg load. In some embodiments, the composition can exhibit improved chemical resistance after 24 hours of contact with a sunscreen relative to a comparative composition that does not contain a polycarbonate copolymer and / or a metal effect additive.

[0084] Another embodiment is an article comprising the composition of any of the above embodiments thereof. The article can be prepared by any method of forming a thermoplastic article, including injection molding and extrusion molding. Articles that benefit from the compositions of the present invention include automotive headlamp housings, automotive door trim, and automotive charging gun housings for electric and hybrid / electric vehicles.

[0085] All ranges disclosed herein include the endpoints, and the endpoints can be combined independently of each other. Each range disclosed herein constitutes a disclosure of any point or sub-range located within the disclosed range.

[0086] The present invention is further illustrated by the following non-limiting examples.

[0087] Examples

[0088] The materials used in these examples are summarized in Table 1.

[0089] Table 1

[0090]

[0091]

[0092] The compositions are summarized in Table 3-5, where the component amounts are expressed in units of weight percentage based on the total weight of the composition. The compositions were mixed on a twin-screw extruder (Toshiba, TEM-37BS), where all components were added to the main throat except for the masterbatches of metal effect additives (MEA3MB and MEA4 MB in Table 1) fed from the side feeder. Mixing was carried out at a screw speed of 400 revolutions per minute and a throughput of 40 kg / h. The additional mixing conditions are summarized in Table 2.

[0093] Table 2

[0094]

[0095]

[0096] The granulated compositions were injection molded to form test articles for property testing. Before injection molding, the pellets were dried at 110 °C for 4 hours. Injection molding was carried out on a FANUC TM SE180 molding machine. The molding conditions are summarized in Table 3.

[0097] Table 3

[0098] Condition Value Hopper Temperature (°C) 50 Zone 1 Temperature (°C) 275 Zone 2 Temperature (°C) 285 Zone 3 Temperature (°C) 300 Nozzle Temperature (°C) 280 Mold Temperature (°C) 90 Screw Speed (rpm) 50 <![CDATA[Back pressure (kgf / cm 2 )]]> 10 Cooling Time (seconds) 20-30 Injection Speed (mm / sec) 50-100 <![CDATA[Maintain pressure (kgf / cm 2 )]]> 800-1000 <![CDATA[Maximum injection pressure (kgf / cm 2 )]]> 1000-1500

[0099] The composition and properties are summarized in Tables 4-6. The melt flow rate, expressed in grams per 10 minutes, was determined according to ASTM D1238-20 at 300 °C and a load of 1.2 kg. Tensile properties were determined at 23 °C according to ASTM D638-14 using Type I specimens and a test speed of 50 mm / min. The tensile stress at break and the tensile modulus are expressed in megapascals. The tensile strain at break is expressed as a percentage. Flexural properties were determined at 23 °C according to ASTM D790-17 using a 50-mm span and a test speed of 1.27 mm / min. The flexural stress at break and the flexural modulus are expressed in megapascals. The notched Izod impact strength, expressed in joules per meter, was determined at 23 °C according to ASTM D256-10 (2018). The unnotched Izod impact strength, expressed in joules per meter, was determined at 23 °C according to ASTM D4812-19e1. The heat deflection temperature (HDT) was determined at a thickness of 3.2 mm and 1.82 MPa according to ASTM D648-18, expressed in degrees Celsius.

[0100] According to Underwriter’s Laboratory Bulletin 94 “Tests for Flammability of Plastic Materials, UL 94”, the flame retardancy of injection-molded combustion rods is determined by a 20 mm vertical burning flame test. Before the test, the combustion rods with a thickness of 0.6 mm are conditioned at 23 °C and 50% relative humidity for at least 48 hours. In the UL94 20 mm vertical burning flame test, a set of five combustion rods is tested. For each rod, the flame is applied to the rod and then removed, and the time required for the rod to self-extinguish (the first burnout time, t1) is recorded. Then the flame is reapplied and removed, and the time required for the rod to automatically extinguish (the second burnout time, t2) and the afterglow time (the glow time, t3) are recorded. To achieve a V-0 rating, the burnout times t1 and t2 of each individual specimen must be less than or equal to 10 seconds; and the total burnout time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 50 seconds; and the second burnout time plus the afterglow time of each individual specimen (t2 + t3) must be less than or equal to 30 seconds; and no specimen may burn or glow to hold the fixture; and the cotton indicator cannot be ignited by burning particles or drips. To achieve a V-1 rating, the burnout times t1 and t2 of each individual specimen must be less than or equal to 30 seconds; and the total burnout time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 250 seconds; and the second burnout time plus the afterglow time of each individual specimen (t2 + t3) must be less than or equal to 60 seconds; and no specimen may burn or glow to hold the fixture; and the cotton indicator cannot be ignited by burning particles or drips. To achieve a V-2 rating, the burnout times t1 and t2 of each individual specimen must be less than or equal to 30 seconds; and the total burnout time of all five samples (t1 plus t2 of all five samples) must be less than or equal to 250 seconds; and the second burnout time plus the afterglow time of each individual specimen (t2 + t3) must be less than or equal to 60 seconds; and no specimen may burn or glow to hold the fixture; however, the cotton indicator can be ignited by burning particles or drips. Compositions that do not meet the V-2 rating are considered non-conforming. The flame retardancy of injection-molded combustion rods is determined for freshly molded (“normal”) rods and “aged” rods that are subjected to 70 °C for 168 hours after molding and before the flame retardancy test.

[0101] The film hardness is determined by a pencil test with a 1 kg load according to ASTM D3363-22. The film hardness grades “B”, “2B”, “3B”, “4B” and “5B” in Table 8-10 correspond to decreasing film hardness.

[0102] Table 4 summarizes the composition and properties of a comparative example and six inventive examples, all of which include a blend of bisphenol A homopolycarbonate and a polyester carbonate including resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units.

[0103] Table 4

[0104]

[0105]

[0106] Table 5 summarizes the composition and properties of a comparative example and three inventive examples, all of which include a blend of two bisphenol A homopolycarbonates and a polyester carbonate including resorcinol meta / terephthalate units, resorcinol carbonate units, and bisphenol A carbonate units.

[0107] Table 5

[0108] Comparative Example 2 Example 7 Example 8 Example 9 Composition BPAPC 1 10 10 10 10 BPAPC 2 44.44 42.44 42.44 42.44 PEC 1 45 45 45 45 MEA 3MB 0 2 0 0 MEA 4MB 0 0 2 0 MEA 5 0 0 0 2 PETS 0.3 0.3 0.3 0.3 UVA 0.2 0.2 0.2 0.2 PEPQ 0.06 0.06 0.06 0.06 Properties MFR at 300°C / 1.2 kg (g / 10 min) 21.4 21 19.5 21.3 Tensile Stress at Break (MPa) 81 84 79 48 Tensile Strain at Break (%) 81 79 79 47 Tensile Modulus (MPa) 2387 2436 2384 2466 Flexural Stress at Break (MPa) 96 97 96 96 Flexural Modulus (MPa) 2400 2420 2410 2410 Notched Izod Impact Strength, 23°C (J / m) 754 88 93 93 HDT (°C) 119 120 120 119

[0109] Table 6 summarizes the composition and properties of a comparative example and six inventive examples, all of which include a blend of two bisphenol A homopolycarbonates and a polycarbonate-polysiloxane including approximately 60 wt% bisphenol A carbonate units and approximately 40 wt% polysiloxane carbonate units.

[0110] Table 6

[0111]

[0112] Table 7 summarizes the composition and properties of a comparative example and two inventive examples, all of which include a blend of two polyester carbonates containing sebacic acid-bisphenol A ester units and bisphenol A carbonate units.

[0113] Table 7

[0114]

[0115]

[0116] Tables 8 - 10 each present the results of film hardness measured by a pencil test as a function of composition.

[0117] Table 8

[0118] Comparative Example 2 Example 7 Example 8 Example 9 Example 18 Example 19 Composition BPAPC 1 10 10 10 10 0 41.11 BPAPC 2 44.44 42.44 42.44 42.44 0 0 PEC 1 45 45 45 45 0 39 PEC 2 0 0 0 0 92.53 0 PEC 3 0 0 0 0 5 0 PC-Si 1 0 0 0 0 0 10 MEA 3MB 0 2 0 0 0 0 MEA 4MB 0 0 2 0 2 2 MEA 5 0 0 0 2 0 0 SAE Oligomer 0 0 0 0 0.1 0 SAN 0 0 0 0 0 0.5 Phosphazene 0 0 0 0 0 7 TBPP 0 0 0 0 0 0.09 PETS 0.3 0.3 0.3 0.3 0.27 0.3 UVA 0.2 0.2 0.2 0.2 0.1 0 PEPQ 0.06 0.06 0.06 0.06 0 0 Properties Film Hardness Measured by Pencil Test 3B B 2B 2B 3B 3B

[0119] Table 9

[0120] Comparative Example 4 Example 16 Composition PEC 2 94.53 92.53 PEC 3 5 5 MEA 4MB 0 2 SAE Oligomer 0.1 0.1 PETS 0.27 0.27 UVA 0.1 0.1 Properties Film Hardness Measured by Pencil Test 4B 2B

[0121] Table 10

[0122]

[0123]

[0124] Table 11 presents the properties of three comparative compositions and three compositions of the present invention. The chemical resistance was evaluated using a sunscreen sold as Banana Boat Sport Ultra Face Lotion SPF 30, which has the following ingredients: water, glyceryl stearate, PEG-100, cetyl alcohol, cetyl dimethicone, propylene glycol, phenoxyethanol, caprylyl glycol, VP / eicosene copolymer, acrylate / C12-C22 alkyl methacrylate copolymer, behenyl alcohol, sodium polyacrylate, chlorphenesin, xanthan gum, disodium EDTA, fragrance, tocopheryl acetate, and Aloe Barbadensis Leaf Juice. For the chemical resistance test, 1 mL of the sunscreen was applied to the center of five tensile bars molded from each of the test compositions. The tensile bars were then exposed to 65 °C and 90% relative humidity (RH) at 1% strain for the time specified in Table 11. A chemical resistance rating of "no change" means that the tensile bar did not break during the test and no cracks were observed in the bar at the end of the test; a rating of "slight cracks" means that the tensile bar did not break during the test and only slight cracks were observed in less than or equal to 2 out of 5 bars at the end of the test; a rating of "apparent cracks" means that the tensile bar did not break during the test, but apparent slight cracks were observed in greater than or equal to 3 out of 5 bars at the end of the test; a rating of "1 / 5 break" means that one of the five tensile bars broke during the test; a rating of "2 / 5 break" means that two of the five tensile bars broke during the test; a rating of "3 / 5 break" means that three of the five tensile bars broke during the test; a rating of "5 / 5 break" means that all five tensile bars broke during the test; a rating of "1 / 5 crack" means that the tensile bars did not break during the test, but one of the five bars showed apparent cracks after the test; a rating of "2 / 5 crack" means that the tensile bars did not break during the test, but two of the five bars showed apparent cracks after the test.

[0125] The chemical resistance test results in Table 11 show that inventive Examples 21-23, which contain 2 wt% of a metal effect additive and at least 5 wt% of a polycarbonate copolymer, exhibit better chemical resistance than Comparative Example 6, which also contains 2 wt% of a metal effect additive but is based on bisphenol A polycarbonate and does not contain a polycarbonate copolymer.

[0126] Table 11

[0127]

[0128]

[0129] Table 12 presents the compositions of four inventive embodiments that vary in terms of the type and amount of the metallic effect additive. Using the above molding conditions, four compositions were injection molded to form articles having a length of 130 mm, a width of 80 mm, and a thickness of 1 mm. The injection molding apparatus includes three plates and a cold runner. Magnified images of the molded samples were visually inspected to evaluate flow line defects. For Example 26, using 2 wt% of MEA4MB, the lowest incidence of flow line defects was observed, where the metal flakes were silver coin-shaped aluminum flakes having a large diameter of 30 to 35 microns, a thickness of 7 to 12 microns, a number-based equivalent spherical diameter D50 of 17 to 22 microns, and a sphericity of about 0.74. The physical properties of the silver coin-shaped aluminum flakes of MEA4MB were characterized using CT Scan imaging using 80 kV X-rays with a 0.25 mm Al filter, a pixel size of 1.2 microns, an exposure time of 1093 ms, a rotation of 360 degrees, and a scan time of 8 hours. The comparison between Example 26 and Example 8 shows that using MEA5MB aluminum flakes is very suitable for applications where a paint-like effect is required, while using MEA3MB aluminum flakes is very suitable for applications where a brighter and more scintillating metallic effect is required.

[0130] Table 12

[0131]

[0132]

[0133] Samples used to evaluate flow line defects were also visually inspected to evaluate welding line defects. For Example 26, using 2 wt% of MEA6MB, the lowest incidence of welding line defects was observed, where the metal flakes were 33-micron, three-dimensional, silver coin-shaped aluminum flakes having a large diameter of 44 to 48 microns, a thickness of 5 to 10 microns, a number-based equivalent spherical diameter D50 of 20 to 25 microns, and a sphericity of about 0.61, as determined by CT Scan imaging.

[0134] The present invention includes at least the following aspects.

[0135] Aspect 1: A composition, based on the total weight of the composition, comprising: 5 to 99.95 wt% of a polycarbonate copolymer selected from the group consisting of: a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units; a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units; a polyester carbonate comprising resorcinol m / p-phthalate units, resorcinol carbonate units and bisphenol A carbonate units; a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units; a cyanophenol-terminated branched bisphenol A polycarbonate; and combinations thereof; 0 to 90 wt% of bisphenol A homopolycarbonate; and 0.05 to 4 wt% of a metallic effect additive; wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 85 to 99.95 wt%.

[0136] Aspect 2: The composition of Aspect 1, wherein the polycarbonate copolymer comprises a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units.

[0137] Aspect 3: The composition of Aspect 1 or 2, wherein the polycarbonate copolymer comprises a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units.

[0138] Aspect 4: The composition of any one of Aspects 1 to 3, wherein the polycarbonate copolymer comprises a polyester carbonate comprising resorcinol m / p-phthalate units, resorcinol carbonate units and bisphenol A carbonate units.

[0139] Aspect 5: The composition of any one of Aspects 1 to 4, wherein the polycarbonate copolymer comprises a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units.

[0140] Aspect 6: The composition of any one of Aspects 1 to 5, wherein the polycarbonate copolymer comprises a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units.

[0141] Aspect 7: The composition of Aspect 6, wherein based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer comprises 70 to 98 wt% of bisphenol A carbonate units and 2 to 30 wt% of polysiloxane carbonate units.

[0142] Aspect 8: The composition of aspect 6, wherein based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer comprises 30 to less than 70 wt% of bisphenol A carbonate units and greater than 30 to 70 wt% of polysiloxane carbonate units.

[0143] Aspect 9: The composition of any one of aspects 1 to 8, wherein the polycarbonate copolymer comprises a cyanophenol-terminated branched bisphenol A polycarbonate.

[0144] Aspect 10: The composition of any one of aspects 1 to 9, wherein the metallic effect additive is selected from the group consisting of metallic pigments, metal oxide-coated metallic pigments, flaky graphite pigments, flaky molybdenum disulfide pigments, pearlescent mica pigments, metal oxide-coated pearlescent mica pigments, and combinations thereof.

[0145] Aspect 11: The composition of any one of aspects 1 to 10, wherein the metallic effect additive comprises aluminum metal.

[0146] Aspect 12: The composition of any one of aspects 1 to 11, wherein the metallic effect additive has a number-based equivalent spherical diameter D50 of 5 to 50 microns or 8 to 30 microns as determined by CTScan imaging.

[0147] Aspect 13: The composition of any one of aspects 1 to 12, wherein the metallic effect additive is provided in the form of an additive masterbatch, and based on the total weight of the additive masterbatch, the additive masterbatch comprises: 70 to 97 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns as determined by CTScan imaging; and 3 to 30 wt% of polyethylene; wherein the sum of the weight percentages of the aluminum particles and the polyethylene is 95 to 100 wt%.

[0148] Aspect 14: The composition of any one of aspects 1 to 12, wherein the metallic effect additive is provided in the form of an additive masterbatch, and the additive masterbatch comprises, based on the total weight of the additive masterbatch, 50 to 90 wt% of bisphenol A homopolycarbonate; 7 to 48.5 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns as determined by CTScan imaging; and 0.3 to 15 wt% of polyethylene; wherein the sum of the weight percentages of the bisphenol A homopolycarbonate, the aluminum particles, and the polyethylene is 95 to 100 wt%.

[0149] Aspect 15: The composition of Aspect 1, wherein the composition comprises 95 to 99.9 wt% of a polycarbonate copolymer; wherein the polycarbonate copolymer comprises a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; 0 to 1 wt% of bisphenol A homopolycarbonate; and 0.1 to 0.5 wt% of a metallic effect additive; wherein the metallic effect additive comprises metallic aluminum; and wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 95 to 99.9 wt%.

[0150] Aspect 16: An article comprising the composition of any one of Aspects 1 to 15.

[0151] Alternatively, the composition, method, and article may comprise, consist of, or consist essentially of any suitable materials, steps, or components disclosed herein. The composition, method, and article may additionally or alternatively be formulated so as to be free or substantially free of any materials (or substances), steps, or components that would otherwise be unnecessary for the function or purpose of the composition, method, and article.

[0152] All ranges disclosed herein include the endpoints, and the endpoints can be combined independently of each other. "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not denote any order, quantity, or importance, but are used to distinguish one element from another. Unless otherwise specified herein or clearly contradicted by the context, the terms "a" and "an" and "the" do not denote a limitation of quantity, but are to be construed as covering the singular and the plural. Unless otherwise expressly stated, "or" means "and / or". References to "an aspect" throughout the specification mean that the particular elements described in connection with that aspect are included in at least one aspect described herein, and may or may not be present in other aspects. As used herein, the term "their combination" includes one or more of the listed elements and is open-ended, allowing for the presence of one or more similar elements not named. Further, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0153] Unless specified to the contrary herein, all test standards are the latest standards in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0154] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. All patents, patent applications, and other references cited are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in the incorporated references, the term from this application prevails over the conflicting term from the incorporated references.

[0155] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group should be understood to have its valency filled by a bond or hydrogen atom as indicated. A dash (“-”) not between two letters or symbols is used to indicate the point of attachment of a substituent. For example, -CHO is attached through the carbon of the carbonyl group.

[0156] As used herein, the term “hydrocarbyl,” whether used alone or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when a hydrocarbyl residue is described as substituted, it can optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, a hydrocarbyl residue can also contain one or more carbonyl, amino, hydroxy, etc., or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term “alkyl” refers to a branched or straight-chain, saturated aliphatic hydrocarbyl group, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, sec-pentyl, and n-hexyl and sec-hexyl. “Alkenyl” refers to a straight-chain or branched monovalent hydrocarbyl group having at least one carbon-carbon double bond (e.g., vinyl (-HC═CH2)). “Alkoxy” refers to an alkyl group attached via oxygen (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butoxy. “Alkylene” refers to a straight-chain or branched, saturated, divalent aliphatic hydrocarbyl group (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). “Cycloalkylene” refers to a divalent cyclic alkylene group, -C n H 2n-x, where x is the number of hydrogens replaced by cyclization. "Cycloalkenyl" means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, where all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing a specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. "Arylene" means a divalent aryl group. "Alkylenearylene" means an arylene group substituted by an alkyl group. "Arylalkylene" means an alkylene group substituted by an aryl group (e.g., benzyl). The prefix "halo-" means a group or compound including one or more of the substituents fluorine, chlorine, bromine, or iodine. Combinations of different halogen atoms (e.g., bromine and fluorine) or only chlorine atoms may be present. The prefix "hetero-" means a compound or group including at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatoms), where the heteroatoms are each independently N, O, S, Si, or P. "Substituted" means a compound or group is substituted by at least one (e.g., 1, 2, 3, or 4) substituents, which may each independently be C 1-9 alkoxy, C 1-9 haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 alkylsulfonyl (-S(=O)2-alkyl), C 6-12 arylsulfonyl (-S(=O)2-aryl), thiol (-SH), thiocyanato (-SCN), toluenesulfonyl (CH3C6H4SO2-), C 3-12 cycloalkyl, C 2-12 alkenyl, C 5-12 cycloalkenyl, C 6-12 aryl, C 7-13 arylalkylene, C 4-12 heterocycloalkyl, and C 3-12 heteroaryl in place of hydrogen, provided that the normal valences of the substituting atoms are not exceeded. The number of carbon atoms indicated in the group does not include any substituents. For example, -CH2CH2CN is a C2 alkyl group substituted by a nitrile group.

[0157] Although specific embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are presently unforeseen or may be unforeseen to the applicant or other skilled artisans in the art may be contemplated. Accordingly, the appended claims, as filed and as they may be amended, are intended to cover all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. A composition, based on the total weight of the composition, comprising: 5 to 99.95 wt% of a polycarbonate copolymer selected from the group consisting of: a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units; a copolycarbonate comprising bisphenol A carbonate units and bisphenol isophorone carbonate units; a polyester carbonate comprising resorcinol meta / terephthalate units, resorcinol carbonate units and bisphenol A carbonate units; a polyester carbonate comprising sebacic acid-bisphenol A ester units and bisphenol A carbonate units; a polycarbonate-polysiloxane copolymer comprising bisphenol A carbonate units and polysiloxane carbonate units; a cyanophenol-terminated branched bisphenol A polycarbonate; and combinations thereof; 0 to 90 wt% of bisphenol A homopolycarbonate; and 0.05 to 4 wt% of a metallic effect additive; Among them, The sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 85 to 99.95 wt%.

2. The composition according to claim 1, wherein, The polycarbonate copolymer includes a copolycarbonate containing bisphenol A carbonate units and 2-phenyl-3,3-bis(4-hydroxyphenyl) benzopyrrolone carbonate units.

3. The composition according to claim 1 or 2, wherein The polycarbonate copolymer includes a copolycarbonate containing bisphenol A carbonate units and bisphenol isophorone carbonate units.

4. The composition according to any one of claims 1 to 3, wherein, The polycarbonate copolymer includes a polyester carbonate containing resorcinol meta / terephthalate units, resorcinol carbonate units and bisphenol A carbonate units.

5. The composition according to any one of claims 1 to 4, wherein, The polycarbonate copolymer includes a polyester carbonate containing sebacic acid-bisphenol A ester units and bisphenol A carbonate units.

6. The composition according to any one of claims 1 to 5, wherein, The polycarbonate copolymer includes a polycarbonate-polysiloxane copolymer containing bisphenol A carbonate units and polysiloxane carbonate units.

7. The composition according to claim 6, wherein Based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer contains 2 to 30 wt% of polysiloxane carbonate units.

8. The composition according to claim 6, wherein, Based on the weight of the polycarbonate-polysiloxane copolymer, the polycarbonate-polysiloxane copolymer contains more than 30 to 70 wt% of polysiloxane carbonate units.

9. The composition according to any one of claims 1 to 8, wherein, The polycarbonate copolymer contains a cyanophenol-terminated branched bisphenol A polycarbonate.

10. The composition according to any one of claims 1 to 9, wherein, The metallic effect additive is selected from the group consisting of metal pigments, metal oxide-coated metal pigments, flake graphite pigments, flake molybdenum disulfide pigments, pearlescent mica pigments, metal oxide-coated pearlescent mica pigments, and combinations thereof.

11. The composition according to any one of claims 1 to 10, wherein, The metallic effect additive includes metallic aluminum.

12. The composition according to any one of claims 1 to 11, wherein, The metallic effect additive has a number-based equivalent spherical diameter D50 of 5 to 50 microns or 8 to 30 microns measured by CTScan imaging.

13. The composition according to any one of claims 1 to 12, wherein, The metallic effect additive is provided in the form of an additive masterbatch comprising: 70 to 97 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns measured by CTScan imaging; and 3 to 30 wt% of polyethylene; wherein the sum of the weight percentages of the aluminum particles and the polyethylene is 95 to 100 wt%.

14. The composition according to any one of claims 1 to 12, wherein, The metallic effect additive is provided in the form of an additive masterbatch, and based on the total weight of the additive masterbatch, the additive masterbatch comprises: 50 to 90 wt% of bisphenol A homopolycarbonate; 7 to 48.5 wt% of aluminum particles having a number-based equivalent spherical diameter D50 of 8 to 30 microns as determined by CTScan imaging; and 0.3 to 15 wt% of polyethylene; wherein the sum of the weight percentages of the bisphenol A homopolycarbonate, the aluminum particles, and the polyethylene is 95 to 100 wt%.

15. The composition according to claim 1, wherein the composition comprises 95 to 99.9 wt% of the polycarbonate copolymer; wherein the polycarbonate copolymer comprises a polyester carbonate containing sebacic acid-bisphenol A ester units and bisphenol A carbonate units; 0 to 1 wt% of the bisphenol A homopolycarbonate; and 0.1 to 0.5 wt% of the metallic effect additive; wherein the metallic effect additive comprises metallic aluminum; and wherein the sum of the weight percentages of the polycarbonate copolymer and the bisphenol A homopolycarbonate is 95 to 99.9 wt%.

16. An article comprising the composition according to any one of claims 1 to 15.

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