Flame retardant polycarbonate compositions formulated without pfas additives

Abstract

Disclosed are flame retardant polycarbonate compositions formulated without PFAS additives, wherein the compositions exhibit high levels of flame retardancy and excellent physical properties. Compositions are disclosed comprising: a) one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbonized salts, with the proviso that the carbonized salts do not contain any halogen atoms. Methods of making such compositions and molded articles molded from such compositions are disclosed.

Description

Technical Field

[0001] This invention discloses flame-retardant polycarbonate compositions formulated without PFAS additives, wherein the compositions exhibit high levels of flame retardancy and excellent physical properties. Methods for preparing such compositions are disclosed. Structures prepared from the disclosed compositions are disclosed. Background Technology

[0002] Polycarbonate and copolymers containing carbonate units are used in a variety of molded structures. Polycarbonate and copolymers containing carbonate units form rigid molded structures. These molded structures are used in a variety of applications, including housings for electronic devices, automotive parts, medical devices, home appliances, speakers, household goods, etc. Flame retardancy is an important safety consideration for such structures. The market continues to demand improved flame retardancy while maintaining the excellent performance of the molded structures. The use of PFAS compounds as flame retardants in polycarbonate compositions is common, and these compounds offer excellent flame retardancy (see US10100192 and US 2023 / 0167296). Concerns exist regarding the use of PFAS compounds.

[0003] What is needed are polycarbonate compositions free of PFAS compound additives that possess the desired flame retardancy while retaining the excellent properties of molded products containing polycarbonate, such as excellent yield tensile strength, tensile strength at break, yield elongation at break, elongation at break, and notched Izod impact strength. Also needed are molding compositions prepared from such compositions that exhibit improved flame retardancy and these excellent properties. Summary of the Invention

[0004] The disclosure includes a) one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbide salts, provided that the carbide salts are free of any halogen atoms. The disclosed compositions may comprise: b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants, and c) about 0.01 to about 1.0% by weight of one or more carbide salts (based on the weight of the composition).

[0005] (b) One or more polyorganosiloxane flame retardants may be polyorganosiloxanes containing one or more of alkyl, aryl, hydride, vinyl, and alkoxy groups. One or more polyorganosiloxane flame retardants may contain one or more of alkyl, aryl, and hydride groups. One or more polyorganosiloxane flame retardants contain one or more of aryl, vinyl, and alkoxy groups. One or more polyorganosiloxanes include one or more polydimethylsiloxanes, polydiphenylsiloxanes, and polymethylphenylsiloxanes.

[0006] c) One or more char salts do not contain any halogen atoms. One or more char salts may include one or more sulfonates. Char salts include one or more aromatic sulfonates. Char salts may include one or more alkali metal salts and alkaline earth metal salts.

[0007] The composition may comprise d) one or more inorganic particles. d) one or more inorganic particles may comprise one or more carbon-based particles, metal oxides, and metal-like oxides. d) one or more inorganic particles may comprise one or more of carbon nanotubes, carbon black, titanium dioxide, magnesium oxide, silicon dioxide, mica, talc, and wollastonite. One or more metal oxides may comprise one or more of titanium dioxide, magnesium oxide, and silicon dioxide. One or more carbon-based particles may be carbon black or carbon nanotubes. d) one or more inorganic particles are present in an amount of about 0 to about 10% by weight of the composition.

[0008] The composition may further comprise e) one or more buffering compounds capable of stabilizing the molecular weight of one or more polycarbonates. The buffering compound may comprise one or more alkali metal phosphates, such as one or more distearate pentaerythritol diphosphate, monohydrogen phosphate, or dihydrogen phosphate, as well as monohydrogen, dihydrogen, or trihydrogen phosphate compounds. One or more alkali metal phosphates may include one or more monohydrogen, dihydrogen, or trihydrogen phosphate compounds. One or more alkali metal phosphates may include sodium dihydrogen phosphate or disodium phosphate. e) One or more buffering compounds may be present in an amount of about 0 to about 0.2% by weight of the composition.

[0009] The composition may contain one or more of the following: f) one or more impact modifiers and g) one or more polysiloxane polycarbonate copolymers. The impact modifier may contain a siloxane core. One or more impact modifiers may be core-shell rubbers containing a siloxane core. One or more impact modifiers may have a (meth)acrylate shell. One or more impact modifiers may be present in an amount of 0 to about 20% by weight of the composition. One or more polysiloxane polycarbonate copolymers may be present in an amount of 0 to about 95% by weight of the composition, wherein the total amount of said polycarbonate includes one or more polysiloxane polycarbonate copolymers.

[0010] The composition may contain one or more glass fibers. The glass fibers may be long glass fibers, short glass fibers, or a combination thereof. The glass fibers may be round or elliptical. The glass fibers may be present in an amount of 0 to about 50% by weight based on the composition.

[0011] One or more polycarbonates may contain up to about 90% by weight or more of one or more recycled polycarbonates. One or more polycarbonates may be almost entirely composed of polycarbonate units. One or more polycarbonates may be almost entirely composed of bisphenol polycarbonate units.

[0012] The composition may comprise: a) about 50 to about 99% by weight of one or more polycarbonates; b) about 0.5 to about 10% by weight of one or more polyorganosiloxanes; c) about 0.01 to about 1.0% by weight of one or more carbide salts; d) about 0 to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.2% by weight of one or more buffering compounds; f) about 0 to about 20% by weight of one or more core-shell impact modifiers comprising a siloxane core; g) about 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; h) 0 to 50% by weight of one or more glass fibers; wherein all amounts are based on the weight of the composition, and the total amount of the polycarbonate may include one or more polysiloxane polycarbonate copolymers.

[0013] Articles prepared from the compositions disclosed herein are disclosed.

[0014] A method is disclosed comprising: a) bringing components of any of the compositions disclosed herein into full contact and mixing at a temperature of about 250°C or higher for about 10 seconds or longer; b) filling a mold with the mixed composition of a); c) forming a solid article from the composition in the mold; and d) removing the formed article from the mold. The contact mixing can be carried out in an extruder and the formed mixture can be transferred from the extruder to the mold.

[0015] The disclosed compositions and articles prepared from the disclosed compositions are free of PFAS-containing additives, including PFAS-containing anti-drip agents and carbide salts. Articles prepared from the compositions exhibit a notched Izod impact strength of about 680 J / m or greater, or 700 J / m or greater, with a standard deviation of about 25 J / m or less. The articles are suitable for use in automobiles, trains, buses, recreational vehicles (RVs), etc. Detailed Implementation

[0016] While this disclosure has been described in conjunction with certain embodiments, it should be understood that this disclosure is not limited to the disclosed embodiments and is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, the scope of which is to be interpreted in the broadest possible sense to cover all such modifications and equivalent structures permitted by law.

[0017] As used herein, "one or more" means that at least one or more of the listed components may be used as disclosed. As used herein, a hydrocarbon group refers to a group containing a backbone of one or more carbon atoms and hydrogen atoms, which may optionally contain one or more heteroatoms. When a hydrocarbon group contains heteroatoms, the heteroatoms may form one or more functional groups known to those skilled in the art. A hydrocarbon group may contain any combination of alicyclic, aliphatic, aromatic, or such segments. Aliphatic segments may be straight-chain or branched. Aliphatic and alicyclic segments may contain one or more double and / or triple bonds. Hydrocarbon groups include alkyl, alkenyl, alkynyl, aryl, cycloalkyl, cycloalkenyl, alkylaryl, and aralkyl groups. Alicyclic groups may contain both cyclic and acyclic portions. A hydrocarbon group means a hydrocarbon group having more than one valence state or any subset described, such as alkylene, alkenyl, alkynyl, aryl, cycloalkylene, cycloalkenylene, alkylenearyl, and aralkylene. As used herein, valence refers to a covalent bond between a hydrocarbon or hydrocarbon-like group and another group, such as a group or atom containing a carbonyl, oxygen, nitrogen, or sulfur, or the base compound mentioned. Unless otherwise stated, weight percent or parts by weight as used herein refers to or is based on the weight of the composition. Tg is the temperature or range of temperatures at which the physical properties of a polymer material (including, for example, mechanical strength) undergo an abrupt change. Tg can be determined by differential scanning calorimetry (DSC). As used herein, post-industrial refers to a source of material generated during the manufacture of goods or products. As used herein, post-consumer refers to a source of material generated after the end consumer has used a consumer product or product made from the material. Original polycarbonate is a polycarbonate that has not been previously used in any composition. The term PFAS refers to perfluorinated and polyfluoroalkyl substances. As used herein, almost all means 95% by weight or higher, 98% by weight or higher, 99% by weight or higher, or 100% by weight.

[0018] Compositions are disclosed comprising a) one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbides, provided that the carbides are free of any halogen atoms. Such compositions may contain one or more of the following: d) one or more inorganic particles, e) one or more buffering compounds capable of stabilizing the molecular weight of one or more polycarbonates, f) one or more core-shell rubber impact modifiers, g) one or more polysiloxane polycarbonate copolymers, and h) one or more glass fibers. The compositions may contain one or more non-halogenated flame retardants, one or more antioxidants, one or more UV absorbers, one or more mold release agents, and / or one or more colorants. The disclosed compositions are free of PFAS compounds. The presence of one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbides (provided that the carbides are free of any halogen atoms), and optionally one or more inorganic particles (including one or more carbon-based particles, metal oxides, and metalloid oxides) contributes to the preparation of PFAS-free polycarbonate compositions that exhibit good flame retardancy and excellent properties as disclosed herein.

[0019] A composition is disclosed comprising: a) about 50 to 99% by weight of one or more polycarbonates, b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants, and c) about 0.01 to about 1.0% by weight of one or more carbide salts (by weight of the composition).

[0020] A composition is disclosed comprising: a) about 50 to about 99% by weight of one or more polycarbonates; b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 1.0% by weight of one or more carbide salts; d) about 0 to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.2% by weight of one or more buffering compounds; f) about 0 to about 20% by weight of one or more impact modifiers; g) about 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and h) about 0 to about 50% by weight of one or more glass fibers; wherein the amounts are all based on the weight of the composition, and the total amount of the polycarbonate may include one or more polysiloxane polycarbonate copolymers.

[0021] A composition is disclosed comprising: a) about 50 to about 99% by weight of one or more polycarbonates; b) about 1.0 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 1.0% by weight of one or more carbide salts; d) 0 to about 10% by weight of one or more inorganic particles; e) 0 to about 0.2% by weight of one or more buffering compounds; f) 0 to about 20% by weight of one or more core-shell impact modifiers comprising a siloxane core; g) 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and h) 0 to about 50% by weight of one or more glass fibers; wherein the amounts are based on the weight of the composition and the total amount of polycarbonate may include one or more polysiloxane polycarbonate copolymers.

[0022] As used herein, polycarbonate refers to a polymer containing carbonate units. Such polymers can be homopolymers consisting essentially of carbonate monomer units (almost all or 100% carbonate monomer units) or copolymers containing one or more other monomer units (comonomer units) and carbonate units. Such copolymers can be block copolymers containing blocks of two or more different monomer units, or random copolymers where different monomer units are randomly distributed along the polymer backbone. Additional monomer units may include any monomer unit that does not negatively affect the inherent properties of polycarbonate, such as heat resistance, impact resistance, moldability, flexural modulus, flexural strength, haze, and transparency, if required by the intended use. Exemplary comonomer units include ester units, polysiloxane units, etc. As disclosed herein, the amount of carbonate monomer units in the copolycarbonate is selected such that the resulting polymer retains the desired properties of polycarbonate. Copolycarbonates may contain greater than 50 mol% of carbonate monomer units, about 75 mol% or more of carbonate monomer units, about 80 mol% or more of carbonate monomer units, or about 85 mol% or more of carbonate monomer units. Copolycarbonates may contain 100 mol% or less of carbonate monomer units, about 99 mol% or less of carbonate monomer units, about 97 mol% or less of carbonate monomer units, or about 95 mol% or less of carbonate monomer units. Copolycarbonates may contain about 1 mol% or more of comonomer units, about 3 mol% or more of comonomer units, or about 5 mol% or more of comonomer units. Copolycarbonates may contain less than 50 mol% of comonomer units, about 25 mol% or less of comonomer units, about 20 mol% or less of comonomer units, or about 15 mol% or less of comonomer units. The polycarbonate units may contain aromatic units in the polymer backbone.

[0023] Polycarbonate production is achieved, for example, by using a phase-interval process, optionally employing a chain terminator (e.g., monophenol) and optionally a trifunctional branching agent or a branching agent with a functionality greater than 3 (e.g., triphenol or tetraphenol), to react the bisphenol with a carbonate halide (preferably phosgene) and / or with an aromatic dicarboxylic acid dihalide (preferably a benzene dicarboxylic acid dihalide). The bisphenols that can be used to produce aromatic polycarbonates and / or aromatic polyester carbonates can correspond to Formula I:

[0024] I

[0025]

[0026] Where A represents a single bond to which other aromatic rings, optionally containing heteroatoms, can be condensed; C 1-5 Alkylene, C 2-5 alkylidene, C 5-6 Cycloalkylidenes, -O-, -SO-, -CO-, -S-, -SO2-, or C 6-12 arylene, or a group of formula II:

[0027] II

[0028]

[0029] Or the group of formula III:

[0030] III

[0031]

[0032] Where B is hydrogen independently in each case, and C 1-12 Alkyl (preferably methyl) or halogen (preferably chlorine and / or bromine); x is 0, 1, or 2 independently in each case; p is 0 or 1; R c and R d They are independent of each other, and for each X 1 It can be selected individually and is hydrogen or C1-C6 alkyl, preferably hydrogen, methyl or ethyl; X 1 Represents carbon; and m represents an integer of 4-7, preferably 4 or 5, provided that R c and R d Simultaneously represents at least one X 1 Alkyl group on an atom.

[0033] Exemplary diphenols include hydroquinone, resorcinol, dihydroxybiphenyl, and bis(hydroxyphenyl)-C. 1-5 Alkanes, bis(hydroxyphenyl)-C 5-6Cycloalkanes, bis(hydroxyphenyl) ethers, bis(hydroxyphenyl) sulfoxides, bis(hydroxyphenyl) ketones, bis(hydroxyphenyl) sulfones, and 4,4″-bis(hydroxyphenyl)diisopropylbenzene, and their derivatives having brominated and / or chlorinated nuclei. Particularly preferred bisphenols are 4,4'-dihydroxybiphenyl, bisphenol A, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 1,1-bis(4-hydroxyphenyl)-cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4-dihydroxydiphenyl sulfide, and 4,4-dihydroxydiphenyl sulfone, and their dibrominated and tetrabrominated or chlorinated derivatives, such as 2,2-bis(3-chloro-4- Bisphenol A (BPA) propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl) propane, or 2,2-bis(3,5-dibromo-4-hydroxyphenyl) propane. 2,2-bis-(4-hydroxyphenyl) propane is particularly preferred. Bisphenols can be used alone or in any mixture. Bisphenols are known from the literature or can be obtained by methods known from the literature. In addition to homopolymers of BPA, exemplary polycarbonates include copolymers of BPA containing up to 15 mol% of other disclosed bisphenols, such as 2,2-bis(3,5-dibromo-4-hydroxyphenyl) propane, relative to the total molar amount of the bisphenols.

[0034] Exemplary chain terminators for the production of polycarbonate include phenolic compounds, including phenol, p-chlorophenol, p-tert-butylphenol, 4-(1,3-dimethyl-butyl)phenol, and 2,4,6-tribromophenol; long-chain alkylphenols, such as monoalkylphenols or dialkylphenols containing a total of 8 to 20 carbon atoms in their alkyl substituents, examples being 3,5-di-tert-butylphenol, p-isooctylphenol, p-tert-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)phenol, and 4-(3,5-dimethylheptyl)phenol. The amount of chain terminator used may be about 0.1 mol% or more, based on the total molar amount of bisphenols used in each case. The amount of chain terminator used may be about 10 mol% or less, based on the total molar amount of bisphenols used in each case.

[0035] The polycarbonate can be branched, for example, by incorporating about 0.05 to about 2.0 mol% of a trifunctional compound or a compound with a functionality greater than 3 relative to the total amount of bisphenol used, such as those containing four or more phenolic groups. The branched polycarbonate used in the disclosed compositions can be prepared by known techniques, for example, several methods disclosed in USP 3,028,365, 4,529,791 and 4,677,162 (which are hereby incorporated in their entirety by reference). Exemplary branching agents include trifunctional or polyfunctional carboxyl chlorides, such as pyromellitic trichloride, cyanuric trichloride, 3,3'-,4,4'-benzophenone tetracarboxylic acid tetrachloride, 1,4,5,8-naphthalene-tetracarboxylic acid tetrachloride, or pyromellitic tetrachloride, in an amount of about 0.01 to about 1.0 mol% (relative to the dicarboxylic acid dichloride used), or trifunctional or polyfunctional phenols, such as phloroglucinol, 4,6-dimethyl-2,4,6-tris(4-hydroxyphenyl)-2-heptene, 4,4-dimethyl-2,4,6-tris(4-hydroxyphenyl)heptane, and 1,3,5-tris(4-hydroxyphenyl) Benzene, 1,1,1-tris(4-hydroxyphenyl)ethane, tris(4-hydroxyphenyl)-phenyl-methane, 2,2-bis[4,4-bis(4-hydroxyphenyl)cyclohexyl]-propane, 2,4-bis[1-(4-hydroxyphenyl)-1-methyl-ethyl]phenol, tetra(4-hydroxyphenyl)-methane, 2,6-bis(2-hydroxy-5-methyl-benzyl)-4-methyl-phenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane, or tetra(4-[1-(4-hydroxyphenyl)-1-methylethyl]-phenoxy)-methane, in an amount of about 0.01 to about 1.0 mol% relative to the amount of bisphenol used. Phenolic branching agents can be placed in the reaction vessel together with the bisphenol. Acyl chloride branching agents can be introduced together with the acyl chloride.

[0036] Copolycarbonates can be prepared by known methods. Polysiloxane monomer units can be used in the preparation of polycarbonate-containing polymers. For example, about 1 to about 25 parts by weight, or about 2.5 to about 25 parts by weight (relative to the total amount of bisphenol to be used), of a polydiorganosiloxane containing hydroxyaryloxy terminals can also be used. These are known (see USP 3,419,634) or can be produced by methods known in the literature. Esterifying monomers can be used in the preparation of polycarbonate-containing polymers. Exemplary esterifying monomers include dicarboxylic acid halides and hydroxycarboxylic acids. The aromatic dicarboxylic acid dihalides used to produce aromatic polyester carbonates can be diacyl chlorides of isophthalic acid, terephthalic acid, diphenyl ether-4,4'-dicarboxylic acid, and naphthalene-2,6-dicarboxylic acid. A mixture of isophthalic acid and terephthalic acid diacyl chlorides in a ratio of about 1:20 to about 20:1 can be used. Carbonyl chlorides, such as phosgene, can be used as bifunctional acid derivatives in the production of polyester carbonates. Aromatic polyester carbonates may also contain incorporated hydroxycarboxylic acids. Polyester carbonates can be linear and / or branched. Branching agents have been disclosed above.

[0037] In addition to monophenols, exemplary chain terminators include chlorocarboxylic acid esters and acyl chlorides of aromatic monocarboxylic acids, which may optionally be C- 1-22 Alkyl or halogen atom substitution, and may also include aliphatic C atoms. 2-22 Monocarboxylic acid chloride. The amount of the chain terminator can be from about 0.1 to about 10 mol relative to the molar number of bisphenol (in the case of phenol chain terminator) and relative to the molar number of dicarboxylic acid dichloride (in the case of monocarboxylic acid chloride chain terminator).

[0038] Polycarbonate or copolymers containing carbonate units can be derived from recycled materials, such as post-consumer recycled materials and / or post-industrial recycled materials. The polycarbonate or copolymer containing carbonate units can be one or more recycled polycarbonates. One or more recycled polycarbonates can be one or more post-consumer recycled polycarbonates, or one or more post-industrial recycled polycarbonates. The composition may contain up to 90% by weight of recycled polycarbonate. The composition may contain about 85% by weight or less, or about 80% by weight or less, of recycled polycarbonate by weight. The composition may contain about 30% by weight or more, about 50% by weight or more, or about 75% by weight or more of recycled polycarbonate by weight. The recycled material can be linear, branched, or a mixture thereof. The recycled material can be branched. The recycled material can be in flake form. The recycled material can be recycled from bottles or other structures where the structure used is shredded into flake form. The recycled material can be formed into other structures, such as granules. Using recycled materials in granular form is the most efficient way to utilize them. Recycled polycarbonate or copolymers containing carbonate units may contain, for example, 0.1 to 1.0% by weight or 0.1 to 0.25% by weight of impurities, such as polyester, based on recycled polycarbonate or copolymers containing carbonate units.

[0039] The composition may contain virgin polycarbonate or a copolymer containing carbonate units in an amount of about 5% by weight or more, about 10% by weight or more, about 20% by weight or more, about 30% by weight or more, or about 40% by weight or more, based on the composition. The composition may also contain virgin polycarbonate or a copolymer containing carbonate units in an amount of 100% by weight or less, about 90% by weight or less, about 60% by weight or less, or about 50% by weight or less, based on the composition.

[0040] One or more polymers containing carbonate monomer units may include polycarbonate, copolycarbonate, or blends of polycarbonate and copolycarbonate. Polycarbonate and / or copolycarbonate may exhibit a weight-average molecular weight sufficient to provide the desired properties for articles prepared from polycarbonate and / or copolycarbonate. The weight-average molecular weight of polycarbonate and / or copolycarbonate may be about 5,000 or greater, about 15,000 or greater, or about 20,000 or greater. The weight-average molecular weight of polycarbonate and / or copolycarbonate may be about 60,000 or less, about 40,000 or less, about 35,000 or less, or about 30,000 or less. Unless otherwise stated, the term "molecular weight" for polycarbonate and / or copolycarbonate herein refers to the weight-average molecular weight (Mw) determined by gel permeation chromatography (GPC) using laser scattering techniques with bisphenol A polycarbonate standards, and is given in grams per mole (g / mole).

[0041] The polycarbonate and / or copolymers used to prepare the disclosed compositions may have melt flow rates that provide the desired processing properties. Melt flow rates may be about 1 or greater, about 5 or greater, about 10 or greater, or about 15 or greater. Melt flow rates may be about 70 or less, about 30 or less, about 28 or less, about 20 or less, or about 15 or less. Mixtures of polycarbonate and / or copolymers containing carbonate units with different melt flow rates may be used to provide composite melt flow rates to enhance the processing of the disclosed compositions. Mixtures of polycarbonate and / or copolymers containing carbonate units with different melt flow rates may contain: polycarbonate and / or copolymers containing carbonate units with low melt flow rates and polycarbonate and / or copolymers containing carbonate units with high melt flow rates. Melt flow rates are determined by measuring the number of grams of material passing through a capillary with a diameter of 25.4 mm over a period of 10 minutes at 300°C and a load of 1.2 kg. The melt flow rate of the disclosed compositions can be about 1 g / 10 min or greater, about 3 g / 10 min or greater, about 5 g / 10 min or greater, 10 g / 10 min or greater, or about 15 g / 10 min or greater. The melt flow rate of the disclosed compositions can be about 70 g / 10 min or less, about 30 g / 10 min or less, about 28 g / 10 min or less, about 22 g / 10 min or less, about 20 g / 10 min or less, or about 10 g / 10 min or less. The melt flow rate of the disclosed compositions can be from about 3 g / 10 min to about 22 g / 10 min. The test protocol is based on ASTM D1238. The plasticizer used in the method can have a capillary diameter of 9.5504 mm and a die size of 2.095 mm.

[0042] The composition may contain polycarbonate or a copolymer containing carbonate units in an amount of about 50% by weight or more, about 80% by weight or more, or about 90% by weight or more, based on the weight of the composition. The composition may also contain polycarbonate or a copolymer containing carbonate units in an amount of about 99% by weight or less, 85% by weight or less, or about 65% by weight or less, based on the weight of the composition.

[0043] Polycarbonate can be linear, branched, or a mixture thereof. Polycarbonate may be a mixture of linear and branched polycarbonate. The presence of branched polycarbonate may have a positive effect on the flame-retardant properties of the disclosed composition. The amount of branched polycarbonate can be any amount that has a positive effect on the properties of the composition, including flame-retardant and mechanical properties. Based on the weight of the composition containing polycarbonate and / or copolymers containing carbonate units, the amount of branched polycarbonate and / or copolymers containing carbonate units can be about 0% by weight or higher, 5% by weight or higher, about 10% by weight or higher, 20% by weight or higher, 30% by weight or higher, 60% by weight or higher, 80% by weight or higher, or 90% by weight or higher. Based on the weight of the composition containing polycarbonate and / or copolymers containing carbonate units, the amount of branched polycarbonate and / or copolymers containing carbonate units may be about 99% by weight or less, 80% by weight or less, about 70% by weight or less, 40% by weight or less, 20% by weight or less, or about 15% by weight or less. Based on the weight of the composition containing polycarbonate and / or copolymers containing carbonate units, the amount of linear polycarbonate and / or copolymers containing carbonate units may be about 0% by weight or more, 5% by weight or more, or about 10% by weight or more. Based on the weight of the composition containing polycarbonate and / or copolymers containing carbonate units, the amount of linear polycarbonate and / or copolymers containing carbonate units may be about 99% by weight or less, 80% by weight or less, about 70% by weight or less, 40% by weight or less, 20% by weight or less, or about 15% by weight or less.

[0044] One or more organosilicon compounds may be used in one or more polysiloxane polycarbonate copolymers; one or more polyorganosiloxane flame retardants; or one or more siloxane-acrylate core-shell rubbers with a siloxane core.

[0045] The composition may contain one or more polysiloxane polycarbonate copolymers. By weight, the composition may contain 0% or more, about 1.0% or more, about 3.0% or more, about 5.0% or more, 10% or more, about 20% or more, or about 40% or more of one or more polycarbonate polysiloxane copolymers. By weight, the composition may contain about 95% or less, about 85% or less, about 75% or less, about 65% or less, or about 50% or less of one or more polycarbonate polysiloxane copolymers. By weight, the composition may contain about 0 to about 95% by weight, about 3.0% to about 85% by weight, about 10% to about 75% by weight, or about 20% to about 65% by weight of one or more polycarbonate polysiloxane copolymers. When the composition does not contain one or more impact modifiers, the composition may contain more than 2.0% by weight of one or more polycarbonate polysiloxane copolymers.

[0046] One or more polycarbonate-polysiloxane copolymers may contain about 1.0% by weight or more, about 5.0% by weight or more, about 10% by weight or more, or about 20% by weight or more of one or more polysiloxane monomer units within the polycarbonate backbone. One or more polycarbonate-polysiloxane copolymers may contain about 99% by weight or less, about 60% by weight or less, about 40% by weight or less, or about 20% by weight or less of one or more polysiloxane monomer units within the polycarbonate backbone. One or more polycarbonate-polysiloxane copolymers may contain about 1.0% to about 99% by weight, about 5.0% to about 60% by weight, or about 10% to about 40% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

[0047] The composition may contain one or more compositions having polyorganosiloxane monomer units. The presence of polyorganosiloxane monomer units enhances the flame retardancy of the composition. The polyorganosiloxane monomer units may be present in the form of one or more polyorganosiloxane flame retardants, one or more polysiloxane polycarbonate copolymers, and one or more siloxane-acrylate core-shell rubbers with a siloxane core. Any one or more polyorganosiloxane monomer units that enhance the flame retardancy of the polycarbonate composition may be used. One or more polyorganosiloxane monomer units may correspond to the formula... : where R 2And D as described in this document. D is selected to provide an effective level of flame retardancy to the composition. Therefore, the D value will vary depending on the type and relative amount of each component in the composition, including the type and amount of polycarbonate, impact modifier, polysiloxane-polycarbonate copolymer, polyorganosiloxane flame retardant, and other flame retardants. Those skilled in the art can determine the appropriate value of D based on the guidelines taught herein without extensive experimentation. D can have an average value of 2 to about 1000, about 3 to about 100, and more specifically about 4 to about 75. In polysiloxane-polycarbonate copolymers, the average value of D is about 40 to about 60. In polysiloxane-polycarbonate copolymers, if the D value is low, for example less than about 40, a relatively large amount of polysiloxane-polycarbonate copolymer may be required. Conversely, in polysiloxane-polycarbonate copolymers, if the D value is high, for example greater than about 40, a relatively small amount of polysiloxane-polycarbonate copolymer may be required.

[0048] Polyorganosiloxane monomer units may be contained in organosilicon compounds having reactive functional groups, said compounds being one or more polyorganosiloxane flame retardants. Examples of one or more polyorganosiloxane flame retardants each contain a plurality of units derived from general formula (1) R 1 a R 2 b SiO (4-a-b) / 2 The single-unit representation, where R 1 This indicates a reactive functional group. Examples of reactive functional groups include alkoxy, aryloxy, polyoxyalkylene, hydrogen, hydroxyl, carboxyl, silanol, amino, mercapto, epoxy, and vinyl groups. Preferably, alkoxy, hydroxyl, hydrogen, epoxy, and vinyl groups are used. R 2 This indicates a hydrocarbon group containing 1 to 12 carbon atoms. Examples of hydrocarbon groups include straight-chain or branched alkyl groups with 1 to 12 carbon atoms, cycloalkyl groups with 5 to 12 carbon atoms, aryl groups with 6 to 12 carbon atoms, and aralkyl groups with 7 to 12 carbon atoms. Specific examples include methyl, ethyl, n-propyl, isopropyl, various butyl groups, various pentyl groups, various hexyl groups, various octyl groups, cyclopentyl, cyclohexyl, phenyl, tolyl, xylyl, benzyl, and phenethyl. a and b represent numbers satisfying the relationships 0 ≦ a ≦ 3, 0 ≦ b ≦ 3, and 0 ≦ a + b ≦ 3. When multiple R groups exist... 1 At that time, the plurality of R 1 They can be the same or different from each other. When there are multiple R... 2 At that time, the plurality of R 2They may be the same or different from each other. One or more polyorganosiloxane flame retardants, each having multiple reactive functional groups of the same type, and one or more polyorganosiloxane flame retardants, each having multiple reactive functional groups of different types, may be used in combination. The number of monomer units in the polyorganosiloxane may be about two or more, or about three or more.

[0049] The composition may comprise one or more polyorganosiloxane flame retardants. These polyorganosiloxane flame retardants may contain one or more of alkyl, aryl, hydride, vinyl, and alkoxy groups. In this context, R 1 It can be one or more of hydrides (hydrogen), hydroxyl, vinyl, and alkoxy, and R 2 It can be one or more of alkyl and aryl groups. One or more polyorganosiloxane flame retardants may contain two or more of alkyl, aryl, and hydride groups. One or more polyorganosiloxane flame retardants may contain one or more, or two or more of alkyl, aryl, and hydride groups. One or more polyorganosiloxane flame retardants may contain aryl and hydride groups. One or more polyorganosiloxane flame retardants may contain one or more, two or more, or all three of aryl, vinyl, and alkoxy groups. In this context, R 1 It can be vinyl and alkoxy, and R 2 It can be aryl. Aryl can be phenyl. Alkyl can be methyl. One or more polyorganosiloxanes may comprise one or more polydialkylsiloxanes, polydiarylsiloxanes, and polyalkylarylsiloxanes. One or more polyorganosiloxane flame retardants comprise one or more polydimethylsiloxanes, polydiphenylsiloxanes, or polymethylphenylsiloxanes, possibly containing hydride groups. One or more polydialkylsiloxanes, polydiarylsiloxanes, and polyalkylarylsiloxanes. Examples of polyorganosiloxanes are polyorganosiloxanes having phenyl, diphenyl, vinyl, or alkoxy groups (e.g., methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy, various pentoxy, various heptoxy, and various octoxy); polyorganosiloxanes having phenyl and diphenyl; polyorganosiloxanes having vinyl and alkoxy groups; and polyorganosiloxanes having phenyl, alkoxy, and vinyl groups. The polyorganosiloxane may be a polyorganosiloxane having phenyl, methoxy, and vinyl groups. Polyorganosiloxane flame retardants can be described as in US7449506, which is incorporated herein by reference.

[0050] The amount of one or more polyorganosiloxane flame retardants can be any amount that enhances the flame retardant properties of the composition. The choice of polyorganosiloxane affects the amount of polyorganosiloxane required to enhance the flame retardant properties of the composition and may need to be adjusted based on the choice of polyorganosiloxane. The amount of polyorganosiloxane flame retardant, by weight of the composition, can be about 0.5% by weight or more, 1.0% by weight or more, about 1.5% by weight or more, or about 2.0% by weight or more. The amount of polyorganosiloxane flame retardant, by weight of the composition, can be about 10.0% by weight or less, about 7.0% by weight or less, about 5.0% by weight or less, about 4.0% by weight or less, or about 3.0% by weight or less.

[0051] The composition may contain one or more organometallic salts used as carbide salts. A carbide salt is any compound that helps maintain the original shape of a plastic article by forming carbon from the compound. The carbon forms a hard shell of a non-flammable material, reducing melting and dripping of the compound in which the carbide salt is located. Any organometallic salt used as a carbide salt may be used, provided that the carbide salt does not contain halogens, such as fluorine. One or more organometallic salts may be one or more salts of aromatic sulfur compounds. One or more organometallic salts may be one or more salts of aromatic sulfonates. One or more salts of aromatic sulfur compounds may include one or more salts of alkali metals, alkaline earth metals, or both. One or more salts of aromatic sulfur compounds may include potassium salts, sodium salts, magnesium salts, calcium salts, or any combination thereof. One or more salts of aromatic sulfur compounds may include one or more sodium or potassium salts. One or more salts of aromatic sulfur compounds may be sulfonates. Sulfate salts may include one or more carbon-containing groups. The number of carbon atoms in a sulfurate salt may be about 15 or less, about 13 or less, about 7 or less, or about 5 or less. The number of carbon atoms in a sulfurate salt may be 1 or more, 2 or more, 3 or more, or 4 or more. The carbon-containing group can be acyclic or aromatic. The sulfur-containing salt may include or consist substantially of one or more sodium p-toluenesulfonate or potassium diphenyl sulfone sulfonate. Organometallic salts of aromatic sulfur compounds may be present in a certain amount to improve the flame retardancy of the composition. The organometallic salt may be present in an amount of about 0.01% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more of the composition. The organometallic salt may be present in an amount of about 2.0% by weight or less, about 1.0% by weight or less, about 0.5% by weight or less, about 0.4% by weight or less, or about 0.25% by weight or less of the composition.

[0052] The disclosed compositions may contain one or more inorganic particles. Any inorganic particles capable of enhancing the flame retardancy and mechanical properties of the composition may be used. The one or more inorganic particles may be one or more carbon-based particles, metal oxides, and metal-like oxides. Exemplary metal or metal-like oxides include Group 3 or 4 metal or non-metal oxides and mixtures thereof, which may be synthetic or naturally occurring. Exemplary metal or metal-like oxides include TiO2, MgO, SiO2, Fe2O3, Al2O3, etc. Exemplary metal or metal-like oxides include TiO2, MgO, and SiO2. One or more metal or metal-like oxides may be mixtures of metals and / or metal-like oxides, such as talc containing MgO and SiO2, mica containing silica and oxygen, and wollastonite calcium silicate. One or more carbon-based particles may be any particulate carbon material capable of improving the flame retardancy of the compositions disclosed herein. Exemplary carbon-based particles may be carbon black or carbon nanotubes. One or more carbon compounds, metals, or metal-like oxides may be present in sufficient amounts to enhance the flame retardancy and mechanical properties of the composition. One or more carbon-based particles, metals, or metal quasi-oxides may be present in an amount sufficient to provide a flame retardancy rating of V0@1.5 mm. By weight of the composition, one or more carbon-based particles, metals, or metal quasi-oxides may be present in an amount of about 0% by weight or more, about 0.2% by weight or more, about 0.3% by weight or more, or about 0.5% by weight or more. By weight of the composition, one or more carbon-based particles, metals, or metal oxides may be present in an amount of about 10% by weight or less, about 5% by weight or less, about 3% by weight or less, or about 2% by weight or less. One or more carbon-based particles, metals, or metal oxides may be nanoparticles. The particle size may be any particle size capable of improving the flame retardancy rating of the composition. The particle size may be about 0.005 micrometers or larger, about 0.01 micrometers or larger, about 0.2 micrometers or larger, or about 0.35 micrometers or larger. The particle size may be about 2.0 micrometers or smaller, or about 1.0 micrometers or smaller. The particle size may be determined using laser diffraction techniques described in ISO 13322. The measured particle size is the average diameter.

[0053] The compositions disclosed herein may contain one or more buffering compounds or buffering systems. Any buffering system that enhances the molecular weight stability of polycarbonate may be used. The buffering system described herein may be one that provides protons (i.e., H+). + Or hydrated hydrogen ions), accepting protons (i.e., H+ ions), + A buffer system can contain a weak acid and its conjugate base. A buffer system can resist pH changes following the addition of a basic or acidic component. A buffer system can be configured based on the total number of protons (i.e., H+). + (or hydrated hydrogen ions), hydroxyl groups (i.e., hydroxide ions or OH-) -The buffer system may be characterized by one or more single-proton, diproton, triproton, or multiproton buffer compounds. Based on the total weight of the composition, the buffer system can stabilize the polycarbonate proportionally to the total amount of buffer system present. The buffer system described herein includes one or more buffers with acidic and basic functions, allowing the pH of the composition to be approximately neutral. The buffer system may include one or more buffer compounds, two or more buffer compounds, three or more buffer compounds, or multiple buffer compounds. The buffer system may contain a single compound. The buffer system may contain a pair of compounds. The buffer system may include inorganic compounds, organic compounds, or both. The buffer system may include counterions. The concentration of the buffer system (i.e., the weight percentage of the total composition) is sufficient to promote increased molecular weight stability of the polycarbonate. The buffer system may include buffer compounds, which are inorganic or organic compounds, that balance the pH of the composition to achieve optimal copolymerization and compounding. Inorganic compounds may include compounds without saturated carbon (i.e., without CH bonds). Inorganic compounds may contain carbon atoms without hydrogen bonds. Organic compounds may include compounds containing saturated carbon (i.e., containing CH bonds). Buffer compounds may include acetates, sulfonates, phosphates, ammonia, formates, or any combination thereof. Buffer systems may include aromatic or aliphatic buffer compounds. Buffer systems may include buffer compound pairs of weak acids and conjugate bases. Buffer compounds may be selected based on a pKa of approximately neutrality. Buffer compounds may maintain the pH of water at approximately neutral. Buffer systems may include Good's buffer.Organic compounds may include 2-(N-morpholino)ethanesulfonic acid (MES), 2-[bis(2-hydroxyethyl)amino]-2-(hydroxymethyl)propane-1,3-diol (bis-trimethylethane), 2-[(2-amino-2-oxoethyl)-(carboxymethyl)amino]acetic acid (ADA), N-(2-acetamido)-2-aminoethanesulfonic acid (ACES), and piperazine-N,N'-bis(2-ethanesulfonic acid). PIPES, 2-hydroxy-3-morpholinopropanesulfonic acid (MOPSO), 1,3-bis(tris(hydroxymethyl)methylamino)propane (bis-6-tripropane), NN-bis(2-hydroxyethyl)-2-aminoethanesulfonic acid (BES), MOPS, 2-[[1,3-dihydroxy-2-(hydroxymethyl)propyl-2-yl]amino]ethanesulfonic acid (TES), 4-(2-hydroxyethyl)-1-piperazine ethanesulfonic acid (HEPES), 3-(N,N-bis[2-hydroxyethyl]amino)-2-hydroxypropanesulfonic acid (DIPSO), 4-(N-morpholino)butyric acid (MOBS), 3-[[1,3-dihydroxy-2-(hydroxymethyl)propyl-2-yl]amino]-2-hydroxypropane-1-sulfonic acid (TAPSO), 4-(2-hydroxyethyl)piperazine-1-(2-hydroxypropanesulfonic acid) HEPPSO, POPSO, 3-[4-(2-hydroxyethyl)piperazin-1-yl]propane-1-sulfonic acid (EPPS or HEPPS), N-(2-hydroxy-1,1-bis(hydroxymethyl)ethyl)glycine (Tricine), glycylglycine (Gly-Gly), 2-(bis(2-hydroxyethyl)amino)acetic acid (Bicine), N-(2-hydroxyethyl)piperazin-N′-(4-butyric acid) (HEPBS), [tris(hydroxymethyl)ethylamino]propanesulfonic acid (TAPS), 2-amino-2-methyl-1,3-propanediol (A (mmediol or AMPD), N-tris(hydroxymethyl)methyl-4-aminobutyric acid (TABS), N-(1,1-dimethyl-2-hydroxyethyl)-3-amino-2-hydroxypropanesulfonic acid (AMPSO), N-cyclohexyl-2-aminoethanesulfonic acid (CHES), 3-(cyclohexylamino)-2-hydroxy-1-propanesulfonic acid (CAPSO), 2-amino-2-methylprop-1-ol (aminomethylpropanol or AMP), N-cyclohexyl-3-aminopropanesulfonic acid (CAPS), 4-(cyclohexylamino)-1-butyric acid (CABS), or any combination thereof. Inorganic compounds include metal phosphates, metal sulfonates, metal acetates, metal formates, etc.

[0054] The buffer system may comprise one or more alkali metal phosphates. Any alkali metal phosphate capable of enhancing the thermal stability of the composition may be used. The alkali metal phosphate may be a sodium metal phosphate or a potassium metal phosphate. Exemplary alkali metal phosphates may be one or more of distearate pentaerythritol disodium phosphate, monohydrogen phosphate, or dihydrogen phosphate, and monohydrogen, dihydrogen, or trihydrogen phosphate compounds. Exemplary alkali metal phosphates may be one or more of monohydrogen, dihydrogen, or trihydrogen phosphate compounds. An alkali metal phosphate may be sodium dihydrogen phosphate. Alkali metal phosphates may be used in any amount to improve the thermal stability of the composition. Based on the weight of the composition, alkali metal phosphates may be used in any amount of about 0% by weight or more, about 0.01% by weight or more, about 0.02% by weight or more, or about 0.03% by weight or more. Based on the weight of the composition, alkali metal phosphates may be used in any amount of about 1.0% by weight or less, about 0.5% by weight or less, about 0.2% by weight or less, or about 0.1% by weight or less.

[0055] The composition may contain one or more impact modifiers. The terms impact modifier and rubber are used interchangeably. Various impact modifiers may be used in the disclosed compositions; such as diene rubber, ethylene propylene rubber, ethylene propylene diene (EPDM) rubber, ethylene copolymer rubber, acrylate rubber, polyisoprene rubber, silicone rubber, silicone-acrylate rubber, polyurethane, thermoplastic elastomers, halogenated rubber, and mixtures thereof. Interpolymers of rubber forming monomers with other copolymerizable monomers are also suitable. The rubber may be present in the formulated composition in an amount sufficient to provide the desired impact properties. Desired impact properties include increased notched Izod, Charpy, Gardner, tensile, dart impact, etc. The composition may contain a mixture of one or more impact modifiers. When the composition contains a mixture of one or more impact modifiers, it is desirable that one or more impact modifiers in the mixture be a siloxane-acrylate core-shell rubber with a siloxane core.

[0056] The rubber can be a diene rubber such as polybutadiene, polyisoprene, polypentadiene, polychloroprene, etc., or a mixture of diene rubbers, i.e., any rubbery polymer of one or more conjugated 1,3-dienes such as 1,3-butadiene. Such rubber includes homopolymers of 1,3-butadiene and copolymers of 1,3-butadiene with one or more copolymerizable monomers such as vinylidene-substituted aromatic compounds (styrene). The diene rubber can be a homopolymer of 1,3-butadiene. An exemplary copolymer of 1,3-butadiene is a block or cone-block rubber comprising at least about 30% by weight of 1,3-butadiene, about 50% by weight, about 70% by weight, or about 90% by weight of 1,3-butadiene, and up to about 70% by weight of vinylidene-substituted aromatic monomers, and up to about 50% by weight, about 30% by weight, or up to about 10% by weight of vinylidene-substituted aromatic monomers, weights based on the weight of the 1,3-butadiene copolymer.

[0057] The impact modifiers used can be those polymers and copolymers that exhibit a second-order transition temperature (sometimes called glass transition temperature (Tg)) for the diene segment not higher than 0°C or not higher than -20°C, as determined using conventional techniques (e.g., ASTM Test Method D 746-52 T). The cis content of the diene rubber can be equal to or less than 99% or less than 97%. The cis content of the diene rubber can be equal to or greater than 20% or greater than 37%, wherein the cis weight percentage is based on the weight of the diene rubber. The rubber can be 1,3-butadiene rubber having at least about 1% by weight of 1,2-vinyl or at least about 7% by weight of 1,2-vinyl based on the weight of the 1,3-butadiene rubber. The 1,3-butadiene rubber can have less than or equal to about 30% by weight of 1,2-vinyl or less than or equal to about 13% by weight of 1,2-vinyl based on the weight of the 1,3-butadiene rubber. Diene rubber may have a weight-average molecular weight of at least about 100 kg / mol or at least about 300 kg / mol. Diene rubber may have a weight-average molecular weight equal to or less than about 900 kg / mol or equal to or less than 600 kg / mol. Diene rubber has a solution viscosity of at least 10 centistokes (cSt) (10 percent (10%) in styrene) or about 30 cSt. Diene rubber may have a solution viscosity equal to or less than about 500 cSt or equal to or less than about 400 cSt. Rubber with grafted and / or adsorbed polymers (if present) is dispersed in a continuous matrix phase as discrete particles. Rubber particles may include a range of sizes with a unimodal, bimodal, or multimodal distribution. The average particle size of rubber particles used herein refers to the volume average diameter. The volume average diameter of a set of particles may be the same as the weight average diameter. The average particle diameter measurement typically includes the polymer grafted onto the rubber particles and occlusions of the polymer within the particles. Unless otherwise specified, the rubber particle sizes disclosed and claimed herein were determined on a Coulter Multisizer II or II e with ACCUCOMP™ software version 2.01 by the following method: approximately 3 polymer sample particles (30–70 mg) were dissolved in 5 mL of dimethylformamide (DMF) by stirring in an ultrasonic bath for approximately 15–20 minutes. 10 mL of electrolyte solution (DMF containing 1% NH4SCN) was mixed with 0.2 mL of the sample solution. The plough stage was used with a 20 μm Coulter tube and 1.16 μm calibration material. The coincidence level indicator reading of the device should be between 5% and 10%. If the reading is higher than 10%, the sample was diluted with electrolyte solution in a beaker, or if the reading is too low, more polymer solution was added dropwise to the DMF. The volume average particle size was reported.The average particle size of the rubber particles can be equal to or greater than about 0.05 micrometers (μm), equal to or greater than about 0.1 μm, and equal to or greater than about 0.5 μm. The average particle diameter of the rubber particles can be equal to or less than about 10 μm, equal to or less than about 5 μm, or equal to or less than about 4 μm.

[0058] Impact modifiers can be core-shell structured impact modifiers (MBS) based on butadiene or styrene-butadiene rubber and methyl methacrylate-styrene grafts, core-shell structured siloxane-acrylate rubbers, core-shell impact modifiers based on acrylate rubbers, etc. Core-shell impact modifiers based on butadiene or styrene-butadiene rubber are impact modifiers based on butadiene or styrene-butadiene rubber grafted with methyl methacrylate or methyl methacrylate-styrene copolymers, such as Kane Ace M732 from Kaneka Japan, and Paraaloid™ EXL2650J, EXL2690, and EXL2691J from Dow Chemical. Core-shell structured siloxane acrylate rubbers can be made from alkyl methacrylates and / or alkyl acrylates, crosslinking agents, and grafting agents. Exemplary alkyl methacrylates and / or alkyl acrylates are C... 1-5 -alkyl esters, such as methyl ester, ethyl ester, n-butyl ester, tert-butyl ester, n-propyl ester, n-hexyl ester, n-octyl ester, n-laurate, and 2-ethylhexyl ester; haloalkyl esters, preferably C-halogenated. 1-5Alkyl esters, such as ethyl chloride acrylate, and mixtures of these monomers. Particularly preferred is n-butyl acrylate. Monomers having one or more polymerizable double bonds can be used as crosslinking agents for the polyalkyl (meth)acrylate rubber component of siloxane acrylate rubbers. Examples of crosslinking monomers are esters of unsaturated monocarboxylic acids having 3 to 8 carbon atoms and unsaturated monohydric alcohols having 3 to 12 carbon atoms, or saturated polyols having 2 to 4 OH groups and 2 to 20 carbon atoms, such as ethylene glycol dimethacrylate, propylene glycol dimethacrylate, 1,3-butanediol dimethacrylate, and 1,4-butanediol dimethacrylate. Such crosslinking agents can be used alone or as a mixture of at least two crosslinking agents. Exemplary grafting agents are allyl methacrylate, triallyl cyanurate, triallyl isocyanurate, or mixtures thereof. Allyl methacrylate can also be used as a crosslinking agent. Such grafting agents can be used alone or as a mixture of at least two grafting agents. The crosslinking agent and grafting agent may be present in an amount from about 0.1% to about 20% by weight of the total weight of the polyalkyl (meth)acrylate rubber component based on the siloxane acrylate rubber. The core may be based on siloxane rubber. Exemplary siloxane acrylate rubbers include, for example, Metalatn S-2100, S-2001, S-2006, etc., purchased from Mitsubishi Rayon, and Kane Ace MR03, etc., purchased from Kaneka. The composition may contain a siloxane-acrylate rubber impact modifier, preferably in an amount of 1% to 8% by weight of the total weight of the composition, more preferably 1% to 6% by weight, and particularly preferably 2.0% to 5.0% by weight. Exemplary core-shell impact modifiers based on acrylate rubber are methyl methacrylate-grafted impact modifiers based on acrylate rubber, including Paraaloid™ EXL2311, EXL2313, EXL2315, EXL2300, EXL2330 and EXL2390 from Dow; and Durathrength® 410, 440 and 480 from Arkema.

[0059] The impact modifier may be a siloxane-acrylate core-shell rubber with a siloxane core (e.g., an organosilicon-based graft copolymer with an organosilicon core component). The siloxane core may comprise about 1.0% by weight or more, about 10% by weight or more, or about 20% by weight or more of the impact modifier. The siloxane core may comprise about 99% by weight or less, about 90% by weight or less, or about 80% by weight or less of the impact modifier. The siloxane core may comprise about 1.0% to about 99% by weight, about 10% to about 90% by weight, or about 20% to about 80% by weight of the impact modifier.

[0060] The compositions disclosed herein contain impact modifiers in amounts of 0% by weight or more, about 0.5% by weight or more, about 1.0% by weight or more, about 2.0% by weight or more, or about 5.0% by weight or more, based on the weight of the composition. The compositions disclosed herein contain impact modifiers in amounts of about 20% by weight or less, about 15% by weight or less, or about 10% by weight or less, based on the weight of the composition. Impact modifiers may affect the effectiveness of flame retardants, therefore the amount and selection of flame retardant compounds may need to be adjusted upwards to provide the desired flame retardant properties.

[0061] The composition may contain one or more non-halogenated flame retardants commonly used in polycarbonate compositions. Non-halogenated means that the flame retardant does not contain halogen atoms. Using a non-halogenated flame retardant means that the composition containing the non-halogenated flame retardant will not release halogens during combustion. The flame retardant may be any flame retardant known for use in polycarbonate-based compositions that provides flame retardant properties and does not negatively affect the impact, heat resistance, flexural modulus, flexural strength, haze, and transparency of the composition. The amount of flame retardant used may be sufficient to meet the flame retardant requirements of the end use and may be used in an amount that will not adversely affect the performance of the article made from the composition. Exemplary flame retardants include phosphorus-containing compounds such as oligophosphates, poly(block-phosphono-oxy-esters), and / or poly(block-phosphono-oxy-carbonates), see USP 7,645,850 (which is incorporated herein in its entirety). Exemplary oligophosphates include bisphenol A bis(diphenyl phosphate) (BAPP). Exemplary additional flame retardants include 1,3-phenyltetra(2,6-dimethylphenyl) ester (Daihachi PX-200).

[0062] One or more non-halogenated flame retardants may be one or more phosphazenes. Any one or more phosphazenes that enhance flame retardancy can be used. Phosphazenes may contain more than one phosphazene unit. Phosphazenes are organic compounds having a –P=N- structure. Phosphazenes can be a linear structure containing one or more phosphazene units, or a cyclic structure containing one or more phosphazene units. The phosphorus atom on the phosphazene structure may be bonded to one or more alkyloxy groups. The alkyloxy group may be an alkoxy, aryloxy, alkyl-substituted aryloxy, alkoxy-substituted aryloxy, or halogen-substituted aryloxy. The alkyloxy group may be an aryloxy or an alkyl-substituted aryloxy. The alkyl group may be C... 1-10 Alkyl, C 1-3Alkyl, methyl, or ethyl compounds. Cyclic phosphazene compounds may contain one or more phosphazene units, or three or more phosphazene units. Cyclic phosphazene compounds may contain 25 or fewer phosphazene units, 10 or fewer phosphazene units, or five or fewer phosphazene units. Linear phosphazene compounds may contain one or more phosphazene units, three or more phosphazene units, five or more phosphazene units, or six or more phosphazene units. Linear phosphazene compounds may contain 10,000 or fewer phosphazene units, 1,000 or fewer phosphazene units, 100 or fewer phosphazene units, or 25 or fewer phosphazene units. Exemplary cyclic phosphazenes include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, and decaphenoxycyclopentaphosphazene. Cyclic phosphazenes can be obtained by reacting ammonium chloride with phosphorus pentachloride at 120 to 130 °C to obtain a mixture containing cyclic and linear phosphazenes, extracting cyclic phosphazenes such as hexachlorocyclotriphosphazene, octachlorocyclotetraphosphazene, and decachlorocyclopentaphosphazene, and then substituting them with phenoxy groups. Exemplary linear phosphazenes include compounds obtained by ring-opening polymerization of hexachlorocyclotriphosphazene obtained by the above method at 220-250 °C, and then substituting the resulting linear dichlorophosphazenes with a degree of polymerization of 3-10,000 (or as previously described) with phenoxy groups. Phosphazene compounds can be crosslinked. Phosphazene compounds can be crosslinked with bisphenol compounds such as 4,4'-diphenylene groups, for example, 4,4'-sulfonyl diphenylene (bisphenol S residue), 2,2-(4,4'-diphenylene), isopropylidene groups, 4,4'-oxodiphenylene groups, 4,4'-thiodiphenylene groups, etc. The phenylene content of cross-linked phenoxyphosphazene compounds is typically 50-99.9% by weight or 70-90% by weight. Cross-linked phenoxyphosphazene compounds may not contain any free hydroxyl groups in their molecules.

[0063] Based on the weight of the composition comprising polycarbonate and / or copolymers containing carbonate units, one or more non-halogenated flame retardants may be present in amounts of about 0.1% by weight or more, about 1% by weight or more, or about 5% by weight or more. Based on the weight of the composition, one or more flame retardants may be present in amounts of about 30% by weight or less, about 20% by weight or less, or about 10% by weight or less.

[0064] The disclosed compositions contain one or more antioxidants. Antioxidants can be introduced into the composition from the ingredients used (e.g., impact modifiers). Antioxidants can be added to the composition alone.

[0065] Antioxidants can be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzyl malonate, aromatic hydroxybenzyl compounds, triazine compounds, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or amino antioxidants. Antioxidants can be one or more of phenol-based compounds and / or phosphite-based antioxidants.

[0066] Phenol-based antioxidants include 2,6-di-tert-butyl-4-methylphenol; 2,6-diphenyl-4-methoxyphenol; 2,2′-methylenebis(6-tert-butyl-4-methylphenol); 2,2′-methylenebis(6-tert-butyl-4-methylphenol); 2,2′-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol]; 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2′-methylenebis(4-methyl-6-cyclohexylphenol); 2,2′-methylenebis(4-methyl-6-nonylphenol); 1,1, 3-Tris(5-tert-butyl-4-hydroxy-2-methylphenyl)butane; 2,2-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)-4-n-dodecyl mercaptobutane; ethylene glycol bis[3,3-bis(3-tert-butyl-4-hydroxyphenyl)butyrate]; 1,1-bis(3,5-dimethyl-2-hydroxyphenyl)-3-(n-dodecylthio)butane; 4,4′-thiobis(6-tert-butyl-3-methylphenol); 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene; 2,2-bis(3,5-di-tert-butyl)butane Dioctadecyl (4-hydroxybenzyl)malonate; n-octadecyl-3-(4-hydroxy-3,5-di-tert-butylphenyl)propionate; tetra[methylene(3,5-di-tert-butyl-4-hydroxycinnamate)]methane; and pentaerythritol tetra(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate. Hydroquinone-based and alkylated hydroquinone antioxidants include 2,6-di-tert-butyl-4-methoxyphenol, 2,5-di-tert-butylhydroquinone, 2,5-di-tert-pentylhydroquinone, 2,6-diphenyl-4-octadecyloxyphenol, and 2,6-di-tert-butylhydroquinone. Hydroquinone, 2,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyphenyl stearate, bis(3,5-di-tert-butyl-4-hydroxyphenyl) adipate. Tocopherol-based antioxidants include α-tocopherol, β-tocopherol, γ-tocopherol, δ-tocopherol, and mixtures thereof (vitamin E). Antioxidants based on O- and N-benzyl compounds include, for example, 3,5,3′,5′-tetra-tert-butyl-4,4′-dihydroxydibenzyl ether and tris(3,5-di-tert-butyl-4-hydroxybenzyl)amine.Antioxidants based on alkylene bisphenols include 2,2'-methylenebis(6-tert-butyl-4-methylphenol), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), 2,2'-methylenebis[4-methyl-6-(α-methylcyclohexyl)phenol], 2,2'-methylenebis(4-methyl-6-cyclohexylphenol), 2,2'-methylenebis(6-nonyl-4-methylphenol), 2 2'-Methylenebis(4,6-di-tert-butylphenol), 2,2'-Ethylenebis(4,6-di-tert-butylphenol), 2,2'-Ethylenebis(6-tert-butyl-4-isobutylphenol), 2,2'-Methylenebis[6-(α-methylbenzyl)-4-nonylphenol], 2,2'-Methylenebis[6-(α,α-dimethylbenzyl)-4-nonylphenol], 4,4'-Methylenebis(2, 6-Di-tert-butylphenol), 4,4′-methylenebis(6-tert-butyl-2-methylphenol), 1,1-bis(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, 2,6-bis(3-tert-butyl-5-methyl-2-hydroxybenzyl)-4-methylphenol, 1,1,3-tris(5-tert-butyl-4-hydroxy-2-methylphenyl)butane, ethylene glycol bis[3,3-bis(3′-tert-butyl- Antioxidants based on hydroxybenzyl malonates include bis[2-(3′-tert-butyl-2′-hydroxy-5′-methylbenzyl)-6-tert-butyl-4-methylphenyl] terephthalate, 1,1-bis-(3,5-dimethyl-2-hydroxyphenyl)butane, 2,2-bis(3,5-di-tert-butyl-4-hydroxyphenyl)propane, and 1,1,5,5-tetra(5-tert-butyl-4-hydroxy-2-methylphenyl)pentane. Antioxidants based on aromatic hydroxybenzyl groups include 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, 1,4-bis(3,5-di-tert-butyl-4-hydroxybenzyl)-2,3,5,6-tetramethylbenzene, and 2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)phenol.Antioxidants based on triazine compounds include 2,4-bis(octylmercapto)-6-(3,5-di-tert-butyl-4-hydroxyaniline)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyaniline)-1,3,5-triazine, 2-octylmercapto-4,6-bis(3,5-di-tert-butyl-4-hydroxyphenoxy)-1,3,5-triazine, and 2,4,6-tri-(3,5-di-tert-butyl- 4-Hydroxyphenoxy)-1,2,3-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)isocyanurate, 2,4,6-tris(3,5-di-tert-butyl-4-hydroxyphenylethyl)-1,3,5-triazine, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)-hexahydro-1,3,5-triazine and 1,3,5-tris(3,5-dicyclohexyl-4-hydroxybenzyl)isocyanurate. Antioxidants based on benzylphosphonates include dimethyl-2,5-di-tert-butyl-4-hydroxybenzylphosphonate, diethyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-3,5-di-tert-butyl-4-hydroxybenzylphosphonate, dioctadecyl-5-tert-butyl-4-hydroxy-3-methylbenzylphosphonate, and calcium salts of monoethyl 3,5-di-tert-butyl-4-hydroxybenzylphosphonate. Antioxidants based on acylaminophenols include, for example, 4-hydroxylauroyl aniline, 4-hydroxystearoyl aniline, and octyl N-(3,5-di-tert-butyl-4-hydroxyphenyl)carbamate. Exemplary antioxidants include esters of D-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctanol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tri(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxalamide, 3-thioundecanool, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, n-octanol, isooctanol, stearyl alcohol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tris(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)isocyanurate, etc. 3-Thioundecanool, 3-Thiopentadecanol, trimethylhexanediol, trimethylolpropane, 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane; 3,9-bis[2-{3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy}-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5.5]-undecane.Exemplary antioxidants include esters of β-(3,5-dicyclohexyl-4-hydroxyphenyl)propionic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, octanol, stearyl alcohol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tri(hydroxyethyl)isocyanurate, N,N'-bis(hydroxyethyl)oxalamide, 3-thioundecanool, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include esters of 3,5-di-tert-butyl-4-hydroxyphenylacetic acid with monohydric or polyhydric alcohols (e.g., with methanol, ethanol, octanol, octadecanol, 1,6-hexanediol, 1,9-nonanediol, ethylene glycol, 1,2-propanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol), tri(hydroxyethyl)isocyanurate, N,N′-bis(hydroxyethyl)oxalamide, 3-thioundecanool, 3-thiopentadecanol, trimethylhexanediol, trimethylolpropane, and 4-hydroxymethyl-1-phospha-2,6,7-trioxabicyclo[2.2.2]octane. Exemplary antioxidants include amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid, such as N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hexamethylenediamide, N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)trimethylenediamide, N,N′-bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazide, and N,N′-bis[2-(3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionyloxy)ethyl]oxalamide (Naugard® XL-1, supplied by Uniroyal). Exemplary antioxidants include ascorbic acid (vitamin C).Amino-based antioxidants include N,N′-diisopropyl-p-phenylenediamine, N,N′-disec-butyl-p-phenylenediamine, N,N′-bis(1,4-dimethylpentyl)-p-phenylenediamine, N,N′-bis(1-ethyl-3-methylpentyl)-p-phenylenediamine, N,N'-bis(1-methylheptyl)-p-phenylenediamine, N,N'-dicyclohexyl-p-phenylenediamine, N,N'-diphenyl-p-phenylenediamine, N,N'-bis(2-naphthyl)-p-phenylenediamine, N-isopropyl-N'-phenyl-p-phenylenediamine, N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, N... -(1-Methylheptyl)-N'-phenyl-p-phenylenediamine, N-cyclohexyl-N'-phenyl-p-phenylenediamine, N,N'-dimethyl-N,N'-disec-butyl-p-phenylenediamine, diphenylamine, N-allyl diphenylamine, 4-isopropoxydiphenylamine, N-phenyl-1-naphthylamine, N-(4-tert-octylphenyl)-1-naphthylamine, N-phenyl-2-naphthylamine, octylated diphenylamine, p,p'-di-tert-octyl diphenylamine, 4-n-butylaminophenol, 4-butyrylaminophenol, 4-nonanoylaminophenol, 4-dodecanoylaminophenol, 4-octadecanoylaminophenol, bis(2-phenyl-2-phenyl-3 ... (4-Methoxyphenyl)amine, 2,6-di-tert-butyl-4-dimethylaminomethylphenol, 2,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, N,N,N',N'-tetramethyl-4,4'-diaminodiphenylethane, 1,2-bis[(2-methylphenyl)amino]ethane, 1,2-bis(phenylamino)propane, (o-tolyl)biguanidine, bis[4-(1',3'-dimethylbutyl)phenyl]amine, tert-octylated N-phenyl-1-naphthylamine, mixtures of monoalkylated and dialkylated tert-butyl / tert-octyl diphenylamine, monoalkylated and dialkylated... Mixtures of alkylated nonyl diphenylamine, mixtures of monoalkylated and dialkylated dodecyl diphenylamine, mixtures of monoalkylated and dialkylated isopropyl / isohexyl diphenylamine, mixtures of monoalkylated and dialkylated tert-butyl diphenylamine, N,N,N′,N′-tetraphenyl-1,4-diaminobut-2-ene, N,N-bis(2,2,6,6-tetramethylpiperidin-4-yl-hexamethylenediamine), bis(2,2,6,6-tetramethylpiperidin-4-yl) sebacate, 2,2,6,6-tetramethylpiperidin-4-one, 2,2,6,6-tetramethylpiperidin-4-ol.Phosphorus antioxidants include tetrakis(2,4-di-tert-butylphenyl)-4,4-biphenylphosphite, tris(2,4-di-tert-butylphenyl) phosphite, 2,2'-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, di(nonylphenyl)pentaerythritol diphosphite, phenyl-bisphenol A-pentaerythritol diphosphite, distearate pentaerythritol diphosphite, dioctyl pentaerythritol diphosphite, and dilauryl pentaerythritol diphosphite. Phosphate esters, including diphenyl pentaerythritol diphosphite, dicyclohexyl pentaerythritol diphosphite, bis(2,4,6-tri-tert-butylphenyl) pentaerythritol diphosphite, 2,2'-ethylidene bis(4,6-di-tert-butylphenyl) fluorophosphite, triisodecyl phosphite, tri-dodecyl phosphite, phenyl isooctyl phosphite, phenyl isooctyl phosphite, phenyl dodecyl phosphite, diphenyl isooctyl phosphite, diphenyl isooctyl phosphite, diphenyl dodecyl phosphite, triphenyl phosphite, tri(mononophenyl) phosphite, and tri(dinonylphenyl) phosphite. The antioxidant may be octadecyl 3,5-di-(tert-butyl)-4-hydroxyhydrocinnamate, which is commercially available from BASF as IRGANOX 1076.

[0067] Exemplary antioxidant additives include, for example, organic phosphites such as tris(nonylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite (e.g., “IRGAFOS 168” or “I-168”), bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, distearate pentaerythritol diphosphite, etc.; alkylated monophenols or polyphenols; alkylation products of polyphenols with dienes, such as tetra[methylene(3,5-di-tert-butyl-4-hydroxycinnamate)methane, etc.; butylation products of p-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with mono- or polyols. Esters; esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with mono- or polyols; esters of thioalkyl or thioaryl compounds, such as distearate thiopropionate, dilaurate thiopropionate, ditridecyl thiodipropionate, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythritol propionate tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) ester, etc.; amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid, etc., or combinations comprising at least one of the aforementioned antioxidants.

[0068] Antioxidants can be present in any amount in the composition and the structure formed therefrom to delay the oxidation of the polymer. Based on the weight of the disclosed composition, the antioxidant can be present in amounts of about 100 parts per million or more, about 200 parts per million or more, about 300 parts per million or more, about 500 parts per million or more, or about 1000 parts per million or more. Based on the weight of the disclosed composition, the antioxidant can be present in amounts of about 10,000 parts per million or less, about 8,000 parts per million or less, or about 6,000 parts per million or less.

[0069] The composition may contain a release agent. Exemplary release agents include any release agents and combinations thereof known in the art. The release agent may be an internal release agent. The release agent may include one or more compatibilizers, such as those taught in the now-expired U.S. Patent 5,212,209A, which is incorporated herein by reference in its entirety for all purposes. Example classes of release agents include aliphatic carboxylic acids; esters of aliphatic carboxylic acids and alcohols; aliphatic hydrocarbon compounds with a number average molecular weight of 200 to 15,000; and polysiloxane alkyl silicone oils. Examples of aliphatic carboxylic acids include saturated or unsaturated aliphatic monovalent, divalent, or trivalent carboxylic acids. Aliphatic carboxylic acids also include alicyclic carboxylic acids. Aliphatic carboxylic acids may be C 6-36 Monovalent or divalent carboxylic acids. Aliphatic carboxylic acids can be C10 or C20. 6-36Aliphatic saturated monovalent carboxylic acids. Specific examples of such aliphatic carboxylic acids include palmitic acid, stearic acid, hexanoic acid, decanoic acid, lauric acid, arachidic acid, behenic acid, tetracosanoic acid, ceric acid, beeswax acid, tritetracosanoic acid, linalic acid, adipic acid, and azelaic acid. Examples of aliphatic carboxylic acids in esters of aliphatic carboxylic acids and alcohols include the same aliphatic carboxylic acids as described above. Examples of alcohols include saturated or unsaturated, monohydric or polyhydric alcohols that may have substituents, such as fluorine or aryl groups. Alcohols can be monohydric or polyhydric saturated alcohols with no more than 30 carbon atoms. Alcohols can be aliphatic saturated monohydric alcohols and aliphatic saturated polyhydric alcohols with no more than 30 carbon atoms. The term "aliphatic" is used herein to also include alicyclic compounds. Specific examples of such alcohols include octanol, decanol, dodecanol, stearyl alcohol, behenol, ethylene glycol, diethylene glycol, glycerol, pentaerythritol, 2,2-dihydroxyperfluoropropanol, neopentyl glycol, bis(trimethylolpropane), and dipentaerythritol. Each of the above esters can be a pure product or a mixture of multiple compounds. Each of the aliphatic carboxylic acid and alcohol that combines to form an ester can be a single type, or two or more types can be used in any proportion and combination. Specific examples of esters of aliphatic carboxylic acids and alcohols include beeswax (a mixture containing lauryl palmitate as a major component), octadecyl stearate, dodecanyl behenate, octadecyl behenate, glyceryl monopalmitate, glyceryl monostearate, glyceryl distearate, glyceryl tristearate, pentaerythritol monopalmitate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristearate, and pentaerythritol tetrastearate. Examples of aliphatic hydrocarbons with a number average molecular weight of 200-15,000 include liquid paraffin, paraffin wax, microcrystalline wax, polyethylene wax, Fischer-Tropsch wax, and α-olefin oligomers with 3-12 carbon atoms. Aliphatic hydrocarbons also include alicyclic hydrocarbons. Each of these hydrocarbons can be partially oxidized. Aliphatic hydrocarbons can be paraffin wax, polyethylene wax, and partially oxidized polyethylene wax is preferred. Paraffin wax and polyethylene wax are more preferred. The number average molecular weight of the aliphatic hydrocarbon must not exceed 5,000. Examples of polysiloxane alkyl silicone oils include dimethyl silicone oil, methylphenyl silicone oil, and diphenyl silicone oil. Release agents may include a single type of the above, or any combination thereof in any proportion may include two or more types of the above.

[0070] The amount of mold release agent is not limited and can be about 0.001% by weight or more, about 0.01% by weight or more, or about 0.1% by weight or more based on the composition. The amount of mold release agent is not limited and can be about 2% by weight or less, about 1% by weight or less, or about 0.6% by weight or less based on the weight of the composition. If the content of the mold release agent is below the lower limit of this range, the demolding effect may be insufficient; on the other hand, if the content of the mold release agent exceeds the upper limit of this range, decreased hydrolysis resistance and mold contamination during injection molding may occur.

[0071] The compositions disclosed herein may include a UV absorber (i.e., a UV stabilizer), which in another embodiment serves to stabilize the color of the composition. When a UV absorber is added, polycarbonate, vinylidene-substituted aromatic compounds, or both may absorb light energy from ultraviolet light as heat. The UV absorber can reduce the weathering effect of the polymer composition (e.g., a composition of polycarbonate and vinylidene-substituted aromatic compounds). The UV absorber may include benzotriazole, hydroxyphenyltriazine, benzophenone, mesothiazine, etc., or any combination thereof. The UV absorber may be present in amounts of about 500 ppm or more, about 1,000 ppm or more, or about 1,500 ppm or more. The UV absorber may be present in amounts of about 10,000 ppm or less, about 8,000 ppm or less, or about 6,000 ppm or less. The UV absorber may be present in amounts of about 500 ppm to about 10,000 ppm.

[0072] The filler may be a reinforcing filler, such as fibers with a length-to-diameter ratio of about 4 or greater. Based on the total weight of the polymer composition, the amount of other fillers (e.g., non-reinforcing fillers, such as talc, clay, etc.) may be about 6% by weight or less, about 4% by weight or less, about 2% by weight or less, or about 1% by weight or less. Reinforcing fillers may be used to increase the strength of the composition and / or reduce its linear coefficient of thermal expansion. Reinforcing fillers may include glass fibers, carbon fibers, metal fibers, or any combination thereof. Other reinforcing fillers include mineral fillers with a needle-like structure (acicular structure), such as wollastonite. The composition may optionally include a component for adsorbing volatile organic compounds. The component may be zeolite, activated carbon, bamboo, charcoal, or a combination thereof.

[0073] The disclosed composition may contain one or more glass fibers. The one or more glass fibers may be short glass fibers, long glass fibers, or a combination thereof. Glass fibers may increase the strength of the polycarbonate composition and / or reduce the linear coefficient of thermal expansion of the composition. Glass fibers may be long-filament glass rovings naturally cut during twin-screw extrusion. The one or more glass fibers may be continuous glass fibers or glass fabrics. Glass fibers may be chopped glass fibers. Chopped glass fibers may be long-chopped glass fibers, short-chopped glass fibers, or a combination thereof. Glass fibers may be of any length that can positively influence the flame-retardant properties of the composition. Glass fibers may be round or oval. Glass fibers may be industrially recycled glass fibers.

[0074] The composition may contain one or more glass fibers in an amount sufficient to positively influence the flame-retardant properties of the composition. The composition may contain one or more glass fibers in an amount of 0% by weight or more, about 5% by weight or more, about 10% by weight or more, or about 20% by weight or more based on the weight of the composition. The composition may contain glass fibers in an amount of about 50% by weight or less, 45% by weight or less, or about 20% by weight or less based on the weight of the composition. The composition may contain one or more glass fibers in an amount of 0% by weight to about 50% by weight, about 5% by weight to about 45% by weight, or about 20% by weight based on the weight of the composition.

[0075] The disclosed compositions may contain one or more additives commonly used in this type of composition. Exemplary additives include: zinc salts, colorants, stabilizers, adsorbents (e.g., zeolite, activated carbon, bamboo charcoal, etc.), antistatic agents, silicone oils, flow promoters, etc. Additives and / or fillers and / or adsorbents may be present in the composition in amounts of about 0.01% by weight or more, about 0.1% by weight or more, about 1% by weight or more, about 2% by weight or more, or about 3% by weight or more, based on the weight of the composition. Additives and / or fillers may be present in amounts of about 40% by weight or less, about 30% by weight or less, about 20% by weight or less, about 15% by weight or less, about 10% by weight or less, or about 5% by weight or less, based on the weight of the composition. Based on the weight of the composition, additives and adsorbents may be present independently in amounts up to 5% by weight, while fillers may be present in amounts up to about 40% by weight.

[0076] The disclosed compositions can be produced by mixing the components in a known manner and melt-mixing and / or melt-extruding them in a conventional unit (such as an internal kneader, extruder, and twin-screw extruder) at a temperature of 250°C to 330°C. Individual components can be continuously and simultaneously mixed in a known manner at temperatures of about 23°C (room temperature) and higher. Mixing can be carried out for a time sufficient to form a homogeneous mixture of the components. The mixing time can be about 10 seconds or longer, 20 seconds or longer, or about 30 seconds or longer. The mixing time can be 600 seconds or less.

[0077] The disclosed compositions can be molded using methods known in the art. Polycarbonate compositions can be molded into useful molded articles by various means, such as injection molding, overmolding, extrusion, rotational molding, blow molding, and thermoforming, to form a variety of molded articles. Such articles may include thin-walled articles for consumer products (such as mobile phones, MP3 players, computers, laptops, cameras, video recorders, electronic tablets, handheld receivers, kitchen utensils, appliance housings, etc.), such as smart meter housings; electrical connectors, lighting equipment components, decorative items, household appliances, roofs, greenhouses, sunrooms, swimming pool railings, light-emitting diodes (LEDs) and lamp panels, extruded film and sheet articles; electrical components, such as relays; and telecommunications components, such as components for base station terminals. This disclosure also contemplates additional manufacturing operations for said articles, such as, but not limited to, molding, in-mold decoration, baking in a paint oven, lamination, and / or thermoforming. The disclosed compositions may be heated to a temperature at which the composition flows, said temperature may be higher than the glass transition temperature of the polycarbonate in the composition. Such temperatures can be above 155°C, above 200°C or higher, or 250°C or higher. Such temperatures can be 400°C or lower, or 300°C or lower. The mold can be heated to facilitate processing, such as to 50°C or higher, 80°C or higher, or 100°C or higher.

[0078] The UL-94 vertical test (20 mm vertical burning test) in the UL standard is a measurement method used to measure the flame retardancy index of unexpanded resins. The purpose of the test is to determine the resistance of plastic materials used in components of equipment and appliances to flame and luminous propagation. UL 94 is used to measure the burning rate and characteristics based on standard samples. The sample size is 12.7 mm x 127 mm, with varying thicknesses. Thickness must be reported when giving a rating. The relevant ratings are: V-2, V-1, and V-0. "V-0" is the most common rating for visible parts requiring increased flame protection. V-0 has the following requirements:

[0079] 1. After each of the two 10-second flame applications, none of the five samples burned for more than 10 seconds.

[0080] 2. The total burning time of ten 10-second flame applications (5 samples, 2 applications each) exceeded 50 seconds.

[0081] 3. None of the five samples produced a flame or glow that burned onto the clamping forceps.

[0082] 4. None of the five samples dripped burning particles that would ignite dry degreased cotton located 305 mm below the sample.

[0083] 5. None of the five samples continued to glow or burn for more than 30 seconds after the flame was removed for the second time.

[0084] Other ratings follow a similar format. The most significant difference in the ratings is the allowed duration of flame or luminous combustion. The flame application time is the same. Here is a brief overview of the required results for V-0, V-1, and V-2: V-0 combustion stops within 10 seconds after two 10-second flame applications to the test strip, with no flame dripping allowed; V-1 combustion stops within 60 seconds after two 10-second flame applications to the test strip, with no flame dripping allowed; and V-2 combustion stops within 60 seconds after two 10-second flame applications to the test strip, with flame dripping allowed.

[0085] The test procedure is outlined here. Samples of a specific size are vertically attached to the fixture and exposed to a 20 mm flame for 10 seconds. Each of the five samples is clamped 300 mm above a layer of dry cotton. A calibration flame is applied for 10 seconds at the bottom edge of the vertically supported test strip, and any afterflame time (t1) is recorded. After the flame is removed, it is applied again for another 10 seconds, and the afterflame time (t2) and afterglow time (t3) are recorded. If one sample fails, a second set of five samples can be tested. Further details can be obtained by contacting UL or by visiting the UL Standards website (http: / / ulstandardsinfonet.ul.com) for copies of this standard and other UL standards. Table 1 defines the specific criteria for V-0, V-1, and V-2 ratings.

[0086]

[0087] illustrate

[0088] 1. A composition comprising: a) one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbon salts, provided that the carbon salts are free of any halogen atoms.

[0089] 2. The composition according to Description 1, wherein the one or more polycarbonates comprise about 90% by weight or more of one or more recycled polycarbonates.

[0090] 3. The composition according to Description 1 or 2, wherein, by weight of the composition, the composition comprises: b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants, and c) about 0.01 to about 1.0% by weight of one or more carbide salts.

[0091] 4. The composition according to any one of the foregoing descriptions, comprising d) one or more inorganic particles.

[0092] 5. The composition according to any one of the foregoing descriptions, wherein d) one or more inorganic particles comprise one or more carbon-based particles, metal oxides, and metal-like oxides.

[0093] 6. The composition according to any one of the foregoing descriptions, wherein d) one or more inorganic particles comprise one or more of carbon nanotubes, carbon black, titanium dioxide, magnesium oxide, silicon dioxide, mica, talc and wollastonite.

[0094] 7. The composition according to any one of the foregoing descriptions, wherein d) one or more inorganic particles are present in an amount of about 0 to about 10% by weight of the composition.

[0095] 8. The composition according to any one of the foregoing descriptions, comprising e) one or more buffer compounds capable of stabilizing the molecular weight of one or more polycarbonates.

[0096] 9. The composition according to any one of the foregoing descriptions, wherein e) one or more buffer compounds comprise one or more alkali metal phosphates.

[0097] 10. The composition according to any one of the foregoing descriptions, wherein e) one or more buffer compounds are present in an amount of about 0 to about 0.2% by weight of the composition.

[0098] 11. The composition according to any one of the foregoing descriptions, wherein the one or more alkali metal phosphates comprise one or more of distearate pentaerythritol diphosphate, monohydrogen phosphate, or dihydrogen phosphate, and monohydrogen, dihydrogen, or trihydrogen phosphate compounds.

[0099] 12. The composition according to any one of the foregoing descriptions, wherein the one or more alkali metal phosphates comprise one or more monohydrogen phosphate, dihydrogen phosphate, or trihydrogen phosphate compounds.

[0100] 13. The composition according to any one of the foregoing descriptions, wherein the one or more alkali metal phosphates comprises sodium dihydrogen phosphate.

[0101] 14. The composition according to any one of the foregoing descriptions, wherein the one or more polycarbonates are substantially entirely polycarbonate units.

[0102] 15. The composition according to any one of the foregoing descriptions, wherein the one or more polycarbonates are substantially entirely bisphenol polycarbonate units.

[0103] 16. The composition according to any one of the foregoing descriptions, comprising f) one or more impact modifiers.

[0104] 17. The composition according to any one of the foregoing descriptions, wherein f) one or more impact modifiers are present in an amount of about 0 to about 20% by weight of the composition.

[0105] 18. The composition according to any one of the foregoing descriptions, comprising f) one or more impact modifiers, said one or more impact modifiers comprising one or more core-shell rubbers having a siloxane core.

[0106] 19. The composition according to Description 18, wherein the siloxane core is about 1.0 to about 99% by weight of the impact modifier.

[0107] 20. The composition according to any one of Descriptions 16-19, wherein f) one or more impact modifiers are present in an amount of about 0.5 to about 20% by weight of the composition.

[0108] 21. The composition according to any one of the foregoing descriptions comprises g) one or more polysiloxane polycarbonate copolymers.

[0109] 22. The composition according to any one of the foregoing descriptions comprises (g) one or more polysiloxane polycarbonate copolymers present in an amount of about 0 to about 95% by weight of the composition, and the total amount of the polycarbonate comprises one or more polysiloxane polycarbonate copolymers.

[0110] 23. The composition according to any one of the foregoing descriptions comprises f) one or more impact modifiers and g) one or more polysiloxane polycarbonate copolymers.

[0111] 24. The composition according to any one of the foregoing descriptions, comprising f) one or more impact modifiers or g) one or more polysiloxane polycarbonate copolymers.

[0112] 25. The composition according to any one of Descriptions 21-24, wherein g) one or more polysiloxane polycarbonate copolymers may contain 1.0 to about 99% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

[0113] 26. The composition according to any one of Descriptions 21-25, wherein the composition comprises g) one or more polysiloxane polycarbonate copolymers in an amount greater than 2.0 to about 95% by weight of the composition, and the total amount of the polycarbonate comprises one or more polysiloxane polycarbonate copolymers.

[0114] 27. The composition according to any one of the foregoing descriptions, comprising h) one or more glass fibers.

[0115] 28. The composition according to any one of the foregoing descriptions, comprising h) one or more glass fibers in an amount of 0 to 50% by weight of the composition.

[0116] 29. The composition according to any one of Descriptions 16-28, wherein the composition comprises h) one or more glass fibers in an amount of about 5.0 to 50% by weight of the composition.

[0117] 30. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants comprises monomer units corresponding to the following formula:

[0118] R 1 a R 2 b SiO (4-a-b) / 2

[0119] Where R 1 It is an independent reactive functional group each time it appears;

[0120] R 2 Each time it appears, it is independently a hydrocarbon group having 1 to 12 carbon atoms; and

[0121] a and b are numbers that independently satisfy the relationships 0≦a≦3, 0≦b≦3, and 0≦a+b≦3 each time they appear.

[0122] 31. The composition according to any one of the foregoing descriptions, wherein:

[0123] R 1 Each time it appears, it is independently one or more of alkoxy, aryloxy, polyoxyalkylene, hydrogen, hydroxy, carboxyl, silanol, amino, mercapto, epoxy, and vinyl groups; and

[0124] R 2 Each time it appears, it is independently one or more of a straight-chain or branched alkyl group having 1 to 12 carbon atoms, a cycloalkyl group having 5 to 12 carbon atoms, an aryl group having 6 to 12 carbon atoms, and an aralkyl group having 7 to 12 carbon atoms.

[0125] 32. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants contain one or more of alkyl, aryl, hydride, vinyl, and alkoxy groups.

[0126] 33. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants contain one or more of alkyl, aryl, and hydride groups.

[0127] 34. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants contains one or more of aryl, vinyl and alkoxy groups.

[0128] 35. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants comprises one or more polydialkylsiloxanes, polydiarylsiloxanes, and polyalkylarylsiloxanes.

[0129] 36. The composition according to any one of the foregoing descriptions, wherein the one or more polyorganosiloxane flame retardants comprises one or more polydimethylsiloxanes, polydiphenylsiloxanes, and polymethylphenylsiloxanes.

[0130] 37. The composition according to any one of the foregoing descriptions, wherein the carbonized salt comprises one or more sulfonates.

[0131] 38. The composition according to any one of the foregoing descriptions, wherein the carbonized salt comprises one or more aromatic sulfonates.

[0132] 39. The composition according to any one of the foregoing descriptions, wherein the carbonized salt comprises one or more alkali metal salts and alkaline earth metal salts.

[0133] 40. The composition according to any one of the foregoing descriptions, wherein the carbonized salt comprises one or more of sodium p-toluenesulfonate or potassium diphenyl sulfonate.

[0134] 41. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0135] a) About 50% to about 99% by weight of one or more polycarbonates;

[0136] b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; and

[0137] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0138] The amount mentioned therein is based on the weight of the composition, expressed by weight.

[0139] 42. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0140] a) About 50% to about 99% by weight of one or more polycarbonates;

[0141] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0142] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0143] d) 0 to about 10% by weight of one or more inorganic particles;

[0144] e) 0 to about 0.5% by weight of one or more buffer compounds;

[0145] f) 0 to about 20% by weight of one or more impact modifiers;

[0146] The amounts mentioned are all based on the weight of the composition by weight.

[0147] 43. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0148] a) About 50% to about 99% by weight of one or more polycarbonates;

[0149] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0150] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0151] d) 0 to about 10% by weight of one or more inorganic particles;

[0152] e) 0 to about 0.5% by weight of one or more buffer compounds;

[0153] f) 0 to about 20% by weight of one or more impact modifiers; and

[0154] g) 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers;

[0155] The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

[0156] 44. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0157] a) About 50% to about 99% by weight of one or more polycarbonates;

[0158] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0159] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0160] d) 0 to about 10% by weight of one or more inorganic particles;

[0161] e) 0 to about 0.5% by weight of one or more buffer compounds;

[0162] f) 0 to about 20% by weight of one or more impact modifiers;

[0163] g) 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and

[0164] h) 0 to about 50% by weight of one or more glass fibers,

[0165] The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

[0166] 45. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0167] a) About 50% to about 99% by weight of one or more polycarbonates;

[0168] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0169] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0170] d) 0 to about 10% by weight of one or more inorganic particles;

[0171] e) 0 to about 0.5% by weight of one or more buffer compounds; and

[0172] f) About 0.5% to about 20% by weight of one or more impact modifiers;

[0173] The amount mentioned therein is based on the weight of the composition, expressed by weight.

[0174] 46. ​​The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0175] a) About 50% to about 99% by weight of one or more polycarbonates;

[0176] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0177] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0178] d) 0 to about 10% by weight of one or more inorganic particles;

[0179] e) 0 to about 0.5% by weight of one or more buffer compounds;

[0180] f) about 0.5 to about 20% by weight of one or more impact modifiers; and

[0181] h) About 5.0 to about 50% by weight of one or more glass fibers,

[0182] The amount mentioned therein is based on the weight of the composition, expressed by weight.

[0183] 47. The composition according to any one of the foregoing descriptions, wherein the composition comprises:

[0184] a) About 50% to about 99% by weight of one or more polycarbonates;

[0185] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0186] c) About 0.05 to about 1.0% by weight of one or more carbonized salts;

[0187] d) About 0.2% to about 10% by weight of one or more inorganic particles;

[0188] e) About 0 to about 0.2% by weight of one or more buffer compounds;

[0189] f) About 0.5% to about 20% by weight of one or more impact modifiers;

[0190] The amounts mentioned are all based on the weight of the composition by weight.

[0191] 48. The composition according to any one of descriptions 1-44, wherein the composition comprises:

[0192] a) About 50% to about 99% by weight of one or more polycarbonates;

[0193] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0194] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0195] d) 0 to about 10% by weight of one or more inorganic particles;

[0196] e) 0 to about 0.5% by weight of one or more buffer compounds; and

[0197] g) More than 2.0% to about 95% by weight of one or more polysiloxane polycarbonate copolymers;

[0198] The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

[0199] 49. The composition according to any one of descriptions 1-44 or 48, wherein the composition comprises:

[0200] a) About 50% to about 99% by weight of one or more polycarbonates;

[0201] b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants;

[0202] c) About 0.01 to about 2.0% by weight of one or more carbonized salts;

[0203] d) 0 to about 10% by weight of one or more inorganic particles;

[0204] e) 0 to about 0.5% by weight of one or more buffer compounds;

[0205] g) greater than 2.0% to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and

[0206] h) About 5.0 to about 50% by weight of one or more glass fibers,

[0207] The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

[0208] 50. The composition according to any one of the foregoing descriptions, wherein the composition comprises one or more of the following: one or more non-halogenated flame retardants, one or more antioxidants, one or more UV absorbers, one or more mold release agents, and one or more colorants.

[0209] 51. The composition according to any one of the foregoing descriptions, wherein the article prepared from the composition achieves UL94 V0@1.5 mm flame retardancy.

[0210] 52. The composition according to description 48, wherein the article prepared from said composition achieves UL94 V0@1.0mm flame retardancy.

[0211] 53. A method comprising: a) contacting and thoroughly mixing the components described in any one of Descriptions 1 to 52 at a temperature of about 250°C or higher for about 10 seconds or longer; b) filling a mold with the mixed composition of a); c) forming a solid article from the composition in the mold; and d) removing the formed article from the mold.

[0212] 54. The method according to description 53, wherein the contact and mixing are carried out in an extruder, and the resulting mixture is transferred from the extruder to a die.

[0213] 55. An article prepared from the composition according to any one of descriptions 1 to 51, exhibiting UL94 V0@1.5mm flame retardancy.

[0214] 56. An article prepared from the composition described in description 48 or 52, exhibiting UL94 V0@1.0 mm flame retardancy.

[0215] Illustrative Examples

[0216] The following examples are provided only to illustrate the invention and are not intended to limit its scope. Unless otherwise stated, all parts and percentages are by weight.

[0217] Illustrative Example 1

[0218] Samples for Examples X1-X25 were prepared according to the following procedure. The components defined in Tables 1 and 2 below were combined and mixed in an extruder. The compositions were mixed and granulated on a twin-screw extruder (Coperion ZSK-26) at approximately 400 rpm, a yield of 80 kg / h, and an extrusion temperature of 290°C. The resulting homogeneous mixture was extruded and granulated. The granules were molded into test specimens according to the test procedures described above for the UL test and the notched Izod test ASTM D256, a single-point test used to measure the resistance of a material to pendulum impact. It is defined as the kinetic energy required to initiate fracture and sustain fracture until the specimen breaks. The notched Izod test was measured at 23°C and reported in J / m. In Examples 17 to 20 of Table 2, PC2 was present in flake (granule) form at a content of 10% by weight and in powder form at a content of 30% by weight. In Table 3, PC2 in Examples 21 to 24 was present in powder form with a content of 25% by weight, and PC2 in Example 25 was present in powder form with a content of 30% by weight.

[0219] Element

[0220] PC1 - PC200-15 polycarbonate, melt flow rate = 15; Mw = 24,500 amu

[0221] PC2 - PC600-3 polycarbonate, melt flow rate = 3; Mw = 35,000 amu

[0222] PC3 - S2000F polycarbonate powder, Mw=27,000 amu

[0223] PCR - Post-consumption recycled polycarbonate - Melt flow rate = 15; Mw = 24,500 amu

[0224] PC-SIL - S2060 PC-siloxane copolymer, melt flow rate = 1; siloxane content 20%.

[0225] POS1 - KR2710 is a low molecular weight organosilicon compound of polyorganosiloxane with a degree of polymerization of about 3 to 4, a phenyl concentration of about 40%, and containing Si-H at an estimated concentration of 0.3 to 0.4 mol / 100 g.

[0226] POS2 - KR511 is a polyorganosiloxane containing phenyl, methoxy, and vinyl groups.

[0227] CSR-MR03 is an organosilicon-based graft copolymer containing more than 70% by weight of an organosilicon core component and a graft polymer shell component mainly derived from acrylate monomers.

[0228] CHAR1 - DD-01 Carbonized Salt Flame Retardant, Sodium p-Toluenesulfonate

[0229] CHAR2 KSS carbon salt flame retardant, potassium salt of diphenyl sulfonate and diphenyl sulfonate disulfonate complex –

[0230] MR1 - L-P861 is a pentaerythritol tetrastearate-based mold release agent.

[0231] MR2 - L-3820 is a fatty acid ester-based release agent.

[0232] AO1-B900 is an antioxidant, a mixture of 80% tris(2,4-di-tert-butylphenyl) phosphite or IRGAFOS 168 and 20% octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate or IRGANOX 1076; UVA1-T234 is a UV absorber, 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol or Tinuvin 234.

[0233] MSP - Sodium dihydrogen phosphate.

[0234] TiO2 - Titanium dioxide

[0235] Table 1

[0236]

[0237] Table 2

[0238]

[0239] X1 shows that the combination of carbide salt and polyorganosiloxane provides good flame retardancy without the use of PFAS compounds. X2-X3 show the use of PC-siloxane copolymers, and the results indicate that good flame retardancy can be achieved without the use of PFAS compounds, without the use of PC-siloxane copolymers. X4-X5 show that good flame retardancy is achieved when the acrylate siloxane core-shell impact modifier has a siloxane core comprising 70% by weight of the core-shell modifier to improve impact resistance. Examples X6-X7 show that the addition of TiO2 improves flame retardancy. X8-X12 show that the carbide salt (potassium salt of diphenyl sulfonate and diphenyl sulfonate disulfonate complex) works well, although it is less efficient compared to (sodium p-toluenesulfonate). X13-X14 show that polyorganosiloxanes with phenyl, methoxy, and vinyl groups function well, although their efficiency is lower compared to polyorganosiloxanes with low molecular weight, a degree of polymerization of about 3 to 4, and a phenyl concentration of about 40% (including an estimated concentration of 0.3 to 0.4 mol / 100 g Si-H (hydride)). X15-X16 show that good flame retardancy is maintained when a heat stabilizer with sodium dihydrogen phosphate buffer is added. X17-X20 show good results obtained using post-consumer recycled polycarbonate. Examples of all claimed compositions show notched Izod results greater than 700 J / m.

[0240] Illustrative Example 2

[0241] Compositions containing PC-siloxane and V-O@1.0 mm

[0242] The samples of Examples X21-X25 contain at least 15% by weight of a PC-siloxane copolymer composition and are free of silicone-based graft copolymers. The samples were prepared according to the following procedure. The components defined in Table 3 were combined and mixed in an extruder. The composition was mixed and granulated on a twin-screw extruder (Coperion ZSK-26) at approximately 400 rpm, a yield of 80 kg / h, and an extrusion temperature of 290°C. The resulting homogeneous mixture was extruded and granulated. The granules were molded into test specimens according to the above-described UL test and notched Izod test ASTM D256 test procedures. The notched Izod test is a single-point test used to measure the resistance of a material to pendulum impact. It is defined as the kinetic energy required to initiate fracture and sustain fracture until the specimen breaks. The notched Izod test is measured at 23°C and reported in J / m. Examples X21 to X24 PC2 were present in powder form at a content of 25% by weight, and Example X25 PC2 was present in powder form at a content of 30% by weight.

[0243] Element

[0244] PC1 - PC200-15 polycarbonate, melt flow rate = 15; Mw = 24,500 amu

[0245] PC2 - PC600-3 polycarbonate, melt flow rate = 3; Mw = 35,000 amu

[0246] PCR - Post-PCR recycled polycarbonate - Melt flow rate = 15; Mw = 24,500 amu

[0247] PC-SIL - S2060 PC-siloxane copolymer, melt flow rate = 1; siloxane content 20%.

[0248] CHAR1 - DD-01 Carbonized Salt Flame Retardant Sodium p-Toluenesulfonate

[0249] POS1 - KR2710 is a low molecular weight organosilicon compound of polyorganosiloxane with a degree of polymerization of about 3 to 4, a phenyl concentration of about 40%, and containing Si-H at an estimated concentration of 0.3 to 0.4 mol / 100 g.

[0250] POS3 - Dow 40-001 is a liquid polyorganosiloxane with methyl, phenyl, and hydroxyl end caps.

[0251] MR2 - L-3820 is a fatty acid ester-based release agent.

[0252] AO1-B900 is an antioxidant, a mixture of 80% tris(2,4-di-tert-butylphenyl) phosphite or IRGAFOS 168 and 20% octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate or IRGANOX 1076.

[0253] MSP - Sodium dihydrogen phosphate.

[0254] CB-BP-800 is carbon black.

[0255] Table 3

[0256]

[0257] X21 and X22 show that a V-0 of 1.0 mm can be achieved using both virgin PC and post-consumer recycled PC. X23 and X24 show that a V-0 of 1.0 mm can be achieved when using different silicone flame retardants, such as Dow 40-001. X25 shows that a V-0 of 1.0 mm can be achieved using 15% PC-siloxane copolymer.

[0258] Illustrative Example 3

[0259] Flame-retardant polycarbonate compositions containing glass fibers that are not formulated with PFAS additives

[0260] Samples for Examples X26-X32 were prepared according to the following procedure. The components defined in Table 4 below were combined and mixed in an extruder. The composition was mixed and granulated on a twin-screw extruder (Coperion ZSK-26) at a speed of approximately 350 rpm, a yield of 60 kg / h, and an extrusion temperature of 290°C. The resulting homogeneous mixture was extruded and granulated. The granules were molded into test samples according to the UL test procedure described above.

[0261] Element

[0262] PC1 - PC200-15 polycarbonate, melt flow rate = 15; Mw = 24,500 amu

[0263] PC2 - PC600-3 polycarbonate, melt flow rate = 3; Mw = 35,000 amu

[0264] PC3 - S2000F polycarbonate powder, Mw=27,000 amu

[0265] PCR - PCR 114 post-consumption recycled polycarbonate - melt flow rate = 15; Mw = 24,500 amu

[0266] PC-SIL - S2060 PC-siloxane copolymer, melt flow rate = 1; siloxane content 20%.

[0267] CSR-MR03 is an organosilicon-based graft copolymer containing more than 70% by weight of an organosilicon core component and a graft polymer shell component mainly derived from acrylate monomers.

[0268] CHAR1 - DD-01 Carbonized Salt Flame Retardant Sodium p-Toluenesulfonate.

[0269] POS1 - KR2710 is a low molecular weight organosilicon compound of polyorganosiloxane with a degree of polymerization of about 3 to 4, a phenyl concentration of about 40%, and containing Si-H at an estimated concentration of 0.3 to 0.4 mol / 100 g.

[0270] MR1 - L-P861 is a mold release agent based on pentaerythritol tetrastearate.

[0271] AO2 - IR2112 tris(2,4-di-tert-butylphenyl) phosphite or IRGAFOS 168.

[0272] AO3 - IR 1010-Pentaerythritol tetra(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate).

[0273] UVA2 - Phenol, 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-hexyloxy.

[0274] MSP - Sodium dihydrogen phosphate.

[0275] Titanium dioxide.

[0276] CB-BP-800 is carbon black.

[0277] GF-GF 936 is glass fiber.

[0278] Table 4

[0279]

[0280] X15 and X16 indicate that only a V-2 rating can be achieved in the absence of polysiloxane impact modifiers and / or polysiloxane polycarbonate copolymers. X17-X18 indicate that even with the addition of TiO2, the combination of MR03, KR2710, and carbide salts can achieve good flame retardancy. X19-X20 indicate that the combination of S2060, KR2710, and carbide salts can achieve good flame retardancy. X21 indicates that good flame retardancy can be maintained when using virgin polycarbonate.

Claims

1. A composition comprising: a) one or more polycarbonates, b) one or more polyorganosiloxane flame retardants, and c) one or more carbon salts, provided that the carbon salts are free of any halogen atoms.

2. The composition of claim 1, wherein, by weight of the composition, the composition comprises: b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants, and c) about 0.01 to about 1.0% by weight of one or more carbide salts.

3. The composition according to claim 1 or 2, comprising d) one or more inorganic particles, wherein the d) one or more inorganic particles are present in an amount of about 0 to about 10% by weight of the composition.

4. The composition according to claim 3, wherein d) one or more inorganic particles comprise one or more carbon-based particles, metal oxides, and metal-like oxides.

5. The composition according to claim 3 or 4, wherein the d) one or more inorganic particles comprise one or more of carbon nanotubes, carbon black, titanium dioxide, magnesium oxide, silicon dioxide, mica, talc and wollastonite.

6. The composition according to any one of the preceding claims, comprising e) one or more buffering compounds capable of stabilizing the molecular weight of the one or more polycarbonates, wherein the e) one or more buffering compounds are present in an amount of about 0 to about 0.2% by weight of the composition.

7. The composition according to claim 6, wherein the e) one or more buffer compounds comprise one or more alkali metal phosphates.

8. The composition according to any one of the preceding claims, comprising f) one or more impact modifiers.

9. The composition according to any one of the preceding claims, comprising f) one or more impact modifiers, said impact modifiers being present in an amount of about 0 to about 20% by weight of said composition.

10. The composition according to any one of claims 8 or 9, wherein the f) one or more impact modifiers comprises one or more core-shell rubbers having a siloxane core.

11. The composition of claim 10, wherein the siloxane core is about 1 to about 99% by weight of the impact modifier.

12. The composition according to any one of the preceding claims, comprising g) one or more polysiloxane polycarbonate copolymers.

13. The composition according to any one of the preceding claims, comprising (g) one or more polysiloxane polycarbonate copolymers present in an amount of about 0 to about 95% by weight of the composition, wherein the total amount of the polycarbonate includes the one or more polysiloxane polycarbonate copolymers.

14. The composition according to any one of the preceding claims, comprising f) one or more impact modifiers and g) one or more polysiloxane polycarbonate copolymers.

15. The composition according to any one of the preceding claims, comprising f) one or more impact modifiers or g) one or more polysiloxane polycarbonate copolymers.

16. The composition according to any one of claims 12 to 15, wherein the g) one or more polysiloxane polycarbonate copolymers may contain about 0 to about 95% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

17. The composition according to any one of the preceding claims, comprising h) one or more glass fibers.

18. The composition according to any one of the preceding claims, comprising h) one or more glass fibers in an amount of 0 to 50% by weight of the composition.

19. The composition according to any one of the preceding claims, wherein the one or more polycarbonates are substantially entirely polycarbonate units.

20. The composition according to any one of the preceding claims, wherein the carbonized salt comprises one or more sulfonates.

21. The composition according to any one of the preceding claims, wherein the carbonized salt comprises one or more alkali metal salts and alkaline earth metal salts of the one or more aromatic sulfonates.

22. The composition according to any one of the preceding claims, wherein the composition comprises: a) about 50% to about 99% by weight of the one or more polycarbonates; b) about 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; and c) About 0.01 to about 2.0% by weight of the one or more of the carbonized salts.

23. The composition according to any one of the preceding claims, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.5% by weight of one or more of the buffer compounds; and f) About 0% to about 20% by weight of one or more impact modifiers.

24. The composition according to any one of the preceding claims, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) About 0 to about 0.5% by weight of one or more buffer compounds; f) about 0 to about 20% by weight of one or more impact modifiers; and g) About 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

25. The composition according to any one of the preceding claims, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) About 0 to about 0.5% by weight of one or more buffer compounds; f) About 0% to about 20% by weight of one or more impact modifiers; g) about 0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and h) about 0 to about 50% by weight of one or more glass fibers, The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

26. The composition according to any one of the preceding claims, wherein the composition comprises: a) about 50% to about 99% by weight of the one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.5% by weight of one or more of the buffer compounds; and f) about 0.5 to about 20% by weight of one or more of the impact modifiers; The amount mentioned therein is based on the weight of the composition, expressed by weight.

27. The composition according to any one of the preceding claims, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.5% by weight of one or more of the buffer compounds; f) about 0.5 to about 20% by weight of one or more impact modifiers; and h) About 5.0 to about 50% by weight of one or more glass fibers, The amount mentioned therein is based on the weight of the composition, expressed by weight.

28. The composition according to any one of claims 1 to 25, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.5% by weight of one or more of the buffer compounds; and g) More than 2.0 to about 95% by weight of one or more polysiloxane polycarbonate copolymers; The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

29. The composition according to any one of claims 1 to 25 or 28, wherein the composition comprises: a) About 50% to about 99% by weight of one or more polycarbonates; b) About 0.5 to about 10% by weight of one or more polyorganosiloxane flame retardants; c) about 0.01 to about 2.0% by weight of the one or more of the aforementioned carbonized salts; d) About 0% to about 10% by weight of one or more inorganic particles; e) about 0 to about 0.5% by weight of one or more of the buffer compounds; g) greater than 2.0% to about 95% by weight of one or more polysiloxane polycarbonate copolymers; and h) About 5.0 to about 50% by weight of one or more glass fibers, The amount is based on the weight of the composition by weight, and the total amount of the polycarbonate includes one or more polysiloxane polycarbonate copolymers.

30. The composition of claim 28, wherein the article prepared from the composition achieves UL94 V0@1.0mm flame retardancy.

31. A method comprising: a) bringing the components of any one of claims 1 to 30 into contact with and thoroughly mixing at a temperature of about 250°C or higher for about 10 seconds or longer, b) filling a mold with the mixture of a), c) forming the composition in the mold into a solid article, and d) removing the formed article from the mold.

32. An article prepared from the composition according to any one of claims 1 to 30, exhibiting UL94 V0@1.5mm flame retardancy.

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