Flame-retardant polycarbonate resin composition containing post-consumer recycling polycarbonate

Abstract

Disclosed is a polycarbonate composition which exhibits a high level of flame retardancy and excellent physical properties, without the need for the presence of a polyfluoroalkyl substance (PFAS) or an anti-drop agent. Disclosed is a polycarbonate composition which exhibits excellent flame retardant properties without using a halogen compound. Methods of making such compositions are disclosed. Structures prepared from the disclosed compositions are disclosed. The composition comprises: a) one or more branched polycarbonates; b) one or more phosphazene-based flame retardants; and c) one or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers.

Description

Cross-reference to related applications

[0001] This application claims priority to PCT application PCT / EP2023 / 076187, filed on 22 September 2023, which in turn claims priority to European patent application No. 22197386, filed on 23 September 2022, all of which are incorporated herein by reference in their entirety. Technical Field

[0002] Polycarbonate compositions exhibiting high levels of flame retardancy and excellent physical properties are disclosed without the need for polyfluoroalkyl substances (PFAS) or anti-drip agents. Polycarbonate compositions exhibiting excellent flame retardant properties without the use of halogen compounds are also disclosed. Methods for preparing such compositions are disclosed. Structures prepared from the disclosed compositions are disclosed. Background Technology

[0003] Polycarbonate and copolymers containing carbonate units are used in a variety of molded structures. Polycarbonate and copolymers containing carbonate units form rigid molded structures. Molded structures can be used for a wide range 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. There is a market demand for improved flame retardancy while maintaining the excellent properties of molded structures. Some polycarbonate formulations contain chlorine, bromine, and / or fluorine compounds as carbides or anti-drip agents. These compounds may release harmful halogen gases during combustion. Some polycarbonate formulations contain salts of carbides, perfluorocarbon sulfur compounds, or aromatic sulfur compounds to improve the flame retardancy of the composition, see U.S. Patent Publication 2020 / 0354569, which is incorporated herein by reference in its entirety for all purposes. Some regulatory agencies consider such compounds to be potentially hazardous. There is a need to recycle used polycarbonate or its copolymers. The use of recycled polycarbonate or its copolymers in molded products is desirable, provided the structure provides flame retardancy and maintains excellent performance. Recycled polycarbonate and its copolymers can be derived from post-consumer waste, such as water bottles, soda bottles, etc. Significant progress has been made in the development of polycarbonate formulations containing post-consumer recycled polycarbonate; see WO2019 / 115506, which discloses a laminate containing a fiber base layer and a polycarbonate-based layer, wherein up to 50 percent of the polycarbonate may be post-consumer recycled polycarbonate. Many polycarbonate users desire polycarbonate with a higher post-consumer recycled content, free of compounds deemed potentially harmful by regulatory agencies, and requiring a UL V-0 flame retardant rating while retaining the excellent physical properties of virgin polycarbonate.

[0004] What is needed are compositions free of compounds deemed potentially harmful by regulatory agencies, which may contain high levels of post-consumer recycled polycarbonate and form a molded structure with the desired flame retardancy, while retaining the excellent properties of polycarbonate-containing molded products, such as high heat distortion rate, a V-0 rating of 1.5 mm, impact softening temperature unaffected by negative impacts, and high notched Izod impact strength. Also needed are molded compositions prepared from such compositions that exhibit improved flame retardancy, are free of compounds considered potentially harmful, and exhibit the excellent properties described above. Summary of the Invention

[0005] This invention discloses compositions comprising: a) one or more branched polycarbonates; b) one or more phosphazene-based flame retardants; and c) one or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers. The one or more branched polycarbonates may comprise one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or combinations thereof. The composition may comprise about 8.0 to about 92% by weight of the one or more branched polycarbonates based on the weight of the composition. The composition may comprise about 4.0 to less than about 8.0% by weight of the one or more phosphazene-based flame retardants based on the weight of the composition.

[0006] The composition may contain about 0.75 to about 4.0% by weight of polysiloxane monomer units. The composition may contain about 1.5 to 5.0% by weight of one or more polysiloxane impact modifiers. The one or more polysiloxane impact modifiers contain about 80 to about 99% by weight of a siloxane core. The one or more polysiloxane impact modifiers may contain one or more polysiloxane core-shell copolymers.

[0007] The composition may comprise about 5.0 to about 95% by weight of one or more polycarbonate-polysiloxane copolymers based on the weight of the composition. The one or more polycarbonate-polysiloxane copolymers may contain about 4.0 to about 15% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

[0008] The composition may contain one or more linear polycarbonates. The composition may contain 0 to about 85% by weight of one or more linear polycarbonates based on the weight of the composition. The one or more linear polycarbonates may contain one or more post-consumer recycled polycarbonates, one or more virgin polycarbonates, or a combination thereof.

[0009] The composition may contain one or more post-consumer recycled polycarbonates. The composition may contain 0 to about 92% by weight of one or more post-consumer recycled polycarbonates based on the weight of the composition. The post-consumer recycled polycarbonates may be branched, linear, or a combination thereof.

[0010] The composition may contain one or more mold release agents, one or more antioxidants, one or more UV absorbers, one or more carbon-based microparticles, one or more metal oxides, one or more metal oxides, one or more additional additives commonly used in polycarbonate-based compositions, or any mixture thereof. The composition may contain about 0 to about 1.0% by weight of a mold release agent based on the weight of the composition. The composition may contain 0 to about 0.5% by weight of one or more antioxidants based on the weight of the composition. The composition may contain 0 to about 0.5% by weight of a UV absorber based on the weight of the composition. The composition may contain 0 to about 1.0% by weight of one or more carbon-based microparticles based on the weight of the composition. The composition may contain 0 to about 8.0% by weight of one or more metal oxides, one or more metal oxides, or mixtures thereof based on the weight of the composition. The composition may be free of any halogen atoms. The composition may be free of anti-drip agents having halogen atoms.

[0011] The composition may have a glass transition temperature of about 131°C or higher. The composition may have a melt flow rate of about 5 to about 20 g / 10 min at 300°C / 1.2 kg. The composition may have UL94 V-0 @ 1.5 mm flame retardancy. The composition may have thermal stability. The composition may retain ductile strength at -20°C, as determined by notched Izod testing. The composition may retain ductile strength when processed at 300°C and held for at least 7 minutes. The composition may have an impact strength of 700 J / m or higher, as determined by notched Izod testing.

[0012] Articles prepared from the compositions disclosed herein are disclosed.

[0013] A method is disclosed comprising: a) contacting and finely mixing components of any of the compositions disclosed herein at a temperature of about 250°C or higher for about 10 seconds or longer; b) filling a mold with the mixed composition of a); 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.

[0014] Compositions and structures prepared from the disclosed compositions may contain high post-consumption recycling content. The compositions may be free of halogenated carbide salts, such as salts of perfluorocarbon-based sulfur compounds. The compositions may be free of halogenated anti-drip agents. Articles prepared from the compositions achieve UL94 V0@1.5 mm flame retardancy. Articles prepared from the compositions achieve UL94 V0@1.5 mm flame retardancy after immersion in water. Articles prepared from the compositions retain ductile strength at -20°C or -30°C, as determined by notched Izod testing. Articles prepared from the compositions retain their ductile impact strength even after treatment at 300°C and a holding time of at least 7 minutes. Articles prepared from the compositions may have an impact strength of 700 J / m or higher, as determined by notched Izod testing.

[0015] According to ASTM D648, articles prepared from the composition exhibit a heat distortion temperature of about 105°C or higher, about 110°C or higher, or about 115°C or higher at 1.8 MPa. Articles prepared from the composition may have a glass transition temperature (Tg) of at least about 131°C or higher, or about 135°C or higher. The articles can be used in automobiles, trains, buses, and recreational vehicles. The articles can also be used in consumer electronics. Detailed Implementation

[0016] Although 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, said group optionally containing one or more heteroatoms. When a hydrocarbon group contains heteroatoms, the heteroatoms may form one or more functional groups well known to those skilled in the art. A hydrocarbon group may contain alicyclic segments, aliphatic segments, aromatic segments, or any combination of 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 means 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 a physical property (including, for example, mechanical strength) of a polymeric material changes abruptly. Tg can be determined by differential scanning calorimetry (DSC) according to the ASTM test method of ASTM D3418-15. As used herein, post-industrial refers to the source of material generated during the manufacture of goods or products. As used herein, post-consumer refers to the source of material generated after the end consumer has used the material in a consumer product or product.

[0018] This invention discloses compositions comprising: a) one or more branched polycarbonates; b) one or more phosphazene-based flame retardants; and c) one or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers. The one or more branched polycarbonates may comprise one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or combinations thereof. Per wt%. The composition may comprise about 8 to about 92 wt% of one or more branched polycarbonates based on the weight of the composition.

[0019] As used herein, polycarbonate refers to a polymer containing carbonate units. Such polymers can be homopolymers consisting essentially of carbonate monomer units or copolymers containing one or more other monomer units (comonomer units) and carbonate units. Such copolymers can be block copolymers containing blocks of two or more different monomer units, or 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. The copolycarbonate may contain more than 50 mol% carbonate monomer units, about 75 mol% or more carbonate monomer units, about 80 mol% or more carbonate monomer units, or about 85 mol% or more carbonate monomer units. Copolycarbonates may contain 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 include aromatic units in the main chain of the polymer.

[0020] 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: I 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: II Or the group of formula III: III 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.

[0021] Examples of bisphenols include hydroquinone, resorcinol, dihydroxybiphenyl, and bis(hydroxyphenyl)-C. 1-5 Alkanes, bis(hydroxyphenyl)-C 5-6 Cycloalkanes, 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.

[0022] 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 the 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 the bisphenols used.

[0023] The composition may contain one or more branched polycarbonates. The composition may contain about 8% by weight or more, about 15% by weight or more, or about 25% by weight or more of one or more branched polycarbonates based on the weight of the composition. The composition may contain about 92% by weight or less, or about 50% by weight or less of one or more branched polycarbonates based on the weight of the composition. The composition may contain about 8% to about 92% by weight, about 15% to about 50% by weight, or about 25% to about 50% by weight of one or more branched polycarbonates based on the weight of the composition. One or more branched polycarbonates may comprise one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or combinations thereof.

[0024] The polycarbonate can be branched, for example, by incorporating a trifunctional compound or a compound with a functionality greater than 3, such as those containing four or more phenolic groups, in a proportion of about 0.05 to about 2.0 mol% relative to the total amount of bisphenol used. 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 acid trichloride, cyanuric acid trichloride, 3,3'-,4,4'-benzophenone tetracarboxylic acid tetrachloride, 1,4,5,8-naphthalene-tetracarboxylic acid tetrachloride, or pyromellitic acid 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, 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. The phenolic branching agent can be placed in the reaction vessel together with the bisphenol. Acyl chloride branching agents can be introduced together with the acyl chloride.

[0025] The composition may contain one or more linear polycarbonates. The composition may contain 0% or more, about 20% or more, or about 40% or more of one or more linear polycarbonates by weight of the composition. The composition may contain about 85% or less, about 80% or less, or about 70% or less of one or more linear polycarbonates by weight of the composition. The composition may contain 0 to about 85% by weight, about 20 to about 85% by weight, about 20 to about 80% by weight, or about 40 to about 70% by weight of one or more linear polycarbonates by weight of the composition. One or more linear polycarbonates may contain one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or combinations thereof. One or more linear polycarbonates may contain one or more post-consumer recycled polycarbonates.

[0026] The disclosed compositions may contain virgin polycarbonate. Virgin polycarbonate is polycarbonate that has not been previously used in any composition. The compositions may contain virgin polycarbonate in amounts 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 compositions may contain virgin polycarbonate in amounts of about 98% by weight or less, about 95% by weight or less, about 65% by weight or less, about 45% by weight or less, about 35% by weight or less, or about 25% by weight or less, based on the composition.

[0027] The composition may contain one or more post-consumer recycled polycarbonates. One or more post-consumer recycled polycarbonates may be derived from recycled materials, such as post-consumer recycled materials. The composition may contain up to 92% by weight of the composition, about 85% or less by weight of the composition, or about 75% or less by weight of recycled polycarbonate, such as post-consumer recycled materials. The composition may contain 0% or more by weight of the composition, about 30% or more by weight of the composition, or about 50% or more by weight of recycled polycarbonate. The composition may contain 0% to about 92% by weight of the composition, about 30% to about 92% by weight of the composition, about 50% to 85% by weight of the composition, or about 50% to 75% by weight of recycled polycarbonate. The recycled material may be linear, branched, or a mixture thereof. The recycled material may be linear. The recycled material may be in sheet form. The recycled material may be recycled from bottles or other structures where the structure used is shredded into sheet form. The recycled material may be formed into other structures, such as granules. Using recycled materials in sheet form is the most efficient way to utilize them. Post-consumer recycled polycarbonate 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 the percentage of post-consumer recycled polycarbonate. Recycled materials may contain post-consumer recycled materials, industrial post-recycled materials, or both.

[0028] Copolycarbonates can be prepared by known methods. 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 end groups 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 process of polymers containing polycarbonates. 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.

[0029] 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).

[0030] 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 amu or greater, about 15,000 amu or greater, or about 20,000 amu or greater. The weight-average molecular weight of polycarbonate and / or copolycarbonate may be about 40,000 amu or less, about 35,000 amu or less, or about 30,000 amu or less. Unless otherwise stated, the “molecular weight” of polycarbonate and / or copolycarbonate in this document refers to the weight-average molecular weight (Mw) determined by gel permeation chromatography (GPC) using laser scattering technique with bisphenol A polycarbonate standards, and is given in grams per mole (g / mole), also known as atomic mass (amu).

[0031] The polycarbonate and / or copolymers used to prepare the disclosed compositions may have melt flow rates that provide the desired processing characteristics. Mixtures of polycarbonate and / or carbonate-containing copolymers 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 carbonate-containing copolymers with different melt flow rates may comprise: polycarbonate and / or carbonate-containing copolymers with low melt flow rates, polycarbonate and / or carbonate-containing copolymers with medium melt flow rates, and polycarbonate and / or carbonate-containing copolymers 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, as measured according to ASTM D1238, at 300°C and a load of 1.2 kg over a period of 10 minutes. 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 30 g / 10 min. This test protocol is based on ASTM D1238. The capillary diameter of the plasticizer is 9.5504 mm, and the die size is 2.095 mm. The low melt flow rate can be from about 0.1 to about 5 g / 10 min; the medium melt flow rate can be from about 5 to about 15 g / 10 min; and the high melt flow rate can be greater than about 15 g / 10 min. The composition may comprise: one or more polycarbonates having a low melt flow rate; one or more polycarbonates having a medium melt flow rate; and one or more polycarbonates having a high melt flow rate. The low melt flow rate can be from about 0.1 to about 5 g / 10 min. The medium melt flow rate can be from about 5 to about 15 g / 10 min. The high melt flow rate can be greater than 15 g / 10 min.

[0032] The composition may contain one or more resins having a high glass transition temperature (Tg). Any resin exhibiting a high Tg and capable of being blended with polycarbonate may be used, wherein the blend provides the desired properties as disclosed herein. In the context, a high Tg may be about 150°C or higher, about 160°C or higher, or about 190°C or higher. The high Tg resin may be one or more high Tg polycarbonates, etc.

[0033] High-temperature polycarbonate can be any polycarbonate with a certain Tg, which can improve the properties of the composition and articles prepared from said composition. The Tg of high-temperature polycarbonate can be about 150°C or higher, about 170°C or higher, or about 190°C or higher. High-temperature polycarbonate can be present in the composition in an amount sufficient to provide the desired properties of the composition. High-temperature polycarbonate can be present in the composition in an amount of about 0% by weight or more, about 10% by weight or more, or about 50% by weight or more based on the weight of the composition. High-temperature polycarbonate can be present in the composition in an amount of about 90% by weight or less, about 60% by weight or less, about 50% by weight or less, or about 10% by weight or less based on the weight of the composition.

[0034] 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 can be any flame retardant known for use in polycarbonate-based compositions that provides flame retardant properties without negatively impacting the composition's impact resistance, heat resistance, flexural modulus, flexural strength, haze, and transparency. The amount of flame retardant used is sufficient to meet the flame retardant requirements of the end use and is used in an amount that will not harmfully affect the properties of the article prepared from the composition.

[0035] One or more non-halogenated flame retardants may be one or more phosphazene-based flame retardants. Any one or more phosphazenes that enhance flame retardancy can be used. Phosphazenes may contain more than one phosphazene unit. A phosphazene is an organic compound having a –P=N- structure. A phosphazene may be a linear structure containing one or more phosphazene units, or a cyclic structure containing one or more phosphazene units. The phosphorus atom on the phosphazene structure may be bonded to one or more alkyloxy groups. The alkyloxy group may be an alkoxy, aryloxy, alkyl-substituted aryloxy, or alkoxy-substituted aryloxy. The alkyloxy group may be an aryloxy or 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, hexaphenoxycyclophosphazene, decaphenoxycyclopentaphosphazene, and hexaphenoxycyclotriphosphazene. Phosphazene compounds may be cross-linked. Phosphazene compounds can be crosslinked with bisphenol compounds, such as 4,4'-diphenylene groups, including 4,4'-sulfonyldiphenylene (bisphenol S residue), 2,2-(4,4'-diphenylene), isopropylidene groups, 4,4'-oxodiphenylene groups, and 4,4'-thiodiphenylene groups. The phenylene content of the crosslinked phenoxyphosphazene compound is typically 50-99.9% by weight or 70-90% by weight. The crosslinked phenoxyphosphazene compound molecule may not contain any free hydroxyl groups. One or more phosphazene-based flame retardants may be hexaphenoxycyclotriphosphazene.

[0036] One or more phosphazene-based flame retardants may be present in any amount that allows the composition to achieve a V-0 rating at 1.5 mm while maintaining its thermal stability. One or more phosphazene-based flame retardants may be present in an amount of about 4.0% by weight or more based on the weight of the composition. One or more flame retardants may be present in an amount of about 8.0% by weight or less, about 6.0% by weight or less, or about 5.0% by weight or less based on the weight of the composition. One or more phosphazene-based flame retardants may be present in an amount of about 4.0% by weight to about 8.0% by weight, about 4.0% by weight to about 6.0% by weight, or about 4.0% by weight to about 5.0% by weight based on the weight of the composition. One or more phosphazene-based flame retardants may be present in an amount of about 4.0% by weight based on the weight of the composition.

[0037] The composition may contain one or more polysiloxanes having a branched structure and organic functional groups. Any silicon compound having a branched structure and organic functional groups can be used to enhance the flame retardant properties of the composition. Organosilicon compounds containing a branched backbone and organic functional groups can be represented by the following general formula: In the formula R 1 R 2 and R 3X represents an organic functional group on the main chain, X represents a terminal functional group, and n, m, and 1 represent the number of moles of a single unit, wherein the organic functional group includes an aromatic group or an aromatic group, and hydrocarbon groups (other than aromatic groups) can be used as organosilicon compounds.

[0038] One or more polysiloxanes may contain total siloxane units (R 3-0 SiO 2-0.5 )Calculate at least 20 mol% of T units (RSiO) 1.5 ) and / or Q-units (SiO) 2.0 The organosilicon compound contains an organosilicone compound in which at least 20 mol% of the organosilicone functional group may be an aromatic group. The aromatic group may be phenyl, biphenyl, naphthalene, or derivatives thereof, or may be phenyl. Side chains other than phenyl may be hydrocarbon groups with no more than 4 carbon atoms, or may be methyl. Terminal groups may be one or more of methyl, phenyl, and / or hydroxyl groups. The weight-average molecular weight of the polysiloxane may be about 3,000 amu or greater, or about 5,000 amu or greater. The weight-average molecular weight of the organosilicon compound may be about 500,000 amu or less, or about 270,000 or less.

[0039] The composition may contain one or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers. The composition may contain about 0.75% by weight or more of polysiloxane monomer units based on the weight of the composition. The composition may contain about 4.0% by weight or less of polysiloxane monomer units based on the weight of the composition. The composition may contain about 0.75% to about 4.0% by weight of polysiloxane monomer units based on the weight of the composition.

[0040] The composition may contain one or more polysiloxane polycarbonate copolymers. The composition may contain about 5.0% or more, about 6.0% or more, or about 7.0% or more of one or more polycarbonate polysiloxane copolymers based on the weight of the composition. The composition may contain about 95% or less, about 20% or less, or about 10% or less of one or more polycarbonate polysiloxane copolymers based on the weight of the composition. The composition may contain about 5.0% to about 95% by weight, about 6.0% to about 20% by weight, or about 7.0% to about 10% by weight of one or more polycarbonate polysiloxane copolymers based on the weight of the composition.

[0041] One or more polycarbonate-polysiloxane copolymers may contain about 4.0% by weight or more, about 6.0% by weight or more, or about 9.0% by weight or more of one or more polysiloxane monomer units within the polycarbonate backbone. One or more polycarbonate-polysiloxane copolymers may contain about 15% by weight or less, about 13% by weight or less, or about 12% by weight or less of one or more polysiloxane monomer units within the polycarbonate backbone. One or more polycarbonate-polysiloxane copolymers may contain about 4.0% to about 15% by weight, about 6.0% to about 13% by weight, or about 9% to about 12% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

[0042] When the composition comprises one or more polycarbonate-polysiloxane copolymers, the composition may contain about 15% by weight or more, or about 20% by weight or more, branched polycarbonate based on the weight of the composition. When the composition comprises one or more polycarbonate-polysiloxane copolymers, the composition may contain about 85% by weight or less, about 75% by weight or less, or about 50% by weight or less, branched polycarbonate based on the weight of the composition. When the composition comprises one or more polycarbonate-polysiloxane copolymers, the composition may contain about 15% to about 85% by weight, about 20% to about 75% by weight, or about 20% to about 50% by weight, branched polycarbonate based on the weight of the composition.

[0043] 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, polysiloxane-acrylate rubber, polyurethane, thermoplastic elastomers, and mixtures thereof. Interpolymers of rubber forming monomers with other copolymerizable monomers are also suitable. Rubber may be present in a sufficient amount in the formulated composition to provide the desired impact properties. Desired impact properties include increased Izod impact strength, Charpy impact strength, Gardner impact strength, tensile strength, dart impact strength, etc.

[0044] 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 about 10% by weight of vinylidene-substituted aromatic monomers, based on the weight of the 1,3-butadiene copolymer. The impact modifiers used can be polymers and copolymers that exhibit a second-order transition temperature, sometimes referred to as the glass transition temperature (Tg) for diene segments, which is not higher than 0°C or -20°C, as determined using conventional techniques (e.g., ASTM Test Method D 746-52 T). 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 micrometers, and equal to or greater than about 0.5 micrometers. The average particle diameter of the rubber particles can be equal to or less than about 10 micrometers, equal to or less than about 5 micrometers, or equal to or less than about 4 micrometers.

[0045] Impact modifiers can be silicone-based impact modifiers. Impact modifiers can be one or more polysiloxane impact modifiers. One or more polysiloxane impact modifiers can be polysiloxane-acrylic polymers with a core-shell structure, etc. One or more polysiloxane-acrylic polymers can be one or more polysiloxane core-shell copolymers. Polysiloxane-acrylic polymers with a core-shell structure can be made from alkyl methacrylates and / or alkyl acrylates, crosslinking agents, and grafting agents. An exemplary alkyl methacrylate and / or alkyl acrylate is C... 1-5Alkyl 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. Particularly preferred is n-butyl acrylate. Monomers having more than one polymerizable double bond can be used as crosslinking agents for the polyalkyl (meth)acrylate rubber component of 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. Based on the total weight of the polyalkyl (meth)acrylate rubber component of the siloxane acrylate rubber, the crosslinking agent and grafting agent may be present in an amount from about 0.1% by weight to about 20% by weight. The core may be based on siloxane rubber.

[0046] The siloxane core may comprise about 80% by weight or more, about 90% by weight or more, or about 95% by weight or more of the impact modifier. The siloxane core may comprise about 99% by weight or less, or about 98% by weight or less of the impact modifier. The siloxane core may comprise about 80% to about 99% by weight, about 90% to about 98% by weight, or about 95% to about 98% by weight of the impact modifier.

[0047] The compositions disclosed herein may contain one or more polysiloxane impact modifiers in an amount of about 1.5% by weight or more, or about 2.0% by weight or more, based on the weight of the composition. The compositions disclosed herein may contain one or more polysiloxane impact modifiers in an amount of about 5.0% by weight or less, about 4.0% by weight or less, or about 3.0% by weight or less, based on the weight of the composition. The compositions disclosed herein contain one or more polysiloxane impact modifiers in an amount of about 1.5% to about 5.0% by weight, about 2.0% to about 4.0% by weight, or about 2.0% to about 3.0% by weight, based on the weight of the composition.

[0048] When the composition contains one or more polysiloxane impact modifiers, the composition may contain about 10% or more, about 15% or more, about 20% or more, or about 25% or more of branched polycarbonate by weight of the composition. When the composition contains one or more polysiloxane impact modifiers, the composition may contain about 92% or less, about 88% or less, about 85% or less, or about 50% or less of branched polycarbonate by weight of the composition. When the composition contains one or more polysiloxane impact modifiers, the composition may contain about 10 to about 92% by weight, about 10 to about 88% by weight, about 15 to about 92% by weight, about 20 to about 85% by weight, or about 25 to about 50% by weight of branched polycarbonate by weight of the composition.

[0049] The disclosed compositions may contain one or more carbon-based microparticles. Any carbon-based microparticles capable of improving the V0@1.5 mm flame retardancy rating may be used. The one or more carbon-based microparticles may be any particulate carbon material capable of improving the flame retardancy of the compositions disclosed herein. Exemplary carbon-based microparticles may be carbon black or carbon nanotubes. The carbon-based microparticles may be carbon black. One or more carbon-based microparticles may be present in an amount sufficient to enhance the flame retardancy of the composition. One or more carbon-based microparticles may be present in an amount sufficient to provide a V0@1.5 mm flame retardancy rating. One or more carbon-based microparticles may be present in an amount of 0% by weight or more, about 0.1% by weight or more, or about 0.3% by weight or more based on the weight of the composition. One or more carbon-based microparticles may be present in an amount of about 1.0% by weight or less, about 0.6% by weight or less, or about 0.5% by weight or less based on the weight of the composition. One or more carbon-based microparticles may be present in an amount of 0 to about 1.0% by weight, about 0.1% to about 0.6% by weight, or about 0.3% to about 0.5% by weight based on the weight of the composition. One or more carbon-based microparticles may be present in particulate form. One or more carbon-based microparticles may be nanoparticles. The particle size may be any size that improves the flame retardant rating of the composition. The particle size may be about 0.015 micrometers or larger, or about 0.017 micrometers or larger. The particle size may be about 0.021 micrometers or smaller, or about 0.019 micrometers or smaller. The particle size may be determined using laser diffraction techniques described in ISO 13322. The determined particle size is the average diameter.

[0050] The disclosed compositions may contain one or more metal oxides, one or more metal oxides or mixtures thereof. Any metal oxide or metal oxide-like material that improves the V0@1.5 mm flame retardancy rating may be used. Exemplary metal oxides or metal oxide-like materials include TiO2, MgO, SiO2, Fe2O3, Al2O3, CuCr2O4, etc. Exemplary metal oxides or metal oxide-like materials include TiO2, CuCr2O4, MgO, and SiO2. One or more metal oxides or metal oxide-like materials may be mixtures of metals and / or metal oxide-like materials, such as talc containing MgO and SiO2. One or more metal oxides may be TiO2 or CuCr2O4. One or more metal oxides or metal oxide-like materials may be present in an amount sufficient to enhance the flame retardancy of the composition. One or more metal oxides or metal oxide-like materials may be present in an amount sufficient to provide a V0@1.5 mm flame retardancy rating. One or more metal oxides or metal oxide-like materials may be present in an amount sufficient to allow the composition to achieve a glass transition temperature (Tg) of at least 135°C. One or more metal oxides or metal-like oxides may be present in amounts of 0% by weight or more, about 2.0% by weight or more, or about 3.0% by weight or more, based on the weight of the composition. One or more metal oxides or metal-like oxides may be present in amounts of about 8.0% by weight or less, about 6% by weight or less, or about 5% by weight or less, based on the weight of the composition. One or more metal oxides or metal-like oxides may be present in amounts of 0 to about 8.0% by weight, about 2.0 to about 6.0% by weight, or about 3.0 to about 5.0% by weight, based on the weight of the composition. One or more metal oxides or metal-like oxides may be present in particulate form. One or more metal oxides or metal-like oxides may be nanoparticles. The particle size may be any particle size that improves the flame retardant rating of the composition. The particle size may be 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 determined particle size is the average diameter. The use of metal oxides or metal-like oxides enables the disclosed compositions to possess laser direct structuring capabilities and may be suitable for antenna applications. The use of the metal oxide CuCr2O4 (Pigment Black 28) enables the disclosed compositions to possess laser direct structuring capabilities.

[0051] The disclosed compositions contain one or more antioxidants. Antioxidants can be introduced into the composition from the components used (e.g., impact modifiers or post-consumer recycled polymers). Antioxidants can be added to the composition alone. Antioxidants can be one or more of phenol, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated 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, phosphorus, hydroquinone and alkylated hydroquinone, tocopherol, O- and N-benzyl compounds, alkylene bisphenols, hydroxybenzylated malonate, aromatic hydroxybenzyl compounds, triazine compounds, benzylphosphonate, acylaminophenol, esters and amides of propionic acid, ascorbic acid, or amino antioxidants without sulfur-containing groups.

[0052] Phenolic 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) -4-hydroxybenzyl)malonide dioctadecyl ester; 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-butyl-4-methoxyphenol. Diphenols, 2,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyanisole, 3,5-di-tert-butyl-4-hydroxyphenyl stearate, and 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.

[0053] 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. Antioxidants may be octadecyl 3,5-di-(tert-butyl)-4-hydroxyhydrocinnamate, commercially available from BASF according to IRGANOX 1076.

[0054] 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.

[0055] Antioxidants may be one or more of phenolic antioxidants and / or phosphorus-based antioxidants. Antioxidants may include both phenolic antioxidants and phosphorus-based antioxidants. Antioxidants may include phenolic antioxidants. Antioxidants may be one or more of phenolic antioxidants and / or phosphorus-based antioxidants, such as phosphite-based antioxidants. Antioxidants may include both phenolic antioxidants and phosphorus-based antioxidants. Antioxidants may be at least one of pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) and tris(2,4-di-tert-butylphenyl) phosphite. Antioxidants may be phenolic antioxidants. Antioxidants may be pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate).

[0056] Antioxidants, which can delay polymer oxidation, may be present in any amount in the composition and the structure formed therefrom. Antioxidants may be present in amounts of 0 parts per million (0 wt%) or greater, about 100 parts per million (0.01 wt%) or greater, or about 200 parts per million (0.02 wt%) or greater, based on the weight of the disclosed composition. Antioxidants may be present in amounts of about 5,000 parts per million (0.5 wt%) or less, about 4,000 parts per million (0.4 wt%) or less, or about 3,000 parts per million (0.3 wt%) or less, based on the weight of the disclosed composition.

[0057] The composition may contain one or more release agents. 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 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. The esters mentioned above can be pure or mixtures of various compounds. Each of the aliphatic carboxylic acids and alcohols combined 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, diphenyl silicone oil, and fluorinated alkyl silicone oil. A single type of release agent may be included, or any combination of two or more types of release agents may be included in any proportion. Exemplary release agents include at least one of aliphatic carboxylic acids or esters of aliphatic carboxylic acids and alcohols. Release agents may be at least one of pentaerythritol tetrastearate, glyceryl monostearate, and octyl dodecyl stearate. A release agent may be pentaerythritol tetrastearate.

[0058] The amount of mold release agent is not limited and can be 0% by weight or more, about 0.3% by weight or more, or about 0.4% by weight or more based on the weight of the composition. The amount of mold release agent is not limited and can be about 1.0% by weight or less, about 0.8% by weight or less, or about 0.4% by weight or less based on the weight of the composition. The amount of one or more mold release agents is not limited and can be 0 to about 1.0% by weight, about 0.3% to about 0.8% by weight, or about 0.4% to about 0.6% by weight 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, mold contamination during injection molding, etc., may occur.

[0059] The compositions disclosed herein may contain one or more UV absorbers (i.e., UV stabilizers), which in another embodiment serve to stabilize the color of the composition. Upon addition of a UV stabilizer, polycarbonate, impact modifiers, and other present polymers may absorb light energy from UV and convert it into heat. The UV absorber can reduce the weathering effect of the polymeric 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 stabilizer may be present in amounts of 0 ppm (0 wt%) or more, about 1,000 ppm (0.1 wt%) or more, or about 1,500 ppm (0.15 wt%) or more, based on the weight of the composition. The UV stabilizer may be present in amounts of 5,000 ppm (0.5 wt%) or less, about 4,000 ppm (0.4 wt%) or less, or about 3,000 ppm (0.3 wt%) or less, based on the weight of the composition. The UV absorber may be present in an amount of about 0 to about 0.5% by weight, about 0.1% to about 0.4% by weight, or about 0.15% to about 0.3% by weight, based on the weight of the composition.

[0060] The disclosed compositions may contain a colorant. The colorant can be any colorant that provides the desired color to the composition or the product prepared therefrom. The colorant can be a pigment or a dye. Exemplary pigments include carbon black, titanium dioxide, zinc sulfide, kaolin, etc. The colorant may be present in sufficient quantity to provide the desired color to the composition or the product prepared therefrom. The amount of colorant present may be about 0.01% or more, about 0.1% or more, or about 1% or more by weight of the disclosed composition. The amount of colorant present may be about 10% or less, about 5% or less, about 1% or less, or about 0.5% or less by weight of the disclosed composition. When the colorant is a pigment, the concentration may be at the higher end of the disclosed range, for example, 0.1-10.0% by weight of the composition. When the colorant is a dye, its amount may be at the lower end of the range, for example, from 0.01% to about 0.5% by weight of the composition. Some pigments may also be particulates as described herein.

[0061] If used, the filler may be a reinforcing filler, such as fibers with a length-to-diameter ratio of about 4.0 or greater. The amount of other fillers (e.g., non-reinforcing fillers, such as talc, clay, etc.) may be about 10% by weight or less, about 4.0% by weight or less, about 2.0% by weight or less, or about 1.0% by weight or less, based on the total weight of the polymeric composition. Reinforcing fillers may be used to increase the strength of the polymeric composition and / or reduce the linear coefficient of thermal expansion of the composition. Reinforcing fillers may include glass fibers, carbon fibers, metal fibers, or any combination thereof. Exemplary fillers include talc, clay, wollastonite, mica, glass, or mixtures thereof. Reinforcing fillers include mineral fillers having a needle-like structure (i.e., 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.

[0062] The disclosed compositions may contain one or more additives commonly used in this type of composition. Exemplary additives include zinc salts, colorants, reinforcing fibers, stabilizers, antistatic agents, silicone oils, flow enhancers, etc. Exemplary anti-ignition additives may also include metal salts of antimony oxide and aromatic sulfur, or mixtures thereof may be used. Compounds that stabilize rubber-modified vinylidene-substituted aromatic copolymer compositions to prevent degradation caused by, but not limited to, heat, light, and oxygen or mixtures thereof may be used. Some of these additives may adsorb volatile organic compounds, such as zeolites, activated carbon, bamboo charcoal, etc.

[0063] Additives and / or fillers and / or adsorbents may be present in the formulated 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. Additives and adsorbents may be present independently in amounts of up to 5% by weight, while fillers may be present in amounts of up to about 40% by weight, based on the weight of the composition.

[0064] The compositions disclosed herein may contain a buffering system. 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.

[0065] 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 0.01% by weight or more, about 0.02% by weight or more, or about 0.03% by weight or more. Alkali metal phosphates may be used in any amount of about 1.0% by weight or less, about 0.2% by weight or less, or about 0.1% by weight or less based on the weight of the composition.

[0066] The disclosed compositions can be produced by mixing the components in a known manner and then melt-blending and / or melt-extruding them in a conventional unit (such as an internal kneader, extruder, and twin-screw extruder) at a temperature of 200°C to 300°C. Individual components can be continuously and simultaneously mixed in a known manner at temperatures of about 23°C (room temperature) and higher.

[0067] The disclosed compositions can be molded using any method 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 and 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 the 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 also be 400°C or lower, or 300°C or lower. The mold can be heated to facilitate processing, such as to 60°C or higher, 80°C or higher, or 100°C or higher.

[0068] 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: 1. After each of the two 10-second flame applications, none of the five samples burned for more than 10 seconds.

[0069] 2. The total burning time of ten 10-second flame applications (5 samples, 2 applications each) exceeded 50 seconds.

[0070] 3. None of the five samples produced a flame or glow that burned onto the clamping forceps.

[0071] 4. None of the five samples dripped burning particles that would ignite dry degreased cotton located 305 mm below the sample.

[0072] 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.

[0073] 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.

[0074] 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 to the bottom edge of the vertically supported test strip for 10 seconds, 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. The following table defines the specific standards for V-0, V-1, and V-2 ratings.

[0075] surface

[0076] Before conducting the UL-94 vertical test (20 mm vertical flammability test), the sample can be immersed in water. The sample should be immersed in distilled or deionized water at 70±2℃ (158±4℉) for 7 days. The water should be completely changed every day for the first 5 days. After immersion, the sample to be tested for flammability needs to be placed in air at a temperature of 23±2℃ (73±4℉) and a relative humidity of 50±10% for 2 weeks.

[0077] Implementation Plan 1. A composition comprising: a) one or more branched polycarbonates; b) one or more linear polycarbonates; c) one or more phosphazene-based flame retardants; and d) one or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers.

[0078] 2. The composition as described in embodiment 1, wherein the composition comprises about 8 to about 92% by weight of one or more branched polycarbonates based on the weight of the composition.

[0079] 3. The composition as described in embodiment 1 or 2, wherein the one or more branched polycarbonates comprise one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or a combination thereof.

[0080] 4. The composition of any one of embodiments 1-3, wherein the composition comprises about 4 to less than about 8% by weight of one or more phosphazene-based flame retardants based on the weight of the composition.

[0081] 5. The composition as described in any of the foregoing embodiments, wherein the composition comprises about 4% by weight of one or more phosphazene-based flame retardants based on the weight of the composition.

[0082] 6. The composition of any one of the preceding claims, wherein the one or more phosphazene-based flame retardants has a cyclic structure containing one or more phosphazene units.

[0083] 7. The composition as described in any of the foregoing embodiments, wherein the one or more phosphazene-based flame retardants are hexaphenoxycyclotriphosphazenes.

[0084] 8. The composition as described in any of the preceding embodiments, wherein the composition contains about 0.75 to about 4.0% by weight of polysiloxane monomer units based on the weight of the composition.

[0085] 9. The composition as described in any of the preceding embodiments, wherein the composition comprises one or more polysiloxane impact modifiers.

[0086] 10. The composition of embodiment 9, wherein the composition comprises about 1.5 to about 5.0% by weight of one or more polysiloxane impact modifiers.

[0087] 11. The composition of embodiment 9 or 10, wherein one or more polysiloxane core-shell copolymers comprise about 80 to about 99% by weight of a siloxane core based on the weight of the one or more polysiloxane core-shell copolymers.

[0088] 12. The composition of any one of embodiments 9-11, wherein the composition comprises about 10 to about 92% by weight of branched polycarbonate based on the weight of the composition.

[0089] 13. The composition of any one of the foregoing embodiments, wherein the one or more polysiloxane impact modifiers comprise one or more polysiloxane core-shell copolymers.

[0090] 14. The composition of any one of embodiments 1-8, wherein the composition comprises one or more polysiloxane polycarbonate copolymers.

[0091] 15. The composition of any one of embodiments 1-8 or 14, wherein the composition comprises about 5 to about 95% by weight of one or more polycarbonate polysiloxane copolymers based on the weight of the composition.

[0092] 16. The composition of any one of embodiments 1-8, 14 or 15, wherein the one or more polycarbonate polysiloxane copolymers comprise about 4.0 to about 15% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

[0093] 17. The composition of any one of embodiments 14-16, wherein the composition comprises about 15 to about 85% by weight of branched polycarbonate based on the weight of the composition.

[0094] 18. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more linear polycarbonates.

[0095] 19. The composition of any one of the foregoing embodiments, wherein the composition comprises 0 to about 85% by weight of one or more linear polycarbonates based on the weight of the composition.

[0096] 20. The composition of any one of the foregoing embodiments, wherein the composition comprises about 20 to about 85% by weight of one or more linear polycarbonates based on the weight of the composition.

[0097] 21. The composition of any one of embodiments 18-20, wherein the one or more linear polycarbonates comprise one or more post-consumer recycled polycarbonates, one or more virgin polycarbonates, or a combination thereof.

[0098] 22. The composition of any one of embodiments 18-21, wherein the one or more linear polycarbonates comprise one or more post-consumption recycled polycarbonates.

[0099] 23. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more post-consumer recycled polycarbonates.

[0100] 24. The composition of any one of the foregoing embodiments, wherein the composition comprises 0 to about 92% by weight of one or more post-consumption recycled polycarbonates.

[0101] 25. The composition of any one of the foregoing embodiments, wherein the composition comprises about 30 to about 92% by weight of one or more post-consumption recycled polycarbonates.

[0102] 26. The composition of any of the preceding claims, wherein the composition comprises one or more mold release agents, one or more antioxidants, one or more UV absorbers, one or more carbon-based microparticles, one or more metal oxides, one or more metal-like oxides, one or more additional additives commonly used in polycarbonate-based compositions, or any mixture thereof.

[0103] 27. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more release agents.

[0104] 28. The composition of embodiment 26 or 27, wherein the composition comprises one or more release agents at a weight percentage of 0 to about 1.0% by weight of the composition.

[0105] 29. The composition of any one of embodiments 26-28, wherein the release agent is at least one of pentaerythritol tetrastearate, glyceryl monostearate, and octyl dodecyl stearate.

[0106] 30. The composition of claim 29, wherein the release agent is pentaerythritol tetrastearate.

[0107] 31. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more antioxidants.

[0108] 32. The composition of embodiment 31, wherein the composition comprises 0 to 0.5% by weight of one or more antioxidants based on the weight of the composition.

[0109] 33. The composition of embodiment 31 or 32, wherein the one or more antioxidants are 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.

[0110] 34. The composition of any one of embodiments 31-33, wherein the one or more antioxidants are one or more of phenolic antioxidants and / or phosphorus-based antioxidants.

[0111] 35. The composition of any one of embodiments 31-34, wherein the one or more antioxidants comprises both phenolic antioxidants and phosphorus-based antioxidants.

[0112] 36. The composition of any one of embodiments 31-35, wherein the one or more antioxidants comprises phenolic antioxidants.

[0113] 37. The composition of any one of embodiments 31-36, wherein the one or more antioxidants are at least one of pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) and tris(2,4-di-tert-butylphenyl) phosphite.

[0114] 38. The composition of embodiment 37, wherein the one or more antioxidants is pentaerythritol tetra(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate).

[0115] 39. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more UV absorbers.

[0116] 40. The composition of embodiment 39, wherein the composition comprises 0 to 0.5% by weight of one or more UV absorbers.

[0117] 41. The composition as described in embodiment 39 or 40, wherein the one or more UV absorbers are one or more of benzotriazole, hydroxyphenyltriazine, benzophenone and mestriazine, or any combination thereof.

[0118] 42. The composition as described in any of the foregoing embodiments, wherein the composition comprises one or more carbon-based microparticles.

[0119] 43. The composition of embodiment 42, wherein the composition comprises 0 to about 1.0% by weight of one or more carbon-based microparticles.

[0120] 44. The composition as described in embodiment 42 or 43, wherein the one or more carbon-based microparticles are carbon black.

[0121] 45. The composition as described in any of the preceding embodiments, wherein the composition comprises one or more metal oxides, one or more metal-like oxides, or mixtures thereof.

[0122] 46. ​​The composition of embodiment 45, wherein the composition comprises 0 to about 8.0% by weight of one or more metal oxides, one or more metal-like oxides or mixtures thereof.

[0123] 47. The composition as described in embodiment 45 or 46, wherein the one or more metal oxides or metal-like oxides are one or more of SiO2, MgO, TiO2 or CuCr2O4.

[0124] 48. The composition of embodiment 47, wherein the one or more metal oxides is TiO2 or CuCr2O4.

[0125] 49. The composition as described in any of the preceding embodiments, wherein the composition has a glass transition temperature of about 131°C or higher.

[0126] 50. The composition of embodiment 49, wherein the composition has a glass transition temperature of about 135°C or higher.

[0127] 51. The composition as described in any of the preceding embodiments, wherein the melt flow rate of the composition at 300°C / 1.2 kg is about 5 to 20 g / 10 min.

[0128] 52. The composition as described in any of the preceding embodiments, wherein the composition has a UL94 V-0 @1.5 mm flame retardancy.

[0129] 53. The composition as described in any of the foregoing embodiments, wherein the composition has thermal stability.

[0130] 54. The composition as described in any of the preceding embodiments, wherein the composition retains ductile strength at -20°C, as determined by a notched Izod test.

[0131] 55. The composition as described in any of the preceding embodiments, wherein the composition retains ductile strength at -30°C, as determined by a notched Izod test.

[0132] 56. The composition as described in any of the preceding embodiments, wherein the composition retains ductile strength when processed at 300°C and held for at least 7 minutes.

[0133] 57. The composition as described in any of the preceding embodiments, wherein the composition has an impact strength of 700 J / m or greater, as determined by a notched Izod test.

[0134] 58. The composition as described in any of the foregoing embodiments, wherein the composition does not contain any halogen atoms.

[0135] 59. The composition as described in any of the preceding embodiments, wherein the composition does not contain an anti-drip agent having halogen atoms.

[0136] 60. An article prepared from a composition according to any one of the foregoing embodiments, having a flame retardancy of UL94V-0 @ 1.5 mm.

[0137] 61. The article as described in embodiment 60 has thermal stability.

[0138] 62. The article of embodiment 60 or 61, wherein the article retains ductile strength at -20°C, as determined by notched Izod test.

[0139] 63. The article of embodiment 60 or 61, wherein the article retains ductile strength at -30°C, as determined by notched Izod test.

[0140] 64. The article of any one of embodiments 60-63, wherein the article retains ductile strength when processed at 300°C and held for at least 7 minutes.

[0141] 65. The article of any one of embodiments 60-64, wherein the article has an impact strength of 700 J / m or greater, as determined by notched Izod test.

[0142] 66. The article of any one of embodiments 60-65 has a glass transition temperature of about 131°C or higher.

[0143] 67. The article of any one of embodiments 60-66 has a glass transition temperature of about 135°C or higher.

[0144] 68. The article of manufacture as described in any one of embodiments 60-67, wherein the article of manufacture is used in consumer electronics products.

[0145] 69. The article of any one of embodiments 60-68, wherein the article has a heat distortion temperature of about 109°C or higher.

[0146] 70. A method comprising: a) contacting and finely mixing the components of any one of embodiments 1-59 at a temperature of about 250°C or higher for about 10 seconds or longer; b) filling a mold with the mixed composition of a); c) forming a solid article of the composition in the mold; and d) removing the formed article of the mold.

[0147] 71. The method according to embodiment 70, wherein the contacting and mixing takes place in an extruder, and the resulting mixture is transferred from the extruder to a die.

[0148] Illustrative Examples 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.

[0149] Several samples of different compositions were prepared and tested to determine flame-retardant polycarbonate compositions containing recycled polycarbonate and free of halogen compounds, which have similar properties to flame-retardant polycarbonate compositions containing recycled polycarbonate containing one or more halogen compounds (Comparative Example 1).

[0150] The samples were prepared according to the following procedure. The materials listed in the table below were compounded and granulated on a twin-screw extruder (Century CX40) with an L / D ratio of about 37 at a speed of about 300 rpm at a temperature of about 260°C to about 290°C and a throughput of 70 kg / h. The samples were molded to a size of 12.7 mm × 127 mm with a thickness of 1.5 mm.

[0151] The melt flow rate of the particles pre-dried at 120°C for 4 hours was determined according to the method described above. Impact strength was determined using the notched Izod impact strength test according to ASTM D256. The UL-94 vertical test (20 mm vertical burning test) as described above was used to determine whether the sample had a V-0 rating. Heat distortion temperature (HDT) was determined according to ASTM D648 at 1.8 mPa. Glass transition (Tg) was determined by differential scanning calorimetry (DSC) according to ASTM test method D3418-15.

[0152] Molded samples of each component were burned at a depth of 1.5 mm after (23°C / 50%RH > 2 days) using the UL-94 vertical test. If the molded sample did not drip, the selected sample component was annealed and burned. Annealed samples were burned at a depth of 1.5 mm after (70°C / 50%RH = 7 days) using the UL-94 vertical test to determine whether the sample dripped.

[0153] The combination of various materials constitutes the components of each test. The list of materials is shown in Table 1.

[0154] Table 1

[0155] The weight percentage of each material in the compositions of Examples 1 and 2-6 is shown in Table 2.

[0156] Table 2

[0157] Comparative Example 1 is a polycarbonate composition containing a halogenated anti-drip agent. Examples 2-6 are polycarbonate compositions without anti-drip agents.

[0158] The features of Comparative Examples 1 and Examples 2-6 are shown in Table 3.

[0159] Table 3

[0160] As shown in Table 3, removing the anti-drip agent (PTFE / SAN) from the PC composition results in a loss of the V0 flame retardancy rating at 1.5 mm.

[0161] The weight percentage of each material in the compositions of Examples 7-12 is shown in Table 4.

[0162] Table 4

[0163] In Examples 7-12, the organopolysiloxane flame retardant was replaced by a novel flame retardant, hexaphenoxycyclotriphosphazene (HPTCP).

[0164] Table 5 shows the features of Examples 7-12.

[0165] Table 5 As shown in Table 5, the E7-E12 series using HPTCP achieved a shorter burn time that met the V2 standard. Despite the shorter burn time, the presence of dripping prevented the rating from reaching V0.

[0166] The weight percentage of each material in the compositions of Examples 13-18 is shown in Table 6.

[0167] Table 6

[0168] To address the dripping issue, a relatively large amount of branched polycarbonate was added to the composition.

[0169] Table 7 shows the features of Examples 13-18.

[0170] Table 7

[0171] As shown in Table 9, Example 13 demonstrates that combining branched polycarbonate with an organopolysiloxane flame retardant achieved a burn time of less than 10 seconds, but dripping remained, resulting in a V2 rating. The dripping problem persisted when using HPTCP (E14-E16), although only one annealed sample in E16 failed with 6% HPTCP. In Example 17, a solution to the dripping problem was found by incorporating 5% HPTCP and 2% polysiloxane core-shell copolymer into the branched PC composition. This combination effectively eliminated dripping, reduced the burn time to below 10 seconds, achieved a V-0 flame retardant rating at 1.5 mm, and had an impact strength of 895 J / m.

[0172] The weight percentage of each material in the compositions of Examples 19-27 is shown in Table 8.

[0173] Table 8

[0174] Based on the results of Experiment 17, additional experiments were conducted to evaluate the use of different amounts of polysiloxane core-shell impact modifier, hexaphenoxycyclotriphosphazene, branched polycarbonate, and post-consumer polycarbonate.

[0175] Table 9 shows the features of Examples 19-27.

[0176] Table 9

[0177] As can be seen from Table 9, the amount of branched polycarbonate affects the ability of polycarbonate compositions containing polysiloxane core-shell impact modifiers, hexaphenoxycyclotriphosphazene, and post-consumption recycled polycarbonate to achieve a V-0 rating.

[0178] The weight percentage of each material in the compositions of Examples 28-34 is shown in Table 10.

[0179] Table 10

[0180] In Examples 28-34, different amounts of hexaphenoxycyclotriphosphazene, branched polycarbonate, post-consumption recycled polycarbonate, and polysiloxane polycarbonate copolymers were used to determine whether using polysiloxane polycarbonate copolymers instead of polysiloxane impact modifiers would produce polycarbonate compositions with properties comparable to those in Examples 17, 19-25, and 27.

[0181] Table 11 shows the features of Examples 28-34.

[0182] Table 11

[0183] As shown in Table 11, polysiloxane polycarbonate copolymers, together with hexaphenoxycyclotriphosphazene, branched polycarbonate, and post-consumption recycled polycarbonate, can be used to produce polycarbonate compositions with V-0 rating, high impact strength, and thermal stability (as shown in Tg).

[0184] Table 12 shows the heat soaking data for experiments 22 and 23, as well as the low-temperature ductility of experiment 23.

[0185] Table 12

Claims

1. A composition comprising: a) One or more branched polycarbonates; b) One or more phosphazene-based flame retardants; and c) One or more polysiloxane impact modifiers or one or more polysiloxane polycarbonate copolymers.

2. The composition of claim 1, wherein the composition comprises about 8 to about 92% by weight of one or more branched polycarbonates based on the weight of the composition.

3. The composition of claim 1 or 2, wherein the one or more branched polycarbonates comprise one or more virgin polycarbonates, one or more post-consumer recycled polycarbonates, or a combination thereof.

4. The composition of any one of claims 1 to 3, wherein the composition comprises about 4 to less than about 8% by weight of one or more phosphazene-based flame retardants based on the weight of the composition.

5. The composition of any one of the preceding claims, wherein the composition comprises about 4% by weight of one or more phosphazene-based flame retardants based on the weight of the composition.

6. The composition of any one of the preceding claims, wherein the one or more phosphazene-based flame retardants has a cyclic structure containing one or more phosphazene units.

7. The composition of any one of the preceding claims, wherein the one or more phosphazene-based flame retardants is hexaphenoxycyclotriphosphazene.

8. The composition of any of the preceding claims, wherein the composition contains about 0.75 to about 4% by weight of polysiloxane monomer units based on the weight of the composition.

9. The composition of any one of the preceding claims, wherein the composition comprises one or more polysiloxane impact modifiers.

10. The composition of claim 9, wherein the composition comprises about 1.5 to about 5.0% by weight of one or more polysiloxane impact modifiers.

11. The composition of claim 9 or 10, wherein one or more polysiloxane impact modifiers comprise about 80 to about 99% by weight of a siloxane core based on the weight of the one or more polysiloxane impact modifiers.

12. The composition of any one of claims 9 to 11, wherein the composition comprises about 10 to about 92% by weight of branched polycarbonate based on the weight of the composition.

13. The composition of any one of the preceding claims, wherein the one or more polysiloxane impact modifiers comprises one or more polysiloxane core-shell copolymers.

14. The composition of any one of claims 1 to 8, wherein the composition comprises one or more polysiloxane polycarbonate copolymers.

15. The composition of any one of claims 1 to 8 or 14, wherein the composition comprises about 5.0 to about 95% by weight of one or more polycarbonate polysiloxane copolymers based on the weight of the composition.

16. The composition of any one of claims 1 to 8, 14 or 15, wherein the one or more polycarbonate polysiloxane copolymers comprise about 4.0 to about 15% by weight of one or more polysiloxane monomer units within the polycarbonate backbone.

17. The composition of any one of claims 14 to 16, wherein the composition comprises about 15 to about 85% by weight of branched polycarbonate based on the weight of the composition.

18. The composition of any one of the preceding claims, wherein the composition comprises one or more linear polycarbonates.

19. The composition of any of the preceding claims, wherein the composition comprises 0 to about 85% by weight of one or more linear polycarbonates based on the weight of the composition.

20. The composition of any one of the preceding claims, wherein the composition comprises about 20 to about 85% by weight of one or more linear polycarbonates based on the weight of the composition.

21. The composition of any one of claims 18 to 20, wherein the one or more linear polycarbonates comprise one or more post-consumer recycled polycarbonates, one or more virgin polycarbonates, or a combination thereof.

22. The composition of any one of claims 18 to 21, wherein the one or more linear polycarbonates comprise one or more post-consumption recycled polycarbonates.

23. The composition of any one of the preceding claims, wherein the composition comprises one or more post-consumption recycled polycarbonates.

24. The composition of any of the preceding claims, wherein the composition comprises 0 to about 92% by weight of one or more post-consumption recycled polycarbonates.

25. The composition of any one of the preceding claims, wherein the composition comprises about 30 to about 92% by weight of one or more post-consumer recycled polycarbonates.

26. The composition of any of the preceding claims, wherein the composition comprises one or more mold release agents, one or more antioxidants, one or more UV absorbers, one or more carbon-based microparticles, one or more metal oxides, one or more metal-like oxides, one or more additional additives commonly used in polycarbonate-based compositions, or any mixture thereof.

27. The composition of any of the preceding claims, wherein the composition comprises one or more release agents.

28. The composition of claim 26 or 27, wherein the composition comprises one or more release agents at a weight percentage of 0 to 1.0% by weight of the composition.

29. The composition of any one of claims 26 to 28, wherein the release agent is at least one of pentaerythritol tetrastearate, glyceryl monostearate, and octyl dodecyl stearate.

30. The composition of claim 29, wherein the release agent is pentaerythritol tetrastearate.

31. The composition of any one of the preceding claims, wherein the composition comprises one or more antioxidants.

32. The composition of claim 31, wherein the composition comprises 0 to 0.5% by weight of one or more antioxidants based on the weight of the composition.

33. The composition of claim 31 or 32, wherein the one or more antioxidants are 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.

34. The composition of any one of claims 31 to 33, wherein the one or more antioxidants are one or more of phenolic antioxidants and / or phosphorus-based antioxidants.

35. The composition of any one of claims 31 to 33, wherein the one or more antioxidants comprise both phenolic antioxidants and phosphorus-based antioxidants.

36. The composition of any one of claims 31 to 35, wherein the one or more antioxidants comprise phenolic antioxidants.

37. The composition of any one of claims 31 to 36, wherein the one or more antioxidants are at least one of pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) and tris(2,4-di-tert-butylphenyl) phosphite.

38. The composition of claim 37, wherein one or more antioxidants are pentaerythritol tetra(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate).

39. The composition of any of the preceding claims, wherein the composition comprises one or more UV absorbers.

40. The composition of claim 39, wherein the composition comprises 0 to 0.5% by weight of one or more UV absorbers based on the weight of the composition.

41. The composition of claim 39 or 40, wherein the one or more UV absorbers are one or more of benzotriazole, hydroxyphenyltriazine, benzophenone and mestriazine, or any combination thereof.

42. The composition of any of the preceding claims, wherein the composition comprises one or more carbon-based microparticles.

43. The composition of claim 42, wherein the composition comprises 0 to about 1.0% by weight of one or more carbon-based microparticles.

44. The composition of claim 42 or 43, wherein the one or more carbon-based microparticles are carbon black.

45. The composition of any of the preceding claims, wherein the composition comprises one or more metal oxides, one or more metal-like oxides, or mixtures thereof.

46. ​​The composition of claim 45, wherein the composition comprises 0 to about 8.0% by weight of one or more metal oxides, one or more metal-like oxides or mixtures thereof.

47. The composition of claim 45 or 46, wherein the one or more metal oxides or metal-like oxides are one or more of SiO2, MgO, TiO2 or CuCr2O4.

48. The composition of claim 47, wherein the one or more metal oxides are TiO2 or CuCr2O4.

49. The composition of any of the preceding claims, wherein the composition has a glass transition temperature of about 131°C or higher.

50. The composition of claim 49, wherein the composition has a glass transition temperature of about 135°C or higher.

51. The composition as claimed in any of the preceding claims, wherein the composition has a melt flow rate of about 5 to 20 g / 10 minutes at 300°C / 1.2 kg.

52. The composition as claimed in any of the preceding claims, wherein the composition has a UL94 V-0 @ 1.5mm flame retardancy.

53. The composition as claimed in any of the preceding claims, wherein the composition has thermal stability.

54. The composition of any of the preceding claims, wherein the composition retains ductile strength at -20°C, as determined by a notched Izod test.

55. The composition of any of the preceding claims, wherein the composition retains ductile strength at -30°C, as determined by a notched Izod test.

56. The composition of any of the preceding claims, wherein the composition retains ductile strength when processed at 300°C and held for at least 7 minutes.

57. The composition of any of the preceding claims, wherein the composition has an impact strength of 700 J / m or greater, as determined by a notched Izod test.

58. The composition as claimed in any of the preceding claims, wherein the composition does not contain any halogen atoms.

59. The composition as claimed in any of the preceding claims, wherein the composition is free of anti-drip agents having halogen atoms.

60. An article prepared from the composition according to any one of the preceding claims, having a flame retardancy of UL94 V-0 @1.5 mm.

61. The article of claim 60, which has thermal stability.

62. The article of claim 60 or 61, wherein the article retains ductile strength at -20°C, as determined by a notched Izod test.

63. The article of claim 60 or 61, wherein the article retains ductile strength at -30°C, as determined by a notched Izod test.

64. The article of any one of claims 60 to 63, wherein the article retains ductile strength when processed at 300°C and held for at least 7 minutes.

65. The article of any one of claims 60 to 64, wherein the article has an impact strength of 700 J / m or greater, as determined by a notched Izod test.

66. The article of any one of claims 60 to 65, having a glass transition temperature of about 131°C or higher.

67. The article of any one of claims 60 to 66, having a glass transition temperature of about 135°C or higher.

68. The article of manufacture as claimed in any one of claims 60 to 67, wherein the article of manufacture is used in a consumer electronics product.

69. The article of any one of claims 60 to 68, wherein the article has a heat distortion temperature of about 109°C or higher.

70. A method comprising: a) Contacting and finely mixing the components of any one of claims 1 to 59 at a temperature of about 250°C or higher for about 10 seconds or longer; b) Fill the mold with the mixture from a); c) Forming the composition in the mold into a solid article; and d) Remove the formed article from the mold.

71. The method of claim 70, wherein the contacting and mixing takes place in an extruder, and the resulting mixture is transferred from the extruder to a die.

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