Thermoplastic compositions, methods for making same, and articles made therefrom

Abstract

The thermoplastic composition includes a specific amount of post-consumer recycled polycarbonate, a polycarbonate-siloxane copolymer, a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate containing repeating units derived from bulky bisphenol groups, and, optionally, one or more linear homopolycarbonates having a specific melt flow rate. The composition can provide a desirable combination of properties, making it particularly useful for various articles, such as consumer electronics.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and benefit of European Patent Application No. 22192155.4, filed August 25, 2022, the contents of which are hereby incorporated by reference in their entirety.

[0002] This disclosure relates to polycarbonate compositions, methods for making same, and articles containing same. [Background technology]

[0003] Polycarbonate (PC) is used extensively for many applications, including electronics, mobility, industry, infrastructure, and healthcare, due to its excellent mechanical, electrical, and flame-retardant properties and wide color space. Products with a smaller carbon footprint are becoming increasingly desirable. Post-consumer recycling (PCR) allows for the reuse of plastic materials by recycling them from end-use products in the market and converting them into raw materials for new products. However, PCR-based materials typically exhibit inferior mechanical properties compared to corresponding virgin materials, for example, due to additional thermal history or degradation that may occur during the recycling process. Furthermore, some PCR materials may possess color, which may narrow the available color space for end-use products. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a continuing need for compositions containing recycled materials that exhibit mechanical properties, flame retardant performance, and color space comparable to virgin materials. It would be particularly advantageous to provide compositions with high PCR content. [Means for solving the problem]

[0005] One aspect of the present disclosure is a thermoplastic composition comprising 30 to 95 weight percent of post-consumer recycled polycarbonate and 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, wherein when the composition comprises the polycarbonate-siloxane copolymer, the branched polycarbonate, or the copolycarbonate comprising phthalimidine carbonate repeat units, the composition comprises 5 to 65 weight percent of an ultra high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, or a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238. and a linear polycarbonate homopolymer comprising at least two of: a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; and an ultra low flow polycarbonate having a melt flow rate of less than 5 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, wherein the weight percent of each component is based on the total weight of the composition.

[0006] Another aspect of the present disclosure is a method for making a composition, the method comprising melt-mixing the components of the composition.

[0007] Another aspect is an article comprising the composition.

[0008] These and other features are exemplified by the following detailed description. DETAILED DESCRIPTION OF THE INVENTION

[0009] The present inventors have discovered that compositions comprising a combination of specific amounts of post-consumer recycled polycarbonate, a polycarbonate component (e.g., virgin polycarbonate), and a linear polycarbonate having a specific melt flow rate can provide a desirable combination of properties.

[0010] Thus, one aspect of the present disclosure is a thermoplastic composition. The thermoplastic composition includes a post-consumer recycled polycarbonate. As used herein, the term "post-consumer recycled polycarbonate" refers to polycarbonate that has been collected or recycled after being previously used in an end-use part, article, or component and utilized by an end user or consumer. Thus, for example, the term is understood to refer to polycarbonate material that would otherwise be disposed of as waste but has instead been collected and recovered (recycled) as an input material in place of new, virgin material for a recycling or manufacturing process. The term includes materials so collected or recycled that have been further treated or processed to facilitate reuse of the material. Thus, for example, the term includes materials that have been reprocessed from collected or recycled materials in a manufacturing process and manufactured into products or components for incorporation into products. Such recycled polycarbonate can be further processed, such as into ground material, flakes, or pellets.

[0011] Post-consumer recycled polycarbonates include polycarbonates. "Polycarbonate," as used herein, means a homopolymer or copolymer having repeating structural carbonate units of formula (1): [ka] (1) In the formula, R 1 At least 60 percent of the total number of groups are aromatic, or each R 1 has at least one C 6-30 Preferably, each R1 can be derived from a dihydroxy compound such as an aromatic dihydroxy compound of formula (2) or a bisphenol of formula (3). [ka] (2) [ka] (3) In formula (2), each R h are independently a halogen atom, e.g., bromine, C 1-10 Hydrocarbyl groups, such as C 1-10 Alkyl, halogen-substituted C 1-10 Alkyl, C 6-10 Aryl or halogen-substituted C 6-10 aryl, and n is 0 to 4.

[0012] In equation (3), R a and R b are each independently a halogen, C 1-12 Alkoxy, or C 1-12 alkyl, and p and q are each independently an integer from 0 to 4, so that when p or q is less than 4, the valence of each carbon of the ring is filled with hydrogen. In one embodiment, p and q are each 0, or p and q are each 1, and R a and R b are each positioned meta to the hydroxy group on each arylene group, C 1-3 An alkyl group, preferably methyl. X a is a bridging group connecting two hydroxy-substituted aromatic groups, wherein the bridging group and the hydroxy substituents of each C6 arylene group are arranged ortho, meta, or para (preferably para) to each other on the C6 arylene group, and are, for example, a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or C 1-18 It is an organic group, which can be cyclic or acyclic, aromatic or non-aromatic, and can further contain heteroatoms such as halogen, oxygen, nitrogen, sulfur, silicon, or phosphorus. For example, X ais substituted or unsubstituted C 3-18 Cycloalkylidene, formula -C(R c )(R d )-C 1-25 Alkylidene (wherein R c and R d are each independently hydrogen, C 1-12 Alkyl, C 1-12 Cycloalkyl, C 7-12 Aryl alkyl, C 1-12 Heteroalkyl, or cyclic C 7-12 heteroarylalkyl), or of the formula -C(=R e )-group (wherein R e is a divalent C 1-12 It can be a hydrocarbon group.

[0013] Examples of bisphenol compounds include 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, and bis(4-hydroxyphenyl). Phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)isobutene, 1,1-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, α,α'-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile , 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane phenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 4,4'-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,6-bis(4-hydroxyphenyl)-1,6-Hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorene, 2,7-dihydroxypyrene, 6,6'-dihydroxy-3,3,3',3'-tetramethylspiro(bis)indane ("spirobiindane bisphenol"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydro carbazole, resorcinol, substituted resorcinol compounds such as 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-t-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, 2,4,5,6-tetrabromoresorcinol, etc., catechol, hydroquinone, substituted hydroquinones such as 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-t-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone, etc.,

[0014] Specific dihydroxy compounds include: resorcinol, 2,2-bis(4-hydroxyphenyl)propane ("bisphenol A" or "BPA"), 3,3-bis(4-hydroxyphenyl)phthalimidine, 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine (N-phenylphenolphthalein bisphenol, also known as "PPPBP"), or 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (isophorone bisphenol).

[0015] In one embodiment, the post-consumer recycled polycarbonate may have a phenolic end group content greater than 5 mole percent, preferably from 10 to 35 mole percent.

[0016] In one embodiment, the post-consumer recycled polycarbonate comprises a homopolycarbonate, such as bisphenol A homopolycarbonate. The post-consumer recycled polycarbonate may contain residual amounts of one or more additives that were present in the polycarbonate composition prior to recycling.

[0017] In one embodiment, the post-consumer recycled polycarbonate may have an L value of 85 or greater, preferably 92 or greater, as determined according to ASTM D2244; a Yellowness Index of 8 or less, preferably 3.5 or less, as determined according to ASTM E313; a Transmission of 70% or greater, preferably 82% or greater, at a thickness of 3 millimeters, as determined according to ASTM D1003; and a Haze of 10 or less, preferably 6 or less, at a thickness of 3 mm, as determined according to ASTM D1003.

[0018] The post-consumer recycled polycarbonate may be present in the composition in an amount of 25 to 95 weight percent, based on the total weight of the composition. Within this range, the post-consumer recycled polycarbonate may be present in the composition in an amount of at least 30 weight percent, or at least 35 weight percent, or at least 40 weight percent, or at least 45 weight percent, or at least 50 weight percent. Also within this range, the post-consumer recycled polycarbonate may be present in the composition in an amount of up to 95 weight percent, or up to 85 weight percent, or up to 80 weight percent, or up to 75 weight percent, or up to 70 weight percent. In one embodiment, the post-consumer recycled polycarbonate may be present in the composition in an amount of 45 to 90 weight percent, or 45 to 80 weight percent, or 50 to 75 weight percent, or 25 to 55 weight percent, or 30 to 50 weight percent. Any combination of the above upper and lower limits is also contemplated herein.

[0019] In addition to the post-consumer recycled polycarbonate, the composition further comprises a polycarbonate component that is a polycarbonate-siloxane copolymer, a polycarbonate-ester, a branched polycarbonate, or a copolycarbonate containing phthalimidine carbonate repeat units polycarbonate copolymer, the polycarbonate component being preferably virgin material.

[0020] In one embodiment, the polycarbonate component is a polycarbonate-siloxane copolymer. The polycarbonate-siloxane copolymer is preferably virgin material, having not been used in an end-use part, article, or component. The polycarbonate-siloxane copolymer comprises polysiloxane blocks containing carbonate repeat units according to formula (1) and repeat diorganosiloxane units as found in formula (4): [ka] (4) wherein each R independently represents C 1-13 A monovalent organic group. For example, R is C 1-13 Alkyl, C 1-13 Alkoxy, C 2-13 Alkenyl, C 2-13 Alkenyloxy, C 3-6 Cycloalkyl, C 3-6 Cycloalkoxy, C 6-14 Aryl, C 6-10 Aryloxy, C 7-13 Aryl alkylene, C 7-13 Arylalkylenoxy, C 7-13 Alkylarylene, or C 7-13 The R group can be alkylaryleneoxy. The group can be fully or partially halogenated with fluorine, chlorine, bromine, or iodine, or a combination thereof. In one embodiment, when a transparent poly(carbonate-siloxane) is desired, R is not substituted with halogen. Combinations of the R groups can be used within the same copolymer.

[0021] The value of E in formula (4) can vary widely depending on the type and relative amount of each component in the thermoplastic composition, the desired properties of the composition, and similar considerations. Generally, E has an average value of 2 to 1,000, preferably 2 to 500, 2 to 200, or 2 to 125, 5 to 80, or 10 to 70. In one embodiment, E has an average value of 10 to 80 or 10 to 40, and in yet another embodiment, E has an average value of 40 to 80 or 40 to 70. When E has a smaller value, e.g., less than 40, it may be desirable to use a relatively larger amount of poly(carbonate-siloxane) copolymer. Conversely, when E has a higher value, e.g., greater than 40, a relatively lower amount of poly(carbonate-siloxane) copolymer can be used. Combinations of first and second (or more) poly(carbonate-siloxane) copolymers can be used, where the average value of E for the first copolymer is less than the average value of E for the second copolymer.

[0022] In one embodiment, the polysiloxane block has the formula (5): [ka] (5) wherein E and R are as defined in formula (4), each R can be the same or different and is as defined above, and Ar can be the same or different and is a substituted or unsubstituted C 6-30 In the formula (5), the Ar group is C 6-30 It can be derived from dihydroxyarylene compounds such as 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxyphenyl)cyclohexane, bis(4-hydroxyphenyl sulfide), and 1,1-bis(4-hydroxy-t-butylphenyl)propane.

[0023] In another embodiment, the polysiloxane block has the formula (6): [ka] (6) where R and E are as described above, and each R 5 are independently divalent C 1-30 The polysiloxane blocks are organic groups and the polymerized polysiloxane units are the reacted residues of their corresponding dihydroxy compounds. In certain embodiments, the polysiloxane blocks have the formula (7): [ka] (7) In the formula, R and E are as defined above. 6 is a divalent C 2-8 Each M in formula (7) can be the same or different and is an aliphatic group, such as halogen, cyano, nitro, C 1-8 Alkylthio, C 1-8 Alkyl, C 1-8 Alkoxy, C 2-8 Alkenyl, C 2-8 Alkenyloxy, C 3-8 Cycloalkyl, C 3-8 Cycloalkoxy, C 6-10 Aryl, C 6-10 Aryloxy, C 7-12 Aralkyl, C 7-12 Aralkoxy, C 7-12 Alkylaryl, or C 7-12 It can be alkylaryloxy, where each n is independently 0, 1, 2, 3, or 4.

[0024] In one embodiment, M is bromo or chloro, alkyl, such as methyl, ethyl, or propyl, alkoxy, such as methoxy, ethoxy, or propoxy, or aryl, such as phenyl, chlorophenyl, or tolyl; R 6 is dimethylene, trimethylene, or tetramethylene, and R is C 1-8 In another embodiment, R is methyl, or a combination of methyl and trifluoropropyl, or a combination of methyl and phenyl. In yet another embodiment, R is methyl, M is methoxy, n is 1, and R 6 is a divalent C 1-3 The specific polysiloxane block is of the formula: [ka] (7a) [ka] (7b) [ka] (7c) or combinations thereof, wherein E has an average value of 2 to 200, 2 to 125, 5 to 125, 5 to 100, 5 to 50, 20 to 80, or 5 to 20.

[0025] The block of formula (7) can be derived from the corresponding dihydroxypolysiloxane, which can be prepared by platinum-catalyzed addition of a hydrogen siloxane with an aliphatic unsaturated monohydric phenol, such as eugenol, 2-alkylphenol, 4-allyl-2-methylphenol, 4-allyl-2-phenylphenol, 4-allyl-2-bromophenol, 4-allyl-2-t-butoxyphenol, 4-phenyl-2-phenylphenol, 2-methyl-4-propylphenol, 2-allyl-4,6-dimethylphenol, 2-allyl-4-bromo-6-methylphenol, 2-allyl-6-methoxy-4-methylphenol, and 2-allyl-4,6-dimethylphenol. The poly(carbonate-siloxane) copolymer can then be produced, for example, by the synthetic procedure described in Hoover, European Patent Application Publication No. 0 524 731 A1, page 5, Preparation 2.

[0026] The poly(carbonate-siloxane) copolymer can contain 50 to 95 weight percent carbonate units and 5 to 50 weight percent siloxane units. Within this range, the poly(carbonate-siloxane) copolymer can contain 50 to 85 weight percent, more preferably 60 to 80 weight percent carbonate units and 15 to 50 weight percent, more preferably 20 to 40 weight percent siloxane units.

[0027] Suitable polycarbonate-siloxane copolymers include, for example, those available from SABIC under the trade name EXL.

[0028] In one embodiment, the polycarbonate component can include a branched polycarbonate. Specifically, in one embodiment, the polycarbonate component can be a branched polycarbonate containing the units described above, 3 mole percent or more of a moiety derived from a branching agent, based on the total moles of polycarbonate, and an endcapping group derived from an endcapping agent having a pKa between 8.3 and 11. The branching agent can include trimellitic acid trichloride, 1,1,1-tris(4-hydroxyphenyl)ethane, or a combination of trimellitic acid trichloride and 1,1,1-tris(4-hydroxyphenyl)ethane, and the endcapping agent is a phenol or a phenol containing a substituent such as a cyano group, an aliphatic group, an olefinic group, an aromatic group, a halogen, an ester group, an ether group, or a combination thereof. In a specific embodiment, the endcapping agent is phenol, pt-butylphenol, p-methoxyphenol, p-cyanophenol, p-cumylphenol, or a combination thereof. In one embodiment, the endcapping agent is a cyanophenol.

[0029] In one embodiment, the polycarbonate component can include a copolycarbonate containing repeat units derived from bisphenol A and bulky bisphenol carbonate units, i.e., those derived from a bisphenol containing at least 18 carbon atoms, e.g., 18 to 60 carbon atoms or 20 to 40 carbon atoms. Exemplary bulky bisphenol carbonate units can include, for example, bulky bisphenol carbonate groups of formulas (8) through (14): [ka] (8) [ka] (9) [ka] (10) [ka] (11) [ka] (12) [ka] (13) [ka] (14) In the formula, R c and R d are each independently, C 1-12 Alkyl, C 2-12 Alkenyl, C 3-8 Cycloalkyl, or C 1-12 alkoxy, and each R f is hydrogen, or both R f together form a carbonyl group, and each R 3 is independently C 1-6 alkyl, and R 4 is hydrogen, C 1-6 alkyl, or optionally 1 to 5 C 1-6 is a phenyl substituted with an alkyl group, and R 6 is independently C 1-3 alkyl, or phenyl, preferably methyl; X a is C 6-12 Polycyclic aryl, C 3-18 Mono- or polycycloalkylene, C 3-18 Mono- or polycycloalkylidene, -C(R f )(R g )-(wherein, R f is hydrogen, C 1-12 Alkyl, or C 6-12 aryl, and R g is C 6-10 Alkyl, C 6-8 Cycloalkyl, or C 6-12 aryl), or -(Q a ) x -G-(Q b ) y - group (in the formula, Q a and Q bare each independently, C 1-3 alkylene, and G is C 3-10 cycloalkylene, x is 0 or 1, and y is 0 or 1), and j, m, and n are each independently 0 to 4. Combinations of high heat bisphenol groups can be used.

[0030] In one aspect, R c and R d are each independently, C 1-3 Alkyl, or C 1-3 alkoxy, and each R 6 is methyl, and each R 3 is independently C 1-3 alkyl, and R 4 is methyl or phenyl, and each R 6 is independently C 1-3 alkyl, or phenyl, preferably methyl; X a is C 6-12 Polycyclic aryl, C 3-18 Mono- or polycycloalkylene, C 3-18 Mono- or polycycloalkylidene, -C(R f )(R g )-(wherein, R f is hydrogen, C 1-12 Alkyl, or C 6-12 aryl, and R g is C 6-10 Alkyl, C 6-8 Cycloalkyl, or C 6-12 aryl), or -(Q 1 ) x -G-(Q 2 ) y - group, (wherein, Q 1 and Q 2 are each independently, C 1-3 alkylene, and G is C 3-10 cycloalkylene, x is 0 or 1, and y is 0 or 1), and j, m, and n are each independently 0 or 1.

[0031] Exemplary bulky bisphenol groups can include those of formulae (13a) and (14a) through (14k): [ka] (13a) [ka] (14a) [ka] (14b) [ka] (14c) [ka] (14d) [ka] (14e) [ka] (14f) [ka] (14g) [ka] (14i) [ka] (14j) [ka] (14k) In the formula, R c and R d is the same as defined for equations (8) to (14), and each R 2 is independently C 1-4 alkyl, m and n are each independently 0 to 4, and each R3 is independently C 1-4 alkyl or hydrogen, and R 4 is C 1-6 Alkyl or optionally 1 to 5 C 1-6 phenyl substituted with an alkyl group, and g is 0 to 10. In certain embodiments, each bond of the bisphenol group is a In one aspect, R c and R d are each independently, C 1-3 Alkyl, or C 1-3 alkoxy, and each R 2 is methyl, x is 0 or 1, y is 1, and m and n are each independently 0 or 1.

[0032] The bulky bisphenol group preferably has the formula (13a-2) or (14a-2): [ka] (13a-2) [ka] (14a-2) In the formula, R 4 is methyl or phenyl, and each R 2 is methyl and g is 1 to 4. Preferably, the bulky bisphenol group is derived from 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine (PPPBP) or 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane (BP-TMC). [ka] (PPPBP basis) [ka] (BP-TMC group)

[0033] In one embodiment, such copolycarbonates can include copolycarbonates comprising bisphenol A carbonate units and 2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine carbonate units (BPA-PPPBP copolymer, commercially available from SABIC under the trade names XHT and CXT), copolymers comprising bisphenol A carbonate units and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane carbonate units (BPA-DMBPC copolymer, commercially available from SABIC under the trade name DMC), and copolymers comprising bisphenol A carbonate units and isophorone bisphenol carbonate units (e.g., available from Bayer under the trade name APEC). In one embodiment, the polycarbonate component can include a BPA-PPPBP copolymer.

[0034] In one embodiment, the composition can include a polycarbonate-ester, such as a poly(aromatic ester-carbonate) comprising bisphenol A carbonate units and isophthalate-terephthalate-bisphenol A ester units, commonly referred to as poly(carbonate-ester) (PCE) or poly(phthalate-carbonate) (PPC), depending on the relative ratio of carbonate and ester units. Another specific poly(ester-carbonate) comprises resorcinol isophthalate and terephthalate units and bisphenol A carbonate units, such as those commercially available from SABIC under the trade name LEXAN SLX.

[0035] For example, in certain embodiments, polyester-carbonates include, in addition to recurring carbonate units of formula (1), recurring ester units of formula (15): [ka] (15) wherein J is a divalent radical derived from an aromatic dihydroxy compound (including reactive derivatives thereof), such as a bisphenol of formula (3), e.g., bisphenol A; and T is a divalent radical derived from an aromatic dicarboxylic acid (including reactive derivatives thereof), preferably isophthalic acid or terephthalic acid, wherein the weight ratio of isophthalic acid to terephthalic acid is from 91:9 to 2:98. Copolyesters containing combinations of different T or J groups can be used. The polyester units can be branched or linear.

[0036] In one embodiment, J is derived from a bisphenol of formula (3), e.g., bisphenol A. In another embodiment, J is derived from an aromatic dihydroxy compound, e.g., resorcinol. A portion of the J groups, e.g., up to 20 mole percent (mol%), may be C 1 -C 2 -C 3 -C 4 -C 5 -C 6 -C 7 -C 8 -C 9 -C 10 -C 11 -C 12 -C 13 -C 14 -C 15 -C 16 -C 17 -C 18 -C 19 -C 20 -C 21 -C 22 -C 23 -C 24 -C 25 -C 26 -C 27 -C 28 -C 29 -C 30 -C 31 -C 32 -C 33 -C 34 -C 35 -C 40 -C 41 -C 42 -C 43 -C 44 -C 45 -C 46 -C 47 -C 48 -C 50 -C 51 -C 52 -C 53 -C 54 -C 55 -C 56 -C 57 -C 58 -C 59 -C 60 -C 61 -C 62 -C 63 -C 64 -C 65 -C 66 -C 67 -C 68 -C 69 -C 70 -C 71 -C 72 -C 73 -C 74 -C 75 -C 76 -C 77 -C 78 -C 79 -C 78 -C 79 -C 71 -C 72 -C 73 -C 74 -C 75 -C 76 -C 77 -C 78 -C 79 -C 79 -C 79 -C 71 -C 7 2-30 It can be an alkylene group such as ethylene, n-propylene, i-proplyene, 1,4-butylene, 1,4-cyclohexylene, or 1,4-methylenecyclohexane. Preferably, all J groups are aromatic.

[0037] Aromatic dicarboxylic acids that can be used to prepare polyester units include isophthalic acid or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, or combinations thereof. Acids containing fused rings can also be present, for example, in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acid. Specific dicarboxylic acids include terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, or combinations thereof. Specific dicarboxylic acids include combinations of isophthalic acid and terephthalic acid, with the weight ratio of isophthalic acid to terephthalic acid being 91:9 to 2:98. A portion of the T groups, for example, up to 20 mol%, can be aliphatic, for example, derived from 1,4-cyclohexanedicarboxylic acid. Preferably, all T groups are aromatic.

[0038] The molar ratio of ester units to carbonate units in the polycarbonate can vary widely depending on the desired properties of the final composition, for example, from 1:99 to 99:1, preferably from 10:90 to 90:10, more preferably from 25:75 to 75:25, or from 2:98 to 15:85.

[0039] A specific poly(ester-carbonate) is one that contains bisphenol A carbonate units and isophthalate / terephthalate-bisphenol A ester units, i.e., poly(bisphenol A carbonate)-co-(bisphenol A-phthalate-ester) of formula (15a): [ka] (15a) where x and y represent the weight percentage of bisphenol A carbonate units and isophthalate / terephthalate-bisphenol A ester units, respectively. Typically, the units are present as blocks. In one embodiment, the weight ratio of carbonate units x to ester units y in the polycarbonate is 1:99 to 50:50, or 5:95 to 25:75, or 10:90 to 45:55. Copolymers of formula (15) containing 35-45 wt% carbonate units and 55-65 wt% ester units, with the ester units having an isophthalate to terephthalate molar ratio of 45:55 to 55:45, are often referred to as poly(carbonate-ester)s (PCEs). Copolymers containing 15-25 wt% carbonate units and 75-85 wt% ester units, with the ester units having an isophthalate to terephthalate molar ratio of 98:2 to 88:12, are often referred to as poly(phthalate-carbonate)s (PPCs).

[0040] In another embodiment, the high heat poly(ester-carbonate) is a poly(carbonate-co-monoarylate ester) of formula (15b) comprising aromatic carbonate units (1) and repeating monoarylate ester units: [ka] (15b) In the formula, R 1 is as defined in formula (1), and each R h are independently a halogen atom, C 1-10 Hydrocarbyl, e.g., C 1-10 Alkyl group, halogen-substituted C 1-10 Alkyl group, C 6-10 Aryl group or halogen-substituted C 6-10 is an aryl group, and n is 0-4. Preferably, each R h independently, C 1-4 alkyl, and n is 0-3, 0-1, or 0. The molar ratio of carbonate units x to ester units z can be from 99:1 to 1:99, or from 98:2 to 2:98, or from 90:10 to 10:90. In one embodiment, the molar ratio of x:z is from 50:50 to 99:1, or from 1:99 to 50:50.

[0041] In one embodiment, the high heat poly(ester-carbonate) comprises monoarylate ester units derived from the reaction of aromatic ester units with resorcinol (or a reactive derivative thereof) of a combination of isophthalic and terephthalic diacids (or a reactive derivative thereof) to provide isophthalate / terephthalate-resorcinol ("ITR" ester units). The ITR ester units can be present in the high heat poly(ester-carbonate) in an amount of 95 mol % or greater, preferably 99 mol % or greater, and even more preferably 99.5 mol % or greater, based on the total number of moles of ester units in the polycarbonate. A preferred high heat poly(ester-carbonate) comprises bisphenol A carbonate units and ITR ester units derived from terephthalic acid, isophthalic acid, and resorcinol, i.e., poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) of formula (15c): [ka] (15c) wherein the molar ratio of x:z is 98:2 to 2:98, or 90:10 to 10:90. In one embodiment, the molar ratio of x:z is 50:50 to 99:1, or 1:99 to 50:50. ITR ester units can be present in the poly(bisphenol A carbonate-co-isophthalate-terephthalate-resorcinol ester) in an amount of 95 mol % or greater, preferably 99 mol % or greater, and even more preferably 99.5 mol % or greater, based on the total number of moles of ester units in the copolymer. Other carbonate units, other ester units, or a combination thereof can be present in a total amount of 1 to 20 mol %, based on the total number of moles of units in the copolymer, such as monoaryl carbonate units of formula (16) and bisphenol ester units of formula (17). [ka] (16) [ka] (17) where, in the formula, R h are each independently C 1-10 is a hydrocarbon group, n is 0-4, and R a and R b are each independently, C 1-12 alkyl, p and q are each independently an integer from 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or a group of the formula -C(R c )(R d )-C 1-13 Alkylidene (wherein R c and R d are each independently hydrogen or C 1-12 Alkyl, or a group of the formula -C(=R e )-group (wherein R e is a divalent C 1-12 The bisphenol ester unit can be a bisphenol A phthalate ester unit of formula (17b): [ka] (17b)

[0042] In one embodiment, poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) (15c) contains 1-90 mol% bisphenol A carbonate units, 10-99 mol% isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1-60 mol% resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof. In another embodiment, poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) contains 10-20 mol% bisphenol A carbonate units, 20-98 mol% isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1-60 mol% resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof.

[0043] The high-heat poly(ester-carbonate) may have a weight-average molecular weight (Mw) of 2,000-100,000 g / mol, preferably 3,000-75,000 g / mol, more preferably 4,000-50,000 g / mol, more preferably 5,000-35,000 g / mol, and even more preferably 17,000-30,000 g / mol. Molecular weight determinations are performed using GPC on a cross-linked styrene-divinylbenzene column at a sample concentration of 1 milligram per milliliter and calibrated with bisphenol A homopolycarbonate standards. Samples are eluted at a flow rate of 1.0 ml / min using methylene chloride as the eluent.

[0044] The polycarbonate component (i.e., polycarbonate-siloxane copolymer, polycarbonate ester, branched polycarbonate, or copolycarbonate containing bulky bisphenol groups) can be present in the composition in an amount of 5 to 70 weight percent, based on the total weight of the composition. Within this range, the polycarbonate component can be present in the composition in an amount of at least 9 weight percent, or at least 10 weight percent, or at least 15 weight percent, or at least 25 weight percent, or at least 40 weight percent, or at least 50 weight percent. Also within this range, the polycarbonate component can be present in the composition in an amount of up to 65 weight percent, or up to 60 weight percent, or up to 55 weight percent, or up to 50 weight percent. In one embodiment, the polycarbonate component can be present in an amount of 5 to 35 weight percent, or 10 to 25 weight percent, or 10 to 30 weight percent, or 35 to 55 weight percent. Combinations of any of the above upper and lower limits are also contemplated.

[0045] When the composition includes a polycarbonate-siloxane copolymer, a branched polycarbonate, or a copolycarbonate containing bulky bisphenol carbonate repeat units, the composition further includes a linear polycarbonate, preferably a linear homopolycarbonate. The linear polycarbonate, when present in the composition together with the polycarbonate-siloxane copolymer, the branched polycarbonate, or the copolycarbonate containing phthalimidine carbonate repeat units, is a combination of at least two polycarbonates having a specific melt flow rate. For example, the linear polycarbonate homopolymers include at least two of: an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min or 20 to 50 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min or 5 to 10 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; and an ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238. The at least two linear polycarbonate homopolymers are preferably selected from the different flow rate categories specified above. For example, the composition does not include two linear polycarbonate homopolymers that both have high flow rates (ie, both in the range of greater than 20 to 54 g / 10 min).

[0046] When the composition includes a polyester-carbonate, one or more of the linear polycarbonate components may or may not be present. When included with a polyester-carbonate, a single linear homopolycarbonate or a combination of two or more may be used. The linear polycarbonate may be as described above.

[0047] Linear polycarbonates can also be characterized in terms of their molecular weight, which ranges from 10,000 to 100,000 g / mol. For example, high-flow polycarbonates can have a weight-average molecular weight of less than 25,000 g / mol. Low-flow polycarbonates can have a weight-average molecular weight of 25,000 to 35,000 g / mol. Ultra-low-flow polycarbonates can have a weight-average molecular weight of greater than 35,000 g / mol. Molecular weight can be determined using gel permeation chromatography (GPC) against linear bisphenol A polycarbonate standards.

[0048] The linear polycarbonate, if present, is preferably virgin polycarbonate.

[0049] The linear polycarbonate can be as described above, for example, comprising repeat units according to formula (1). An exemplary linear homopolymer containing bisphenol A carbonate units (BPA-PC) is commercially available from SABIC under the trade name LEXAN.

[0050] When present, the composition can comprise linear polycarbonate homopolymer in an amount from 5 to 65 weight percent, based on the total weight of the composition. Within this range, the composition can comprise polycarbonate in an amount of at least 10 weight percent, or at least 12 weight percent, or at least 15 weight percent. Also within this range, the composition can comprise polycarbonate in an amount of up to 45 weight percent, or up to 40 weight percent, or up to 35 weight percent, or up to 30 weight percent, or up to 25 weight percent, or up to 20 weight percent.

[0051] In one embodiment, the composition comprises 25 to 90 weight percent post-consumer recycled polycarbonate; 5 to 70 weight percent polycarbonate-siloxane copolymer, or branched polycarbonate, or copolycarbonate containing repeat units derived from bulky bisphenol groups; and 5 to 65 weight percent of an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; and and a linear polycarbonate homopolymer comprising at least two ultra-low flow polycarbonates having a melt flow rate of less than 5 g / 10 min as determined at 300° C. and 1.2 kg in accordance with D1238.

[0052] Various combinations of the linear homopolycarbonates having different melt flow rates are contemplated herein. For example, a linear polycarbonate homopolymer can include a high flow polycarbonate and a low flow polycarbonate, a low flow polycarbonate and an ultra-low flow polycarbonate, or a low flow polycarbonate and an ultra-high flow polycarbonate.

[0053] In one embodiment, the composition can include 5 to 35 weight percent of a high-flow polycarbonate and 4 to 10 weight percent of a low-flow polycarbonate. In one embodiment, the composition can include 1 to 10 weight percent of a low-flow polycarbonate and 8 to 15 weight percent of an ultra-low-flow polycarbonate. In one embodiment, the composition can include 8 to 22 weight percent of a low-flow polycarbonate and 20 to 35 weight percent of an ultra-high-flow polycarbonate.

[0054] In one embodiment, when the composition includes a polycarbonate-siloxane copolymer, the linear polycarbonate homopolymer can include a high flow rate polycarbonate and a low flow rate polycarbonate or a low flow rate polycarbonate and an ultra-low flow rate polycarbonate. In one embodiment, when the composition includes a copolycarbonate containing repeat units derived from bulky bisphenol groups (e.g., phthalimidine groups), the linear polycarbonate homopolymer can include a low flow rate polycarbonate and an ultra-high flow rate polycarbonate. In one embodiment, when the composition includes a branched polycarbonate, the linear polycarbonate homopolymer can include a high flow rate polycarbonate and a low flow rate polycarbonate.

[0055] In certain embodiments, the composition can include 45 to 90 weight percent post-consumer recycled polycarbonate, 5 to 35 weight percent polycarbonate-siloxane copolymer, and 5 to 40 weight percent linear polycarbonate homopolymer, including high flow polycarbonate and low flow polycarbonate, or low flow polycarbonate and ultra-low flow polycarbonate.

[0056] In another particular embodiment, the composition can include 25 to 55 weight percent post-consumer recycled polycarbonate, 10 to 25 weight percent of a copolycarbonate including phthalimidine carbonate repeat units, and 30 to 55 weight percent of a linear polycarbonate homopolymer including a low flow polycarbonate and an ultra-high flow polycarbonate.

[0057] In another particular embodiment, the composition can include 40 to 60 weight percent post-consumer recycled polycarbonate, 10 to 30 weight percent branched polycarbonate containing cyanophenol end groups, and 10 to 30 weight percent linear polycarbonate homopolymer including low flow polycarbonate and high flow polycarbonate.

[0058] In another particular embodiment, the composition can include 20 to 60 weight percent post-consumer recycled polycarbonate, 35 to 55 weight percent polycarbonate-ester, and optionally, 15 to 35 weight percent high flow polycarbonate.

[0059] The thermoplastic composition can optionally further contain various additives commonly incorporated into polycarbonate compositions, provided that the additive(s) are selected so as not to significantly adversely affect the desired properties of the polycarbonate composition, particularly the color of the composition. Such additives can be mixed at a suitable mixing time during the mixing of the components to form the composition. Additives include, for example, impact modifiers, fillers, reinforcing agents, antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV) stabilizers, plasticizers, lubricants, mold release agents, antistatic agents, colorants (e.g., titanium dioxide, carbon black, and organic dyes), surface effect additives, radiation stabilizers, flame retardants, and drip-proofing agents. Combinations of additives can be used, such as combinations of stabilizers (e.g., heat stabilizers), flame retardants, and color packages. Generally, additives can be used in amounts generally known to be effective. For example, the total amount of additives (other than impact modifiers, fillers, or reinforcing agents) can be from 0.001 to 10.0 wt%, or from 0.01 to 5 wt%, each based on the total weight of polymer in the composition.

[0060] In one embodiment, the composition can optionally further comprise a flame retardant. Useful flame retardants include organic compounds containing phosphorus, bromine, or chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants may be preferred in certain applications for regulatory reasons, such as organic phosphates and organic compounds containing phosphorus-nitrogen bonds.

[0061] Flame retardant aromatic phosphates include triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl)phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, and 2-ethylhexyl diphenyl phosphate. Di- or polyfunctional aromatic phosphorus-containing compounds are also useful, such as resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl) phosphate of hydroquinone, and bis(diphenyl) phosphate of bisphenol A, respectively, and their oligomeric and polymeric counterparts.

[0062] Flame retardant compounds containing phosphorus-nitrogen bonds include phosphazenes, phosphonitrilic chlorides, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl)phosphine oxide. These flame retardant additives are commercially available. In one embodiment, the organophosphorus flame retardant containing phosphorus-nitrogen bonds is a phosphazene or cyclic phosphazene of the formula: [ka] or [ka] wherein w1 is 3 to 10,000, w2 is 3 to 25, or 3 to 7, and each R w independently, C 1-12The R groups are alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkylene groups, in which at least one hydrogen atom of these groups can be substituted with a group having an N, S, O, or F atom, or an amino group. For example, each R w can be a substituted or unsubstituted phenoxy, amino, or polyoxyalkylene group. w can further be a bridge to another phosphazene group. Exemplary bridges include bisphenol groups, such as bisphenol A groups. Examples include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decafenoxycyclopentaphosphazene, and the like. In one embodiment, the phosphazene has a structure represented by the following formula: [ka]

[0063] Commercially available phenoxyphosphazenes having the above structure are LY202, manufactured and distributed by Lanyin Chemical Co., Ltd., FP-110, manufactured and distributed by Fushimi Pharmaceutical Co., Ltd., and SPB-100, manufactured and distributed by Otsuka Chemical Co., Ltd.

[0064] Halogenated materials can also be used as flame retardants, for example, bisphenols, of which the following are representative: 2,2-bis-(3,5-dichlorophenyl)-propane, bis-(2-chlorophenyl)-methane, bis(2,6-dibromophenyl)-methane, 1,1-bis-(4-iodophenyl)-ethane, 1,2-bis-(2,6-dichlorophenyl)-ethane, 1,1-bis-(2-chloro-4-iodophenyl)-ethane. 1,1-bis-(2-chloro-4-methylphenyl)-ethane, 1,1-bis-(3,5-dichlorophenyl)-ethane, 2,2-bis-(3-phenyl-4-bromophenyl)-ethane, 2,6-bis-(4,6-dichloronaphthyl)-propane, and 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3-bromo-4-hydroxyphenyl)-propane. Other halogenated materials include 1,3-dichlorobenzene, 1,4-dibromobenzene, 1,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'-dibromobiphenyl, and 2,4'-dichlorobiphenyl, and decabromodiphenyl oxide, as well as oligomeric and polymeric halogenated aromatic compounds such as copolycarbonates of bisphenol A and tetrabromobisphenol A and carbonate precursors such as phosgene. Metal synergists, such as antimony oxide, can also be used with the flame retardants.

[0065] Alternatively, the thermoplastic composition can be essentially free of chlorine and bromine, which is defined as having a bromine or chlorine content of 100 parts per million (ppm) by weight or less, 75 ppm or less, or 50 ppm or less, based on the total parts by weight of the composition.

[0066] Inorganic flame retardants can also be used, e.g., C 1-16Alkyl sulfonates such as potassium perfluorobutanesulfonate (Rimar's salt), potassium perfluorooctanesulfonate, tetraethylammonium perfluorohexanesulfonate, and potassium diphenylsulfonesulfonate, salts of Na2CO3, K2CO3, MgCO3, CaCO3, and BaCO3, or fluoro-anion complexes such as Li3AlF6, BaSiF6, KBF4, K3AlF6, KAlF4, K2SiF6, or Na3AlF6.

[0067] When present, the flame retardant may be included in the composition in an amount of 0.01 to 10 weight percent. Within this range, the flame retardant may each be present in an amount of 0.1 to 10 weight percent, or 1 to 10 weight percent, or 1 to 8 weight percent, or 2 to 6 weight percent, or 3 to 5 weight percent, based on the total weight of the composition.

[0068] The heat stabilizer additive can include an organic phosphite (e.g., triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, tris-(mixed mono- and dinonylphenyl) phosphite, etc.), a phosphonate (e.g., dimethylbenzene phosphonate, etc.), a phosphate (e.g., trimethyl phosphate, etc.), or a combination thereof. The heat stabilizer can be tris(2,4-di-t-butylphenyl) phosphate, available as IRGAPHOS 168. The heat stabilizer is generally used in an amount of 0.01 to 5 wt %, based on the total weight of the polymer in the composition.

[0069] Light stabilizers or ultraviolet (UV) absorbing additives (also called UV stabilizers) can also be used. Light stabilizer additives include benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, and 2-hydroxy-4-n-octoxybenzophenone, or combinations thereof.

[0070] UV absorbing additives include hydroxybenzophenones, hydroxybenzotriazoles, hydroxybenzotriazines, cyanoacrylates, oxanilides, benzoxazinones, aryl salicylates, monoesters of diphenols such as resorcinol monobenzoate, 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (CYASORB 5411), 2-hydroxy-4-n-octyloxybenzophenone (CYASORB 531), 2-[4,6-biphenyl]benzophenone (CYASORB 541 ... s(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol (CYASORB1164), 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (CYASORBUV-3638), poly[(6-morpholino-s-triazine-2,4-diyl)[(2,2,6,6-tetramethyl-4-piperidyl)imino]-hexamethylene[(2,2,6,6-tetramethyl-4-piperidyl)imino]], 2-hydroxy-4-octyloxybenzophenone (UV UVINUL™ 3008), 6-tert-butyl-2-(5-chloro-2H-benzotriazol-2-yl)-4-methylphenyl (UVINUL™ 3026), 2,4-di-tert-butyl-6-(5-chloro-2H-benzotriazol-2-yl)-phenol (UVINUL™ 3027), 2-(2H-benzotriazol-2-yl)-4,6-di-tert-pentylphenol (UVINUL™ 3028), 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol phenol (UVINUL3029), 1,3-bis[(2'cyano-3',3'-diphenylacryloyl)oxy]-2,2-bis-{[(2'-cyano-3',3'-diphenylacryloyl)oxy]methyl}-propane (UVINUL3030), 2-(2H-benzotriazol-2-yl)-4-methylphenol (UVINUL3033), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (UVINUL3034), ethyl-2-cyano-3,3-Diphenylacrylate (UVINUL3035), (2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (UVINUL3039), N,N'-bisformyl-N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)hexamethylenediamine (UVINUL4050H), bis-(2,2,6,6-tetramethyl-4-piperidyl)sebacate (UVINUL4077H), bis-(1,2,2,6,6-pentamethyl-4-piperdiyl)sebacate + methyl-(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate (UVINUL4092H) 1,3-bis [(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL3030), 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one), 1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane, TINUVIN 234, nanosized inorganic materials such as titanium oxide, cerium oxide, and zinc oxide (all having particle sizes of 100 nanometers or less), or combinations thereof. The UV absorber can be used in an amount of 0.01 to 1 part by weight, based on 100 parts by weight of polycarbonate and impact modifier. UV absorbers that may be particularly useful with the polycarbonate compositions disclosed herein include 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol (e.g., CYASORB™ 5411, available from Cytec Industries, Inc., Woodland Park, NJ) and 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (e.g., CYASORB UV-3638, available from Cytec Industries, Inc., Woodland Park, NJ).(Commercially available from Woodland Park, NJ), or combinations thereof. The UV stabilizer may be present in an amount of 0.01 to 1 wt %, preferably 0.1 to 0.5 wt %, and more preferably 0.15 to 0.4 wt %, based on the total weight of the polycarbonate composition.

[0071] Plasticizers, lubricants, or mold release agents can also be used. There is considerable overlap between these types of materials, and examples include: phthalate esters, such as dioctyl-4,5-epoxy-hexahydrophthalate, tris-(octoxycarbonylethyl)isocyanurate, tristearin, difunctional or polyfunctional aromatic phosphates, such as resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl)phosphate of hydroquinone and bis(diphenyl)phosphate of bisphenol A, poly-α-olefins, epoxidized soybean oil, silicones, such as silicone oil, esters, such as fatty acid esters, and the like. alkyl stearyl esters, e.g., methyl stearate, stearyl stearate, pentaerythritol tetrastearate, etc.; combinations of methyl stearate with hydrophilic and hydrophobic nonionic surfactants (including polyethylene glycol polymers, polypropylene glycol polymers, poly(ethylene glycol-co-propylene glycol) copolymers, or combinations thereof), e.g., methyl stearate and polyethylene-polypropylene glycol copolymers in a suitable solvent; waxes, e.g., beeswax, montan wax, paraffin wax, etc.

[0072] The thermoplastic composition can optionally minimize or eliminate various components not specifically provided herein. For example, the composition can exclude polymers other than post-consumer recycled polycarbonates, polycarbonate-siloxane copolymers, polycarbonate esters, branched polycarbonates, copolycarbonates containing carbonate repeat units derived from bulky bisphenol groups, and linear polycarbonate homopolymers. In one embodiment, the composition can include less than 1 weight percent, or less than 0.5 weight percent, or less than 0.1 weight percent, or less than 0.01 weight percent of a laser direct structuring additive. In one embodiment, the composition can exclude a laser direct structuring additive.

[0073] Methods for producing the compositions of the present disclosure are also provided. Thermoplastic compositions can be produced by various methods. For example, the powdered polycarbonate and other optional components, optionally with any fillers, can be first blended in a high-speed mixer or by hand mixing. The blend is then fed through a hopper into the throat of a twin-screw extruder. Alternatively, at least one of the components can be incorporated into the composition by feeding it directly into the throat, or downstream through a side stuffer, or by compounding it into a masterbatch with the desired polymer and feeding it into the extruder. The extruder is generally operated at a temperature higher than that required to induce flow of the composition. The extrudate can be immediately quenched in a water bath and pelletized. The pellets thus prepared can be ¼ inch or less in length as desired. Such pellets can be used for subsequent molding, shaping, or forming.

[0074] Shaped, formed, cast, or molded articles comprising the polycarbonate composition are also provided. The polycarbonate composition can be molded into useful shaped articles by various methods, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming. The articles can be molded articles, thermoformed articles, extruded films, extruded sheets, honeycomb structures, one or more layers of multilayer articles, substrates for coated articles, and substrates for metallized articles. Exemplary articles include computer and business machine housings, such as housings for monitors, handheld electronic device housings, such as housings for mobile phones, electrical connectors, and components of lighting fixtures, decorative items, household appliances, roofs, greenhouses, sunrooms, swimming pool enclosures, electronic device casings, and signs. In addition, the polycarbonate composition can be used for applications such as automotive panels and trim. Examples of suitable articles are exemplified by, but not limited to, the following: aircraft, automobiles, trucks, military vehicles (including automobiles, aircraft, and watercraft), scooters, and motorcycle exterior and interior components, such as panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, dashboards, grilles, mirror housings, pillar appliques, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezel ... enclosures, license plate enclosures, roof racks, and footboards, enclosures, housings, panels, and components for outdoor vehicles and equipment, enclosures for electrical and telecommunications equipment, outdoor furniture, aircraft components, boats and marine equipment such as trim, enclosures, and housings, outboard motor housings, depth sounder housings, personal watercraft, jet skis, swimming pools, spas, hot tubs, stairs, stair cladding, building and construction applications such as glass windows, roofs, windows, floors, decorative window treatments or decorations, treated glass covers for photographs, paintings, posters, and similar display items, wall panels, and doors, countertops, protected graphics,Outdoor and indoor signage, enclosures, housings, panels, and parts for automated teller machines (ATMs), computers, desktop computers, portable computers, laptop computers, handheld computer housings, monitors, printers, keyboards, fax machines, copiers, telephones, telephone bezels, mobile phones, radio transmitters, radio receivers, lawn and garden tractors, mowers, and tools, such as enclosures, housings, panels, and parts for lawn and garden tools, window and door trim, sporting goods and toys, enclosures, housings, panels, and parts for snowmobiles, recreational vehicles, etc. Applications include automotive vehicle panels and components, playground equipment, shoelaces, articles made from a combination of plastic and wood, golf course markers, utility pit covers, lighting fixtures, luminaires, network interface device housings, transformer housings, air conditioning unit housings, cladding or seating for public transportation, cladding or seating for trains, subways, or buses, meter housings, antenna housings, cladding for satellite television dishes, coated helmets and personal protective equipment, coated synthetic or natural fabrics, coated painted articles, coated dyed articles, coated fluorescent articles, coated foam articles, and similar uses.

[0075] The compositions of the present disclosure can be particularly useful in articles for consumer electronics applications. For example, the article can be a component of a consumer electronic device, such as a game console, game controller, handheld game console, mobile phone, television, personal computer, tablet computer, laptop computer, personal digital assistant, portable media player, digital camera, portable music player, appliance, power tool, robot, toy, greeting card, home entertainment system, loudspeaker, or sound bar. In one embodiment, the article can be an electronic housing for an adapter, mobile phone, smartphone, GPS device, laptop computer, tablet computer, e-reader, copier, or solar device. [Example]

[0076] This disclosure is further illustrated by the following non-limiting examples.

[0077] <Example> The materials used in the examples below are listed in Table 1.

[0078] [Table 1]

[0079] [Table 2]

[0080] The compositions of the following examples were prepared by blending the ingredients together and extruding them in a 25- or 37-mm twin-screw extruder. The compositions were then injection molded. The temperature profiles for the compounding and injection molding conditions are summarized in Tables 2 and 3, respectively.

[0081] [Table 3]

[0082] [Table 4]

[0083] Physical measurements were performed using the tests and test methods described below.

[0084] Tensile properties were measured according to ASTM D638 or ISO 527 on standard tensile bars at a test speed of 50 mm / min.

[0085] Flexural properties were measured according to ASTM D790 at a test speed of 2.54 mm / min or according to ISO 178 standard at a test speed of 2 mm / min.

[0086] Notched Izod impact strength (INI) was determined according to ASTM D256 under a load of 5 lbf at different temperatures, e.g., 23°C, -20°C, or -30°C. All ASTM INI determinations were performed on 3.2 mm thick sample plaques. For testing at -20°C and -30°C, specimens were placed in a freezer for more than 4 hours and then removed within 5 seconds for testing at room temperature.

[0087] Heat deflection temperatures (HDT) were determined according to ASTM D648 under a load of 1.82 MPa, according to ISO75 / Af under a load of 1.8 MPa or according to ISO75 / Bf under a load of 0.45 MPa.

[0088] Light transmission and haze were characterized according to ASTM D1003 using color chips having a thickness of 2.54 millimeters.

[0089] Flammability testing was performed according to the procedures in Underwriter's Laboratory Bulletin 94, 5th Edition, dated October 29, 1996, including revisions through December 12, 2003, entitled "Tests for Flammability of Plastic Materials for Parts in Devices and Appliances" (ISBN 0-7629-0082-2). Several ratings are applicable based on burn rate, time to extinguishment, resistance to dripping, and whether or not the drip is burning. According to this procedure, materials can be classified as UL94HB, V-0, V-1, V-2, 5VA, or 5VB. Specimens were aged at 23°C and 50% RH for more than 2 days or at 70°C for 168 hours before testing. Specifically, a set of five flame bars was tested in the UL 94 50W (20mm) vertical flame test. For each bar, a flame was applied to the bar, then removed, and the time required for the bar to self-extinguish (first afterflame time, t1) was recorded. The flame was then reapplied and removed, and the time required for the bar to self-extinguish (second afterflame time, t2) and the afterflame glow time (afterglow time, t3) were recorded. To achieve a V-0 rating, the afterflame times t1 and t2 for each individual specimen must be 10 seconds or less, the total afterflame time for all five specimens (t1 + t2 for all five specimens) must be 50 seconds or less, the second afterflame time + afterglow time (t2 + t3) for each individual specimen must be 30 seconds or less, and none of the specimens could burn up to the holding clamps and glow, and the cotton indicator could not be ignited by flame particles or droplets.To achieve a V-1 rating, the afterflame times t1 and t2 for each individual specimen must be 30 seconds or less, the total afterflame time for all five specimens (t1 + t2 for all five specimens) must be 250 seconds or less, the second afterflame time + afterglow time (t2 + t3) for each individual specimen must be 60 seconds or less, none of the specimens can burn up to the holding clamps and glow, and the cotton indicator cannot be ignited by a particle or drop of flame. To achieve a V-2 rating, the afterflame times t1 and t2 for each individual specimen must be 30 seconds or less, the total afterflame time for all five specimens (t1 + t2 for all five specimens) must be 250 seconds or less, and the second afterflame time + afterglow time (t2 + t3) for each individual specimen must be 60 seconds or less, and none of the specimens can burn up to the holding clamps and glow, but the cotton indicator can be ignited by a particle or drop of flame. To achieve an HB rating, a material must not have a burn rate greater than 40 mm / min over a 75 mm span for specimens having a thickness of 3 to 13 mm, and must not have a burn rate greater than 75 mm / min over a 75 mm span for specimens having a thickness less than 3.0 mm in the horizontal burn test. If the material stops burning before the 100 mm reference mark, an HB rating can also be obtained.

[0090] The carbon footprint of each composition was characterized according to the Intergovernmental Panel on Climate Change (IPCC) method (IPCC 2013 GWP100a V1.03).

[0091] The compositions and test results are shown in Table 4. In Table 4, the amount of each component is provided in weight percent based on the total weight of the composition.

[0092] [Table 5]

[0093] [Table 6]

[0094] [Table 7]

[0095] As shown in Tables 4 and 5, despite the high levels of post-consumer recycled polycarbonate in compositions Ex.1-Ex.10, these examples exhibited comparable mechanical properties and flame retardancy to the comparative examples containing only virgin materials. Thus, the compositions according to the present disclosure can significantly reduce the carbon footprint compared to the comparative examples, thereby contributing to sustainability. Thus, a significant improvement is provided by the compositions according to the present disclosure.

[0096] The disclosure further includes the following aspects.

[0097] Aspect 1: A thermoplastic composition comprising 30 to 95 weight percent post-consumer recycled polycarbonate and 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a polycarbonate-ester, or a branched polycarbonate, or a copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, wherein when the composition comprises the polycarbonate-siloxane copolymer, the branched polycarbonate, or the copolycarbonate comprising phthalimidine carbonate repeat units, the composition is also capable of producing 5 to 65 weight percent of an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a linear polycarbonate homopolymer comprising at least two of: a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300°C and 1.2 kg according to ASTM D1238; and an ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min, as determined at 300°C and 1.2 kg according to ASTM D1238, wherein the weight percent of each component is based on the total weight of the composition.

[0098] Aspect 2: The thermoplastic composition of Aspect 1, wherein the post-consumer recycled polycarbonate comprises bisphenol A polycarbonate, and preferably the post-consumer recycled polycarbonate has an L value of 85 or greater, and preferably 92 or greater, as determined in accordance with ASTM D2244; a Yellowness Index of 8 or less, and preferably 3.5 or less, as determined in accordance with ASTM E313; a Transmittance at a thickness of 3 millimeters, as determined in accordance with ASTM D1003, of 70% or greater, and preferably 82% or greater; and a Haze at a thickness of 3 mm, as determined in accordance with ASTM D1003, of 10 or less, and preferably 6 or less.

[0099] Aspect 3: A method for producing a polycarbonate from 25 to 90 weight percent post-consumer recycled polycarbonate, 5 to 70 weight percent of a polycarbonate-siloxane copolymer, or a branched polycarbonate, or a copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, and 5 to 65 weight percent of an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238, and a polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238. and a linear polycarbonate homopolymer comprising at least two ultra-low flow polycarbonates having a melt flow rate of less than 5 g / 10 min, as determined at 300° C. and 1.2 kg according to D1238.

[0100] Embodiment 4: The thermoplastic composition of any of Embodiments 1 to 3, comprising a polycarbonate copolymer, wherein the polycarbonate-siloxane comprises a siloxane amount of from 5 to 50 weight percent, or from 15 to 50 weight percent, or from 20 to 40 weight percent, based on the weight of the polycarbonate-siloxane copolymer.

[0101] Embodiment 5: The thermoplastic composition of any of embodiments 1 to 3, comprising a copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, preferably a copolycarbonate comprising phthalimidine carbonate repeat units, more preferably a bisphenol A carbonate-2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine carbonate copolymer.

[0102] Embodiment 6: The thermoplastic composition of any of embodiments 1 to 3, comprising a branched polycarbonate, preferably wherein the branched polycarbonate is a branched polycarbonate homopolymer comprising cyanophenol end groups.

[0103] Embodiment 7: The thermoplastic composition of any of embodiments 1 to 6, wherein the linear polycarbonate homopolymer comprises a high flow rate polycarbonate and a low flow rate polycarbonate, or a low flow rate polycarbonate and an ultra-low flow rate polycarbonate, or a low flow rate polycarbonate and an ultra-high flow rate polycarbonate; preferably, the composition comprises a polycarbonate-siloxane copolymer, and the linear polycarbonate homopolymer comprises a high flow rate polycarbonate and a low flow rate polycarbonate, or a low flow rate polycarbonate and an ultra-low flow rate polycarbonate; or the composition comprises a copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, and the linear polycarbonate homopolymer comprises a low flow rate polycarbonate and an ultra-high flow rate polycarbonate; or the composition comprises a branched polycarbonate, and the linear polycarbonate homopolymer comprises a high flow rate polycarbonate and a low flow rate polycarbonate.

[0104] Embodiment 8: The thermoplastic composition of any of embodiments 1 to 3, comprising 45 to 90 weight percent post-consumer recycled polycarbonate, 5 to 35 weight percent polycarbonate-siloxane copolymer, and 5 to 40 weight percent linear polycarbonate homopolymer, comprising a high flow polycarbonate and a low flow polycarbonate, or a low flow polycarbonate and an ultra-low flow polycarbonate.

[0105] Embodiment 9: The thermoplastic composition of any of embodiments 1 to 3, comprising 25 to 55 weight percent post-consumer recycled polycarbonate, 10 to 25 weight percent copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, and 30 to 55 weight percent linear polycarbonate homopolymer comprising a low flow polycarbonate and an ultra-high flow polycarbonate.

[0106] Embodiment 10: The thermoplastic composition of any of embodiments 1 to 3, comprising 40 to 60 weight percent post-consumer recycled polycarbonate, 10 to 30 weight percent of a branched polycarbonate comprising cyanophenol end groups, and 10 to 30 weight percent of a linear polycarbonate homopolymer comprising a low flow polycarbonate and a high flow polycarbonate.

[0107] Embodiment 11: The thermoplastic composition of embodiment 1 or 2, comprising a polycarbonate-ester, preferably the polycarbonate-ester comprising resorcinol isophthalate and terephthalate repeat units and bisphenol A carbonate repeat units.

[0108] Embodiment 12: The thermoplastic composition of embodiment 11, comprising 20 to 60 weight percent post-consumer recycled polycarbonate, 35 to 55 weight percent polycarbonate ester, and optionally 15 to 35 weight percent high flow polycarbonate.

[0109] Embodiment 13: The thermoplastic composition of any of embodiments 1 to 12, further comprising 0.01 to 10 weight percent of a flame retardant.

[0110] Embodiment 14: A method for making the composition of any of embodiments 1 to 13, comprising melt-mixing the components of the composition.

[0111] Embodiment 15: An article comprising the composition of any of embodiments 1 to 13, wherein the article is preferably an appliance part.

[0112] The compositions, methods, and articles may optionally comprise, consist of, or consist essentially of any suitable material, step, or ingredient disclosed herein. The compositions, methods, and articles may additionally, or alternatively, be formulated to be devoid of, or substantially free of, any material (or species), step, or ingredient that is not otherwise required to achieve the function or purpose of the compositions, methods, and articles.

[0113] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. "Combinations" include blends, mixtures, alloys, reaction products, and the like. Terms such as "first," "second," and the like do not denote order, quantity, or importance; rather, they are used to distinguish one element from another. The terms "a," "an," or "the" do not denote a limitation of quantity and should be interpreted to encompass both the singular and the plural unless otherwise stated herein or clearly contradicted by context. "Or" means "and / or" unless expressly stated otherwise. Throughout the specification, reference to "one embodiment" means that a particular element described in connection with an embodiment is included in at least one embodiment described herein and may or may not be present in other embodiments. As used herein, the term "combinations thereof" includes one or more of the listed elements and is not limited, allowing for the presence of one or more similar elements not named. In addition, it should be understood that the described elements can be combined in any suitable manner in various embodiments.

[0114] Unless specified to the contrary herein, all test standards are the latest standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0115] Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in an incorporated reference, the term in this application shall take precedence over the conflicting term in the incorporated reference.

[0116] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valence filled by the indicated bond or hydrogen atom. A dash ("-") that is not between two letters or symbols is used to indicate the point of attachment for a substituent. For example, -CHO is attached through the carbon of a carbonyl group.

[0117] As used herein, the term "hydrocarbyl," whether used alone or as a prefix, subscript, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain a combination of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when a hydrocarbyl residue is described as substituted, it may optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituted residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or may contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" refers to branched or straight-chain saturated aliphatic hydrocarbon groups, such as methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n- and s-hexyl. "Alkenyl" means a straight- or branched-chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). "Alkoxy" means an alkyl group linked through oxygen (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" means a straight- or branched-chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). "Cycloalkylene" means a divalent cyclic alkylene group, -C n H 2n-xwhere x is the number of hydrogens replaced by the cyclization(s). "Cycloalkenyl" refers to a monovalent group having one or more rings and one or more carbon-carbon double bonds within the rings, all ring members being carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbon group containing the specified number of carbon atoms, e.g., phenyl, tropone, indanyl, or naphthyl. "Arylene" refers to a divalent aryl group. "Alkylarylene" refers to an arylene group substituted with an alkyl group. "Arylalkylene" refers to an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" refers to a group or compound containing one or more fluoro, chloro, bromo, or iodo substituents. Combinations of different halo atoms (e.g., bromo and fluoro) or only chloro atoms can be present. The prefix "hetero" means that the compound or group contains at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatoms), where the heteroatom(s) are each independently N, O, S, Si, or P. "Substituted" means that the compound or group contains, in place of a hydrogen, each independently, C 1-9 Alkoxy, C 1-9 Haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 Alkylsulfonyl (-S(=O)2-alkyl), C 6-12 Arylsulfonyl (-S(=O)2-aryl), thiol (-SH), thiocyano (-SCN), tosyl (CH3C6H4SO2-), C 3-12 Cycloalkyl, C 2-12 Alkenyl, C 5-12 Cycloalkenyl, C 6-12 Aryl, C 7-13 Aryl alkylene, C 4-12 Heterocycloalkyl, and C 3-12 Heteroaryl means substituted with at least one (e.g., 1, 2, 3, or 4) substituents, which may be heteroaryl, provided that the standard valence of the substituted atom is not exceeded. The number of carbon atoms indicated in the group excludes any substituents. For example, the group -CHCHCN is a C alkyl group substituted with a nitrile.

[0118] While particular embodiments have been described, presently unforeseen or unforeseen alternatives, modifications, variations, improvements, and substantial equivalents may occur to applicant or those skilled in the art. It is therefore intended that the appended claims, as filed and as they may be amended, shall embrace all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. 30 to 95 weight percent post-consumer recycled polycarbonate; 5 to 70 weight percent, a polycarbonate-siloxane copolymer, or Polycarbonate-ester, or Branched polycarbonate, or a copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; A thermoplastic composition comprising: When the composition comprises the polycarbonate-siloxane copolymer, the branched polycarbonate, or the copolycarbonate containing phthalimidine carbonate repeat units, the composition further comprises: 5 to 65 weight percent, an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; and an ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min as determined at 300° C. and 1.2 kg according to ASTM D1238; and further comprising a linear polycarbonate homopolymer comprising at least two of: A thermoplastic composition, wherein the weight percent of each component is based on the total weight of said composition.

2. The post-consumer recycled polycarbonate comprises bisphenol A polycarbonate, and preferably the post-consumer recycled polycarbonate is an L value of 85 or greater, preferably 92 or greater, as determined in accordance with ASTM D2244; a Yellowness Index, determined in accordance with ASTM E313, of less than or equal to 8, preferably less than or equal to 3.5; a transmittance of 70% or greater, preferably 82% or greater, at a thickness of 3 millimeters, as determined in accordance with ASTM D1003; and A haze of 10 or less, preferably 6 or less, at a thickness of 3 mm as determined according to ASTM D1003. The thermoplastic composition of claim 1 having

3. 25 to 90 weight percent of the post-consumer recycled polycarbonate; 5 to 70 weight percent, the polycarbonate-siloxane copolymer, or the branched polycarbonate, or the copolycarbonate containing carbonate repeating units derived from bulky bisphenol groups; 5 to 65 weight percent, an ultra-high flow polycarbonate having a melt flow rate of 55 to 85 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a high flow polycarbonate having a melt flow rate of greater than 20 to 54 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; a low flow polycarbonate having a melt flow rate of 5 to 19 g / 10 min, as determined at 300° C. and 1.2 kg according to ASTM D1238; and Ultra-low flow polycarbonate having a melt flow rate of less than 5 g / 10 min as determined at 300° C. and 1.2 kg according to ASTM D1238 The linear polycarbonate homopolymer comprising at least two of the following: The thermoplastic composition of claim 1 or 2, comprising:

4. 4. The thermoplastic composition of any one of claims 1 to 3, comprising a polycarbonate copolymer, the polycarbonate-siloxane copolymer comprising a siloxane amount of from 5 to 50 weight percent, or from 15 to 50 weight percent, or from 20 to 40 weight percent, or from 25 to 50 weight percent, based on the weight of the polycarbonate-siloxane copolymer.

5. 4. The thermoplastic composition according to any one of claims 1 to 3, wherein the copolycarbonate comprises carbonate repeat units derived from bulky bisphenol groups, preferably a copolycarbonate comprising phthalimidine carbonate repeat units, more preferably the copolycarbonate is a bisphenol A carbonate-2-phenyl-3,3'-bis(4-hydroxyphenyl)phthalimidine carbonate copolymer.

6. 4. The thermoplastic composition according to any one of claims 1 to 3, comprising a branched polycarbonate, preferably the branched polycarbonate is a branched polycarbonate homopolymer comprising cyanophenol end groups.

7. The linear polycarbonate homopolymer is the high flow polycarbonate and the low flow polycarbonate, or the low flow polycarbonate and the ultra low flow polycarbonate, or The low flow polycarbonate and the ultra-high flow polycarbonate and preferably the composition comprises the polycarbonate-siloxane copolymer, and the linear polycarbonate homopolymer comprises the high flow polycarbonate and the low flow polycarbonate or the low flow polycarbonate and the ultra low flow polycarbonate; or the composition comprises the copolycarbonate comprising carbonate repeat units derived from bulky bisphenol groups, and the linear polycarbonate homopolymer comprises the low flow polycarbonate and the ultra-high flow polycarbonate; or 7. The thermoplastic composition of claim 1, wherein the composition comprises the branched polycarbonate and the linear polycarbonate homopolymer comprises the high flow polycarbonate and the low flow polycarbonate.

8. 45 to 90 weight percent of the post-consumer recycled polycarbonate; 5 to 35 weight percent of said polycarbonate-siloxane copolymer; 5 to 40 weight percent, the high flow polycarbonate and the low flow polycarbonate, or The low flow polycarbonate and the ultra low flow polycarbonate a linear polycarbonate homopolymer comprising: The thermoplastic composition of claim 1 , comprising:

9. 25 to 55 weight percent of the post-consumer recycled polycarbonate; the copolycarbonate containing 10 to 25 weight percent of carbonate repeat units derived from bulky bisphenol groups; 30 to 55 weight percent of a linear polycarbonate homopolymer comprising said low flow polycarbonate and said ultra high flow polycarbonate; The thermoplastic composition of claim 1 , comprising:

10. 40 to 60 weight percent of the post-consumer recycled polycarbonate; 10 to 30 weight percent of said branched polycarbonate containing cyanophenol end groups; a linear polycarbonate homopolymer comprising 10 to 30 weight percent of said low flow polycarbonate and said high flow polycarbonate; The thermoplastic composition of claim 1 , comprising:

11. 3. The thermoplastic composition of claim 1 or 2, comprising said polycarbonate-ester, preferably said polycarbonate-ester comprising resorcinol isophthalate and terephthalate repeat units and bisphenol A carbonate repeat units.

12. 20 to 60 weight percent of the post-consumer recycled polycarbonate; 35 to 55 weight percent of said polycarbonate-ester; optionally, 15 to 35 weight percent of said high flow polycarbonate; The thermoplastic composition of claim 11 comprising:

13. 13. The thermoplastic composition of any one of claims 1 to 12, further comprising 0.01 to 10 weight percent of a flame retardant.

14. 14. A method for making the composition of any one of claims 1 to 13, comprising the step of melt-mixing the components of the composition.

15. 14. An article comprising a composition according to any one of claims 1 to 13, preferably an appliance part.

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