Polycarbonate compositions, methods for making same, and articles including polycarbonate compositions

Abstract

The polycarbonate composition includes specific amounts of bisphenol A homopolycarbonate, a polycarbonate containing repeating units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol, and a polyester-carbonate. The composition can exhibit a desirable combination of properties, including low haze and good scratch resistance. Methods for making the composition and articles containing the composition are also disclosed.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of European Patent Application No. 22202291.5, filed October 18, 2022, the contents of which are incorporated herein by reference in their entirety.

[0002] The present disclosure relates to polycarbonate compositions having improved optical properties and scratch resistance, methods of making, and articles prepared from the polycarbonate compositions. [Background technology]

[0003] Polycarbonate (PC) has excellent impact strength and transparency, but tends to lack scratch resistance. Efforts to improve scratch resistance include, for example, applying a hard coating to the composition or incorporating scratch-resistant additives into the composition. These approaches are not desirable for all applications. For example, hard coatings introduce expensive additional processing steps into the manufacturing process. Summary of the Invention [Problem to be solved by the invention]

[0004] Thus, there remains a continuing need in the art for scratch-resistant compositions that also have good mechanical properties, including impact strength, tensile properties, and weatherability. Particularly desirable are compositions that have good optical clarity. [Means for solving the problem]

[0005] A polycarbonate composition comprising: 10 to 60 weight percent of a bisphenol A homopolycarbonate, based on the total weight of the composition; a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene bridged bisphenol in an amount effective to provide a substituted or unsubstituted cyclohexylidene bridged bisphenol content of 25 weight percent or less, based on the total weight of the composition; and a polyester-carbonate comprising ester units derived from isophthalic acid, terephthalic acid, and resorcinol; the composition having a weight ratio of cyclohexylidene bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) of less than 2.5.

[0006] The method of making the polycarbonate composition involves melt mixing the components of the composition and optionally extruding the composition.

[0007] An article comprises the polycarbonate composition.

[0008] The above-mentioned features and other features are illustrated by the figures and detailed description that follow.

[0009] The following figures represent exemplary embodiments. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a graph of 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane carbonate (DMBPC) content versus haze for several example compositions. DETAILED DESCRIPTION OF THE INVENTION

[0011] Thus, a composition is provided herein that combines good scratch resistance, mechanical properties, and weather resistance. As a further advantageous feature, the composition can exhibit low haze, facilitating the formulation of compositions with specific colors. The composition includes specific amounts of bisphenol A homopolycarbonate, a polycarbonate containing repeating units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol, and a polyester-carbonate.

[0012] The polycarbonate composition thus represents one aspect of the present disclosure. The composition includes a bisphenol A homopolycarbonate. The bisphenol A homopolycarbonate is represented by the formula (1): [ka] (1) It has the repeating structural carbonate unit:

[0013] Bisphenol A polycarbonate homopolymers can be produced from bisphenol A (2,2-bis(4-hydroxyphenyl)propane, or BPA) by known processes such as interfacial polymerization and melt polymerization, as described, for example, in WO 2013 / 175448 A1 and WO 2014 / 072923 A1. Endcapping agents can be included to provide terminal groups during polymerization, such as monocyclic phenols, e.g., phenol, p-cyanophenol, and C 1~22Examples of suitable endcapping agents include alkyl-substituted phenols such as p-cumylphenol, resorcinol monobenzoate, and p-tert-butylphenol, monoethers of diphenols such as p-methoxyphenol, monoesters of diphenols such as resorcinol monobenzoate, functionalized chlorides of aliphatic monocarboxylic acids such as acryloyl chloride and methacryloyl chloride, and monochloroformates such as phenyl chloroformate, alkyl-substituted phenyl chloroformates, p-cumylphenyl chloroformate, and toluene chloroformate. Phenol and para-cumylphenol are particularly preferred. Combinations of different endcapping agents can be used. Branched polycarbonate blocks can be prepared by adding branching agents during polymerization, such as trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxyphenylethane, isatin-bis-phenol, tris-phenol TC (1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1,1-bis(p-hydroxyphenyl)-ethyl)alpha,alpha-dimethylbenzyl)phenol), 4-chloroformylphthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid. Branching agents can be added at levels of 0.05 to 4.0 weight percent (wt%), e.g., 0.05 to 2.0 wt%. Combinations including linear and branched polycarbonates can be used.

[0014] The bisphenol A polycarbonate homopolymer may be a linear bisphenol A polycarbonate homopolymer, optionally end-capped with phenol or para-cumylphenol, and have a weight average molecular weight of 10,000 to 100,000 grams / mole (g / mol), or 10,000 to 75,000 g / mol, or 18,000 to 40,000 g / mol, or 20,000 to 40,000 g / mol, or 20,000 to 38,000 g / mol, as measured by gel permeation chromatography (GPC) using a cross-linked styrene-divinylbenzene column and calibrated to bisphenol A polycarbonate standards. GPC samples are prepared at a concentration of 1 milligram / milliliter (mg / mL) and eluted at a flow rate of 1.5 mL / min.

[0015] In one embodiment, two or more bisphenol A polycarbonate homopolymers may be present. For example, the bisphenol A polycarbonate homopolymer may include a first bisphenol A polycarbonate homopolymer having a first weight average molecular weight and a second bisphenol A polycarbonate homopolymer having a second weight average molecular weight, where the first and second weight average molecular weights are not the same. If present, the weight ratio of the first bisphenol A polycarbonate homopolymer to the second bisphenol A polycarbonate homopolymer may be 10:1 to 1:10, or 5:1 to 1:5, or 3:1 to 1:3, or 2:1 to 1:2.

[0016] The bisphenol A homopolycarbonate may be present in the composition in an amount of 10 to 60 weight percent, based on the total weight of the composition. Within this range, the bisphenol A homopolycarbonate may be present in an amount of, for example, 10 to 55 weight percent, or 14 to 60 weight percent, or 14 to 55 weight percent, or 15 to 60 weight percent, or 15 to 55 weight percent, or 10 to 50 weight percent, or 12 to 50 weight percent, or 14 to 50 weight percent, or 10 to 45 weight percent, or 12 to 45 weight percent, or 14 to 45 weight percent, each based on the total weight of the composition.

[0017] In addition to the bisphenol A homopolycarbonate, the composition includes a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol. The repeat units derived from the substituted or unsubstituted cyclohexylidene-bridged bisphenol are represented by the formula (2): [ka] (2) [In the formula, R a and R b are each independently C 1~12 alkyl, and R g is C 1~12 alkyl, p and q are each independently 0 to 4, and t is 0 to 10. a and R b At least one of each of R is positioned meta to the cyclohexylidene bridging group. a and R b are each independently C 1~4 alkyl, and R g is C 1~4 alkyl, p and q are each 0 or 1, and t is 0 to 5. In one embodiment, R a , R b , and R gare each methyl, p and q are each 0 or 1, and t is 0 or 3, preferably 0. In yet another embodiment, p and q are each 0 and each R g is methyl and t is 3. In another embodiment, p and q are each 1 and R is 0, so that the cyclohexylidene bridging group is unsubstituted cyclohexylidene. a and R b are methyl groups, and t is 0. For example, cyclohexylidene crosslinked polycarbonate is represented by the formula (3) [ka] (3) It may also contain repeating units according to the formula:

[0018] As used herein, "polycarbonate" includes homopolymers (e.g., all repeat units according to formula (2) or (3)), copolymers containing repeat units derived from different bisphenols, and copolymers containing carbonate units according to formula (2) or (3) and other types of polymer units, such as ester units or siloxane units.

[0019] In one embodiment, the cyclohexylidene-bridged polycarbonate may be a copolycarbonate further comprising repeat units derived from a bisphenol different from the cyclohexylidene-bridged bisphenol. For example, the copolycarbonate may be a polycarbonate represented by the formula (4): [ka] (4) [In the formula, each R 1 has at least one C 6~30 For example, each R 1 can be derived from a dihydroxy compound such as an aromatic dihydroxy compound of formula (5) or a bisphenol of formula (6). [ka] (5) [ka] (6)

[0020] In formula (5), 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. In formula (6), R a and R b are each independently a halogen, C 1~12 Alkoxy, or C 1~12 When R is alkyl and p or q is less than 4, p and q are each independently an integer from 0 to 4, such that the valence of each carbon in 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 C's located meta to the hydroxyl group on each arylene group. 1~3 An alkyl group, preferably a methyl group. X a is a bridging group connecting two hydroxy-substituted aromatic groups, and the bridging group and the hydroxy substituents of each C6 arylene group are positioned 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 An organic group, which may be cyclic or acyclic, aromatic or non-aromatic, and may further contain heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorus. For example, X a is a substituted or unsubstituted C 3~18 Cycloalkylidene; Formula -C(R c )(R d )-(wherein, R c and Rd 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 C is heteroarylalkyl 1~25 Alkylidene; or formula -C(=R e )-(wherein, R e is a divalent C 1~12 It may also be a group of the formula (which is a hydrocarbon group).

[0021] 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, bis(4-hydroxyphenyl)-1-naphthylmethane ... )phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 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)acetonitrile, 2,2-bis(3-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 , 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-dihydroxy 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, and 2,4,5,6-tetrabromoresorcinol; 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, and 2,3,5,6-tetrabromohydroquinone.

[0022] 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), and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (isophorone bisphenol).

[0023] In one embodiment, polycarbonates comprising repeat units derived from substituted or unsubstituted cyclohexylidene-bridged bisphenols have the following structure: [ka] and a first carbonate repeat unit having the structure [ka] [In the formula, R a , R b , and R g are each independently C 1~12 is an alkyl group, and R c and R d are each independently hydrogen, C 1~12 Alkyl, cyclic C 1~12 Alkyl, C 7~12 Aryl alkyl, C 1~12 Heteroalkyl, or cyclic C 7~12 and a second carbonate repeat unit having the formula:

[0024] In one embodiment, the cyclohexylidene crosslinked polycarbonate is a copolycarbonate that further comprises repeat units derived from bisphenol A. For example, the first polycarbonate may comprise repeat units of formulas (2) and (4a). [ka] (2) and [ka] (4a)

[0025] In one embodiment, polycarbonates comprising repeat units derived from substituted or unsubstituted cyclohexylidene-bridged bisphenols have the following structure: [ka] [wherein the molar ratio of x to y is 25:75 to 75:25].

[0026] The cyclohexylidene bridged polycarbonate comprises repeat units derived from a substituted or unsubstituted cyclohexylidene bridged bisphenol in an amount effective to provide a substituted or unsubstituted cyclohexylidene bridged bisphenol content of 25 weight percent or less, or 22 weight percent or less, or from greater than 0 weight percent to 25 weight percent, or from greater than 0 weight percent to 22 weight percent, or from 1 to 25 weight percent, or from 1 to 22 weight percent, or from 5 to 25 weight percent, or from 5 to 22 weight percent, each based on the total weight of the composition.

[0027] In one embodiment, the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol may have a substituted or unsubstituted cyclohexylidene-bridged bisphenol content of from 40 to 60 weight percent, or from 45 to 55 weight percent, or from 47 to 53 weight percent, based on the total weight of the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol, respectively.

[0028] The polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol may be present in the composition in an amount of, for example, 5 to 45 weight percent, based on the total weight of the composition, provided that the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol is present in an amount sufficient to provide a substituted or unsubstituted cyclohexylidene-bridged bisphenol content of 25 weight percent or less. Within this range, the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol may be present in an amount of 7 to 43 weight percent, or 10 to 40 weight percent, respectively, based on the total weight of the composition.

[0029] The composition further includes a polyester-carbonate. The polyester-carbonate includes repeating units derived from isophthalic acid, terephthalic acid, and resorcinol. For example, the polycarbonate-ester may be represented by the formula (7): [ka] (7) [wherein J is a divalent group derived from an aromatic dihydroxy compound of formula (5), such as resorcinol, or a bisphenol of formula (6), such as bisphenol A, and T is a divalent group derived from a dicarboxylic acid, including terephthalic acid and isophthalic acid.] Specific dicarboxylic acids include a combination of isophthalic acid and terephthalic acid, and the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98.

[0030] The molar ratio of ester units to carbonate units in the polyester-carbonates can vary widely, 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, depending on the desired properties of the final composition.

[0031] In one embodiment, the polyester-carbonate has the formula [ka] [In the formula, R 1 is expressed as follows: [ka] (In the formula, R a and R b are each independently a halogen, C 1~12 Alkoxy, or C 1~12 alkyl, p and q are each independently an integer of 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or C 1~60 is an organic group) derived from an aromatic dihydroxy compound, R h independently for each occurrence, a halogen atom, C 1~10 Alkyl group, halogen-substituted C 1~10 Alkyl group, C 6~10 Aryl group or halogen-substituted C 6~10 an aryl group, and n is 0 to 4.

[0032] In one embodiment, the polyester-carbonate comprises aromatic ester units and monoarylate ester units derived from the reaction of a diacid combination of isophthalic acid and terephthalic acid (or a reactive derivative thereof) with resorcinol (or a reactive derivative thereof) to provide isophthalate / terephthalate-resorcinol ("ITR" ester units). The ITR ester units may be present in the polyester-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. Preferred polyester-carbonates comprise bisphenol A carbonate units and ITR ester units derived from terephthalic acid, isophthalic acid, and resorcinol, i.e., formula (8): [ka] (8) The poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) may comprise a poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) of the formula (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. The ITR ester units may be present in the poly(bisphenol A carbonate-co-isophthalate-terephthalate-resorcinol ester) in an amount of 95 mol % or more, preferably 99 mol % or more, and even more preferably 99.5 mol % or more, based on the total number of moles of ester units in the copolymer. Other carbonate units, other ester units, or a combination thereof may be present in a total amount of 1 to 20 mol % based on the total number of moles of units in the copolymer, for example, monoaryl carbonate units of formula (9) and monoaryl carbonate units of formula (10): [ka] (9) [ka] (10) [In the formula, R h are each independently C 1~10 is a hydrocarbon group, n is 0 to 4, and R a and R b are each independently C 1~12 alkyl, p and q are each independently an integer of 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, where R c and R d are each independently hydrogen or C 1~12 Alkyl, or a group of the formula -C(=R e )- group, where R e is a divalent C 1~12 The bisphenol ester unit is a bisphenol ester unit represented by the formula (10a): [ka] (10a) The bisphenol A phthalate ester unit may be:

[0033] In one embodiment, the poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) comprises 1 to 90 mol% bisphenol A carbonate units, 10 to 99 mol% isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1 to 60 mol% resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof. In another embodiment, the poly(bisphenol A carbonate-co-isophthalate / terephthalate-resorcinol ester) comprises 10 to 20 mol% bisphenol A carbonate units, 20 to 98 mol% isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1 to 60 mol% resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof. In one embodiment, the ester units derived from isophthalic acid, terephthalic acid, and resorcinol are present in the polyester-carbonate in an amount of 10 to 30 weight percent based on the total weight of the polyester-carbonate.

[0034] The polyester-carbonate may have a Mw of 2,000 to 100,000 g / mol, preferably 3,000 to 75,000 g / mol, more preferably 4,000 to 50,000 g / mol, more preferably 5,000 to 35,000 g / mol, and even more preferably 25,000 to 35,000 g / mol. Molecular weight measurements are performed using gel permeation chromatography (GPC) on a cross-linked styrene-divinylbenzene column at a sample concentration of 1 milligram per milliliter, calibrated with bisphenol A homopolycarbonate standards. Samples are eluted with methylene chloride at a flow rate of 1.0 ml / min.

[0035] The polyester-carbonate may be present in the composition in an amount such that the weight ratio of cyclohexylidene-bridged bisphenol to isophthalic acid, terephthalic acid, and resorcinol ester units is less than 2.5, or less than 2.25. The ratio of cyclohexylidene-bridged bisphenol to isophthalic acid, terephthalic acid, and resorcinol ester units may be greater than 0, e.g., from 0.1 to less than 2.5, or from 0.1 to less than 2.25, or from 0.3 to less than 2.5, or from 0.3 to less than 2.25, or from 0.5 to less than 2.5, or from 0.5 to less than 2.25. For example, the polyester-carbonate may be present in the composition in an amount of 35 to 55 weight percent, based on the total weight of the composition, provided that the weight ratio of cyclohexylidene-bridged bisphenol to isophthalic acid, terephthalic acid, and resorcinol ester units is within the aforementioned limits. Within this range, the polyester-carbonate may be present in an amount from 37 to 53 weight percent, or from 40 to 50 weight percent, or from 42 to 48 weight percent, each based on the total weight of the composition.

[0036] In one embodiment, the polycarbonate composition may comprise 15 to 55 weight percent of a bisphenol A homopolycarbonate, 35 to 55 weight percent of a polyester-carbonate, and 5 to 45 weight percent of a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol. The cyclohexylidene-bridged bisphenol content of the composition may be 22 weight percent or less. The weight ratio of cyclohexylidene-bridged bisphenol to isophthalic acid, terephthalic acid, and resorcinol ester units may be less than 2.25.

[0037] The thermoplastic composition may optionally further comprise an additive composition. The additive composition may include one or more additives selected to achieve desired properties, provided that the additives are also selected so as not to significantly adversely affect the desired properties of the thermoplastic composition. The additive composition or individual additives may be mixed at a suitable time during the mixing of the components to form the composition. The additives may be soluble or insoluble in polycarbonate. The additive composition may include flow modifiers, fillers (e.g., particulate polytetrafluoroethylene (PTFE), glass, carbon, minerals, or metals), reinforcing agents (e.g., glass fibers), antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV) light stabilizers, UV absorbing additives, plasticizers, lubricants, release agents (e.g., mold release agents), antistatic agents, antifog agents, antimicrobial agents, colorants (e.g., dyes or pigments), surface effect additives, radiation stabilizers, flame retardants, anti-drip agents (e.g., PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or combinations thereof. For example, a combination of heat stabilizers, mold release agents, and ultraviolet light stabilizers may be used. The additives may be used in amounts generally known to be effective. For example, the total amount of the additive composition (excluding any impact modifiers, fillers, or reinforcing agents) may be 0.1 to 10 weight percent, based on the total weight of the composition.

[0038] In one embodiment, the composition may include a heat stabilizer additive. Heat stabilizer additives include organic phosphites (e.g., triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, tris-(mixed mono- and di-nonylphenyl) phosphite, etc.), phosphonates (e.g., dimethylbenzene phosphonate, etc.), phosphates (e.g., trimethyl phosphate, etc.), or combinations thereof. The heat stabilizer may be tris(2,4-di-t-butylphenyl) phosphate, available as IRGAPHOS™ 168. Heat stabilizers are generally used in an amount of 0.01 to 5 wt %, based on the total weight of the composition.

[0039] There is considerable overlap in plasticizers, lubricants, and mold release agents, including, for example, phthalate esters (e.g., octyl-4,5-epoxy-hexahydrophthalate), tris-(octoxycarbonylethyl)isocyanurate, di- or polyfunctional aromatic phosphates (e.g., resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl)phosphate of hydroquinone, and bis(diphenyl)phosphate of bisphenol A); poly-alpha-olefins; epoxidized soybean oil; silicones, including silicone oils (e.g., poly(dimethyldiphenylsiloxane)); fatty acid esters (e.g., C 1~32 Alkyl stearyl esters, such as methyl stearate and stearyl stearate, and esters of stearic acid, such as pentaerythritol tetrastearate and glycerol tristearate (GTS), waxes, such as beeswax, montan wax, and paraffin wax, or combinations thereof, are generally used in an amount of 0.01 to 5% by weight based on the total weight of the composition.

[0040] Light stabilizers or ultraviolet light (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.

[0041] 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-bis(2 ,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol (CYASORB™ 1164); 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) (CYASORB™ UV-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 (U 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 (UVINUL™ 3029), 1,3-bis[(2'cyano-3',3'-diphenylacryloyl)oxy]-2,2-bis-{[(2'-cyano-3',3'-diphenylacryloyl)oxy]methyl}-propane (UVINUL™ 3030), 2-(2H-benzotriazol-2-yl)-4-methylphenol (UVINUL™ 3033), 2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (UVINUL™ 3034), ethyl-2-cyano-3,3-Diphenylacrylate (UVINUL™ 3035), (2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (UVINUL™ 3039), N,N'-bisformyl-N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)hexamethylenediamine (UVINUL™ 4050H), bis-(2,2,6,6-tetramethyl-4-piperidyl)-sebacate (UVINUL™ 4077H), bis-(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate + methyl-(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate (UVINUL™ 4092H) 1,3-bis[ (2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane (UVINUL™ 3030); 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; all nanosized inorganic materials with particle sizes of 100 nanometers or less, such as titanium oxide, cerium oxide, and zinc oxide, or combinations thereof. UV absorbers can be used in amounts 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 in 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., Cytec Industries,UV stabilizers include CYASORB™ UV-3638, commercially available from Epson Corporation, 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.

[0042] Possible fillers, or reinforcing agents, include, for example, mica, clay, feldspar, quartz, quartzite, perlite, tripolitic rock, diatomaceous earth, aluminum silicate (mullite), synthetic calcium silicate, fused silica, fumed silica, sand, boron nitride powder, borosilicate powder, calcium sulfate, calcium carbonate (e.g., chalk, limestone, marble, and synthetic precipitated calcium carbonate), talc (including fibrous, modular, acicular, and flaky talc), wollastonite, hollow or solid glass spheres, silicate spheres, cenospheres, aluminosilicates or (armospheres), kaolin, silicon carbide, Included are alumina, boron carbide, iron, nickel, or copper whiskers, continuous and chopped carbon or glass fibers, molybdenum sulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, barite, TiO2, aluminum oxide, magnesium oxide, particulate or fibrous aluminum, bronze, zinc, copper, or nickel, glass flakes, flaked silicon carbide, flaked aluminum diboride, flaked aluminum, steel flakes, natural fillers such as fibrous cellulose such as wood flour, cotton, sisal, jute, starch, lignin, ground nut husks, or rice grain husks, reinforcing organic fibrous fillers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyester, polyethylene, aromatic polyamide, aromatic polyimide, polyetherimide, polytetrafluoroethylene, and poly(vinyl alcohol), and combinations thereof. The fillers and reinforcing agents can be coated with a layer of metallic material to enhance electrical conductivity, or surface-treated with silane to improve adhesion and dispersibility with the polymer matrix. The fillers are used in an amount of 1 to 200 parts by weight, based on 100 parts by weight of the total composition. In one embodiment, the composition is free of fillers.

[0043] Colorants such as pigment or dye additives may also be present. Useful pigments may include inorganic pigments, such as metal oxides and mixed metal oxides, such as zinc oxide, titanium dioxide, iron oxide, and the like; sulfides, such as zinc sulfide; aluminates; sodium sulfosilicates, sulfates, chromates, and the like; carbon black; zinc ferrite; ultramarine blue; organic pigments, such as azo, diazo, quinacridone, perylene, naphthalenetetracarboxylic acid, flavanthrone, isoindolinone, tetrachloroisoindolinone, anthraquinone, entrone, dioxazine, phthalocyanine, and azo lakes; Pigment Red 101, Pigment Red 122, Pigment Red 149, Pigment Red 177, Pigment Red 179, Pigment Red 202, Pigment Violet 29, Pigment Blue 15, Pigment Blue 60, Pigment Green 7, Pigment Yellow 119, Pigment Yellow 147, Pigment Yellow 150, Pigment Brown 24, Pigment Blue 29, or combinations thereof.

[0044] Dyes are generally organic materials, such as coumarin dyes, e.g., coumarin 460 (blue), coumarin 6 (green), Nile Red, etc.; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hydrocarbon dyes; scintillation dyes, e.g., oxazole or oxadiazole dyes; aryl or heteroaryl substituted poly(C 2~8)Olefin dyes;Carbocyanine dyes;Indanthrone dyes;Phthalocyanine dyes;Oxazine dyes;Carbostyril dyes;Naphthalenetetracarboxylic acid dyes;Porphyrin dyes;Bis(styryl)biphenyl dyes;Acridine dyes;Anthraquinone dyes;Cyanine dyes;Methine dyes;Arylmethane dyes;Azo dyes;Indigoid dyes, thioindigoid dyes, diazonium dyes;Nitro dyes;Quinoneimine dyes;Aminoketone dyes;Tetrazolium dyes;Thiazole dyes;Perylene dyes, perinone dyes;Bis-benzoxazolidine thiophenes (BBOT); triarylmethane dyes; xanthene dyes; thioxanthene dyes; naphthalimide dyes; lactone dyes; pyrazolone dyes; fluorophores, such as anti-Stokes shift dyes that absorb in the near-infrared wavelengths and emit in the visible wavelengths; luminescent dyes, such as 7-amino-4-methylcoumarin; 3-(2'-benzothiazolyl)-7-diethylaminocoumarin; 2-(4-biphenylyl)-5-(4-t-butylphenyl)-1,3,4-oxadiazole; 2,5-bis-(4-biphenylyl)-oxazole; 2,2 '-Dimethyl-p-quaterphenyl;2,2-Dimethyl-p-terphenyl;3,5,3'''',5''''-Tetra-t-butyl-p-quinquephenyl;2,5-Diphenylfuran;2,5-Diphenyloxazole;4,4'-Diphenylstilbene;4-Dicyanomethylene-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran;1,1'-Diethyl-2,2'-carbocyanine iodide;3,3'-Diethyl-4,4',5,5'-dibenzothiatricarbocyanine iodide;7-Dimethylamino-1-methyl 2-(4-(4-dimethylaminophenyl)-1,3-butadienyl)-3-ethylbenzothiazolium perchlorate; 3-diethylamino-7-diethyliminophenoxazonium perchlorate; 2-(1-naphthyl)-5-phenyloxazole; 2,2'-p-phenylene-bis(5-phenyloxazole); rhodamine 700; rhodamine 800; pyrene, chrysene, rubrene, coronene, and the like; or combinations thereof.

[0045] In one embodiment, the polycarbonate composition may be, for example, a color selected from the group consisting of Solvent Green 3, Solvent Green 28, Solvent Red 52, Solvent Red 111, Solvent Red 135, Solvent Red 169, Solvent Red 179, Solvent Red 207, Disperse Red 22, Vat Red 41, Solvent Orange 60, Solvent Orange 63, Solvent Violet 13, Solvent Violet 14, Solvent Violet 50, and Aqua Red 169. The colorant compositions may include colorants known as Minoketone Black, Solvent Black 7, Nigrosine dye, Disperse Blue 73, Solvent Blue 97, Solvent Blue 101, Solvent Blue 104, Solvent Blue 138, Disperse Yellow 160, Solvent Yellow 84, Solvent Yellow 93, Solvent Yellow 98, Solvent Yellow 163, Solvent Yellow 160:1, and mixtures comprising at least one of the foregoing colorants. Preferred colorants may include Solvent Red 207, Disperse Orange 47, Solvent Green 3, and mixtures comprising at least one of the foregoing colorants.

[0046] The colorants can be employed in amounts and combinations sufficient to darken and opaque the molded article, more specifically, to provide the lightness values ​​described below. The specific amount of colorant employed will depend, among other factors, on the solubility and extinction coefficient of the colorant in the polycarbonate composition and whether it is employed in combination with one or more additional colorants. Suitable amounts and combinations can be readily determined by those skilled in the art guided by this disclosure. Typical colorant amounts can be, for example, 0.1 to 1 weight percent based on the total weight of the composition, e.g., 0.5 to 1 weight percent based on the total weight of the composition.

[0047] In one embodiment, when present, the colorant composition can provide the polycarbonate composition with a black color, for example, piano black, or jet black.

[0048] In one embodiment, the composition may include a flame retardant. Useful flame retardants may include organic compounds containing phosphorus, bromine, or chlorine. Due to regulatory reasons, non-brominated and non-chlorinated phosphorus-containing flame retardants, such as organic phosphate esters and organic compounds containing phosphorus-nitrogen bonds, may be preferred in certain applications.

[0049] Aromatic phosphate esters that are flame retardants 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), the bis(diphenyl) phosphate of hydroquinone, and the bis(diphenyl) phosphate of bisphenol A, and their oligomeric and polymeric counterparts.

[0050] Flame retardant compounds containing phosphorus-nitrogen bonds include phosphazenes, phosphonitrilic acid chlorides, phosphoric acid ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl)phosphine oxides. These flame retardant additives are commercially available. In one embodiment, the organophosphorus flame retardant containing phosphorus-nitrogen bonds is represented by 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 1~12 The phosphazenes are phosphazenes or cyclic phosphazenes in which the R is an alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkylene group. In the aforementioned groups, 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 may be a substituted or unsubstituted phenoxy, amino, or polyoxyalkylene group. w may be further crosslinked to another phosphazene group. Exemplary crosslinks include bisphenol groups, such as bisphenol A groups. Examples include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decafenoxycyclopentaphosphazene, and the like. In one embodiment, the phosphazene is represented by the formula: [ka] It has a structure represented by the following formula:

[0051] Commercially available phenoxyphosphazenes having the above structure include LY202 manufactured and sold by Lanyin Chemical Co., Ltd., FP-110 manufactured and sold by Fushimi Pharmaceutical Co., Ltd., and SPB-100 manufactured and sold by Otsuka Chemical Co., Ltd.

[0052] Halogenated substances can also be used as flame retardants, for example, bisphenols, the following being 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 the copolycarbonate 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.

[0053] Alternatively, the thermoplastic composition may be essentially free of chlorine and bromine, which is defined as having a bromine or chlorine content of 100 parts per million (ppm) or less, 75 ppm or less, or 50 ppm or less, based on the total parts by weight of the composition.

[0054] Inorganic flame retardants can also be used, for example, C 1~16Alkyl sulfonates, such as potassium perfluorobutanesulfonate (Rimar's salt), potassium perfluorooctanesulfonate, tetraethylammonium perfluorohexanesulfonate, and potassium diphenylsulfonate; NaCO 3、 K2CO 3、 MgCO 3、 CaCO 3、 and salts such as BaCO3, or fluoroanion complexes such as Li3AlF 6、 BaSiF 6、 KBF 4、 K3AlF 6、 KAlF 4、 K2SiF 6、 Or Na3AlF6.

[0055] 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 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, each based on the total weight of the composition.

[0056] The polycarbonate composition may optionally be free of other components not specifically described herein. For example, the polycarbonate composition may be free of thermoplastic polymers other than bisphenol A homopolycarbonate, polycarbonates containing repeating units derived from substituted or unsubstituted cyclohexylidene-bridged bisphenols, and polyester-carbonates. For example, the composition may minimize or be free of polyesters (e.g., polyesters may be present in an amount of 1 weight percent or less, and preferably, no polyesters are included in the composition). The composition may optionally be free of polycarbonates other than bisphenol A homopolycarbonate, polycarbonates containing repeating units derived from substituted or unsubstituted cyclohexylidene-bridged bisphenols, and polyester-carbonates, such as polycarbonate-siloxane copolymers. The polycarbonate composition may optionally be free of impact modifiers, such as silicone impact modifiers, methyl methacrylate-butadiene-styrene copolymers, acrylonitrile-butadiene, styrene copolymers, etc., or combinations thereof. The composition may optionally be free of halogenated flame retardants, such as brominated flame retardants, for example, brominated polycarbonates (e.g., polycarbonates containing brominated carbonates include units derived from 2,2',6,6'-tetrabromo-4,4'-isopropylidenediphenol (TBBPA) and carbonate units derived from at least one dihydroxy aromatic compound that is not TBBPA), brominated epoxies, etc., or combinations thereof. The composition may optionally be free of phosphorus-containing flame retardants.

[0057] The composition can advantageously exhibit one or more desirable properties. For example, it has been found that by combining a bisphenol A homopolymer, a polycarbonate containing repeating units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol, and a polyester-carbonate in specific amounts, improved scratch resistance can be unexpectedly obtained. The composition can also exhibit good optical properties.

[0058] In one embodiment, a molded sample of the composition may exhibit a haze of less than 2.5, or less than 2, or less than 1.5, measured using a 2.5 mm thick plaque according to ASTM-D1003-00.

[0059] In one embodiment, molded samples of the composition can exhibit a scratch onset of visibility of less than 20 Newtons (N), or less than 18 N. Scratch resistance can be measured according to ASTM D7027-13 / ISO 19252:08, according to the procedures further described in the examples.

[0060] The polycarbonate composition may further exhibit good color. For example, the polycarbonate composition may have an L* value of 20 to 35, or 25 to 35, or 25 to 30, an a* value of 0.1 to 0.3, or 0.1 to 0.2, or 0.15 to 0.2, and a b* value of -1.5 to -0.5, or -1.1 to -0.5, or -1.1 to -0.74, when measured in reflectance mode according to CIE Lab method in accordance with ASTM E308-08 at a 10-degree observation angle, with a D65 illuminant and specular reflection excluded, using a 3.2 millimeter thick sample.

[0061] The composition may also exhibit a desirable combination of mechanical properties. For example, molded samples of the composition may exhibit a notched Izod impact strength of greater than 40 J / m when measured at 23° C. under a load of 5 lbf according to ASTM D256. Molded samples of the composition may exhibit a tensile strength at break of greater than 60 MPa and a tensile elongation at break of greater than 100% when measured at a rate of 50 mm / min using Type I strip specimens according to ASTM D638.

[0062] The polycarbonate compositions of the present disclosure can be produced according to various methods. For example, bisphenol A homopolymer, a polycarbonate containing repeating units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol, and a polyester-carbonate, along with optional fillers, can be first blended using a high-speed mixer or by hand. This blend can then be fed to the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding it directly through the extruder and / or downstream via a side stuffer, or by compounding it into a masterbatch with the desired polymer and feeding it to the extruder. The extruder is generally operated at a temperature higher than that required to cause the composition to flow. The extrudate is immediately quenched in a water bath and pelletized. The pellets thus prepared can be ¼ inch or less in length, if desired. These pellets can be used for subsequent molding, shaping, or forming.

[0063] Shaped, molded, cast, or molded articles comprising the compositions are also provided. The compositions can be formed into shaped articles by a variety of methods, including injection molding, extrusion, rotational molding, blow molding, and thermoforming. The article can be a molded article, a thermoformed article, an extruded film, an extruded sheet, a honeycomb structure, one or more layers of a multilayer article, a substrate of a coated article, or a substrate of a metallized article.

[0064] Articles comprising the compositions can be used in a variety of consumer products. In one aspect, the article can be an automotive component. In one aspect, the article can be a consumer electronic component, such as a housing for a consumer electronic device.

[0065] Specific articles may include, but are not limited to, automotive exterior components (e.g., grilles, mirror housings, pillars, spoilers, logos, roof rails, bezels, trim, fenders), automotive interior components (e.g., trim parts, electronic housings, instrument panel components, navigation systems, housing frames), storage boxes, personal equipment parts, home appliance components, furniture, appliance housings (e.g., robot vacuums, drones), and consumer electronic devices (e.g., device housings or components for laptops, mobile phones, tablets, batteries, wireless charging, AR / VR goggles).

[0066] In one embodiment, the article is an automobile bumper, an automobile exterior component, an automobile mirror housing, an automobile wheel cover, an automobile instrument panel or trim, an automobile glove box, an automobile door fixture or other interior trim, an automobile exterior light, an automobile part in the engine bay, an agricultural tractor or device part, a window or component thereof, a construction machinery vehicle or device part thereof, a watercraft or personal watercraft part, an off-road vehicle or off-road vehicle part, plumbing fixtures, a valve or pump, an air conditioning heating or cooling component, a furnace or heat pump part, a computer housing, a computer housing or business machine housing or component, a monitor housing or component, a computer router, a desktop printer, a large office / industrial printer, an electronic component, a projector component, an electronic display component, a copier component, a scanner component, Electronic printer toner cartridges, portable electronic device housings, portable device housings, hair dryers, irons, coffee makers, toasters, washing machines or washing machine parts, microwave ovens, ovens, power tools, electrical components, electrical enclosures, lighting components, lighting fixture components, dental medical instruments, medical instruments, medical or dental lighting components, aircraft parts, train or railway parts, seating components, side walls, ceiling components, cooking equipment, medical equipment trays, animal cages, textiles, laser welded medical equipment, fiber optics, lenses (automatic and non-automatic), mobile phone parts, greenhouse components, sunroom components, fire helmets, safety shields, safety glasses, gasoline pump parts, humidifier housings, thermostat regulator housings, air conditioning unit drain pans, outdoor cabinets, telecommunications equipment enclosures or infrastructure, simple network detection systems The electrical equipment may be a Network Detection System (SNIDS) device, a network interface device, a smoke detector, a plenum space component or device, a medical scanner, an X-ray machine, a component of a medical application or device, an electrical box or enclosure, and an electrical connector, construction or agricultural machinery, and a turbine blade.

[0067] In one aspect, the article is an aircraft interior or train interior component, an inspection window, a turn hatch, a ventilator, an air gasper, a ventilation grille, an armrest, a baggage storage door, a balcony component, a cabinet wall, a ceiling panel, a door pull, a door handle, a duct housing, an electronics enclosure, an equipment housing, an equipment panel, a floor panel, a food cart, a food tray, a countertop surface, a handle, a television housing, a light panel, a magazine rack, a telephone housing, a room divider, a trolley cart component, a seat back, a seat component, a handrail component, a seat housing, a shelf, a side wall, a speaker housing, a storage compartment. The material may be a toilet, a storage bin housing, a toilet seat, a tray table, a tray, a trim panel, a window molding, a window slide, a balcony component, a balusters, a ceiling panel, a life jacket cover, a storage bin cover, a window dust cover, a layer of an electrochromic device, a television, electronic display, gauge, or instrument panel lens, a light cover, a light diffuser, a light tube, a light pipe, a mirror, a room divider, a handrail, a refrigerator door, a shower door, a sink cistern, a trolley cart container, a trolley cart side panel, or a window. [Example]

[0068] The present disclosure is further illustrated by the following non-limiting examples.

[0069] The materials used in the following examples are listed in Table 1.

[0070] [Table 1]

[0071] The components of the composition were compounded and extruded. Molded parts for physical testing were prepared by injection molding. The test methods are listed in Table 2 below.

[0072] [Table 2]

[0073] <Examples 1 to 8> Table 3 shows the compositions and properties of Examples 1 to 8. The amount of each component is given as a weight percent based on the total weight of the composition.

[0074] [Table 3]

[0075] The addition of DMBPC-BPA copolycarbonate slightly improves modulus and tensile strength at yield, as well as elongation at yield, as shown in Table 3. The Izod impact strength was observed to decrease with increasing amounts of DMBPC-BPA copolycarbonate, but the multiaxial impact strength remained at 100% ductility at similar total energy values.

[0076] Examples 5-8 in Table 3 show three compositions that were colored using the same colorant package to achieve a "piano black" appearance. As can be seen from the L*a*b* color measurements shown in Table 3, as well as gloss measurements from three angles, the aesthetics and appearance of the three compositions were essentially identical and consistent with visual assessment (e.g., by the naked eye).

[0077] Compared to Comparative Example 5*, the compositions according to Examples 6 and 7 showed a slight decrease in modulus and tensile properties. However, both the compositions of Examples 6 and 7 showed a significant improvement in elongation at break and total energy for multiaxial impact compared to Comparative Example 5* at both room temperature and 0°C. The notched Izod impact strength of Examples 6 and 7 was also significantly improved compared to Comparative Example 5*.

[0078] Scratch test measurements were performed in accordance with ASTM D7027-13 / ISO 19252:08 using an SMS scratch tester equipped with a stylus with a 1 mm spherical indenter at a scratch speed of 100 mm / min. The results of the scratch tests are shown in Table 4. The results are reported in terms of visible damage in Newtons (N), which is the force at which a scratch becomes visible.

[0079] [Table 4]

[0080] As shown in Table 4, compared to the BPC-PC homopolymer composition (shown as Example 8*), the introduction of DMBPC copolymer significantly improves scratch resistance, and when DMBPC and ITR copolycarbonate are included in the composition at the same DMBPC loading, the scratch resistance improves even more significantly.

[0081] Additional formulations were prepared and tested as shown in Tables 5 and 6. The amount of each component is provided as a weight percent based on the total weight of the composition.

[0082] [Table 5]

[0083] [Table 6]

[0084] As shown in Tables 5 and 6, an unexpected increase in haze is observed when the amount of DMBPC in the composition exceeds 25 wt %. This is also shown in Figure 1, which shows the haze of the composition as a function of DMBPC content. Thus, the compositions of the present disclosure can exhibit a desirable combination of properties.

[0085] Additional formulations were prepared and tested as shown in Table 7. The amount of each component is provided as a weight percent based on the total weight of the composition.

[0086] [Table 7]

[0087] As shown in Table 7, the amount and type of additives such as mold release agents and slip promoters may be varied.

[0088] Additional formulations were prepared and tested as shown in Table 8. The amount of each component is provided as a weight percent based on the total weight of the composition.

[0089] [Table 8]

[0090] As shown in Table 8, when the weight ratio of cyclohexylidene-bridged bisphenol to (isophthalic acid, terephthalic acid, and resorcinol ester units) is outside the range defined in this disclosure, the desired combination of properties is not obtained. Specifically, when the weight ratio of cyclohexylidene-bridged bisphenol to (isophthalic acid, terephthalic acid, and resorcinol ester units) is 2.5 or greater, the composition does not achieve the desired haze. Thus, the present inventors have unexpectedly discovered that specific combinations of components in specific amounts described in this disclosure can unexpectedly provide a desired combination of properties. Thus, the present disclosure provides a significant improvement.

[0091] The present disclosure further encompasses the following aspects.

[0092] Aspect 1: A polycarbonate composition comprising: 10 to 60 weight percent of a bisphenol A homopolycarbonate, based on the total weight of the composition; a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene bridged bisphenol in an amount effective to provide a substituted or unsubstituted cyclohexylidene bridged bisphenol content of 25 weight percent or less, based on the total weight of the composition; and a polyester-carbonate comprising ester units derived from isophthalic acid, terephthalic acid, and resorcinol, wherein the polycarbonate composition has a weight ratio of cyclohexylidene bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) of less than 2.5.

[0093] Embodiment 2: The polycarbonate composition of embodiment 1, having a weight ratio of cyclohexylidene-bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) less than 2.25.

[0094] Embodiment 3: The polycarbonate composition of embodiment 1 or 2, wherein the polycarbonate composition exhibits a haze of less than 2.5, or less than 2, or less than 1.5, as measured using 2.5 mm thick plaques according to ASTM-D1003-00.

[0095] Embodiment 4: The polycarbonate composition of any one of embodiments 1 to 3, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol is present in an amount of 5 to 45 weight percent, based on the total weight of the composition.

[0096] Aspect 5: The polycarbonate composition of any one of aspects 1 to 4, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol has the following structure: [ka] and a first carbonate repeat unit having the formula: The following structure [ka] [In the formula, R a , R b , and R g are each independently C 1~12 is an alkyl group, and R c and R d are each independently hydrogen, C 1~12 Alkyl, cyclic C 1~12 Alkyl, C 7~12 Aryl alkyl, C 1~12 Heteroalkyl, or cyclic C 7~12 and a second carbonate repeat unit having the formula:

[0097] Aspect 6: The polycarbonate composition of any one of aspects 1 to 5, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol has the following structure: [ka] wherein the molar ratio of x to y is 25:75 to 75:25.

[0098] Embodiment 7: The polycarbonate composition of any one of embodiments 1 to 6, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol has a substituted or unsubstituted cyclohexylidene-bridged bisphenol content of 40 to 60 weight percent, based on the total weight of the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol.

[0099] Embodiment 8: The polycarbonate composition of any one of embodiments 1 to 7, wherein the polyester-carbonate is a compound represented by the formula: [ka] [In the formula, R 1 is expressed as follows: [ka] (In the formula, R a and R b are each independently a halogen, C 1~12 Alkoxy, or C 1~12 alkyl, p and q are each independently an integer of 0 to 4, and X a is a single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or C 1~60 is an organic group) derived from an aromatic dihydroxy compound, R h independently for each occurrence, a halogen atom, C 1~10 Alkyl group, halogen-substituted C 1~10 Alkyl group, C 6~10 Aryl group or halogen-substituted C 6~10 an aryl group, and n is 0 to 4.

[0100] Embodiment 9: The polycarbonate composition of any one of embodiments 1 to 8, wherein the ester units derived from isophthalic acid, terephthalic acid, and resorcinol are present in the polyester-carbonate in an amount from 10 to 30 weight percent, based on the total weight of the polyester-carbonate.

[0101] Embodiment 10: The polycarbonate composition of any one of embodiments 1 to 9, comprising, based on the total weight of the composition, 10 to 50 weight percent of a bisphenol A homopolycarbonate; 35 to 55 weight percent of a polyester-carbonate; and 5 to 45 weight percent of a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene bridged bisphenol; and having a cyclohexylidene bridged bisphenol content of 22 weight percent or less, wherein the weight ratio of cyclohexylidene bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) is less than 2.25.

[0102] Embodiment 11: The polycarbonate composition of any one of embodiments 1 to 10, further comprising 0.1 to 10 weight percent of an additive composition, based on the total weight of the polycarbonate composition.

[0103] Embodiment 12: The polycarbonate composition of embodiment 11, wherein the additive composition comprises a flame retardant, a colorant composition, a stabilizer, a mold release agent, or a combination thereof.

[0104] Embodiment 13: A method of making the polycarbonate composition of any one of embodiments 1 to 12, comprising melt-mixing the components of the composition, and optionally extruding the composition.

[0105] Embodiment 14: An article comprising the polycarbonate composition of any one of embodiments 1 to 12.

[0106] The compositions, methods, and articles can optionally comprise, consist of, or consist essentially of any suitable material, step, or component disclosed herein. The compositions, methods, and articles can additionally or alternatively be formulated to be free of, or substantially free of, any material (or species), step, or ingredient that is not necessary to achieve the function or purpose of the compositions, methods, and articles.

[0107] All ranges disclosed herein are inclusive of 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, but are used to distinguish one element from another. The terms "a," "an," and "the" do not denote limitations of quantity and should be construed to encompass both the singular and the plural unless otherwise indicated herein or clearly contradicted by context. "Or" means "and / or" unless expressly stated otherwise. References throughout this specification to "one embodiment" mean that the particular element described in connection with that 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" is open, including one or more of the listed elements and permitting the presence of one or more similar elements, but not named. It is further understood that the listed elements may be combined in any suitable manner in the various embodiments.

[0108] Unless otherwise specified 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.

[0109] Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by those skilled 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.

[0110] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency satisfied 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 of a substituent. For example, -CHO is attached through the carbon of a carbonyl group.

[0111] As used herein, the term "hydrocarbyl," whether used by itself or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue may be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It may 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 substituent residue. Thus, particularly when described as substituted, the hydrocarbyl residue may 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 a branched or straight-chain saturated aliphatic hydrocarbon group, such as methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n- and s-hexyl. "Alkenyl" refers to a straight- or branched-chain monovalent hydrocarbon group having at least one carbon-carbon double bond, such as ethenyl (-HC=CH). "Alkoxy" refers to an alkyl group attached through oxygen (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" refers to a straight- or branched-chain saturated divalent aliphatic hydrocarbon group, such as methylene (-CH-) or propylene (-(CH)-). "Cycloalkylene" refers to a divalent cyclic alkylene group, -C n H 2n-xwhere x is the number of hydrogens replaced by the cyclization. "Cycloalkenyl" refers to a monovalent group having one or more rings and one or more carbon-carbon double bonds within the ring, where all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbon group containing a specified number of carbon atoms, such as 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), each heteroatom being independently N, O, S, Si, or P. "Substituted" means that the compound or group contains, each independently, C in place of a hydrogen. 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, but not exceeding the normal valence of the substituted atom. The number of carbon atoms shown in the group excludes any optional substituents. For example, -CHCHCN is a C alkyl group substituted with a nitrile.

[0112] While particular embodiments have been described, alternatives, variations, modifications, improvements, and substantial equivalents may occur to applicant or those skilled in the art that are presently unforeseen or impossible to conceive, and it is accordingly intended that the appended claims, as filed and as they may be amended, shall embrace all such alternatives, variations, modifications, improvements, and substantial equivalents.

Claims

1. 10 to 60 weight percent bisphenol A homopolycarbonate, based on the total weight of the composition; a polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol in an amount effective to provide a substituted or unsubstituted cyclohexylidene-bridged bisphenol content of 25 weight percent or less, based on the total weight of the composition; and 1. A polycarbonate composition comprising a polyester-carbonate comprising ester units derived from isophthalic acid, terephthalic acid, and resorcinol, A polycarbonate composition characterized by having a weight ratio of cyclohexylidene-bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) of less than 2.

5.

2. 10. The polycarbonate composition of claim 1, having a weight ratio of cyclohexylidene-bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) of less than 2.

25.

3. 3. The polycarbonate composition of claim 1 or 2, characterized in that it exhibits a haze of less than 2.5, or less than 2, or less than 1.5, as measured using a 2.5 mm thick plaque according to ASTM-D1003-00.

4. 4. The polycarbonate composition of any one of claims 1 to 3, wherein the polycarbonate comprising repeat units derived from the substituted or unsubstituted cyclohexylidene-bridged bisphenol is present in an amount of 5 to 45 weight percent, based on the total weight of the composition.

5. 5. The polycarbonate composition according to claim 1, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol is The following structure 【Chemistry 1】 a first carbonate repeat unit having the formula: The following structure 【Chemistry 2】 [In the formula, R ａ , R ｂ , and R ｇ are each independently C １～１２ is an alkyl group, R ｃ and R ｄ are each independently hydrogen, C １～１２ Alkyl, cyclic C １～１２ Alkyl, C ７～１２ Aryl alkyl, C １～１２ Heteroalkyl, or cyclic C ７～１２ heteroarylalkyl, p and q each independently represent 0 to 4; and t is 0 to 10; and A polycarbonate composition comprising:

6. 6. The polycarbonate composition of claim 1, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol has the structure: 【Transformation 3】 wherein the molar ratio of x to y is from 25:75 to 75:

25.

7. 7. The polycarbonate composition of any one of claims 1 to 6, wherein the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol has a substituted or unsubstituted cyclohexylidene-bridged bisphenol content of 40 to 60 weight percent, based on the total weight of the polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol.

8. 8. The polycarbonate composition of claim 1, wherein the polyester-carbonate is a compound represented by the formula: 【Chemistry 4】 [In the formula, R １ is expressed as follows: 【Transformation 5】 (In the formula, R ａ and R ｂ are each independently a halogen, C １～１２ Alkoxy, or C １～１２ alkyl, p and q are each independently an integer of 0 to 4, and X ａ represents a single bond, -O-, -S-, -S(O)-, -S(O) ２ -, -C(O)-, or C １～６０ is an aromatic dihydroxy compound of the formula (I), R ｈ represents independently at each occurrence a halogen atom, C １～１０ Alkyl group, halogen-substituted C １～１０ Alkyl group, C ６～１０ Aryl group or halogen-substituted C ６～１０ an aryl group, and n is 0 to 4.

9. 9. The polycarbonate composition of any one of claims 1 to 8, wherein the ester units derived from isophthalic acid, terephthalic acid, and resorcinol are present in the polyester-carbonate in an amount of 10 to 30 weight percent, based on the total weight of the polyester-carbonate.

10. 10. The polycarbonate composition of claim 1, comprising, based on the total weight of the composition: 10 to 50 weight percent of said bisphenol A homopolycarbonate; 35 to 55 weight percent of said polyester-carbonate; and from 5 to 45 weight percent of said polycarbonate comprising repeat units derived from a substituted or unsubstituted cyclohexylidene-bridged bisphenol; having a cyclohexylidene-bridged bisphenol content of not more than 22 weight percent; A polycarbonate composition characterized in that the weight ratio of said cyclohexylidene-bridged bisphenol:(isophthalic acid, terephthalic acid, and resorcinol ester units) is less than 2.

25.

11. 11. The polycarbonate composition of any one of claims 1 to 10, further comprising 0.1 to 10 weight percent of an additive composition, based on the total weight of the polycarbonate composition.

12. 12. The polycarbonate composition of claim 11, wherein the additive composition comprises a flame retardant, a colorant composition, a stabilizer, a mold release agent, or a combination thereof.

13. 13. A method for producing the polycarbonate composition of any one of claims 1 to 12, comprising melt-mixing the components of the composition and optionally extruding the composition.

14. An article comprising the polycarbonate composition of any one of claims 1 to 12.

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