Polycarbonate compositions and articles formed therefrom

Abstract

A fiber-reinforced composite is formed by curing a prepreg having a layer of a molding material, e.g., sheet molding compound and / or bulk molding compound, on a continuous fiber reinforced (CFR) thermoplastic tape. The CFR thermoplastic tape has a thermoplastic matrix that can bond to the molding material. The formed fiber-reinforced composite advantageously can have improved mechanical characteristics by including the CFR thermoplastic tape.

Description

POLYCARBONATE COMPOSITIONS AND ARTICLES FORMED THEREFROM CLAIM OF PRIORITY

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 516,388 bearing Attorney Docket Number 1202312 and filed on July 28, 2023, which is hereby incorporated by reference in its entirety. TECHNICAL FIELD

[0002] Embodiments of the present disclosure are generally related to polycarbonate compositions. More particularly, polycarbonate compositions include the reaction product of a reactive polymer composition including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer. BACKGROUND

[0003] Polycarbonate compositions are widely used in a variety of applications, such as in the automotive industry, because of their desirable impact strength. However, polycarbonate compositions may not have a scratch resistance necessary for such applications. Conventionally, to improve scratch resistance, a coating may be applied to the article formed from the polycarbonate composition, which increases processing time and costs. Alternatively, additives may be included in the polycarbonate composition to increase the scratch resistance. But, inclusion of such additives may result in an undesirably low transparency.

[0004] Accordingly, a need exists for polycarbonate compositions that are easily processed and have both advantageous scratch resistance and transparency. SUMMARY

[0005] Embodiments of the present disclosure are directed to polycarbonate compositions including the reaction product of a reactive polymer composition, the reactive polymer composition including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer.

[0006] According to some embodiments, a polycarbonate composition is provided. The polycarbonate composition includes the reaction product of a reactive polymer composition. The reactive polymer composition includes, based on a total weight of the polycarbonate composition, 71 wt% to 99.8 wt% of an aromatic polycarbonate polymer, 0.2 wt% to 15 wt% of a reactive epoxy compound, and 1 wt% to 25 wt% of an acrylate polymer. The aromatic polycarbonate polymer has a melt flow index of 5 g / 10 min to 25 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg. The reactive epoxy compound has an epoxy equivalent weight of 172 g / eq to 2900 g / eq, as measured according to ASTM D1652. The acrylate polymer has a weight average molecular weight of 7,000 g / mol to less than 30,000 g / mol. The polycarbonate composition has a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1. The polycarbonate composition has a transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm.

[0007] According to other embodiments, a method of preparing a polycarbonate composition is provided. The method includes preparing a reactive polymer composition and reacting the reactive polymer composition in a transesterification process. The polycarbonate composition includes the reaction product of a reactive polymer composition. The reactive polymer composition includes, based on a total weight of the polycarbonate composition, 71 wt% to 99.8 wt% of an aromatic polycarbonate polymer, 0.2 wt% to 15 wt% of a reactive epoxy compound, and 1 wt% to 25 wt% of an acrylate polymer. The aromatic polycarbonate polymer has a melt flow index of 5 g / 10 min to 25 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg. The reactive epoxy compound has an epoxy equivalent weight of 172 g / eq to 2900 g / eq, as measured according to ASTM D1652. The acrylate polymer has a weight average molecular weight of 7000 g / mol to less than 30,000 g / mol. The polycarbonate composition has a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1. The polycarbonate composition has an average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm.

[0008] Additional features and advantages of the embodiments described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilledin the art from that description or recognized by practicing the embodiments described herein, including the detailed description, which follows and the claims. DRAWINGS

[0009] FIG.1 is a schematic view of an article, according to one or more embodiments shown and described herein;

[0010] FIG. 2 is a schematic view of another article, according to one or more embodiments shown and described herein;

[0011] FIG.3 are photographs of articles, according to one or more embodiments shown and described herein; and

[0012] FIG.4 are photographs of comparative articles. DETAILED DESCRIPTION

[0013] Reference will now be made in detail to various embodiments of polycarbonate compositions and related processes.

[0014] The disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the subject matter to those skilled in the art.

[0015] Definitions

[0016] Unless otherwise expressly defined, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art. The terminology used in the disclosure herein is for describing particular embodiments only and is not intended to be limiting.

[0017] Unless otherwise expressly stated, it not intended that any method disclosed herein be construed as requiring that its steps be performed in a specific order, nor that any article set forth herein be construed as requiring specific orders or orientations to its individual components.

[0018] Unless otherwise expressly stated, it is intended that any composition or mixture disclosed herein may comprise, consist essentially of, or consist of the disclosed components.

[0019] As used herein, the singular form of a term is intended to include the plural form of the term, unless the context clearly indicates otherwise.

[0020] As used herein, numerical values are not strictly limited to the exact numerical value recited. Instead, unless otherwise expressly stated, each numerical value is intended to mean both the exact numerical value and “about” the numerical value, which encompasses a functionally equivalent range surrounding that numerical value, such that either possibility is contemplated as an embodiment disclosed herein.

[0021] The amount of a component (e.g., aromatic polycarbonate polymer, reactive epoxy compound, and acrylate polymer) in the reactive polymer composition is provided herein in weight percent (wt%), based on a total weight of the polycarbonate composition (i.e., the reaction product of the reactive polymer composition), unless otherwise noted.

[0022] As used herein, “0 wt%” means that the composition is free of or does not include the given component.

[0023] As used herein, the term “melt flow index” refers to a measure of ease of flow of a melted material through an orifice at a specified temperature and load, as measured according to ASTM D1238.

[0024] As used herein, the term “epoxy equivalent weight” refers to a measure of the epoxy content of an epoxy compound, as measured according to ASTM D1652.

[0025] As used herein, the terms “number average molecular weight” and “Mn” refer to the total weight of the polymer divided by the total number of molecules in the polymer, as measured according to gel permeation chromatography at 25 °C. The total weight is represented by the following formula:where Niis the number of molecules with weigi. e oa number is represented by the following formula:The number average molecular weight is the following formula:

[0026] As used herein, the terms “weight average molecular weight” and “Mw” refer to the total weight of all chains in the polymer divided by the total number of chains, as measured according to gel permeation chromatography at 25 °C. The weight average molecular weight is given by the following formula:

[0027] As used herein, the term “polydispersity index” refers to the ratio of the weight average molecular weight to the number average molecular weight, and it gives a measure of the distribution of the molecular weight within a sample. It has a value greater than or equal to one; it is equal to one only if all the molecules have the same weight (i.e. if it is monodisperse), and the further away it is, the larger the spread of molecular weights. The polydispersity index is given by the following formula:

[0028] “Scratch resistance” refers to the property that resists “whitening” under critical normal load applied through a tip having a 1 mm diameter on the surface of a substance sample while the sample is moving. “Whitening” of the scratched surface is a key damage mechanism that has prompted much concern in automotive and other applications where surface aesthetics is important. This type of damage may be undesirable because it is evident to the human eye. Scratch resistance is a function of multiple phenomenon, including surface hardening and reduction of coefficient of friction. Various methods are used to measure scratch and mar performance, such as the Taber test, pencil hardness, Rtech scratch tester, and Ericsson methods. Additionally, profilometry and microscopy may provide valuable data, although they may not be used beyond fundamental studies. Unless otherwise indicated, scratch resistance may be determined by a measurement on a Taber Five Finger Scratch Tester according to FLTM BO 162- 1.

[0029] As used herein, the term “transparency” refers to the percentage of light that passes through a material, as measured according to ASTM D1003 at the given wavelength and an article thickness of 1.3 mm.

[0030] As used herein, the term “average transparency” refers to the average of transparency measurements, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and an article thickness of 1.3 mm.

[0031] As used herein, the term “haze” refers to the percentage of light that scatters in a material, as measured according to ASTM D1003 at 10°, using illuminant D65, and an article thickness of 1.3 mm.

[0032] As used herein, the term “pencil hardness” refers to the hardness of a material as measured according to ASTM D3363,

[0033] As used herein, the term “gloss value” refers to the ratio of the reflectivity of light to the reflectance of a standard surface at 60°, as measured according to ASTM D2457.

[0034] As used herein, the term “impact strength” refers to the Notched Izod Impact strength or the kinetic energy needed to initiate fracture and continue the fracture until an article formed from the polycarbonate composition described herein is broken, as measured according to ISO 180 at 23 °C.

[0035] As used herein, the term “tensile strength” refers to the maximum stress that a material can withstand while stretching before breaking, as measured according to ASTM D638-14 at 23 °C and a rate of strain of 0.2 in / min.

[0036] As used herein, the term “elongation at break” to the maximum strain, as a percentage that a material can withstand before ultimate failure as measured according to ASTM D638 at 23 °C.

[0037] As used herein, the term “flexural modulus” refers to the ratio of stress to strain in the elastic region of flexural deformation, as measured according to ASTM D790-17 at 23 °C.

[0038] As used herein, the term “flexural strength” refers to the maximum bending stress that may be applied to a material before it yields, as measured according to ASTM D790-17 at 23 °C.

[0039] As used herein, the term “homopolymer” refers to a polymer having repeating units of a single type of monomer.

[0040] As used herein, the term “copolymer” refers to a polymer that is made up of two or more monomer species.

[0041] As used herein, the term “formed from” (including related terms such as “forming”) refers to, with respect to an article (or component of an article) and a polycarbonate material, that the article (or component of the article) is extruded, molded, shaped, pressed, or otherwise made, in whole or in part, from the polycarbonate material under sufficient heating to enable such forming. As such, the term “formed from” (including related terms such as “forming”) means, in some embodiments, the article (or component of an article) can comprise, consist essentially of, or consist of, the material; and, in other embodiments, the article (or component of an article) consists of the material because the article (or component of an article) is, for example, made by an extrusion process or a molding process.

[0042] Usefulness

[0043] As discussed hereinabove, polycarbonate compositions are widely used in a variety of applications, such as in the automotive industry, because of their desirable impact resistance. However, polycarbonate compositions may not have a scratch resistance necessary for such applications (e.g., at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1). Conventionally, to improve scratch resistance, a coating may be applied to the article formed from the polycarbonate composition, which increases processing time and costs. Alternatively, additives may be included in the polycarbonate composition to increase the scratch resistance. But, such additives may result in an undesirably low transparency (e.g., average transparency less than 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm).

[0044] Disclosed herein are polycarbonate compositions. Specifically, the polycarbonate compositions disclosed herein include the reaction product of a reactive polymer composition including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer. Advantageously, the polycarbonate compositions may have improved scratch resistance (e.g., at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1) while having improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm). The reactive epoxy compound imparts improved scratch resistance and transparency. Moreover, the reactive epoxy compound may improve the compatibility between the aromatic polycarbonate polymer and an acrylate polymer included in the polycarbonate composition, which may further improve scratch resistance while having improved transparency. Additionally, the polycarbonate compositions eliminate the need for extra processing steps, such as the application of a coating, to achieve improved scratch resistance.

[0045] Accordingly, the polycarbonate compositions disclosed herein may be used to form any article that requires both improved scratch resistance and improved transparency. The polycarbonate compositions are especially useful for forming articles in the automotive industry, such as headlights, taillights, interior body parts, and door handles.

[0046] The polycarbonate compositions disclosed herein may generally be described as the reaction product of a reactive polymer composition, the reactive polymer composition including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer.

[0047] Aromatic Polycarbonate Polymer

[0048] The reactive polymer compositions disclosed herein include an aromatic polycarbonate polymer. The aromatic polycarbonate polymer imparts impact strength, which may be desirable in certain applications, and imparts a melt flow index to improve flow during processing.

[0049] In embodiments, the aromatic polycarbonate polymer may have a melt flow index of 5 g / 10 min to 25 g / 10 min, as measured at 300 °C and 1.2 kg, such that the resulting polycarbonate composition is processable. In embodiments, the aromatic polycarbonate polymer may have a melt flow index, as measured at 300 °C and 1.2 kg, greater than or equal to 5 g / 10 min, greater than or equal to 8 g / 10 min, greater than or equal to 10 g / 10 min, or even greater than or equal to 12 g / 10 min. In embodiments, the aromatic polycarbonate polymer may have a melt flow index, as measured at 300 °C and 1.2 kg, less than or equal to 25 g / 10 min, less than or equal to 23 g / 10 min, less than or equal to 20 g / 10 min, less than or equal to 18 g / 10 min or even less than or equal to 16 g / 10 min. In embodiments, the aromatic polycarbonate polymer may have a melt flow index, as measured at 300 °C and 1.2 kg, from 5 g / 10 min to 25 g / 10 min, from 5 g / 10 min to 23 g / 10 min, from 5 g / 10 min to 20 g / 10 min, from 5 g / 10 min to 18 g / 10 min, from 5 g / 10 min to 16 g / 10 min, from 8 g / 10 min to 25 g / 10 min, from 8 g / 10 min to 23 g / 10 min, from 8 g / 10 min to 20 g / 10 min, from 8 g / 10 min to 18 g / 10 min, from 8 g / 10 min to 16 g / 10 min, from 10 g / 10 min to 25 g / 10 min, from 10 g / 10 min to 23 g / 10 min, from 10 g / 10 min to 20 g / 10 min, from 10 g / 10 min to 18 g / 10 min, from 10 g / 10 min to 16 g / 10 min, from 12 g / 10 min to 25 g / 10 min, from 12 g / 10 min to 23 g / 10 min, from 12 g / 10 min to 20 g / 10 min, from 12 g / 10 min to 18 g / 10 min, or even from 12 g / 10 min to 16 g / 10 min, or any and all sub-ranges formed from any of these endpoints.

[0050] In embodiments, the aromatic polycarbonate polymer may have a weight average molecular weight of 25,000 g / mol to 100,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a weight average molecular weight greater than or equal to 25,000 g / mol or even greater than or equal to 50,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a weight average molecular weight less than or equal to 100,000 g / mol or even less thanor equal to 75,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a weight average molecular weight from 25,000 g / mol to 100,000 g / mol, from 25,000 g / mol to 75,000 g / mol, from 50,000 g / mol to 100,000 g / mol, or even from 50,000 g / mol to 75,000 g / mol, or any and all sub-ranges formed from any of these endpoints.

[0051] In embodiments, the aromatic polycarbonate polymer may have a number average molecular weight of 5,000 g / mol to 50,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a number average molecular weight greater than or equal to 5,000 g / mol or even greater than or equal to 15,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a number average molecular weight less than or equal to 50,000 g / mol, less than or equal to 40,000 g / mol, or even less than or equal to 30,000 g / mol. In embodiments, the aromatic polycarbonate polymer may have a number average molecular weight from 5,000 g / mol to 50,000 g / mol, from 5,000 g / mol to 40,000 g / mol, from 5,000 g / mol to 30,000 g / mol, from 15,000 g / mol to 50,000 g / mol, from 15,000 g / mol to 40,000 g / mol, or even from 15,000 g / mol to 40,000 g / mol, or any and all sub-ranges formed from any of these end points.

[0052] In embodiments, the aromatic polycarbonate polymer may have a polydispersity index of 1.5 to 5. In embodiments, the aromatic polycarbonate polymer may have a polydispersity index greater than or equal to 1.5 or even greater than or equal to 2. In embodiments, the aromatic polycarbonate polymer may have a polydispersity index less than or equal to 5, less than or equal to 4, or even less than or equal to 3. In embodiments, the aromatic polycarbonate polymer may have a polydispersity index from 1.5 to 5, from 1.5 to 4, from 1.5 to 3, from 2 to 5, from 2 to 4, or even from 2 to 3, or any and all sub-ranges formed from any of these endpoints.

[0053] In embodiments, the reactive polymer composition may comprise a minimum amount of the aromatic polycarbonate polymer (e.g., greater than or equal to 71 wt%) to ensure a desired impact strength and melt flow index are imparted to the polycarbonate composition. The amount of the aromatic polycarbonate polymer may be limited (e.g., less than or equal to 99.8%) to ensure that an improved scratch resistance (e.g., a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1), improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thicknessof 1.3 mm, and a desired pencil hardness (e.g., pencil hardness of at least B) may be achieved. Accordingly, in embodiments, the reactive polymer composition may comprise, based on a total weight of the polycarbonate composition, 71 wt% to 99.8 wt% of the aromatic polycarbonate polymer. In embodiments, the amount of the aromatic polycarbonate polymer in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, greater than or equal to 71 wt%, greater than or equal to 75 wt%, greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or even greater than or equal to 95 wt%. In embodiments, the amount of the aromatic polycarbonate polymer in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, less than or equal to 99.8 wt%, less than or equal to 99 wt%, less than or equal to 97 wt%, less than or equal to 95 wt%, less than or equal to 90 wt%, or even less than or equal to 85 wt%. In embodiments, the amount of the aromatic polycarbonate polymer in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, from 71 wt% to 99.8 wt%, from 71 wt% to 99 wt%, from 71 wt% to 97 wt%, from 71 wt% to 95 wt%, from 71 wt% to 90 wt%, from 71 wt% to 85 wt%, from 75 wt% to 99.8 wt%, from 75 wt% to 99 wt%, from 75 wt% to 97 wt%, from 75 wt% to 95 wt%, from 75 wt% to 90 wt%, from 75 wt% to 85 wt%, from 80 wt% to 99.8 wt%, from 80 wt% to 99 wt%, from 80 wt% to 97 wt%, from 80 wt% to 95 wt%, from 80 wt% to 90 wt%, from 80 wt% to 85 wt%, from 85 wt% to 99.8 wt%, from 85 wt% to 99 wt%, from 85 wt% to 97 wt%, from 85 wt% to 95 wt%, from 85 wt% to 90 wt%, from 90 wt% to 99.8 wt%, from 90 wt% to 99 wt%, from 90 wt% to 97 wt%, from 90 wt% to 95 wt%, from 95 wt% to 99.8 wt%, from 95 wt% to 99 wt%, or even from 95 wt% to 97 wt%, or any and all sub-ranges formed from any of these endpoints.

[0054] Suitable commercial embodiments of the aromatic polycarbonate polymer are available under the IUPILON brand from Mitsubishi, such as grade S-3000UR; under the LEXAN brand from Sabic, such as grades 143 and 145; under the MAKROLON brand from Covestro; and under the CALIBRE brand from Trinseo.

[0055] Reactive Epoxy Compound

[0056] The reactive polymer compositions disclosed herein include a reactive epoxy compound. The reactive epoxy compound reacts with the aromatic polycarbonate polymer viatransesterification process and grafts onto the aromatic polycarbonate polymer backbone, thereby imparting scratch resistance and transparency to the resulting polycarbonate composition. Epoxide groups present in the reactive epoxy compound undergo a reaction with hydroxyl groups present as an end group of the aromatic polycarbonate polymer or obtained as intermediate due to chain scission on exposure to heat in the melt phase. Increasing epoxy equivalent weight leads to increased potential for crosslinking as an epoxy polymer backbone forms the link between two aromatic polycarbonate polymers. The mechanism may also be classified as a ring opening reaction for epoxide groups. Moreover, the reactive epoxy compound may impart polarity to the reactive polymer composition. The ring opening of the epoxide group results in a hydroxyl group. Increased hydroxyl group density may increase the polarity and / or increase inter-chain hydrogen bonding, thereby increasing compatibility between the aromatic polycarbonate polymer and the acrylate polymer. This increased compatibility, in turn, helps to improve transparency.

[0057] In embodiments, the reactive epoxy compound may have an epoxy equivalent weight of 172 g / eq to 2900 g / eq. In embodiments, the reactive epoxy compound may have an epoxy equivalent weight greater than or equal to 172 g / eq, greater than or equal to 250 g / eq, greater than or equal to 500 g / eq, greater than or equal to 750 g / eq, greater than or equal to 1000 g / eq, greater than or equal to 1250 g / eq, or even greater than or equal to 1500 g / eq. In embodiments, the reactive epoxy compound may have an epoxy equivalent weight less than or equal to 2900 g / eq, less than or equal to 2500 g / eq, less than or equal to 2000 g / eq, less than or equal to 1500 g / eq, less than or equal to 1000 g / eq, or even less than or equal to 500 g / eq. In embodiments, the reactive epoxy compound may have an epoxy equivalent from 172 g / eq to 2900 g / eq, from 172 g / eq to 2500 g / eq, from 172 g / eq to 2000 g / eq, from 172 g / eq to 1500 g / eq, from 172 g / eq to 1000 g / eq, from 172 g / eq to 500 g / eq, from 250 g / eq to 2500 g / eq, from 250 g / eq to 2000 g / eq, from 250 g / eq to 1500 g / eq, from 250 g / eq to 1000 g / eq, from 250 g / eq to 500 g / eq, from 500 g / eq to 2500 g / eq, from 500 g / eq to 2000 g / eq, from 500 g / eq to 1500 g / eq, from 500 g / eq to 1000 g / eq, from 750 g / eq to 2500 g / eq, from 750 g / eq to 2000 g / eq, from 750 g / eq to 1500 g / eq, from 750 g / eq to 1000 g / eq, from 1000 g / eq to 2500 g / eq, from 1000 g / eq to 2000 g / eq, from 1000 g / eq to 1500 g / eq, from 1250 g / eq to 2500 g / eq, from 1250 g / eq to 2000 g / eq, from 1250 g / eq to 1500 g / eq, from 1500 g / eq to 2500 g / eq, or even from 1500 g / eq to 2000 g / eq, or any and all sub-ranges formed from any of these endpoints.

[0058] In embodiments, the reactive epoxy compound has a weight average molecular weight of 350 g / mol to 50,000 g / mol. In embodiments, the reactive epoxy compound has a weight average molecular weight greater than or equal to 350 g / mol, greater than or equal to 550 g / mol, or even greater than or equal to 750 g / mol. In embodiments, the reactive epoxy compound has a weight average molecular weight less than or equal to 50,000 g / mol, less than or equal to 30,000 g / mol, less than or equal to 10,000 g / mol, less than or equal to 5,000 g / mol, or even less than or equal to 1,000 g / mol. In embodiments, the reactive epoxy compound has a from 350 g / mol to 50,000 g / mol, from 350 g / mol to 30,000 g / mol, from 350 g / mol to 10,000 g / mol, from 350 g / mol to 5,000 g / mol, from 350 g / mol to 1,000 g / mol, from 550 g / mol to 50,000 g / mol, from 550 g / mol to 30,000 g / mol, from 550 g / mol to 10,000 g / mol, from 550 g / mol to 5,000 g / mol, from 550 g / mol to 1,000 g / mol, from 750 g / mol to 50,000 g / mol, from 750 g / mol to 30,000 g / mol, from 750 g / mol to 10,000 g / mol, from 750 g / mol to 5,000 g / mol, or even from 750 g / mol to 1,000 g / mol, or any and all sub- ranges formed from any of these endpoints.

[0059] In embodiments, the reactive epoxy compound may comprise a cycloaliphatic epoxy resin, a solid bisphenol A epoxy resin, a liquid bisphenol A epoxy resin, a novolac epoxy resin, a glycidylamine epoxy resin, a bisphenol F-resin, an aliphatic epoxy resin diluent, an aromatic epoxy resin diluent, or a combination thereof. In embodiments, the aliphatic epoxy resin diluent may comprise a poly(ethylene glycol) diglycidyl ether. In embodiments, the aromatic epoxy resin diluent may comprise 2,2-bis[4-(glycidyloxy)phenyl]propane. In embodiments, the reactive epoxy compound may comprise a bisphenol A epoxy resin, 2,2-bis[4- (glycidyloxy)phenyl]propane, a poly(ethylene glycol) diglycidyl ether, or a combination thereof.

[0060] In embodiments, the bisphenol A epoxy resin may be defined by the following formula:wherein each R is individually an alkyl group and n = 3 to 180.

[0061] In embodiments, the 2,2-bis[4-(glycidyloxy)phenyl]propane may be defined by the following formula:

[0062] Inbeing defined by the following formula:wherein n is from 400 to 1000.

[0063] In embodiments, the reactive epoxy compound may comprise at least two epoxy functional groups per compound. In these embodiments, the at least two epoxy functional groups per compound may help to ensure adequate reaction with and grafting to the aromatic polycarbonate polymer.

[0064] In embodiments, the reactive epoxy compound may comprise a telechelic epoxy compound. In these embodiments, the telechelic epoxy compound may help to ensure adequate reaction with and grafting to the aromatic polycarbonate polymer.

[0065] In embodiments, the reactive polymer composition may comprise a minimum amount of reactive epoxy compound (e.g., greater than or equal to 0.2 wt%) to ensure an improved scratch resistance and transparency is achieved. In embodiments, the amount of the reactive epoxy compound in the reactive polymer composition may be limited (e.g., less than or equal to 15 wt%) to maintain the processability of the resulting polycarbonate composition. Accordingly, in embodiments, the reactive polymer composition may comprise, based on a total weight of thepolycarbonate composition, 0.2 wt% to 15 wt% of the reactive epoxy compound. In embodiments, the amount of the reactive epoxy compound in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, greater than or equal to 0.2 wt%, greater than or equal to 0.5 wt%, greater than or equal to 1 wt%, greater than or equal to 3 wt%, or even greater than or equal to 5 wt%. In embodiments, the amount of the reactive epoxy compound in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, less than or equal to 15 wt%, less than or equal to 13 wt%, less than or equal to 10 wt%, less than or equal to 8 wt%, less than or equal to 5 wt%, or even less than or equal to 3 wt%. In embodiments, the amount of the reactive epoxy compound in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, from 0.2 wt% to 15 wt%, from 0.2 wt% to 13 wt%, from 0.2 wt% to 10 wt%, from 0.2 wt% to 8 wt%, from 0.2 wt% to 5 wt%, from 0.2 wt% to 3 wt%, from 0.5 wt% to 15 wt%, from 0.5 wt% to 13 wt%, from 0.5 wt% to 10 wt%, from 0.5 wt% to 8 wt%, from 0.5 wt% to 5 wt%, from 0.5 wt% to 3 wt%, from 1 wt% to 15 wt%, from 1 wt% to 13 wt%, from 1 wt% to 10 wt%, from 1 wt% to 8 wt%, from 1 wt% to 5 wt%, from 1 wt% to 3 wt%, from 3 wt% to 15 wt%, from 3 wt% to 13 wt%, from 3 wt% to 10 wt%, from 3 wt% to 8 wt%, from 3 wt% to 5 wt%, from 5 wt% to 15 wt%, from 5 wt% to 13 wt%, from 5 wt% to 10 wt%, or even from 5 wt% to 8 wt%, or any and all sub-ranges formed from any of these endpoints.

[0066] Suitable commercial embodiments of the reactive epoxy compound are available under the LAPOX brand from Atul Ltd., such as bisphenol A epoxy resin grade P-4 and glycidylamine epoxy resin grade ARPN-54; under the EPOTEC brand from Aditya Birla Advance Materials, such as bisphenol A epoxy resin grades YD 907, YD 909, YD 942, YD 972, novolac epoxy resin grades YDPN 638 and YDPN 631, and aliphatic epoxy resin diluent grade YDH 184; under the D.E.R. brand from Olin, such as 2,2-bis[4-(glycidyloxy)phenyl]propane grade 332; under the DAICEL from Tri-iso, such as cycloapliphatic epoxy resin grade EHPE 3150; under the EPIKOTE brand from Westlake Epoxy, such as liquid bisphenol A epoxy resin grade 828; under the EPON brand from Westlake Epoxy, such as solid bisphenol A epoxy resin grade 1002F and bisphenol F- resin grade 862; and from Sigma Aldrich, such as aliphatic epoxy resin diluents including poly(ethylene glycol) diglycidyl ether, 1,4-butanediol diglycidyl ether, and poly(dimethylsiloxane) diglycidyl ether and aromatic epoxy resin diluents including bisphenol Adiglycidyl ether, bis[4-(glycidyloxy)phenyl]methane, glycidyl end-capped poly(bisphenol A-co- epichlorohydrin), and N,N-diglycidyl-4-glycidyloxyaniline.

[0067] Acrylate Polymer

[0068] The reactive polymer compositions disclosed herein include an acrylate polymer. The acrylate polymer imparts scratch resistance to the resulting polycarbonate composition. As described herein, reactive epoxy compound may impart polarity to the reactive polymer composition. Accordingly, the reactive epoxy compound may help improve the compatibility between the aromatic polycarbonate polymer and the acrylate polymer, thereby further improving scratch resistance while having improved transparency. Additionally, the acrylate polymer may help reduce the processing effect imparted by the reactive epoxy compound, such that a relatively higher amount of reactive epoxy compound may be included in the reactive polymer composition (e.g., 3 wt% to 10 wt% of the reactive epoxy compound).

[0069] In embodiments, the acrylate polymer may have a weight average molecular weight of 7000 g / mol to less than 30,000 g / mol to ensure an improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm) is achieved. Including acrylate polymers having a weight average molecular weight greater than or equal to 30,000 g / mol may result in a transparency less than 75%. In embodiments, the acrylate polymer may have a weight average molecular

[0070] In embodiments, the acrylate polymer may comprise acrylate homopolymer, acrylate copolymer, poly-alkyl acrylate, or a combination thereof. In embodiments, the acrylate copolymer may comprise polyacryl methacrylate-co-acrylate. In embodiments, the poly-alkyl acrylate may comprise poly(methyl methacrylate).

[0071] The amount of acrylate polymer in the reactive polymer composition may be less than or equal to 25 wt% to ensure improved scratch resistance and desirable mechanism properties, such as impact resistance. Accordingly, in embodiments, the reactive polymer composition may comprise, based on a total weight of the polycarbonate composition, 1 wt% to 25 wt% of the acrylate polymer. In embodiments, the amount of the acrylate polymer in the reactive polymercomposition may be, based on a total weight of the polycarbonate composition, greater than or equal to 1 wt%, greater than or equal to 3 wt%, greater than or equal to 5 wt%, or even greater than or equal to 7 wt%. In embodiments, the amount of the acrylate polymer in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, less than or equal to 25 wt%, less than or equal to 20 wt%, less than or equal to 15 wt%, or even less than or equal to 10 wt%. In embodiments, the amount of the acrylate polymer in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, from 1 wt% to 25 wt%, from 1 wt% to 20 wt%, from 1 wt% to 15 wt%, from 1 wt% to 10 wt%, from 3 wt% to 25 wt%, from 3 wt% to 20 wt%, from 3 wt% to 15 wt%, from 3 wt% to 10 wt%, from 5 wt% to 25 wt%, from 5 wt% to 20 wt%, from 5 wt% to 15 wt%, from 5 wt% to 10 wt%, from 7 wt% to 25 wt%, from 7 wt% to 20 wt%, from 7 wt% to 15 wt%, or even from 7 wt% to 10 wt%, or any and all sub-ranges formed from any of these endpoints.

[0072] Suitable commercial embodiments of the acrylate polymer are available under the ELVACITE brand from Mitsubishi Chemical Company, such as poly(methyl methacrylate) (MW= 7 kDa) grade 4333.

[0073] Silica

[0074] The reactive polymer compositions disclosed herein may further include silica. Silica, in combination with the reactive epoxy compound, may further improve the scratch resistance of the resulting polycarbonate composition.

[0075] In embodiments, the silica may have a mean particle size of 10 microns to 60 microns, as measured according to dynamic laser scattering, to ensure an improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm) is achieved. Silica having a mean particle size greater than 60 microns may result in an average transparency less than 75%. In embodiments, the silica may have a mean particle size greater than or equal to 10 microns, greater than or equal to 20 microns, greater than or equal to 30 microns, or even greater than or equal to 40 microns. In embodiments, the silica may have a mean particle size less than or equal to 60 microns, less than or equal to 50 microns, less than or equal to 40 microns, or even less than or equal to 30 microns. In embodiments, the silica may have a mean particle size from 10microns to 60 microns, from 10 microns to 50 microns, from 10 microns to 40 microns, from 10 microns to 30 microns, from 20 microns to 60 microns, from 20 microns to 50 microns, from 20 microns to 40 microns, from 20 microns to 30 microns, from 30 microns to 60 microns, from 30 microns to 50 microns, from 30 microns to 40 microns, from 40 microns to 60 microns, or even from 40 microns to 50 microns, or any and all sub-ranges formed from any of these endpoints.

[0076] In embodiments, the silica may comprise precipitated silica to ensure that an improved scratch resistance (a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1) may be achieved.

[0077] A minimum amount of silica may be included in the reactive polymer composition (e.g., greater than or equal to 0.1 wt%) to help further improve the scratch resistance of the resulting polycarbonate composition. The amount of the silica may be limited (less than 0.5 wt%) to ensure that an improved transparency is achieved. Accordingly, in embodiments, the reactive polymer composition may comprise, based on a total weight of the polycarbonate composition, 0.1 wt% to less than 0.5 wt% of the silica. In embodiments, the amount of the silica in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, greater than or equal to 0.1 wt%. In embodiments, the amount of the silica in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, less than 0.5 wt%, less than or equal to 0.4 wt%, less than or equal to 0.3 wt%, or even less than or equal to 0.2 wt%. In embodiments, the amount of the silica in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, from 0.1 wt% to less than 0.5 wt%, from 0.1 wt% to 0.4 wt%, from 0.1 wt% to 0.3 wt%, or even from 0.1 wt% to 0.2 wt%, or any and all sub-ranges formed from any of these endpoints.

[0078] In some embodiments, articles formed from polycarbonate compositions including silica may have observable specks of silica, even though such articles have improved scratch resistance (e.g., at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1) while having improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm). As such, in certainembodiments, it may be desirable to have a reactive polymer composition free of silica. Accordingly, in some embodiments, the reactive polymer composition may comprise 0 wt% silica.

[0079] Suitable commercial embodiments of the silica are available from Brisil, such as precipitated silica.

[0080] Slip Additive

[0081] The reactive polymer compositions disclosed herein may further include a slip additive. Slip additive, in combination with the reactive epoxy compound, may further improve the scratch resistance by reducing the coefficient of friction of the resulting polycarbonate composition.

[0082] In embodiments, the slip additive may comprise a fatty acid or derivatives thereof.

[0083] A minimum amount of the slip additive (e.g., greater than or equal to 0.5 wt%) may be included in the reactive polymer composition to ensure the coefficient of friction of the resulting polycarbonate composition is reduced. The amount of the slip additive may be limited (e.g., less than or equal to 5 wt%) to ensure an improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm) may be achieved. Accordingly, in embodiments, the reactive polymer composition may comprise, based on a total weight of the polycarbonate composition, 0.5 wt% to 5 wt% of a slip additive. In embodiments, the amount of the slip additive in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, greater than or equal to 0.5 wt%, greater than or equal to 1 wt%, or even greater than or equal to 1.5 wt%. In embodiments, the amount of the slip additive in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, less than or equal to 5 wt%, less than or equal to 3 wt%, or even less than or equal to 2 wt%. In embodiments, the amount of the slip additive in the reactive polymer composition may be, based on a total weight of the polycarbonate composition, from 0.5 wt% to 5 wt%, from 0.5 wt% to 4 wt%, from 0.5 wt% to 3 wt%, from 1 wt% to 5 wt%, from 1 wt% to 4 wt%, from 1 wt% to 3 wt%, from 1.5 wt% to 5 wt%, from 1.5 wt% to 4 wt%, or even from 1.5 wt% to 3 wt%, or any and all sub-ranges formed from any of these endpoints.

[0084] Suitable commercial embodiments of the slip additive are available under the INCROMAX brand from Cargill such as fatty acid grade 300.

[0085] Other Additives

[0086] The reactive polymer compositions disclosed herein may further include other additives. Other additives include conventional or commercially available plastics additives. Those skilled in the art of thermoplastics compounding, without undue experimentation, may select suitable additives from available references, for example, E.W. Flick, “Plastics Additives Database,” Plastics Design Library (Elsevier 2004).

[0087] Such additional optional other additives may be used in any amount that is sufficient to obtain a desired processing or performance property for the material or component formed therefrom. The amount should not be wasteful of the additive nor detrimental to the processing or performance of the material or article formed therefrom.

[0088] Non-limiting examples of additional optional other additives may include ultra violet absorbers, light stabilizer, antioxidants, processing aid, coloring agent (pigments or dyes), catalyst, curing agent, or a combination thereof. In embodiments, the catalyst may comprise a transesterification catalyst, such as zinc acetyl acetanoate, tetrabutyl titanate, N,N′- bis(salicylidene)ethylenediaminocobalt(II), lantanium acetylacetonate, and 1- methylimidazole. In embodiments, the curing agent may comprise as an epoxy curing agent, such as dianhydride.

[0089] Suitable commercial embodiments of the ultra violet absorber are available under the TINUVIN brand from BASF, such as grade 326. Suitable commercial embodiments of the light stabilizer are available under the UNVINUL brand from BASF, such as grade 4050. Suitable commercial embodiments of the antioxidant are available under the IRGANOX brand from BASF, such as grade 1076; and under the IRGAFOS brand from BASF, such as grade 168.

[0090] Method for Preparing Polycarbonate Compositions

[0091] In embodiments, a method of preparing a polycarbonate composition may comprise preparing a reactive polymer composition as disclosed herein and reacting the reactive polymercomposition in a transesterification process. During the transesterification process, the reactive epoxy compound reacts with the aromatic polycarbonate polymer and grafts onto the aromatic polycarbonate polymer backbone, thereby imparting scratch resistance and transparency to the resulting polycarbonate composition. Moreover, as described herein, the reactive epoxy compound may impart polarity to the reactive polymer composition, thereby increasing compatibility between the aromatic polycarbonate polymer and the acrylate polymer and improving transparency.

[0092] The step of preparing a reactive polymer composition may comprise premixing the components of the reactive polymer composition, including the aromatic polycarbonate polymer, the reactive epoxy compound, and the acrylate polymer. The aromatic polycarbonate polymer may be pre-dried at 80 °C to 100 °C for 4 hours and then premixed with the other components at 25 °C. In embodiments, the step of reacting the reactive polymer composition disclosed herein may be performed in a single step, thereby saving time and costs.

[0093] In some embodiments, the step of reacting the reactive polymer composition may be performed in melt phase during an extrusion process. For example, the prepared reactive polymer composition may be fed into a machine (e.g., injection molder or compression molder) and melt- mixed at a temperature greater than or equal to a melt temperature of the reactive polymer composition. In embodiments, the reactive polymer composition may be melt-mixed at a screw speed from 300 rpm to 400 rpm, at a temperature from 250 °C and 310 °C, and for a time from 30 s to 90 s.

[0094] Due to having a relatively high transparency achieved by the polycarbonate compositions disclosed herein, the polycarbonate compositions may be relatively easily colored by including colorants, pigments, or dyes.

[0095] Polycarbonate Compositions

[0096] As described herein, the polycarbonate compositions may have improved scratch resistance (e.g., at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1) while having improved transparency (e.g., average greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nmincrements and at an article thickness of 1.3 mm). The reactive epoxy compound imparts improved scratch resistance and transparency. Moreover, the reactive epoxy compound may improve the compatibility between the aromatic polycarbonate polymer and an acrylate polymer included in the polycarbonate composition, which may further improve scratch resistance while having improved transparency.

[0097] In embodiments, the polycarbonate composition may have a scratch resistance rating of at least 2 at greater than or equal to 4N, greater than or equal to 5N, greater than or equal to 6N, or even greater than or equal to 7N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1.

[0098] In embodiments, the polycarbonate composition may have a scratch depth reduction, relative to a conventional polycarbonate, greater than or equal to 70%, greater than or equal to 80%, or even greater than or equal to 90%, as measured using a profilometer under a 5 N to 10 N load.

[0099] In embodiments, the polycarbonate composition may have a transparency greater than or equal to 75%, greater than or equal to 77%, greater than or equal to 80%, greater than or equal to 83%, or even greater than or equal to 85%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm. In embodiments, the polycarbonate composition may have a transparency in the range of 75% to 100%, in the range of 77% to 95%, in the range of 80% to 92%, in the range of 83% to 91%, or in the range of 85% to 90%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm.

[0100] In embodiments, the polycarbonate composition may have a haze less than or equal to 40%, less than or equal to 30%, less than or equal to 20%, or even less than or equal to 10%, as measured according to ASTM D1003 at 10°, using illuminant D65, and an article thickness of 1.3 mm.

[0101] In embodiments, the polycarbonate composition may exhibit a single Tg, which is indicative of the compatibility between the aromatic polycarbonate polymer and an acrylate polymer included in the polycarbonate composition.

[0102] In embodiments, the polycarbonate composition may have pencil hardness of B to 2H, as measured according to ASTM D3363.

[0103] In embodiments, the polycarbonate composition may have a gloss value greater than or equal to 80 Gloss Units (GU), greater than or equal to 85 GU, or even greater than or equal to 90 GU.

[0104] In embodiments, the polycarbonate composition may have an impact strength of 5 kJ / m2to 90 kJ / m2. In embodiments, the polycarbonate composition may have an impact strength greater than or equal to 5 kJ / m2, greater than or equal to 10 kJ / m2, greater than or equal to 25 kJ / m2, or even greater than or equal to 50 kJ / m2. In embodiments, the polycarbonate composition may have an impact strength less than or equal to less than or equal to 90 kJ / m2, less than or equal to 70 kJ / m2, less than or equal to 50 kJ / m2, or even less than or equal to 30 kJ / m2. In embodiments, the polycarbonate composition may have an impact strength from 5 kJ / m2to 90 kJ / m2, from 5 kJ / m2to 70 kJ / m2, from 5 kJ / m2to 50 kJ / m2, from 5 kJ / m2to 30 kJ / m2, from 10 kJ / m2to 90 kJ / m2, from 10 kJ / m2to 70 kJ / m2, from 10 kJ / m2to 50 kJ / m2, from 10 kJ / m2to 30 kJ / m2, from 25 kJ / m2to 90 kJ / m2, from 25 kJ / m2to 70 kJ / m2, from 25 kJ / m2to 50 kJ / m2, from 25 kJ / m2to 30 kJ / m2, from 50 kJ / m2to 90 kJ / m2, or even from 50 kJ / m2to 70 kJ / m2, or any and all sub-ranges formed from any of these endpoints.

[0105] In embodiments, the polycarbonate composition may have a melt flow index greater than or equal to 1 g / 10 min, greater than or equal to 5 g / 10 min, greater than or equal to 10 g / 10 min, greater than or equal to 20 g / 10 min, or even greater than or equal to 30 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg. In embodiments, the polycarbonate composition may have a melt flow index less than or equal to 60 g / 10 min, less than or equal to 40 g / 10 min, or even less than or equal to 20 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg. In embodiments, the polycarbonate composition may have a melt flow index from 1 g / 10 min to 60 g / 10 min, from 1 g / 10 min to 40 g / 10 min, from 1 g / 10 min to 20 g / 10 min, from 5 g / 10 min to 60 g / 10 min, from 5 g / 10 min to 40 g / 10 min, from 5 g / 10 min to 20 g / 10 min, from 10 g / 10 min to 60 g / 10 min, from 10 g / 10 min to 40 g / 10 min, from 10 g / 10 min to 20 g / 10 min, from 20 g / 10 min to 60 g / 10 min, from 20 g / 10 min to 40 g / 10 min, from 30 g / 10 min to 60 g / 10 min, from30 g / 10 min to 40 g / 10 min, from 30 g / 10 min to 20 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg.

[0106] In embodiments, the polycarbonate composition may have a tensile strength greater than or equal to 40 MPa or even greater than or equal to 50 MPa. In embodiments, the polycarbonate composition may have a tensile strength less than or equal to 75 MPa or even less than or equal to 65 MPa. In embodiments, the polycarbonate composition may have a tensile strength from 40 MPa to 75 MPa, from 40 MPa to 65 MPa, from 50 MPa to 75 MPa, or even from 50 MPa to 65 MPa, or any and all sub-ranges formed from any of these endpoints.

[0107] In embodiments, the polycarbonate composition may have an elongation at break greater than or equal to 5%, greater than or equal to 25%, or even greater than or equal to 50%. In embodiments, the polycarbonate composition may have an elongation at break less than or equal to 125% or even less than or equal to 100%. In embodiments, the polycarbonate composition may have an elongation at break from 5% to 125%, from 5% to 100%, from 25% to 125%, from 25% to 100%, from 50% to 125%, or even from 50% to 100%, or any and all sub-ranges formed from any of these endpoints.

[0108] In embodiments, the polycarbonate composition may have a flexural modulus greater than or equal to 1500 MPa or even greater than or equal to 2000 MPa. In embodiments, the polycarbonate composition may have a flexural modulus less than or equal to 3000 MPa or even less than or equal to 2500 MPa. In embodiments, the polycarbonate composition may have a flexural modulus from 1500 MPa to 3000 MPa, from 1500 MPa to 2500 MPa, from 2000 MPa to 3000 MPa, or even from 2000 MPa to 2500 MPa, or any and all sub-ranges formed from any of these endpoints.

[0109] In embodiments, the polycarbonate composition may have a flexural strength greater than or equal to 70 MPa or even greater than or equal to 80 MPa. In embodiments, the polycarbonate composition may have a flexural strength less than or equal to 120 MPa or even less than or equal to 100 MPa. In embodiments, the polycarbonate composition may have a flexural strength from 70 MPa to 120 MPa, from 70 MPa to 100 MPa, from 80 MPa to 120 MPa, or even from 80 MPa to 100 MPa, or any and all sub-ranges formed from any of these endpoints.

[0110] Method of Forming Articles from Polycarbonate Compositions

[0111] In embodiments, an article formed from the polycarbonate compositions disclosed herein may be formed by at least one of injection molding, compression molding, blow molding, profile and sheet extrusion. In embodiments, the method for preparing a polycarbonate composition disclosed herein may further comprise injection molding the polycarbonate composition to form an article.

[0112] The article may be formed into any shape for further processing or for the intended end use. For example, in embodiments, the polycarbonate composition may be immediately cooled down and pelletized after exiting the extruder. The pellets resulting from extrusion may be subjected to further processing, such as injection molding, blow molding, compression molding, or profiled extrusion, to convert the pellets to the final article.

[0113] Articles Formed from Polycarbonate Compositions

[0114] Referring now to FIG. 1, in embodiments, an article 100 may comprise the polycarbonate composition as disclosed herein. The article 100 is shown as being generally rectangular, but may have any form suitable for its intended use. As discussed herein, the polycarbonate compositions may be used in any article that requires both improved scratch resistance and improved transparency. The polycarbonate compositions are especially useful for forming articles in the automotive industry, such as headlights, taillights, interior body parts, and door handles.

[0115] As discussed herein, conventionally, to improve scratch resistance, a coating may be applied to the article formed from the polycarbonate composition, which increases processing time and costs. As such, the polycarbonate compositions may eliminate the need for extra processing steps, such as the application of a coating, to achieve improved scratch resistance.

[0116] The article 100 has at least one external facing surface 102. For example, article 100 may be a headlight for an automobile and the at least one external facing surface would face out and away from the automobile. As discussed herein, conventionally, to improve scratch resistance, a coating may be applied to the article formed from the polycarbonate composition, which increases processing time and costs. The external facing surface 102 of the article 100 may becoating free, while still achieving improved scratch resistance and transparency due to being formed from the polycarbonate composition described herein.

[0117] Referring now to FIG.2, in embodiments an article 200 may comprise the polycarbonate composition as disclosed herein. As shown, the article 200 comprises a pellet. The polycarbonate composition may be formed into pellets (e.g., after exiting an extruder and using a pelletizer) to allow for further processing. EXAMPLES

[0118] Non-limiting examples of various embodiments of the disclosed invention are provided.

[0119] Table 1 shows sources of ingredients used to form example polycarbonate compositions E1-E48 and comparative polycarbonate compositions C1-C12.

[0120] Table 1 Ingredients Chemical Description Brand and Grade Source i iii

[0121] Tables 2 and 3 below show the formulations of example polycarbonate compositions E1-E48 and comparative compositions C1-C12. Table 2 includes example polycarbonate compositions E1-E48, polycarbonate compositions including a polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer. Table 3 includes comparative polycarbonate compositions C1-C12. The polycarbonate compositions were formed by pre-drying the aromatic polycarbonate polymer at 80 °C to 100 °C for 4 hours and then premixing the dried aromatic polycarbonate polymer with the other components at 25 °C

[0122] Table 2 Compositions E1 E2 E3 E4 E5 IUPILON S-3000UR 85.00 85.00 85.00 87.50 85.00

[0123] Table 2 cont. CompositionsE6 E7 E8 E9 E10IUPILON S-3000UR 87.50 87.40 84.90 83.65 83.55

[0124] Table 2 cont. Compositions E11 E12 E13 E14 E15 IUPILON S-3000UR 82.05 89.50 87.50 85.00 87.00

[0125] Table 2 cont. CompositionsE16 E17 E18 E19 E20IUPILON S-3000UR 85.00 82.50 89.50 87.50 85.00

[0126] Table 2 cont. Compositions E21 E22 E23 E24 E25

[0127] Table 2 cont. Compositions E26 E27 E28 E29 E30 IUPILON S-3000UR 84.80 86.80 84.80 82.30 89.30

[0128] Table 2 cont. CompositionsE31 E32 E33 E34 E35IUPILON S-3000UR 87.30 84.80 86.80 84.80 82.30

[0129] Table 2 cont. Compositions E36 E37 E38 E39 E40

[0130] Table 2 cont. Compositions E41 E42 E43 E44 E45 IUPILON S-3000UR 79.50 86.50 84.50 82.00 84.00

[0131] Table 2 cont. CompositionsE46 E47 E48IUPILON S-3000UR 82.00 79.50 80.00

[0132] Table 3 Compositions C1 C2 C3 C4 C5

[0133] Table 3 cont.Compositions C6 C7 C8 C9 C10 IUPILON S-3000UR 85.00 92.50 85.00 95.00 95.00

[0135] Table 4 below shows the scratch resistance load, haze, and average transparency of example articles EA1-EA12 and comparative articles CA1-CA11 formed via injection molding from example and comparative polycarbonate compositions as indicated in the table. Table 5 below shows the transparency in 10 nm increments from 400 nm to 700 nm (in %) of example articles EA1-EA8 and EA12 and comparative articles CA1 and CA3-CA11 formed from example and comparative polycarbonate compositions as indicated in the table. Photographs of example articles EA1-EA12 are shown in FIG.3 and photographs of comparative articles CA1-CA11 are shown in FIG.4.

[0136] Table 4 cont. Articles EA1 EA2 EA3 EA4 EA5 Composition E1 E2 E3 E4 E5

[0137] Table 4 cont. Articles EA6 EA7 EA8 EA9 EA10 Composition E6 E7 E8 E9 E10

[0138] Table 4 cont. Articles EA11 EA12 Composition E11 E48

[0139] Table 4 cont. Articles CA1 CA2 CA3 CA4 CA5

[0140] Table 4 cont. Articles CA6 CA7 CA8 Composition C6 C7 C9

[0141] Table 4 cont. Articles CA9 CA10 CA11 Composition C10 C11 C12

[0142] Table 5 Articles EA1 EA2 EA3 EA4 EA5 Composition E1 E2 E3 E4 E5

[0143] Table 5 cont. Articles EA6 EA7 EA8 EA12 Composition E6 E7 E8 E48

[0144] Table 5 cont. Articles CA1 CA3 CA4 CA5 CA6 Composition C1 C3 C4 C5 C6

[0145] Table 5 cont. Articles CA7 CA8 CA9 CA10 CA11 Composition C7 C9 C10 C11 C12

[0146] As exemplified by example articles EA1-EA11, articles formed from polycarbonate compositions as disclosed herein, including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer, have improved scratch resistance (e.g., at least 2 at greater than or equal to 4N) while having improved transparency (e.g., average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm).

[0147] Referring back to Table 4, comparative articles CA1 and CA2, articles formed from polycarbonate compositions comprising IUPILON S-3000UR (aromatic polycarbonate polymer) and lacking a reactive epoxy compound and an acrylate polymer, had a scratch resistant rating 2 load of 2N and 3N, respectively. As exemplified by comparative articles CA1 and CA2, articles formed from aromatic polycarbonate polymer and lacking a reactive epoxy compound and an acrylate polymer have poor scratch resistance.

[0148] Referring again to Table 4, comparative articles CA3 and CA4, articles formed from polycarbonate compositions comprising IUPILON S-3000UR (aromatic polycarbonate polymer) and silica and lacking a reactive epoxy compound and an acrylate polymer, had improved scratch resistance (e.g., at least 2 at greater than or equal to 4N) while having improved transparency (e.g., average transparency greater than or equal to 75%). However, these articles included specks of silica, which may be undesirable.

[0149] Referring again to Table 4, comparative articles CA5-CA8, articles formed from polycarbonate compositions comprising IUPILON S-3000UR (aromatic polycarbonate polymer) and ELVACITE 4333 or ELVACITE 2008C (acrylate polymer) and lacking a reactive epoxy compound, each had an average transparency less than 75%. While not wishing to be bound by theory, it is believed that the reduced transparency was due to the lack of compatibility between the aromatic polycarbonate and the acrylate polymer.

[0150] Referring back to Table 4, comparative article CA9, an article formed from a polycarbonate composition comprising IUPILON S-3000UR (aromatic polycarbonate polymer) and LAPOX P-4 (reactive epoxy compound) and lacking an acrylate polymer, was too brittle to measure scratch resistance. As exemplified by comparative article CA9, articles formed fromaromatic polycarbonate polymer and a reactive epoxy compound and lacking an acrylate polymer have poor scratch resistance.

[0151] Referring again to Table 4, comparative article CA10, an article formed from a polycarbonate composition comprising IUPILON S-3000UR (aromatic polycarbonate polymer), LAPOX P-4 (reactive epoxy compound), ELVACITE 4333 (acrylate polymer), and silica, had an average transparency less than 75%. As exemplified by comparative article CA10, articles formed from a polycarbonate composition including greater than or equal to 0.5 wt% silica have poor transparency.

[0152] Referring back to Table 4, comparative article CA11, an article formed from a polycarbonate composition comprising IUPILON S-3000UR (aromatic polycarbonate polymer), LAPOX P-4 (reactive epoxy compound), and ELVACITE 2008C (acrylate polymer (MW = 30 kDa)), had an average transparency less than 75%. While not wishing to be bound by theory, it is believed that the reduced transparency was due to the relatively high weight average molecular weight of the acrylate polymer.

[0153] Table 6 below shows the pencil hardness of example articles EA9-EA11 and comparative article CA1 formed from example and comparative polycarbonate compositions as indicated in the table.

[0154] Table 6 Articles EA9 EA10 EA11 CA1 C i i E9 E10 E11 C1

[0155] As exemplified by example articles EA9-EA11, in addition to improved scratch resistance and improved transparency, articles formed from polycarbonate compositions as disclosed herein, including an aromatic polycarbonate polymer, a reactive epoxy compound, and an acrylate polymer, may also have desirable mechanical properties, such as pencil hardness.

[0156] Every document cited herein is incorporated herein by reference in its entirety unless otherwise specified. The citation of any document is not to be construed as an admission that it is prior art with respect to any invention disclosed or claimed herein. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0157] It will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

Claims

CLAIMS 1. A polycarbonate composition comprising: the reaction product of a reactive polymer composition, the reactive polymer composition comprising, based on a total weight of the polycarbonate composition: 71 wt% to 99.8 wt% of an aromatic polycarbonate polymer, wherein the aromatic polycarbonate polymer has a melt flow index of 5 g / 10 min to 25 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg; 0.2 wt% to 15 wt% of a reactive epoxy compound, wherein the reactive epoxy compound has an epoxy equivalent weight of 172 g / eq to 2900 g / eq, as measured according to ASTM D1652; and 1 wt% to 25 wt% of an acrylate polymer, wherein the acrylate polymer has a weight average molecular weight of 7,000 g / mol to less than 30,000 g / mol, wherein the polycarbonate composition has a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1; and wherein the polycarbonate composition has an average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm.

2. The polycarbonate composition of claim 1, wherein the polycarbonate composition exhibits a single Tg.

3. The polycarbonate composition of claim 1 of claim 2, wherein the aromatic polycarbonate polymer comprises a weight average molecular weight of 25,000 g / mol to 100,000 g / mol.

4. The polycarbonate composition of any of the preceding claims, wherein the aromatic polycarbonate polymer comprises a number average molecular weight of 5,000 g / mol to 50,000 g / mol.

5. The polycarbonate composition of any of the preceding claims, wherein the aromatic polycarbonate polymer comprises a polydispersity index of 1.5 to 5.

6. The polycarbonate composition of any of the preceding claims, wherein reactive epoxy compound has a weight average molecular weight of 350 g / mol to 50,000 g / mol.

7. The polycarbonate composition of any of the preceding claims, wherein reactive epoxy compound comprises a cycloaliphatic epoxy resin, a bisphenol A epoxy resin, a novolac epoxy resin, a glycidylamine epoxy resin, a bisphenol F-resin, an aliphatic epoxy resin diluent, an aromatic epoxy resin diluent, or a combination thereof.

8. The polycarbonate composition of claim 7, wherein the reactive epoxy compound comprises the bisphenol A epoxy resin, 2,2-bis[4-(glycidyloxy)phenyl]propane, a poly(ethylene glycol) diglycidyl ether, or a combination thereof.

9. The polycarbonate composition of claim 8, wherein the reactive epoxy compound comprises the bisphenol A epoxy resin, the bisphenol A epoxy resin being defined by the following formula:

10. The polycarbonate composition of claim 8 or claim 9, wherein the reactive epoxy compound comprises the 2,2-bis[4-(glycidyloxy)phenyl]propane, the 2,2-Bis[4- (glycidyloxy)phenyl]propane being defined by the following formula:

11. The polycarbonate composition of any of claims 8-10, wherein the reactive epoxy compound comprises the poly(ethylene glycol) diglycidyl ether, the poly(ethylene glycol) diglycidyl ether being defined by the following formula:wherein n is from 400 to 12. The polycarbonate composition of any of the preceding claims, wherein the reactive epoxy compound comprises at least two epoxy functional groups per compound.

13. The polycarbonate composition of any of the preceding claims, wherein the reactive epoxy compound comprises a telechelic epoxy compound.

14. The polycarbonate composition of any of the preceding claims, wherein the reactive polymer composition comprises, based on a total weight of the polycarbonate composition, 3 wt% to 20 wt% of the acrylate polymer.

15. The polycarbonate composition of any of the preceding claims, wherein the acrylate polymer comprises acrylate copolymer, poly-alkyl acrylate, or a combination thereof.

16. The polycarbonate composition of claim 15, wherein the acrylate copolymer comprises polyacryl methacrylate-co-acrylate.

17. The polycarbonate composition of claim 15, wherein the poly-alkyl acrylate comprises poly(methyl methacrylate).

18. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition has a scratch resistance rating of at least 2 at greater than or equal to 5N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1.

19. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition comprises a scratch depth reduction, relative to a conventional polycarbonate, greater than 70%, as measured using a profilometer under a 5 N to 10 N load.

20. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition has a pencil hardness of B to 2H, as measured according to ASTM D3363.

21. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition has a haze less than or equal to 40%, as measured according to ASTM D1003 at 10°, using illuminant D65, and an article thickness of 1.3 mm.

22. The polycarbonate composition of any of the preceding claims, wherein the reactive polymer composition further comprises silica, where in the silica has a mean particle size of 10 microns to 60 microns, as measured according to dynamic laser scattering.

23. The polycarbonate composition of claim 22, wherein the silica comprises precipitated silica.

24. The polycarbonate composition of claim 22 or claim 23, wherein the reactive polymer composition comprises, based on a total weight of the polycarbonate composition, 0.1 wt% to less than 0.5 wt% of the silica.

25. The polycarbonate composition of any of claims 1-21, wherein the reactive polymer composition comprises 0 wt% silica.

26. The polycarbonate composition of any of the preceding claims, wherein the reactive polymer composition further comprises, based on a total weight of the polycarbonate composition, 0.1 wt% to 2.5 wt% of a slip additive.

27. The polycarbonate composition of any of the preceding claims, wherein the reactive polymer composition further comprises an additive, the additive comprising ultra violet absorbers, light stabilizer, antioxidants, processing aid, coloring agent (pigments or dyes), or a combination thereof.

28. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition has a gloss value greater than or equal to 80 GU.

29. The polycarbonate composition of any of the preceding claims, wherein the polycarbonate composition has an impact strength of 5 kJ / m2to 90 kJ / m2, as measured according to ASTM D256- 10 at 23 °C.

30. An article comprising the polycarbonate composition of any of the preceding claims, wherein the article has at least one external facing surface and the at least one external facing surface is coating free.

31. An article comprising the polycarbonate composition of any of claims 1-29, wherein the article comprises a pellet.

32. A method of preparing a polycarbonate composition comprising preparing a reactive polymer composition; and reacting the reactive polymer composition in a transesterification process; wherein the reactive polymer composition comprises: 71 wt% to 99.8 wt% of an aromatic polycarbonate polymer, wherein the aromatic polycarbonate polymer has a melt flow index of 5 g / 10 min to 25 g / 10 min, as measured according to ASTM D1238 at 300 °C and 1.2 kg;0.2 wt% to 15 wt% of a reactive epoxy compound, wherein the reactive epoxy compound has an epoxy equivalent weight of 172 g / eq to 2900 g / eq, as measured according to ASTM D1652; and 1 wt% to 25 wt% of an acrylate polymer, wherein the acrylate polymer has a weight average molecular weight of 7,000 g / mol to less than 30,000 g / mol, wherein the polycarbonate composition has a scratch resistance rating of at least 2 at greater than or equal to 4N, as measured on a Taber Five Finger Scratch Tester according to FLTM BO 162-1; and wherein the polycarbonate composition has an average transparency greater than or equal to 75%, as measured according to ASTM D1003 from 500 nm to 700 nm in 10 nm increments and at an article thickness of 1.3 mm.

33. The method of claim 32, wherein the step of reacting the reactive polymer composition is performed in a single step.

34. The method of claim 32 or claim 33, wherein the step of reacting the reactive polymer composition is performed in melt phase during an extrusion process.

35. The method of any of claims 32-34, wherein the method further comprises injection molding the polycarbonate composition to form an article.

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