Low gloss thermoplastic composition, method of making, and articles formed therefrom

1. A thermoplastic composition comprising a resin composition comprising:

50 wt % to 98 wt % polycarbonate,

1 wt % to 30 wt % acrylonitrile-styrene-acrylate terpolymer, and

1 wt % to 20 wt % low gloss additive comprising the reaction product of a polyepoxide and an ethylenically unsaturated nitrile containing copolymer,

wherein the weight percentages are based upon a combined weight of the polycarbonate, acrylonitrile-styrene-acrylate terpolymer, and low gloss additive;

wherein the 60° gloss of the thermoplastic composition is measured to be less than or equal to 90 GU on 3 millimeter color chips according to ASTM D2457.

2. The thermoplastic composition of claim 1 , comprising 65 wt % to 96 wt % polycarbonate, 2 wt % to 25 wt % acrylonitrile-styrene-acrylate terpolymer, and 2 to 10 wt % low gloss additive.

3. The thermoplastic composition of claim 2 wherein the polycarbonate comprises bisphenol A polycarbonate having a weight averaged molecular weight of 10,000 to 50,000, as measured by gel permeation chromatography.

4. The thermoplastic composition of claim 2 comprising 73 wt % to 94 wt % polycarbonate, 3 wt % to 20 wt % acrylonitrile-styrene-acrylate terpolymer and 3 wt % to 7 wt % low gloss additive.

5. The thermoplastic composition of claim 4 wherein the acrylonitrile-styrene-acrylate terpolymer is a core-shell impact modifier.

6. The thermoplastic composition of claim 5 wherein the shell is styrene-acrylonitrile copolymer and the core is a crosslinked acrylate rubber.

7. The thermoplastic composition of claim 6 wherein the core is a crosslinked butylacrylate rubber.

8. The thermoplastic composition of claim 1 comprising 78 wt % to 93 wt % polycarbonate, 4 wt % to 15 wt % acrylonitrile-styrene-acrylate terpolymer; and 3 wt % to 7 wt % low gloss additive.

9. The thermoplastic composition of claim 1 wherein the polyepoxide is an alicyclic polyepoxide.

10. The thermoplastic composition of claim 9 wherein the alicyclic polyepoxide is 3,4-epoxycyclohexyl 3,4-epoxycyclohexylcarboxylate.

11. The thermoplastic composition of claim 9 wherein the ethylenically unsaturated nitrile containing copolymer comprises styrene and acrylonitrile.

12. The thermoplastic composition of claim 9 wherein the low gloss additive further comprises a polycarbonate.

13. The thermoplastic composition of claim 1 additionally comprising an impact modifier, filler, antioxidant, heat stabilizer, light stabilizer, ultraviolet light absorber, plasticizer, mold release agent, lubricant, antistatic agent, colorant, flame retardant, anti-drip agent, or a combination comprising one or more of these.

14. The thermoplastic composition of claim 13 wherein the colorant is present in an amount of 0.01 to 10 weight percent of the combined weights of the polycarbonate, acrylonitrile-styrene-acrylate terpolymer, and low gloss additive.

15. A method of preparing a thermoplastic composition comprising melt-combining:

50 wt % to 98 wt % polycarbonate,

1 wt % to 30 wt % acrylonitrile-styrene-acrylate terpolymer, and

1 wt % to 20 wt % low gloss additive comprising the reaction product of a polyepoxide and an ethylenically unsaturated nitrile containing copolymer,

wherein the melt combining is done at a temperature of 220 to 300° C.

16. The method of claim 15 wherein the low gloss additive is prepared by melt combining

the polyepoxide,

the ethylenically unsaturated nitrile containing copolymer, and

an epoxide ring-opening catalyst

at a temperature of 220 to 300° C. to form a reaction product, and melt combining the reaction product with a polycarbonate at a temperature of up to 350° C., wherein the melt combining is done by extrusion.

17. The method of claim 15 wherein the thermoplastic composition comprises 50 to 98 weight percent of the polycarbonate, 1 to 30 weight percent of the acrylonitrile-styrene-acrylate terpolymer, and 1 to 20 weight percent of the low gloss additive, and wherein the sum of the weight percentages of polycarbonate, acrylonitrile-styrene-acrylate terpolymer, and low gloss additive is 100 weight percent.

18. A thermoplastic composition prepared by the method of claim 15 .

19. The thermoplastic composition of claim 18 wherein the thermoplastic composition has a 60° gloss measured to be less than or equal to 90 GU on 3 millimeter color chips according to ASTM D2457.

20. An article comprising the thermoplastic composition of claim 1 .

21. A resin composition comprising:

50 wt % to 98 wt % polycarbonate,

1 wt % to 30 wt % acrylonitrile-styrene-acrylate terpolymer, and

1 wt % to 20 wt % low gloss additive comprising the reaction product of

a polyepoxide and

an ethylenically unsaturated nitrile containing copolymer,

wherein the 60° gloss of the thermoplastic composition is measured to be less than or equal to 90 GU on 3 millimeter color chips according to ASTM D2457.

22. A method of preparing a thermoplastic composition comprising melt combining

a polyepoxide, and

an ethylenically unsaturated nitrile containing copolymer, with

an epoxide ring-opening catalyst

to form a reaction product;

melt combining the reaction product with a first polycarbonate to form a low gloss additive; and melt combining

50 wt % to 98 wt % second polycarbonate,

1 wt % to 30 wt % acrylonitrile-styrene-acrylate terpolymer, and

1 wt % to 20 wt % of the low gloss additive,

wherein the melt combining is done by extrusion, and wherein the thermoplastic composition has a 60° gloss measured to be less than or equal to 90 GU on 3 millimeter color chips according to ASTM D2457.

23. An article, comprising the thermoplastic composition of claim 1 .