Low gloss thermoplastic composition

1. A composition consisting essentially of, based on the total weight of the composition:

a) from about 30 to 80 wt. % of a polycarbonate component,

b) from about 5 to about 50 wt. % of a polyester component, wherein when polybutylene terephthalate is present in the composition, the polybutylene terephthalate is present in conjunction with at least one other polyester that is not polybutylene terephthalate;

c) about 2 to about 25 wt. % of an impact modifier;

d) from at least about 0.1 wt. % to less than about 5.0 wt. % of a multifunctional additive compound comprising a silane and an epoxy group; and optionally

e) an additive selected from the group consisting of a stabilizer, a pigment, a nucleant, a catalyst quencher, and combinations thereof;

wherein an epoxy functionalized polymer is not present,

wherein the viscosity of the composition is less than about 500 Pa-s at 271° C. and 640 s −1 as measured by capillary rheometry following the ISO 11443 standard, and

wherein an unpainted part molded from the composition has a surface molded against a polished surface with a gloss below about 5 gloss units when measured at 20° incident angle using a gloss meter, and the gloss is at least substantially uniform over the part surface.

2. The composition in accordance with claim 1 , wherein the polycarbonate is present in an amount from about 45 to 75 wt. %, the polyester is present in an amount from about 10 to about 45 wt. %, and the impact modifier is present in an amount from about 4 to about 20 wt. %.

3. The composition in accordance with claim 1 , wherein the multifunctional additive compound is selected from the group consisting of trimethoxy silanes, triethoxy silanes, and combinations thereof.

4. The composition in accordance with claim 3 , wherein the multifunctional additive compound is selected from the group consisting of beta-(3,4 epoxycyclohexyl)ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, and combinations thereof.

5. A part molded from the composition of claim 1 , said part being unpainted and having a polished surface where gloss has been reduced from the original gloss after molding by at least about 80% by holding the part at 85 to 90° C. for at least about 2 minutes, wherein said gloss is at least substantially uniform over the part surface.

6. A part molded from the composition of claim 1 , wherein the part is unpainted and has a textured surface with a gloss below about 10 gloss units, when measured at 60° incident angle, using a gloss meter, wherein gloss is at least substantially uniform over the part surface.

7. The composition of claim 1 , wherein the impact modifier is selected from the group consisting of a styrene-acrylonitrile grafted polybutadiene, a styrene-acrylonitrile grafted polybutadiene wherein the grafted polybutadiene also contains methyl methacrylate as a part of the graft, a methyl methacrylate-butadiene-styrene, and a copolymer of methyl methacrylate, butyl acrylate, and dimethylsiloxane.

8. An article molded from the composition of claim 1 .

9. The article of claim 8 , wherein the article has a large surface area and/or which in ordinary use is viewed in direct light sources comprising daylight, horizon, or cool white fluorescence.

10. The article of claim 8 , wherein the article is a an automotive part, a consumer electronic device, a power tool housing, a recreational vehicle part, power equipment for landscaping and farm use, telecommunication equipment, or fitness equipment.

11. The article of claim 8 , wherein the article is a vehicular instrument panel, a horizontal or vertical vehicle body panel, a bezel, a knob, a radio panel, a heater control panel, an exterior housing, a wheel well trim, or a spoiler.

12. The article of claim 8 , wherein the article is an interior vehicular trim part or an exterior vehicular trim part.

13. The article of claim 8 , wherein the polycarbonate is present in an amount from about 45 to 75 wt. %, the polyester is present in an amount from about 10 to about 45 wt. %, and the impact modifier is present in an amount from about 4 to about 20 wt. %.

14. The article of claim 8 , wherein the multifunctional additive compound is selected from the group consisting of trimethoxy silanes, triethoxy silanes, and combinations thereof.

15. The article of claim 8 , wherein the multifunctional additive compound is selected from the group consisting of beta-(3,4-epoxycyclohexyl) ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, and combinations thereof.

16. The article of claim 8 , wherein the impact modifier is selected from the group consisting of a styrene-acrylonitrile grafted polybutadiene, a styrene-acrylonitrile grafted polybutadiene wherein the grafted polybutadiene also contains methyl methacrylate as a part of the graft, methyl methacrylate-butadiene-styrene, and a copolymer of methyl methacrylate, butyl acrylate, and dimethylsiloxane.

17. The article of claim 8 , wherein the composition comprises a quenching reagent.

18. The article of claim 8 , wherein the quenching reagent is selected from the group consisting of phosphorous acid, phosphoric acid, and transition metal phosphates.

19. The article of claim 8 , wherein the polyester is polyethylene terephthalate.

20. The article of claim 8 , wherein the polyester comprises a polybutylene terephthalate and a non-polybutylene terephthalate polyester, wherein the polybutylene terephthalate and non-polybutylene terephthalate polyester have a weight ratio from 9:1 to 1:9.

21. The article of claim 8 , wherein the polyester comprises polyethylene terephthalate, and the composition further comprises a reaction product of (i) the multifunctional additive compound containing a silane and an epoxy group and (ii) the polyethylene terephthalate.

22. The article of claim 8 , wherein the polyester comprises polybutylene terephthalate, and the composition comprises a reaction product of (i) the multifunctional additive compound containing a silane and an epoxy group and (ii) the polybutylene terephthalate.

23. The article of claim 8 , wherein the composition comprises a reaction product of (i) the multifunctional additive compound comprising a silane and an epoxy group and (ii) a polyester having at least one acid end group.

24. The article of claim 8 , wherein the article has a gloss that is reduced by at least about 20% compared to an article formed from the same composition in which the multifunctional additive compound comprising a silane and an epoxy group is absent.

25. The article of claim 8 , wherein the gloss is measured on a surface molded against a polished surface.

26. The article of claim 8 , wherein the gloss is measured on a textured surface.

27. The article of claim 8 , wherein the gloss measured on a surface molded against a polished surface is below about 7 gloss units when measured at a 20° incident angle.

28. The article of claim 8 , wherein the gloss measured on a textured surface is below about 10 gloss units when measured at a 60° incident angle.

29. The composition in accordance with claim 1 , wherein the polyester is polyethylene terephthalate.

30. The composition of claim 1 wherein the polyester comprises a polybutylene terephthalate and a non-polybutylene terephthalate polyester, wherein the polybutylene terephthalate and non-polybutylene terephthalate polyester have a weight ratio from 9:1 to 1:9.

31. A process wherein (a), (b), (c), and (d) of claim 1 are combined under reactive conditions.

32. The composition of claim 1 , wherein the polyester comprises polyethylene terephthalate, and the composition further comprises a reaction product of (i) the multifunctional additive compound containing a silane and an epoxy group and (ii) the polyethylene terephthalate.

33. The composition of claim 1 , wherein the polyester comprises polybutylene terephthalate, and the composition comprises a reaction product of (i) the multifunctional additive compound containing a silane and an epoxy group and (ii) the polybutylene terephthalate.

34. The composition of claim 1 , comprising a reaction product of (i) the multifunctional additive compound comprising a silane and an epoxy group and (ii) a polyester having at least one acid end group.

35. A method for reducing gloss comprising heating an article molded from the composition of claim 1 , and thereby further reducing the gloss of the molded article.

36. The method of claim 35 , wherein the article is subjected to heating for less than 30 minutes.

37. The composition of claim 1 , wherein the at least one polyester that is not polybutylene terephthalate is polyethylene terephthalate.

38. The composition of claim 1 , wherein the polyester component is selected from the group consisting of poly(ethylene terephthalate), poly(1,4-butylene terephthalate), poly(ethylene naphthanoate), poly(butylene naphthanoate), poly(cyclohexanedimethylene terephthalate), polycyclohexylenedimethylene ethylene terephthalate, polypropylene terephthalate, and mixtures thereof.

39. A method for forming an article having low gloss comprising molding the composition of claim 1 .

40. The method of claim 39 , wherein the polycarbonate is present in an amount from about 45 to 75 wt. %, the polyester is present in an amount from about 10 to about 45 wt. %, and the impact modifier is present in an amount from about 4 to about 20 wt. %.

41. The method of claim 39 , wherein the multifunctional additive is selected from the group consisting of trimethoxy silanes, triethoxy silanes, and combinations thereof.

42. The method of claim 39 , wherein the multifunctional additive is selected from the group consisting of beta-(3,4-epoxycyclohexyl)ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, and combinations thereof.

43. The method of claim 39 , wherein the impact modifier is selected from the group consisting of a styrene-acrylonitrile grafted polybutadiene, a styrene-acrylonitrile grafted polybutadiene wherein the grafted polybutadiene also contains methyl methacrylate as a part of the graft, methyl methacrylate-butadiene-styrene, and a copolymer of methyl methacrylate, butyl acrylate, and dimethylsiloxane.

44. The method of claim 39 , wherein the composition comprises a quenching reagent.

45. The method of claim 44 , wherein the quenching reagent is selected from the group consisting of phosphorous acid, phosphoric acid, and transition metal phosphates.

46. The method of claim 39 , wherein the polyester is polyethylene terepthalate.

47. The method of claim 39 , wherein the polyester comprises a polybutylene terephthalate and a non-polybutylene terephthalate polyester, wherein the polybutylene terephthalate and non-polybutylene terephthalate polyester have a weight ratio from 9:1 to 1:9.

48. The method of claim 39 , wherein the polyester comprises polyethylene terephthalate, and the composition further comprises a reaction product of (i) the multifunctional additive containing a silane and an epoxy group and (ii) the polyethylene terephthalate.

49. The method of claim 39 , wherein the polyester comprises polybutylene terephthalate, and the composition comprises a reaction product of (i) the multifunctional additive containing a silane and an epoxy group and (ii) the polybutylene terephthalate.

50. The method of claim 39 , wherein the composition comprises a reaction product of (i) the multifunctional additive comprising a silane and an epoxy group and (ii) a polyester having at least one acid end group.

51. The method of claim 39 , wherein the article has a gloss that is reduced by at least about 20% compared to an article formed from the same composition in which the multifunctional additive comprising a silane and an epoxy group is absent.

52. The method of claim 39 , wherein the gloss is measured on a surface molded against a polished surface.

53. The method of claim 39 , wherein the gloss is measured on a textured surface.

54. The method of claim 39 , wherein the gloss measured on a surface molded against a polished surface is below about 7 gloss units when measured at a 20° incident angle.

55. The method of claim 39 , wherein the gloss measured on a textured surface is below about 10 gloss units when measured at a 60° incident angle.

56. A part molded from the composition of claim 1 , wherein the part is unpainted and has a surface molded against a polished surface with a gloss below about 5 gloss units, when measured at 20° incident angle, using a gloss meter, wherein said gloss is at least substantially uniform over the part surface.

57. A composition consisting essentially of:

a) from about 45 to 75 wt. % of a polycarbonate component,

b) from about 10 to about 45 wt. % of a polyester component, wherein when polybutylene terephthalate is present in the composition, the polybutylene terephthalate is present in conjunction with at least one other polyester that is not polybutylene terephthalate;

c) from about 4 to about 20 wt. % of an impact modifier; and

d) a multifunctional additive compound selected from the group consisting of beta-(3,4-epoxycyclohexyl)ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, and combinations thereof in an amount of greater than about 0.1 wt. %; and optionally

e) an additive selected from the group consisting of a stabilizer, a pigment, a nucleant, a catalyst quencher, and combinations thereof;

wherein an epoxy functionalized polymer is not present, and

wherein an unpainted part molded from the composition has a polished surface with a gloss below about 5 gloss units when measured at 20° incident angle using a gloss meter, and the gloss is at least substantially uniform over the part surface.

58. The composition of claim 57 , wherein the viscosity of the composition is less than about 500 Pa-s at 271° C. and 640 s −1 as measured by capillary rheometry following the ISO 11443 standard.