Polymer compositions, method of manufacture, and articles formed therefrom

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

from 10 to 80 wt. % of a modified polybutylene terephthalate copolymer that (1) is derived from polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate and polyethylene terephthalate copolymers and (2) has at least one residue derived from the polyethylene terephthalate component;

from 10 to 80 wt. % of a polycarbonate;

from 0 to 20 wt. % of an impact modifier;

from 8 to less than 25 wt. % of a reinforcing filler;

from 0 to 5 wt. % of a fibrillated fluoropolymer;

from 0 to 5 wt. % of an additive selected from the group consisting of antioxidants, mold release agents, colorants, quenchers, stabilizers, and combinations thereof,

wherein the composition has a heat deflection temperature of at least 110° C., measured in accordance with ASTM D648 on 3.2 mm thick molded bars at 0.455 MPa.

2. The composition of claim 1 , wherein the amount of fibrillated fluoropolymer is from 0.1 to less than 2.5 wt. %.

3. The composition of claim 2 , wherein the composition exhibits an improved Notched Izod impact strength that is at least 20% more than the Notched Izod impact strength of an identical composition without the fibrillated fluoropolymer, wherein the notched Izod impact strength is measured in accordance with ASTM D 256 at 23° C. on 3.2 mm thick bars; and

the composition has a flexural modulus that is higher or within 5% of the flexural modulus of an identical composition without the fibrillated fluoropolymer, wherein flexural modulus is measured in accordance with ASTM D790 at 23° C.

4. The composition of claim 2 , wherein

the composition exhibits an improved Notched Izod impact strength that is at least 40% more than the Notched Izod impact strength of an identical composition without the fibrillated fluoropolymer; wherein the Notched Izod impact strength is measured in accordance with ASTM D256 on 3.2 mm thick bars at 23° C.; and

the composition has a flexural modulus that is higher or within 5% of the flexural modulus of an identical composition without the fibrillated fluoropolymer, wherein flexural modulus is measured in accordance with ASTM D790 at 23° C.

5. The composition of claim 2 , wherein

the composition exhibits an improved Notched Izod impact strength that is at least 100% more than the Notched Izod impact strength of an identical composition without the fibrillated fluoropolymer, wherein the notched Izod impact strength is measured in accordance with ASTM D 256 at 23° C.; and

the composition has a flexural modulus that is higher or within 5% of the flexural modulus of an identical composition without the fibrillated fluoropolymer, wherein flexural modulus is measured in accordance with ASTM D790 at 23° C.

6. The composition of claim 1 , wherein the residue derived from the polyethylene terephthalate component is selected from the group consisting of ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin-containing compounds, aluminum-containing compounds, aluminum, aluminum salts, 1,3-cyclohexane dimethanol isomers, 1,4-cyclohexane dimethanol isomers, alkaline earth metal salts, alkali salts, phosphorous-containing compounds and anions, sulfur-containing compounds and anions, naphthalene dicarboxylic acids, 1,3-propane diol groups, and combinations thereof.

7. The composition of claim 1 , wherein the at least one residue derived from the polyethylene terephthalate component comprises mixtures of ethylene glycol and diethylene glycol groups.

8. The composition of claim 7 , wherein the residue derived from the polyethylene terephthalate component further comprises isophthalic acid groups.

9. The composition of claim 1 , wherein the modified polybutylene terephthalate copolymer is derived from a 1,4-butanediol that is derived from biomass.

10. The composition of claim 1 , wherein the polycarbonate comprises units derived from bisphenol A.

11. The composition of claim 1 , wherein the impact modifier is a core-shell polymer selected from the group consisting of methyl (meth)acrylate-butadiene-styrenes, acrylonitrile-styrene-acrylates, acrylonitrile-butadiene-styrenes, butyl acrylate impact modifiers, ethyl acrylate impact modifiers, and combinations thereof.

12. The composition of claim 1 , wherein the impact modifier is an acrylonitrile-butadiene-styrene.

13. The composition of claim 1 , wherein the impact modifier is a methyl methacrylate-butadiene-styrene.

14. The composition of claim 1 , wherein the reinforcing filler is selected from the group consisting of calcium carbonate, mica, epoxy-coated mica, kaolin, talc, epoxy-coated talc, epoxysilane-coated talc, hydrous aluminosilicate, wollastonite, glass fibers, carbon fibers, magnesium carbonate, sulfates of barium, calcium sulfate, titanium, nanoclay, silica, hydroxides of aluminum, ammonium or magnesium, zirconia, nanoscale titania, silicon carbide, and combinations thereof.

15. The composition of claim 14 , wherein the reinforcing filler is a talc having an average particle size of 0.3 to 3 micrometers.

16. The composition of claim 1 , wherein the fluoropolymer is encapsulated by an encapsulating polymer selected from the group consisting of styrene-acrylonitrile copolymers, acrylonitrile-butadiene-styrene copolymers, alpha-alkyl-styrene-acrylonitrile copolymers, alpha-methylstyrene-acrylonitrile copolymers, styrene-butadiene rubbers, methyl methacrylates, and combinations thereof.

17. The composition of claim 1 , wherein the fluoropolymer comprises styrene-acrylonitrile encapsulated poly(tetrafluoroethylene).

18. The composition of claim 1 , wherein the composition comprises an additive selected from the group consisting of heat stabilizers, UV stabilizers, colorants, antioxidants, quenchers, mold release agents, and combinations thereof.

19. The composition of claim 1 , wherein the composition comprises less than 10 wt % of polybutylene terephthalate derived from a monomeric glycol component and a monomeric dicarboxylic acid component.

20. A composition comprising:

from 20 to 70 wt. % of a modified polybutylene terephthalate copolymer that (1) is derived from polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate and polyethylene terephthalate copolymers and (2) has at least one residue derived from the polyethylene terephthalate component;

from 15 to 70 wt. % of a polycarbonate comprising carbonate units derived from bisphenol-A;

from 3 to 15 wt. % of a core-shell acrylonitrile-butadiene-styrene or methyl methacrylate-butadiene-styrene impact modifier;

from 8 to 20 wt. % of a talc;

from 0.2 to less than 2.5 wt. % of styrene-acrylonitrile encapsulated poly(tetrafluoroethylene); and

from 0 to 5 wt. % of an additive selected from the group consisting of antioxidants, mold release agents, colorants, quenchers, stabilizers, and combinations thereof;

wherein the composition exhibits an improved Notched Izod impact strength that is at least 20% more than the Notched Izod impact strength of an identical composition without the fibrillated fluoropolymer, wherein the notched Izod impact strength is measured in accordance with ASTM D 256 at 23° C. on 3.2 mm thick bars; and

the composition has a flexural modulus that is higher or within 5% of the flexural modulus of an identical composition without the fibrillated fluoropolymer, wherein flexural modulus is measured in accordance with ASTM D790 at 23° C.

21. The composition of claim 20 , wherein the composition consists essentially of the poly(butylene terephthalate), the polycarbonate, the impact modifier, the talc, the additive, and the poly(tetrafluoroethylene).

22. A composition comprising:

from 20 to 50 wt. % of a modified polybutylene terephthalate;

from 40 to 60 wt. % of a bisphenol-A polycarbonate;

from 3 to 15 wt. % of a core-shell methyl methacrylate-butadiene-styrene impact modifier;

from 8 to 20 wt. % of a talc having an average particle size of 0.5 to 2 micrometers;

from 1 to less than 2.5 wt. % of styrene-acrylonitrile encapsulated poly(tetrafluoroethylene); and

from 0.1 to 4 wt. % of an additive composition comprising an additive selected from the group consisting of antioxidants, mold release agents, colorants, quenchers, stabilizers, and combinations thereof;

wherein the composition exhibits an improved Notched Izod impact strength that is at least 20% more than the Notched Izod impact strength of an identical composition without the fibrillated fluoropolymer, wherein the notched Izod impact strength is measured in accordance with ASTM D 256 at 23° C. on 3.2 mm thick bars; and

the composition has a flexural modulus that is higher or within 5% of the flexural modulus of an identical composition without the fibrillated fluoropolymer, wherein flexural modulus is measured in accordance with ASTM D790 at 23° C.

23. The composition of claim 22 , wherein the composition consists essentially of the polybutylene terephthalate, the polycarbonate, the impact modifier, the talc, the additive, and the poly(tetrafluoroethylene).

24. A method of forming a composition comprising melt blending the components of the composition of claim 1 .

25. A method of making an article, comprising melt blending the components of the composition of claim 1 , and shaping the melt blended composition by injection molding, extrusion molding, rotation molding, foam molding, calendar molding, blow molding, thermoforming, compaction, or melt spinning to form the article.

26. An article comprising the composition of claim 1 .

27. The article of claim 26 , wherein the article is a door handle.

28. The article of claim 26 , wherein the article is a lid for a container.

29. The composition of claim 7 , wherein the residue derived from the polyethylene terephthalate component comprises 0.1 to 10 mole percent of the ethylene glycol groups and 0.1 to 10 mole percent of the diethylene glycol groups, based on the total moles of diol in the modified polybutylene terephthalate copolymer.

30. The composition of claim 8 , wherein the residue derived from the polyethylene terephthalate component comprises 0.1 to 10 mole percent of the isophthalic acid groups, based on 100 mole percent of diacid in the modified polybutylene terephthalate copolymer.

31. The composition of claim 8 , wherein the residue derived from the polyethylene terephthalate component comprises a total amount of the diethylene glycol, ethylene glycol, and isophthalic acid groups of more than 0 and less than or equal to 23 equivalents, relative to the total of 100 equivalents of diol and 100 equivalents of diacid in the modified polybutylene terephthalate copolymer.

32. The composition of claim 1 , wherein the residue derived from the polyethylene terephthalate component comprises 0.1 to 10 mole percent of ethylene glycol, diethylene glycol, and cyclohexanedimethanol groups, individually or in combination, based on 100 mole percent of diol in the modified polybutylene terephthalate copolymer.

33. The composition of claim 1 , wherein the residue derived from the polyethylene terephthalate component comprises 0.1 wt. % to 2 wt. % of ethylene glycol groups, based on the weight of the modified polybutylene terephthalate copolymer.

34. The composition of claim 1 , wherein the residue derived from the polyethylene terephthalate component comprises more than 0 to 1000 ppm of an inorganic residue selected from the group consisting of antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin-containing compounds, aluminum-containing compounds, aluminum, aluminum salts, alkaline earth metal salts, alkali salts, calcium, magnesium, sodium and potassium salts, phosphorous-containing compounds and anions, sulfur-containing compounds and anions, and combinations thereof.