Thermoplastic compositions, method of manufacture, and uses thereof

1. A composition comprising a combination of:

(a) from more than 45 to less than 93 weight percent of a crystalline or semi-crystalline thermoplastic polyester component selected from poly(butylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate) copolymers, poly(ethylene terephthalate) copolymers, and combinations thereof;

(b) from greater than 9 to less than 25 weight percent of an amorphous poly(ester-carbonate);

(c) from 5 to 30 weight percent of a glass fiber; and

(d) optionally, from 0.01 to 5 wt. % of an antioxidant, mold release agent, colorant, stabilizer, or a combination thereof;

wherein an article having a 2 mm thickness and molded from the composition has

(i) a near infrared transmission at 960 nanometers of greater than 30 percent and

(ii) a Vicat softening temperature of at least 170° C.,

wherein an article having a 2 mm thickness and molded from the composition has a 10 percent improvement in percent transmission at 960 nanometers as compared to an article having a 2 mm thickness and molded from the same composition comprising (a) and not (b).

2. The composition of claim 1 wherein the crystalline or semi-crystalline thermoplastic is poly(butylene terephthalate).

3. The composition of claim 1 wherein the crystalline or semi-crystalline thermoplastic is poly(ethylene terephthalate).

4. The composition of claim 1 wherein the amorphous thermoplastic is a poly(ester-carbonate) comprising arylate ester units and carbonate units.

5. The composition of claim 4 wherein the ester units are present as arylate blocks comprising units derived from a 1,3-dihydroxybenzene and an aromatic dicarboxylic acid; and wherein the carbonate units are present as carbonate blocks alternating with the arylate blocks.

6. The composition of claim 5 wherein the arylate blocks comprise units derived from an unsubstituted resorcinol or a substituted resorcinol and an isophthalic acid, terephthalic acid or a combination thereof.

7. The composition of claim 5 wherein the carbonate blocks are bisphenol A carbonate blocks, unsubstituted resorcinol carbonate blocks, or a combination thereof.

8. The composition of claim 4 wherein the poly(ester-carbonate) comprises isophthalate-terephthalate-resorcinol arylate blocks and bisphenol A carbonate blocks.

9. The composition of claim 4 wherein the ester units are present as phthalate ester units derived from polymerization of a bisphenol and an aromatic dicarboxylic acid; and the carbonate units are derived from a bisphenol.

10. The composition of claim 9 wherein the bisphenol is bisphenol A and the aromatic dicarboxylic acid is a phthalic acid.

11. The composition of claim 10 wherein the aromatic dicarboxylic acid is selected from the group selected form isophthalic, terephthalic acid, and combinations thereof.

12. The composition of claim 1 wherein the glass fiber has an average diameter of 3 to 30 micrometers.

13. The composition of claim 1 , further comprising from 0.01 to 5 weight percent of an antioxidant, mold release agent, colorant, stabilizer, or a combination thereof.

14. A method of manufacturing the composition of claim 1 , comprising melt blending the components (a), (b), and optionally (c) and/or (d).

15. A molded article for laser welding comprising an extruded composition claim 1 .

16. A process for welding a first article comprising the composition of claim 1 to a second thermoplastic article, at least a portion of a surface of the first article being in physical contact with at least a portion of a surface of the second thermoplastic article, the process comprising

applying laser radiation to the first article, wherein the radiation passes through the first article and the radiation is absorbed by the second article and sufficient heat is generate to weld the first article to the second article.

17. The process of claim 16 , wherein the second article comprises a thermoplastic comprising a material sufficient to absorb the radiation.

18. The process of claim 17 , wherein the second article comprises a thermoplastic polymer is selected from polycarbonate, polyester, polycarbonate copolymers, polyester copolymers, and combinations thereof.

19. A laser welded, molded article comprising:

an upper layer comprising a copolymer composition comprising:

(a) from more than 45 to less than 93 weight percent of a crystalline or semi-crystalline thermoplastic polyester component selected from poly(butylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate) copolymers poly(ethylene terephthalate) copolymers, and combinations thereof;

(b) from greater than 9 to less than 25 weight percent of an amorphous thermoplastic poly(ester-carbonate), wherein the ester units are present as arylate blocks comprising units derived from a 1,3-dihydroxybenzene and an aromatic dicarboxylic acid; and wherein the carbonate units are present as carbonate blocks alternating with the arylate blocks,

(c) optionally, from 5 to 30 weight percent of a filler, and

(d) optionally, from 0.01 to 5 weight percent of an antioxidant, mold release agent, colorant, stabilizer, or a combination thereof;

wherein a sample having a 2 mm thickness and molded from the copolymer composition has

(i) a near infrared transmission at 960 nanometers of greater than 30 percent, and

(ii) a Vicat softening temperature of at least 170° C.;

a lower layer comprising a thermoplastic polymer; and

a laser welded bond between the upper layer and the lower layer;

wherein an article having a 2 mm thickness and molded from the composition has a 10 percent improvement in percent transmission at 960 nanometers as compared to an article having a 2 mm thickness and molded from the same composition comprising (a) and not (b).

20. A composition comprising a combination of:

(a) from more than 45 to less than 86 weight percent of a crystalline or partially polyester component selected from crystalline poly(butylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate) copolymers, poly(ethylene terephthalate) copolymers, and combinations thereof;

(b) from more than 11 to less than 25 weight percent of an amorphous poly(ester-carbonate);

(c) from 15 to 30 weight percent glass filler; and

(d) optionally from 0.01 to 5 weight percent of an antioxidant, mold release agent, colorant, stabilizer, or a combination thereof;

wherein an article having a 2 mm thickness and molded from the composition has

(i) a near infrared transmission at 960 nanometers of greater than 30 percent and

(ii) a Vicat softening temperature of at least 170° C.;

wherein an article having a 2 mm thickness and molded from the composition has a 10 percent improvement in percent transmission at 960 nanometers as compared to an article having a 2 mm thickness and molded from the same composition comprising (a) and not (b).

21. The composition of claim 20 wherein the amorphous poly(ester-carbonate) comprises phthalate ester units derived from polymerization of a bisphenol A and an aromatic dicarboxylic acid selected from the group selected form isophthalic, terephthalic acid, and combinations thereof; and wherein the carbonate units are derived from bisphenol A.