Thermoplastic polycarbonate copolymer compositions, methods of their manufacture, and articles thereof

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

88 to 98 wt % of a poly(carbonate-arylate ester), wherein the poly(carbonate-arylate ester) is a poly(carbonate-monoaryl arylate ester), a poly(carbonate-monoaryl arylate ester) comprising siloxane units, or a combination comprising at least one of the foregoing; and

2 to 12 wt % of bisphenol A bis(diphenyl phosphate);

optionally, up to 5 wt % of an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein an article molded from the composition has

a maximum average heat release (MAHRE) of less than or equal to 90 kW/m 2 determined according to ISO 5660-1 on a 3 mm thick plaque, and

a smoke density after 4 minutes (Ds-4) of less than or equal to 300 determined according to ISO 5659-2 on a 3 mm thick plaque,

wherein the poly(carbonate-monoaryl arylate ester) comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and monoarylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

wherein the poly(carbonate-monoaryl arylate ester) comprising siloxane units comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and arylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

siloxane units of the formula

wherein

each R is independently a C 1-13 monovalent hydrocarbon group, and

E has an average value of 2 to 500; and

wherein poly(carbonate-arylate ester) is a combination of a poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester) and a poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester)-co-poly(siloxane) comprising, a based on the total weight of the poly(carbonate-arylate ester)s,

20 to 80 wt % of the poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester); and

20 to 80 wt % of the poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester)-co-poly(siloxane) which comprises siloxane units of the formula

or a combination thereof, wherein E has an average value of 5 to 60, and the siloxane units are present in an amount effective to provide 0.1 to 10 wt % of siloxane units, based on the weight of the poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester)-co-poly(siloxane).

2. The composition of claim 1 , wherein the siloxane units are present in an amount effective to provide 0.5% to 7% siloxane units based on the weight of the composition.

3. A train or aircraft interior component comprising the composition of claim 1 .

4. The composition of claim 1 , wherein the bisphenol A bis(diphenyl phosphate) is effective to provide phosphorus in an amount of 0.3% to 0.8%, based on the weight of the composition.

5. The composition of claim 1 , having a transparency of more than 85% and a haze of less than 3%, each measured according to ASTM D 1003 (2007) using illuminant C on plaques with 3 mm thickness.

6. The composition of claim 1 , wherein no or substantially no flame retarding brominated compounds, flame retardant salts, or a combination comprising at least one of the foregoing are present in the composition.

7. The composition of claim 6 , wherein the brominated compound is a brominated polycarbonate, and the flame retardant salt is potassium perfluorobutane sulfonate, potassium perfluorooctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, Na 2 CO 3 , K 2 CO 3 , MgCO 3 , CaCO 3 , and BaCO 3 , an inorganic phosphate salt, Li 3 AlF 6 , BaSiF 6 , KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 , Na 3 AlF 6 , or a combination comprising at least one of the foregoing.

8. The composition of claim 6 , wherein no or substantially no brominated polycarbonate, boron phosphate, or C 1-6 alkyl sulfonate salt is present in the composition.

9. An article comprising the composition of claim 1 , selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article.

10. The article of claim 9 , having a thickness of 0.1 to 10 mm.

11. The article of claim 9 , having a thickness of 0.5 to 5 mm.

12. The article of claim 9 , wherein the article is a transportation component.

13. The article of claim 12 , wherein the component is a partition, a room divider, a seat back, a food tray, a trim panel, an interior display panel, an interior wall, a side wall, an end wall, a ceiling panel, a door lining, a flap, a box, a hood, a louver, an insulation material, a handle, a body shell for a window, a window frame, an enclosure for an electronic device, a door, a luggage rack, a luggage container, an interior side of a gangway membrane, an interior lining of a gangway, or a component of a luggage compartment, a display unit, a television, a refrigerator door, a tray table, a food cart, a magazine rack, an air flow regulator, a door, a table, or a seat.

14. A method of manufacture of an article, comprising molding, extruding, foaming, or casting the composition of claim 1 .

15. A thermoplastic composition comprising, based on the total weight of the composition,

88 to 98 wt % of a poly(carbonate-arylate ester), wherein the poly(carbonate-arylate ester) is a poly(carbonate-monoaryl arylate ester), a poly(carbonate-monoaryl arylate ester) comprising siloxane units, or a combination comprising at least one of the foregoing; and

2 to 12 wt % of bisphenol A bis(diphenyl phosphate);

optionally, up to 5 wt % of an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein an article molded from the composition has

a maximum average heat release (MAHRE) of less than or equal to 90 kW/m 2 determined according to ISO 5660-1 on a 3 mm thick plaque, and

a smoke density after 4 minutes (Ds-4) of less than or equal to 300 determined according to ISO 5659-2 on a 3 mm thick plaque,

wherein the poly(carbonate-monoaryl arylate ester) comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and

monoarylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

wherein the poly(carbonate-monoaryl arylate ester) comprising siloxane units comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and arylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

siloxane units of the formula

wherein

each R is independently a C 1-13 monovalent hydrocarbon group, and

E has an average value of 2 to 500; and

wherein the poly(carbonate-arylate ester) is a poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester).

16. A train or aircraft interior component comprising the composition of claim 15 .

17. The composition of claim 15 , wherein the bisphenol A bis(diphenyl phosphate) is effective to provide phosphorus in an amount of 0.3% to 0.8%, based on the weight of the composition.

18. The composition of claim 15 , having a transparency of more than 85% and a haze of less than 3%, each measured according to ASTM D 1003 (2007) using illuminant C on plaques with 3 mm thickness.

19. The composition of claim 15 , wherein no or substantially no flame retarding brominated compounds, flame retardant salts, or a combination comprising at least one of the foregoing are present in the composition.

20. The composition of claim 19 , wherein the brominated compound is a brominated polycarbonate, and the flame retardant salt is potassium perfluorobutane sulfonate, potassium perfluorooctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, Na 2 CO 3 , K 2 CO 3 , MgCO 3 , CaCO 3 , and BaCO 3 , an inorganic phosphate salt, Li 3 AlF 6 , BaSiF 6 , KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 , Na 3 AlF 6 , or a combination comprising at least one of the foregoing.

21. The composition of claim 19 , wherein no or substantially no brominated polycarbonate, boron phosphate, or C 1-6 alkyl sulfonate salt is present in the composition.

22. An article comprising the composition of claim 15 , selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article.

23. The article of claim 22 , having a thickness of 0.1 to 10 mm.

24. The article of claim 22 , having a thickness of 0.5 to 5 mm.

25. The article of claim 22 , wherein the article is a transportation component.

26. The article of claim 25 , wherein the component is a partition, a room divider, a seat back, a food tray, a trim panel, an interior display panel, an interior wall, a side wall, an end wall, a ceiling panel, a door lining, a flap, a box, a hood, a louver, an insulation material, a handle, a body shell for a window, a window frame, an enclosure for an electronic device, a door, a luggage rack, a luggage container, an interior side of a gangway membrane, an interior lining of a gangway, or a component of a luggage compartment, a display unit, a television, a refrigerator door, a tray table, a food cart, a magazine rack, an air flow regulator, a door, a table, or a seat.

27. A method of manufacture of an article, comprising molding, extruding, foaming, or casting the composition of claim 15 .

28. A thermoplastic composition comprising, based on the total weight of the composition,

88 to 98 wt % of a poly(carbonate-arylate ester), wherein the poly(carbonate-arylate ester) is a poly(carbonate-monoaryl arylate ester), a poly(carbonate-monoaryl arylate ester) comprising siloxane units, or a combination comprising at least one of the foregoing; and

2 to 12 wt % of bisphenol A bis(diphenyl phosphate);

optionally, up to 5 wt % of an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein an article molded from the composition has

a maximum average heat release (MAHRE) of less than or equal to 90 kW/m 2 determined according to ISO 5660-1 on a 3 mm thick plaque, and

a smoke density after 4 minutes (Ds-4) of less than or equal to 300 determined according to ISO 5659-2 on a 3 mm thick plaque,

wherein the poly(carbonate-monoaryl arylate ester) comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and

monoarylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

wherein the poly(carbonate-monoaryl arylate ester) comprising siloxane units comprises

repeating carbonate units of the formula

wherein

R a and R b are each independently are each independently C 1-12 alkyl,

p and q are each independently integers of 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group; and arylate ester units of the formula

wherein

R h is each independently a halogen or C 1-10 hydrocarbon group, and

n is 0 to 4; and

siloxane units of the formula

wherein

each R is independently a C 1-13 monovalent hydrocarbon group, and

E has an average value of 2 to 500; and

wherein the poly(carbonate-arylate ester) is a poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol ester)-co-poly(siloxane).

29. The composition of claim 28 , wherein the siloxane units are present in an amount effective to provide 0.5% to 7% siloxane units based on the weight of the composition.

30. A train or aircraft interior component comprising the composition of claim 28 .

31. The composition of claim 28 , wherein the bisphenol A bis(diphenyl phosphate) is effective to provide phosphorus in an amount of 0.3% to 0.8%, based on the weight of the composition.

32. The composition of claim 28 , having a transparency of more than 85% and a haze of less than 3%, each measured according to ASTM D 1003 (2007) using illuminant C on plaques with 3 mm thickness.

33. The composition of claim 28 , wherein no or substantially no flame retarding brominated compounds, flame retardant salts, or a combination comprising at least one of the foregoing are present in the composition.

34. The composition of claim 33 , wherein the brominated compound is a brominated polycarbonate, and the flame retardant salt is potassium perfluorobutane sulfonate, potassium perfluorooctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, Na 2 CO 3 , K 2 CO 3 , MgCO 3 , CaCO 3 , and BaCO 3 , an inorganic phosphate salt, Li 3 AlF 6 , BaSiF 6 , KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 , Na 3 AlF 6 , or a combination comprising at least one of the foregoing.

35. The composition of claim 33 , wherein no or substantially no brominated polycarbonate, boron phosphate, or C 1-6 alkyl sulfonate salt is present in the composition.

36. An article comprising the composition of claim 28 , selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article.

37. The article of claim 36 , having a thickness of 0.1 to 10 mm.

38. The article of claim 36 , having a thickness of 0.5 to 5 mm.

39. The article of claim 36 , wherein the article is a transportation component.

40. The article of claim 39 , wherein the component is a partition, a room divider, a seat back, a food tray, a trim panel, an interior display panel, an interior wall, a side wall, an end wall, a ceiling panel, a door lining, a flap, a box, a hood, a louver, an insulation material, a handle, a body shell for a window, a window frame, an enclosure for an electronic device, a door, a luggage rack, a luggage container, an interior side of a gangway membrane, an interior lining of a gangway, or a component of a luggage compartment, a display unit, a television, a refrigerator door, a tray table, a food cart, a magazine rack, an air flow regulator, a door, a table, or a seat.

41. A method of manufacture of an article, comprising molding, extruding, foaming, or casting the composition of claim 28 .