Thermoplastic compositions, methods of their manufacture, and articles thereof

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

a polycarbonatesiloxane-arylate;

2 to 15 wt % of a core-shell impact modifier;

a flame retardant comprising a bromine-containing polymer or oligomer effective to provide 1.5 to 5 wt % of bromine, based on the total weight of the polymers in the composition, an aromatic organophosphorus compound effective to provide 0.1 to 2.0 wt % of phosphorus, based on the total weight of the polymers in the composition, or a combination comprising at least one of the foregoing; and

optionally 5 to 80 wt % of a polyetherimide;

wherein a formed sample of the composition has

a flame time of less than 15 seconds, a burn length of less than 6 inches, and a drip extinguishing time of less than 3 seconds, each measured using the method of FAR 25.853(d), in accordance with FAR 25.853(a)(1)(i) at a thickness of 1.5 mm;

an OSU integrated 2 minute test value of less than 65 kW-min/m 2 and a peak heat release value of less than 65 kW/m 2 as measured at 1.5 mm in accordance with FAR 25.853(d); and

a notched Izod value of greater than or equal to 2 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

2. The composition of claim 1 , wherein a sample of the composition has at least one of the following properties:

i) an average peak smoke density within 4-minute equal to or less than 200 as regulated by FAR 25-853(d); an average peak smoke density within 4-minute equal to or less than 150 as regulated by airbus ABD0031/ATS1000;

ii) a smoke extracted from a NBS smoke chamber and measured by Draeger tube having an average concentration of the following gas components: HF<100 ppm, HCl<150 ppm, HCN<150 ppm, SO 2 /H 2 S<100 ppm, NO/NO 2 <100 ppm, and CO<1000 ppm;

iii) a 2 minute integrated heat release rate of less than or equal to 65 kilowatt-minutes per square meter (kW-min/m 2 ) and a peak heat release rate of less than 65 kilowatts per square meter (kW/m 2 ) as measured using the method according to Part IV, OSU Heat Release of FAR/JAR 25.853, Amendment 25-116; and

iv) a maximum averaged rate of heat emission of less than or equal to 90 kW/m 2 with 50 kW/m 2 irradiance level test condition according to ISO 5660-1.

3. The thermoplastic composition of claim 1 , wherein the flame retardant comprises the bromine-containing polymer or oligomer effective to provide 1.5 to 5 wt % of bromine, based on the total weight of the polymers in the composition; and wherein the sample of the composition has a notched Izod value of greater than or equal to 5 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

4. The composition of claim 1 , comprising, based on the total weight of the polymers in the thermoplastic composition,

a polycarbonatesiloxane-arylate;

1 to 4 wt % of a core-shell impact modifier comprising a butyl acrylate-methyl methacrylate copolymer having a core of poly(butyl acrylate) and a grafted shell of poly(methyl methacrylate) and a rubber grafted acrylonitrile-butadiene-styrene copolymer with rubber content greater than 50% by weight of the copolymer, a butyl acrylate-styrene-acrylonitrile copolymer, or a combination comprising at least one of the foregoing; and

an aromatic organophosphorus compound that provides 0.1 to 2.0 wt % of phosphorus;

wherein a sample of the composition has a notched Izod value of greater than or equal to 4 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

5. The composition of claim 1 , comprising, based on the total weight of the polymers in the thermoplastic composition,

a polycarbonatesiloxane-arylate;

2 to 15 wt % of a core-shell impact modifier;

an aromatic organophosphorus compound effective to provide 0.1 to 2.0 wt % of phosphorus, based on the total weight of the polymers in the composition; and

5 to 80 wt. % or 10 to 60 wt. % of the polyetherimide.

6. The composition of claim 1 , wherein the polycarbonatesiloxane-arylate comprises

0.2 to 10 wt % siloxane units,

50 to 99.6 wt % arylate units, and

0.2 to 49.8 wt % carbonate units,

each based on the weight of the polycarbonatesiloxane-arylate.

7. The composition of claim 1 , wherein

the arylate units are isophthalate-terephthalate-resorcinol ester units;

the carbonate units are bisphenol A carbonate units, resorcinol carbonate units, or a combination thereof; and

the siloxane units are of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200.

8. The composition of claim 1 , wherein the core-shell impact modifier comprises a core comprising an acrylate rubber, a silicone rubber, or a butadiene based rubber, and a shell derived from a vinyl aromatic compound, a vinyl cyanide, an alkyl(meth)acrylate, (meth)acrylic acid, or a combination comprising at least at least one of the foregoing.

9. The composition of claim 1 , wherein the core-shell impact modifier comprises methacrylate-butadiene-styrene core-shell impact modifier, butyl acrylate-styrene-acrylonitrile, acrylonitrile-butadiene-styrene, silicone-acrylic-based rubber, butyl acrylate-methyl methacrylate polymer having a core of poly(butyl acrylate) and a shell of poly(methyl methacrylate), or a combination comprising at least one of the foregoing.

10. The composition of claim 1 , where the aromatic organophosphorus compound comprises at least one organic aromatic group and at least one phosphorus-containing group, or an organic compound having at least one phosphorus-nitrogen bond.

11. The composition of claim 10 , wherein the aromatic organophosphorus compound is bisphenol A bis(diphenyl phosphate), triphenyl phosphate, resorcinol bis(diphenyl phosphate), tricresyl phosphate, a phenol/bi-phenol polyphosphate, an oligomeric phosphate ester, or a combination comprising at least one of the foregoing.

12. The composition of claim 1 , comprising, based on the total weight of the polymers in the composition,

2 to 8.5 wt % of a core-shell impact modifier having a core of poly(butyl acrylate) and a shell of poly(methyl methacrylate);

75 to 90 wt % of a 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);

5 to 15 wt % of a bromine-containing polymer comprising brominated carbonate units derived from 2,2′,6,6′-tetrabromo-4,4′-isopropylidenediphenol and carbonate units derived from bisphenol A; and

optionally, up to 12 wt % of an additive, wherein the additive is a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein a sample of the composition has a notched Izod value of greater than or equal to 10 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3 or 3.2 mm.

13. The composition of claim 1 , comprising, based on the total weight of the polymers in the composition,

2 to 8 wt % of a core-shell impact modifier having a core of poly(butyl acrylate) and a shell of poly(methyl methacrylate);

80 to 98 wt % of a 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);

an aromatic phosphorus compound effective to provide 0.1 to 2 wt % of phosphorus;

and optionally, up to 12 wt % of an additive comprising a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein the aromatic organophosphorus compound is of the formula

wherein

each of R 16 , R 17 , R 18 , and R 19 is phenyl, X is of the formula

each n is 1, and q is 1-5; and

wherein a sample of the composition has a notched Izod value of greater than or equal to 10 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

14. The composition of claim 1 , comprising, based on the total weight of the polymers in the composition,

2 to 15 wt % of a core-shell impact modifier having a core of poly(butyl acrylate) and a shell of poly(methyl methacrylate);

30 to 60 wt % of a 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);

40 to 60 wt % of a polyetherimide;

optionally, an aromatic phosphorus compound in an effective amount to provide 0.1 to 2 wt % of phosphorus; and

optionally, up to 12 wt % of an additive comprising a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,

wherein the aromatic organophosphorus compound is of the formula

wherein

each of R 16 , R 17 , R 18 , and R 19 is phenyl,

X is of the formula

each n is 1, and

q is 1-5;

wherein a sample of the composition has

a flame time of less than 15 seconds, a burn length of less than 6 inches, and a drip extinguishing time of less than 5 seconds, each measured using the method of FAR25.853, in accordance with FAR 25.853(a)(1)(i) at a thickness of 1.5 mm; and

a notched Izod value of greater than or equal to 10 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

15. The composition of claim 13 , wherein the composition comprises 2 to 8 wt % of bisphenol A bis(diphenyl phosphate).

16. The composition of claim 1 further comprising 1 to 5 wt % of talc.

17. An article comprising the composition of claim 1 , wherein the article is 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.

18. The article of claim 17 , wherein the article is a transportation component.

19. The article of claim 17 , wherein the article is a thermoformable decorative laminate comprising a surface layer, a backing layer, and a color layer disposed between the surface layer and the backing layer, wherein the surface layer, the backing layer, or both comprise the composition of claim 1 .

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

21. A thermoplastic composition comprising, based on the total weight of the polymers in the thermoplastic composition,

a polycarbonatesiloxane-arylate;

2 to 15 wt % of a core-shell impact modifier;

a bromine-containing polymer or oligomer effective to provide 1.5 to 5 wt % of bromine, based on the total weight of the polymers in the composition; and

an aromatic organophosphorus compound effective to provide 0.1 to 2.0 wt % of phosphorus, based on the total weight of the polymers in the composition;

wherein a sample of the composition has a notched Izod value of greater than or equal to 5 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.

22. A thermoplastic composition comprising, based on the total weight of the polymers in the thermoplastic composition,

a polycarbonatesiloxane-arylate;

2 to 15 wt % of a core-shell impact modifier;

a bromine-containing polymer or oligomer effective to provide 1.5 to 5 wt % of bromine, based on the total weight of the polymers in the composition; and

5 to 80 wt % of a polyetherimide;

wherein a sample of the composition has a notched Izod value of greater than or equal to 5 ft-lbs/in at 23° C. in accordance to ASTM D256 at a thickness of 3.2 mm.