Weatherable thermoplastic compositions, method of manufacture, and articles therefrom

1. An article comprising a thermoplastic composition, the thermoplastic composition comprising

a polyaryl ester;

a polymer different from the polyaryl ester; and

a phthalone compound according to the formula:

wherein

Z 1 represents the atoms necessary to complete a 9- to 13-membered single or fused aromatic ring structure,

Z 2 represents the atoms necessary to complete a pyridine or quinoline ring, each R 1 and each R 2 are independently halogen, an alkyl group, an aryl group, a heterocyclic group, an alkoxy group, an aryloxy group, an aromatic or aliphatic thioether group, an aromatic or aliphatic carboxylic acid ester group, or an aromatic or aliphatic amide group,

a is 0 to 6, b is 0 to 4, n is 1 or 2, and

X is present only if n=2, and is a single bond or a divalent organic radical bonded to the Z 1 ring structure through an ether, ketone, or thio linkage;

wherein

the phthalone compound is present in an amount of 0.001 to 0.1 weight percent based on the total weight of the thermoplastic composition when the article has a thickness of 0.035 to 0.49 millimeters; and

the phthalone compound is present in an amount of 0.0001 to 0.01 weight percent based on the total weight of the thermoplastic composition when the article has a thickness of 0.5 to 3 millimeters.

2. The article of claim 1 , wherein the polyaryl ester comprises at least 5 wt %, based on the weight of the polyaryl ester, of repeating units of the formula

in which at least 80 percent of the total number of T groups, and/or at least 80 percent of the total J groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic.

3. The article of claim 1 , wherein the polyaryl ester is a copolymer of a polyaryl ester derived from resorcinol or bisphenol A and a mixture of isophthalic acid, halide, or anhydride, terephthalic acid, halide, or anhydride, and a polycarbonate derived from bisphenol A and a carbonate source.

4. The article of claim 2 ,

wherein at least 80 percent of the total number of T groups containing aromatic moieties are derived from isophthalic acid and/or terephthalic acid; and

at least 80 percent of the total number of J groups contain aromatic moieties derived from resorcinol or bisphenol A and the balance thereof are aliphatic, alicyclic, or aromatic.

5. The article of claim 1 , wherein the polyaryl ester comprises:

from 5 wt % to 30 wt % of ester repeat units represented by the formula:

in which at least 90 percent of the total number of T groups, and/or at least 90 percent of the total J groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic; and

from 70 wt % to 95 wt % of carbonate repeat units represented by the formula:

in which at least 60 percent of the total number of R 1 groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic;

wherein the weight percentages are based on the weight of the polymer and with the proviso that the sum of wt % of the ester repeat units and the wt % of the carbonate repeat units is 100.

6. The article of claim 5 , wherein

at least 90 percent of the total number of T groups contain aromatic moieties derived from isophthalic acid and/or terephthalic acid; and

all of the R 1 groups contain aromatic moieties, preferably wherein all of the R 1 groups are derived from bisphenol A and/or resorcinol.

7. The article of claim 6 , wherein the T groups are derived from isophthalic acid and/or terephthalic acid, the J groups are derived from resorcinol, and the R 1 groups are derived from bisphenol A, resorcinol, or a combination comprising at least one of the foregoing.

8. The article of claim 1 , wherein the polymer different from the polyaryl ester is a polycarbonate.

9. The article of claim 1 , wherein the phthalone compound is according to the formula:

wherein

R 1.1 , R 1.2 , R 1.3 , R 1.4 , R 2.1 , R 2.2 , R 2.3 , and R 2.4 are each independently hydrogen, halogen, a C 1 -C 18 alkyl group, a C 6 -C 12 aryl group, a C 1 -C 18 alkoxy group, or a C 6 -C 12 aryloxy group,

n and X are as defined in claim 1 , and

X is present in place of one of R 1.1 , R 1.2 , R 1.3 , or R 1.4 when n is 2.

10. The article of claim 1 , wherein the phthalone compound is

or a combination comprising at least one of the foregoing.

11. The article of claim 1 , comprising 0.0001 wt % to 1 wt % of the phthalone compound, based on the total weight of the thermoplastic compositions.

12. The article of claim 1 ,

wherein the phthalone compound exhibits photobleaching in the region of light from 400-450 nm and the polyaryl ester exhibits photoyellowing in the region of 400-450 nm;

wherein the phthalone compound has a decomposition onset temperature, of at least 250° C., as determined according to ASTM E2550-11; and

wherein an opaque color chip comprising the thermoplastic composition has a Delta E color shift of less than 6, after weathering for 1000 hours according to ASTM G155-05a.

13. The article of claim 1 , further comprising a blue colorant, a UV stabilizer, an impact modifier, fillers, reinforcing agents, antioxidants, heat stabilizers, light stabilizers, plasticizers, lubricants, mold release agents, antistatic agents, epoxides, carbon black, organic dyes, surface effect additives, radiation stabilizers, flame retardants, anti-drip agents, or a combination comprising at least one of the foregoing.

14. The article of claim 1 , wherein the composition is free of dyes with thermal stability less than 270° C. and/or UV-VIS absorption more than 450 nm and that exhibit photobleaching in the region of light from 400 to 450 nm.

15. The article of claim 1 , wherein the article is an electronic display window, an illuminant lens or cover, an automotive component;

a fender, a grille, an applique, a visor and/or a trim part for agricultural tractors or equipment, industrial or construction equipment, recreational vehicles, golf carts, all-terrain vehicles, marine ships, watercrafts, and lawn care equipment;

a component, a fender, a grille, an applique, a visor and/or a trim part for an automotive vehicle or truck, or a component of a marine buoy; or

a sheet, a multi-layered sheet, a multi-wall sheet, a multi-layered-multiwall sheet, or a combination comprising at least one of the foregoing.

16. The article of claim 1 , wherein the article comprises a polymer coating disposed on the surface of the article, the polymer coating comprising the thermoplastic composition of claim 1 to protect said article from weathering effects.

17. A method of making the article of claim 1 , the method comprising heating the composition to a melt temperature of at least 250° C., and extruding or molding the article.

18. The article of claim 1 , wherein

the phthalone compound is present in an amount of 0.01 to 0.05 weight percent based on the total weight of the thermoplastic composition when the article has a thickness of 0.035 to 0.49 millimeters; and

the phthalone compound is present in an amount of 0.0001 to 0.005 weight percent based on the total weight of the thermoplastic composition when the article has a thickness of 0.5 to 3 millimeters.