Thermoplastic composition with balanced chemical resistance and impact properties

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

5 to 30 wt. % of a poly(arylene ether-sulfone); and

50 to 95 wt. % of a poly(carbonate-siloxane) consisting of carbonate units and siloxane units, and optionally a polycarbonate homopolymer;

optionally, 0.5 to 25 wt. % of a poly(etherimide);

wherein a sample of the composition has

a notched Izod impact value of greater than or equal to 30 kJ/m 2 , measured at 23° C. according to ISO 180/1A using multipurpose 3.0 mm test specimen in accordance with ISO 3167 TYPE A;

a tensile yield strength retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527; and

an elongation at break retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527.

2. The composition of claim 1 , comprising, based on the total weight of the composition:

5 to 30 wt. % of the poly(arylene ether-sulfone);

50 to 95 wt. % of the polycarbonate component comprising the poly(carbonate-siloxane) and optionally the polycarbonate homopolymer; and

0.5 to 25 wt. % of a poly(carbonate-arylate ester) compatibilizer, a poly(carbonate-arylate ester-siloxane) compatibilizer, or a combination comprising at least one of the foregoing.

3. The composition of claim 2 , wherein the composition comprises the poly(carbonate-arylate ester) compatibilizer, the poly(carbonate-arylate ester) compatibilizer comprising bisphenol A carbonate units and arylate ester units of the formula

wherein

R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,

p and q are each independently 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of the formula C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group.

4. The composition of claim 3 , wherein

the poly(carbonate-arylate ester) compatibilizer is a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 55 to 65 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45 or

the poly(carbonate-arylate ester) is a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 75 to 85 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 98:2 to 88:12.

5. The composition of claim 2 , wherein the composition comprises the poly(carbonate-arylate ester) compatibilizer, and the poly(carbonate-arylate ester) compatibilizer comprises bisphenol A carbonate units, arylate ester units of the formula

optionally, monoaryl carbonate units of the formula

 and

optionally, bisphenol ester units of the formula

wherein, in the foregoing formulas

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

n is 0 to 4,

R a and R h are each independently a 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 1-13 alkylidene of formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-12 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-12 hydrocarbon group.

6. The composition of claim 5 , wherein the poly(carbonate-arylate ester) compatibilizer comprises

70 to 90 mol % of bisphenol A carbonate units,

10 to 30 mol % of isophthalic acid-terephthalic acid-resorcinol ester units, and

optionally, 1 to 60 mol % resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A ester units, or a combination thereof.

7. The composition of claim 2 ,

wherein the poly(carbonate-arylate ester-siloxane) compatibilizer 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.

8. The composition of claim 7 , wherein in the poly(carbonate-arylate ester-siloxane) compatibilizer,

the carbonate units are bisphenol A carbonate units;

the arylate ester units are isophthalic acid-terephthalic acid-resorcinol units; 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 5 to 30.

9. The composition of claim 7 , wherein the poly(carbonate-arylate ester-siloxane) compatibilizer comprises

1 to 40 mol % of the bisphenol A carbonate units,

50 to 95 mol % of isophthalic acid-terephthalic acid-resorcinol units, and

the siloxane units in an amount effective to provide 0.1 to 10 wt % of siloxane units, based on the weight of the poly(carbonate-ester-siloxane).

10. The composition of claim 7 , comprising, based on the weight of the composition:

5 to 30 wt. % of the polyphenylene sulfone comprising the units of the formula

50 to 80 wt. % of the poly(carbonate-siloxane);

10 to 20 wt. % of the poly(carbonate-arylate ester-siloxane) compatibilizer; and

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

wherein the poly(carbonate-siloxane) comprises

bisphenol A carbonate units, and

siloxane units of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane),

wherein poly(carbonate-arylate ester-siloxane) compatibilizer comprises bisphenol A carbonate units; isophthalic acid-terephthalic acid-resorcinol units; and siloxane units of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 5 to 30, and

wherein a sample of the composition has

a notched Izod impact value of greater than or equal to 40 kJ/m 2 , measured at 23° C. according to ISO 180/1A using multipurpose 3.0 mm test specimen in accordance with ISO 3167 TYPE A.

11. The composition of claim 1 , wherein the poly(arylene ether-sulfone) is of the formula

—[Ar 1 —SO 2 —Ar 2 —O] t —[Ar 3 —O] s —

wherein t is greater than 1, and s is 0 or greater than one, and each Ar 1 , Ar 2 , and Ar 3 is the same or different, and is a group of formula

wherein

c is 0 or 1,

R a and R b are each independently a linear or branched C 1-10 alkyl, linear or branched C 2-10 alkenyl, linear or branched C 2-10 alkynyl, C 6-18 aryl, C 7-20 alkylaryl, C 7-20 arylalkyl, C 5-10 cycloalkyl, C 5-20 cycloalkenyl, linear or branched C 1-10 alkylcarbonyl, C 6-18 arylcarbonyl, halogen, nitro, cyano, a halogen, C 1-12 alkoxy, or 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.

12. The composition of claim 11 , wherein the poly(arylene ether-sulfone) comprises units of the formula

or a combination comprising at least one of the foregoing units.

13. The composition of claim 1 , wherein the poly(carbonate-siloxane) comprises

bisphenol carbonate units of the formula

wherein

R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,

p and q are each independently 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of formula C(R c )(R d ) wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group; and

polysiloxane units of the formula

wherein

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

E has an average value of 2 to 200.

14. The composition of claim 13 , wherein 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, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane).

15. The composition of claim 1 , further comprising an additive selected from a processing aid, a heat stabilizer, an ultraviolet light absorber, a colorant, a flame retardant, or a combination comprising at least one of the foregoing.

16. An article selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a honeycomb structure, a foamed article, one or more layers of a multi-layer article, a substrate for a coated article, and a substrate for a metallized article comprising the composition of claim 1 .

17. The article of claim 16 , wherein the article is a component of

a consumer electronic device selected from a gaming console, a gaming controller, a portable gaming device, a cellular telephone, a television, a personal computer, a tablet computer, a laptop computer, a personal digital assistant, a portable media player, a, a digital camera, a portable music player, an appliance, a power tool, a robot, a toy, a greeting card, a home entertainment system, and active loudspeaker, or a soundbar or

a train or aircraft interior component selected from 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.

18. A method of manufacture of an article, comprising molding, extruding, or casting the composition of claim 1 to form the article.

19. A thermoplastic composition, comprising, based on the weight of the composition:

10 to 25 wt. % of a polyphenylene sulfone comprising the units of the formula

35 to 42 wt. % of a poly(bisphenol-A carbonate) homopolymer;

35 to 42 wt. % of a poly(carbonate-siloxane); and

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

wherein the poly(carbonate-siloxane) comprises

bisphenol A carbonate units, and

siloxane units of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane),

wherein a sample of the composition has a notched Izod impact value of greater than or equal to 60 kJ/m 2 , measured at 23° C. according to ISO 180/1A using multipurpose 3.0 mm test specimen in accordance with ISO 3167 TYPE A;

a tensile yield strength retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527; and

an elongation at break retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527.

20. A thermoplastic composition, comprising, based on the weight of the composition:

5 to 30 wt. % of a polyphenylene sulfone comprising the units of the formula

50 to 80 wt. % of a poly(carbonate-siloxane);

10 to 20 wt. % of a poly(carbonate-arylate ester); and

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

wherein the poly(carbonate-siloxane) comprises

bisphenol A carbonate units, and

siloxane units of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of dimethylsiloxane units based on the total weight of the poly(carbonate-siloxane),

wherein the poly(carbonate-arylate ester) is a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 55 to 65 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45, or a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 75 to 85 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 98:2 to 88:12, or a combination thereof, and

wherein a sample of the composition has

a notched Izod impact value of greater than or equal to 40 kJ/m 2 , measured at 23° C. according to ISO 180/1A using multipurpose 3.0 mm test specimen in accordance with ISO 3167 TYPE A;

a tensile yield strength retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527; and

an elongation at break retention of 80% and higher after exposure of an ISO tensile bar for 24 hours to sunscreen under 0.5% strain compared to a non-exposed reference tested according to ISO 527.