COPOLYCARBONATE COMPOSITIONS HAVING ENHANCED OPTICAL PROPERTIES, ARTICLES FORMED THEREFROM, AND METHODS OF MANUFACTURE

1 . A thermoplastic composition comprising:

a copolycarbonate comprising bisphenol A carbonate units and second carbonate units of the formula

wherein

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

each R 3 is independently a C 1-6 alkyl,

R 4 is hydrogen, C 2-6 alkyl or phenyl optionally substituted with 1 to 5 C 1-6 alkyl groups,

p, q, and j are each independently 0 to 4,

optionally a bisphenol A homopolycarbonate; and

2 to 40 ppm of an organosulfonic stabilizer of the formula

wherein

each R 7 is independently a C 1-30 alkyl, C 6-30 aryl, C 7-30 alkylarylene, C 7-30 arylalkylene, or a polymer unit derived from a C 2-32 ethylenically unsaturated aromatic sulfonic acid or its ester, and

R 8 is C 1-30 alkyl; or R 8 is a group of the formula —S(═O) 2 —R 7 ;

wherein the second carbonate units are present in an amount of 20 to 49 mol % based on the sum of the moles of the copolycarbonate and the bisphenol A homopolycarbonate; and

wherein the thermoplastic composition has a Vicat B120 of 160° C. or higher measured according to ISO 306 and a yellowness index of less than 12, measured according to ASTM D1925 on a plaque of 2.5 mm thickness molded at a temperature of 355° C. for a residence time of 10 minutes.

2 . The thermoplastic composition of claim 1 , wherein the second carbonate repeating units in the copolycarbonate are of the formula

wherein R 5 is hydrogen, phenyl or methyl.

3 . The thermoplastic composition of claim 1 , wherein the copolycarbonate comprises from 15 to 90 mole percent of the bisphenol A carbonate units and 10 to 85 mole percent of the second carbonate units, each based on the total number of carbonate units in the copolycarbonate.

4 . The thermoplastic composition of claim 1 , wherein the copolycarbonate comprises from 50 to 90 mole percent of the bisphenol A carbonate units and 10 to 50 mole percent of the second carbonate units, and has less than 15 mole percent of the second carbonate units directly coupled to another second carbonate unit, each based on the total number of carbonate units in the copolycarbonate.

5 . The thermoplastic composition of claim 1 , wherein the copolycarbonate further comprises at least 5 mole percent of a third carbonate unit different from the bisphenol A carbonate units and the second carbonate units, the third carbonate unit comprising units of the formula

or a combination thereof, wherein

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

each R 6 is independently C 1-3 alkyl or phenyl,

X a is a C 6-12 polycyclic aryl, C 3-18 mono- or polycycloalkylene, C 3-18 mono- or polycycloalkylidene, -(Q 1 ) x -G-(Q 2 ) y - group wherein Q 1 and Q 2 are each independently a C 1-3 alkylene, G is a C 3-10 cycloalkylene, x is 0 or 1, and y is 1, or —C(P 1 )(P 2 )— wherein P 1 is C 1-12 alkyl and P 2 is C 6-12 aryl, and

m and n are each independently 0 to 4.

6 . The thermoplastic composition of claim 5 wherein the copolycarbonate comprises from 15 to 70 mole percent of the bisphenol A carbonate units, 5 to 50 mole percent of the second carbonate units, and 5 to 50 mole percent of the third carbonate units, each based on the total number of carbonate units in the copolycarbonate.

7 . The thermoplastic composition of claim 1 ,

wherein the copolycarbonate comprises less than 2 ppm by weight of each of an ion of lithium, sodium, potassium, calcium, magnesium, ammonium, chlorine, bromine, fluorine, nitrite, nitrate, phosphite, phosphate, sulfate, formate, acetate, citrate, oxalate, trimethylammonium, and triethylammonium, as measured by ion chromatography.

8 . The thermoplastic composition of claim 1 , wherein in the organosulfonic stabilizer each R 7 is independently a C 6-12 aryl, C 7-24 alkylarylene, or a polymer unit derived from a C 2-14 ethylenically unsaturated aromatic sulfonic acid or its C 1-30 alkyl ester; and R 8 is C 1-24 alkyl, or a group of the formula —S(═O) 2 —R 7 wherein R 7 is a C 6-12 aryl or C 7-24 alkylarylene.

9 . The thermoplastic composition of claim 1 , wherein in the organosulfonic stabilizer

R 7 is a C 6-12 aryl, C 7-24 alkylarylene, or a polymer unit derived from a C 2-14 ethylenically unsaturated aromatic sulfonic acid or its ester; and R 8 is C 1-24 alkyl, or a group of the formula —S(═O) 2 —R 7 wherein R 7 is a C 6-12 aryl or C 7-24 alkylarylene; or

R 7 is a C 7-10 alkylarylene or a polymer unit derived from a C 2-14 ethylenically unsaturated aromatic sulfonic acid, and R 8 is C 1-25 alkyl, or a group of the formula —S(═O) 2 —R 7 wherein R 7 is a C 7-10 alkylarylene; or

R 7 is a polymer unit derived from a C 2-14 ethylenically unsaturated aromatic sulfonic acid; or

R 7 is a C 1-10 alkyl ester of a C 7-12 alkylarylene sulfonic acid; or

R 7 is a group of the formula —S(═O) 2 —R 1 wherein R 7 is a C 6-12 aryl or C 7-24 alkylarylene.

10 . The thermoplastic composition of claim 1 , wherein the organosulfonic stabilizer comprises butyl tosylate, ethyl tosylate, p-toluenesulfonic anhydride, octadecyl p-toluenesulfonate, or a combination comprising at least one of the foregoing.

11 . The thermoplastic composition claim 1 , wherein the stabilizer is present in an amount of 2 ppm to 20 ppm, based on the total weight of the thermoplastic composition.

12 . The thermoplastic composition of claim 1 , wherein the thermoplastic composition has a bisphenol A purity of equal to or greater than 99.6%, or of equal to or greater than 99.7% measured by high performance liquid chromatography.

13 . The thermoplastic composition of claim 1 , wherein the polycarbonate homopolymer is present in an amount of 10 to 90 wt %, based on the total weight of the thermoplastic composition.

14 . The thermoplastic composition of claim 1 , comprising:

a copolycarbonate comprising bisphenol A carbonate units and second carbonate units of the formula

wherein R 5 is hydrogen, phenyl, or methyl;

a bisphenol A homopolycarbonate; and

2 to 20 ppm of an organosulfonic stabilizer comprising a C 1-30 alkyl ester of p-toluenesulfonic acid;

wherein the thermoplastic composition has 25 mol % to 49 mol % of second carbonate units based on the sum of the moles of the copolycarbonate and the bisphenol A homopolycarbonate.

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

60 to 70 wt % of a copolycarbonate comprising bisphenol A carbonate units and second carbonate units of the formula

wherein R 5 is hydrogen, phenyl or methyl;

25 to 40 wt % of a bisphenol A homopolycarbonate; and

2 to 20 ppm of an organosulfonic stabilizer comprising a C 1-30 alkyl ester of p-toluenesulfonic acid;

wherein the thermoplastic composition has 25 mol % to 49 mol % of second carbonate units based on the sum of the moles of the copolycarbonate and the bisphenol A homopolycarbonate.

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

60 to 70 wt % of a copolycarbonate comprising bisphenol A carbonate units and second carbonate units of the formula

wherein R 5 is phenyl or methyl;

25 to 40 wt % of a bisphenol A homopolycarbonate; and

4 to 10 ppm of an organosulfonic stabilizer comprising butyl tosylate;

wherein the thermoplastic composition has 30 mol % to 40 mol % of second carbonate units based on the sum of the moles of the copolycarbonate and the bisphenol A homopolycarbonate.

17 . The composition of claim 16 , wherein the copolycarbonate has a hydroxyl end group content of less than 200 ppm and the bisphenol A homopolycarbonate has a hydroxyl end group content of less than 150 ppm.

18 . The composition of claim 16 , wherein the bisphenol A homopolycarbonate has a sulfur content of less than 2 ppm, or the copolycarbonate, the bisphenol A homopolycarbonate, or both are derived from a bisphenol A having a sulfur content of less than 2 ppm, each as measured by a Total Sulfur Analysis based on combustion and coulometric detection.

19 . An article comprising the copolymer of claim 1 , wherein the article is a molded article, a thermoformed article, an extruded layer, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article.

20 . The article of claim 19 , wherein the article is a lens, a light guide, a waveguide, a collimator, an optical fiber, a window, a door, a visor, a display screen, an electronic device, a scientific or medical device, a safety shield, a fire shield, wire or cable sheathing, a mold, a dish, a tray, a screen, an enclosure, glazing, packaging, a gas barrier, an anti-fog layer, or an anti-reflective layer.

21 . The article of claim 19 , wherein the article is a component of a device comprising a lens, a device comprising a light guide, a device comprising a waveguide, a device comprising a collimator, a device comprising an optical fiber, a device comprising a lighting element, a device comprising a window, a device comprising a door, or the article is a structural component of a vehicle, a building, or an appliance, or the article is a component of a medical device, a component of a display screen, a component of an electronic device, a component of a safety device, a component of a screen, a component of conveyor, a component of a mold, a component of a dish, a component of an enclosure, a component of packaging, a component of a gas barrier, a component of an encapsulant, a component of a label, a component of a gas barrier, a component of an anti-fog assembly, or a component of an anti-reflective assembly.