EP4021978A1 - Transparent, high heat, flame-retardant compositions for thin wall applications - Google Patents

Abstract

A transparent composition comprising: greater than 40 to 97.5 weight percent of apoly(carbonate-bisphenol phthalate ester) comprising 1-50 weight percent of aromatic carbonateunits and 50-99 weight percent of bisphenol phthalate ester units, each based on the sum of theweight of the carbonate units and the bisphenol phthalate ester units; 2.5-60 weight percent of ahigh heat copolycarbonate derived from high heat carbonate units derived from 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, 4,4 -(1-phenylethylidene)bisphenol, 4,4 -(3,3-dimethyl-2,2-dihydro-1H-indene-1,1-diyl)diphenol, 1,1-bis(4-hydroxyphenyl)cyclododecane, 3,8-dihydroxy-5a,10b-diphenyl-coumarano-2',3',2,3-coumarane, or a combination thereof; and 0.1-0.5 weight percent of a C1-16 alkyl sulfonate saltflame retardant, wherein the transparent composition has a low halogen content, improvedflammability and a percent transmission of greater than 80% as determined according to ASTMD1003, a haze of less than 5%, or less than 2%, or less than 1% as determined according to ASTM D1003 at a thickness of 2.5 millimeter, or a combination thereof.

Description

TRANSPARENT, HIGH HEAT, FLAME-RETARDANT COMPOSITIONS FOR THIN

WALL APPLICATIONS

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 62/894075, filed on August 30, 2019, which is incorporated herein by reference in its entirety.

BACKGROUND

[0001] This disclosure relates to polycarbonate compositions, and in particular to transparent polycarbonate compositions, methods of manufacture, and uses thereof.

[0002] Polycarbonates are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances.

[0003] There accordingly remains a need in the art for transparent compositions having high heat resistance. It would be a further advantage if the compositions had improved flammability ratings at low thicknesses.

BRIEF DESCRIPTION

[0004] A transparent composition comprising: greater than 40 to 97.5 weight percent of a poly(carbonate-bisphenol phthalate ester) comprising 1-50 weight percent of aromatic carbonate units and 50-99 weight percent of bisphenol phthalate ester units, each based on the sum of the weight of the carbonate units and the bisphenol phthalate ester units; 2.5-60 weight percent of a high heat copolycarbonate derived from high heat carbonate units derived from l,l-bis(4- hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, 4,4'-(l- phenylethylidene)bisphenol, 4,4'-(3,3-dimethyl-2,2-dihydro-lH-indene-I,l-diyl)diphenol, 1,1- bis(4-hydroxyphenyl)cyclododecane, 3,8-dihydroxy-5a,10b-diphenyl-coumarano-2’,3’,2,3- coumarane, or a combination thereof, and optionally, low heat carbonate units, preferably bisphenol A carbonate units; 0.1-0.5 weight percent of a Ci-i₆ alkyl sulfonate salt flame retardant; optionally, 1-30 weight percent of a homopolycarbonate, optionally, 2-40 parts per o p million of an organosulfonic stabilizer of the formula ^r7 ,X O _ , _wherein R⁷ is a Ci-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, R⁸ is hydrogen, Ci-₃₀ alkyl; or a group of the formula -S(=0)_2-R⁷; optionally, 0.1-5 weight percent of an additive composition, wherein the amount of the poly(carbonate-bisphenol phthalate ester), the high heat copolycarbonate, the sulfonate salt flame retardant, the optional bisphenol A homopolycarbonate, the optional organosulfonic stabilizer, and the optional additive composition is based on the total weight of the transparent composition, which sums to 100 weight percent; wherein the transparent composition has a bromine or chlorine content, or a combined bromine and chlorine content of less than or equal to 100 parts per million by weight, less than or equal to 75 parts per million by weight, or less than or equal to 50 parts per million by weight, each based on the total parts by weight of the composition; and wherein a molded sample of the transparent composition has a UL 94 rating of V0 at a thickness of 1.5 millimeter, UL 94 rating of V0 at a thickness 1.2 millimeter, UL 94 rating of V0 at a thickness 1.0 millimeter, UL 94 rating of V0 at a thickness 0.8 millimeter, or a combination thereof; and a percent transmission of greater than 80% as determined according to ASTM D1003, a haze of less than 5%, or less than 2%, or less than 1% as determined according to ASTM D1003 at a thickness of 2.5 millimeter, or a combination thereof

[0005] In another aspect, a method of manufacture comprises combining the above- described components to form a transparent composition.

[0006] In yet another aspect, an article comprises the above-described transparent composition.

[0007] In still another aspect, a method of manufacture of an article comprises molding, extruding, or shaping the above-described transparent composition into an article.

[0008] The above described and other features are exemplified by the following drawings, detailed description, examples, and claims.

DETAILED DESCRIPTION

[0009] There is a need for transparent thin-walled articles having a UL-94 flammability rating of V0 at low wall thickness (i.e., 1.0 mm and lower). In particular, compositions for thin- walled compositions are needed having a UL-94 flammability rating of V0 at 1.0 millimeter (mm) and/or 0.8 mm. In addition, there is an increasing demand for more environmentally friendly polycarbonate compositions without bromine and chlorine. Some commercially available chlorine-free and bromine-free transparent compositions include anti -drip agents that result in decreased transparency or increased haziness. Other commercially available polycarbonate compositions that include chlorine-free and bromine-free flame retardants possess good flammability ratings at low thicknesses, but these materials have insufficient heat resistance for some high heat applications. For example, it is known that phosphonate or phosphazene flame retardants may decrease the heat resistance of polycarbonate compositions.

[0010] Surprisingly and unexpectedly, the inventors hereof have discovered transparent polycarbonate compositions having high heat resistance and flammability ratings of VO at thicknesses of 1.5 mm, 1.2 mm, 1.0 mm, and/or 0.8 mm. These compositions comprise a poly(carbonate-bisphenol phthalate ester), a high-heat copolycarbonate derived from high heat carbonate units and optionally, low heat carbonate units, and a Ci-i₆ alkyl sulfonate salt flame retardant.

[0011] The transparent compositions have a bromine or chlorine content, or a combined bromine and chlorine content of less than or equal to 100 parts per million by weight, less than or equal to 75 parts per million by weight, or less than or equal to 50 parts per million by weight, each based on the total parts by weight of the composition. A molded sample of the transparent compositions have a UL 94 rating of V0 at a thickness of 1.5 mm, a UL 94 rating of V0 at a thickness of 1.2 mm, a UL 94 rating of V0 at a thickness of 1.0 mm, a UL 94 rating of V0 at a thickness of 0.8 mm, a percent transmission of greater than 80% determined according to ASTM D1003 at a thickness of 1.0 mm and/or 2.5 mm, and a haze of less than 5%, or less than 2%, or less than 1% determined according to ASTM D1003 at a thickness of 2.5 millimeter.

[0012] The individual components of the transparent compositions are described in further detail below.

[0013] “Polycarbonate” as used herein means a polymer having repeating structural carbonate units of formula (1)

O

- R¹ — O — C - O - (l) in which at least 60 percent of the total number of R¹ groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic. In an aspect, each R¹ is a C6-30 aromatic group, that is, contains at least one aromatic moiety. R¹ may be derived from an aromatic dihydroxy compound of the formula HO-R'-OH, in particular of the formula

HO-A^Y^-OH wherein each of A¹ and A² is a monocyclic divalent aromatic group and Y¹ is a single bond or a bridging group having one or more atoms that separate A¹ from A². In an aspect, one atom separates A¹ from A². Specifically, each R¹ may be derived from a bisphenol of formula (2) wherein R^a and R^b are each independently a halogen, Ci-12 alkoxy, or Ci-12 alkyl, and p and q are each independently integers of 0-4. It will be understood that when p or q is less than 4, the valence of each carbon of the ring is filled by hydrogen. Also in formula (2), X^a is a C1-60 bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each G, arylene group are disposed ortho, meta, or para (specifically para) to each other on the Ce arylene group. In an aspect, the bridging group X^a is single bond, -0-, -S-, -S(O)-, -S(0)2-, -C(O)-, or a C1-₆₀ organic group. The C1-₆₀ organic bridging group may be cyclic or acyclic, aromatic or non-aromatic, and may further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. The C_1-60 organic group may be disposed such that the Ce arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C_1-60 organic bridging group. In an aspect, p and q is each 1, and R^a and R^b are each a C_1-3 alkyl group, specifically methyl, disposed meta to the hydroxy group on each arylene group.

[0014] “Polycarbonates” include homopolycarbonates (wherein each R¹ in the polymer is the same), copolymers comprising different R¹ moieties in the carbonate (“copolycarbonates”), and copolymers comprising carbonate units and other types of polymer units, such as ester units.

[0015] A specific type of copolymer is a poly(ester-carbonate), also known as a polyester-polycarbonate. Such polycarbonates further contain, in addition to recurring carbonate units of formula (1), repeating ester units of formula (3) wherein J is a divalent group derived from an aromatic dihydroxy compound (including a reactive derivative thereof), such as a bisphenol of formula (2), e.g., bisphenol A; and T is a divalent group derived from an aromatic dicarboxylic acid (including a reactive derivative thereof), preferably isophthalic or terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. Copolyesters containing a combination of different T or J groups may be used. The polyester units may be branched or linear.

[0016] In an aspect, J is derived from a bisphenol of formula (2), e.g., bisphenol A. In an aspect, a portion of the groups J, for example up to 20 mole percent (mol%) may be an aromatic dihydroxy compound, e.g., resorcinol, or C2-30 alkylene group having a straight chain, branched chain, or cyclic (including polycyclic) structure, for example ethylene, n-propylene, i-proplyene, 1,4-butylene, 1,4-cyclohexylene, or 1, 4-methyl enecyclohexane. Preferably, all J groups are bisphenol groups of formula (2).

[0017] Aromatic dicarboxylic acids that may be used to prepare the polyester units include isophthalic or terephthalic acid, l,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, or a combination thereof. Acids containing fused rings may also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specific dicarboxylic acids include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, or a combination thereof. A specific dicarboxylic acid comprises a combination of isophthalic acid and terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91 :9 to 2:98. A portion of the groups T, for example up to 20 mol%, may be aliphatic, for example derived from 1,4-cyclohexane dicarboxylic acid. Preferably all T groups are aromatic.

[0018] The molar ratio of ester units to carbonate units in the polycarbonates may vary broadly, for example 1:99 to 99:1, preferably 10:90 to 90:10, more preferably 25:75 to 75:25, or 2:98 to 15:85, depending on the desired properties of the final composition.

[0019] Specific poly(ester-carbonate)s are those including bisphenol A carbonate units and isophthalate/terephthalate-bisphenol A ester units, i.e., a poly (bisphenol A carbonate)-co- (bisphenol A-phthalate-ester) of formula (4a) wherein x and y represent the weight percent of bisphenol A carbonate units and isophthalate/terephthalate -bisphenol A ester units, respectively. Generally, the units are present as blocks. In an aspect, the weight ratio of carbonate units x to ester units y in the polycarbonates is 1:99 to 50:50, or 5:95 to 25:75, or 10:90 to 45:55. Copolymers of formula (5) comprising 35- 45 wt% of carbonate units and 55-65 wt% of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45 are often referred to as poly(carbonate- ester)s (PCE). Copolymers comprising 15-25 wt% of carbonate units and 75-85 wt% of ester units wherein the ester units have a molar ratio of isophthalate to terephthalate from 98:2 to 88:12 are often referred to as poly(phthalate-carbonate)s (PPC).

[0020] The poly(ester-carbonate)s may for example may have, for example, an Mw of 2,000-100,000 g/mol, preferably 3,000-75,000 g/mol, more preferably 4,000-50,000 g/mol, more preferably 5,000-35,000 g/mol, and still more preferably 17,000-30,000 g/mol. Molecular weight determinations are performed using GPC using a cross linked styrene-divinyl benzene column, at a sample concentration of 1 milligram per milliliter, and as calibrated with bisphenol A homopolycarbonate standards. Samples are eluted at a flow rate of 1.0 ml/min with methylene chloride as the eluent.

[0021] The poly(ester-carbonate)s (e.g., poly(carbonate-bisphenol phthalate ester)s) may be, for example, present from greater than 40-97.5 wt%, 45-97.5 wt%, 49-97.5 wt%, 41-90 wt%, 50-90 wt%, or 40-60 wt%, each based on the total weight of the composition.

[0022] The transparent composition includes a high heat copolycarbonate that includes a high heat carbonate group, optionally together with a low heat carbonate group. A combination of different high heat groups or low heat groups may be used.

[0023] The low heat carbonate group may be derived from bisphenols of formula (2) as described above wherein X^a is a Ci-is bridging group. For example, X^a may be a C3-6 cycloalkylidene, a Ci-₆ alkylidene of the formula -C(R^c)(R^d) - wherein R^c and R^d are each independently hydrogen, C1-5 alkyl, or a group of the formula -C(=R^e)- wherein R^e is a divalent Ci-₅ hydrocarbon group. Some illustrative examples of dihydroxy compounds that may be used in the manufacture of the low heat monomer units are described, for example, in WO 2013/175448 Al, US 2014/0295363, and WO 2014/072923. In an aspect, the low heat carbonate group is derived from bisphenol A, which provides the low heat group of the following formula. (Bisphenol A group)

[0024] The high heat carbonate group is derived from a high heat bisphenol monomer. As used herein, a high heat bisphenol monomer is a monomer where the corresponding homopolycarbonate of the monomer has a glass transition temperature (Tg) of 170°C or higher, determined per ASTM D3418 with a 20 °C/min heating rate. Examples of such high heat bisphenol groups include groups of formulas (6) to (12) wherein R^c and R^d are each independently a Ci-12 alkyl, C2-12 alkenyl, C3-8 cycloalkyl, or Ci-12 alkoxy, each R^f is hydrogen or both R_f together are a carbonyl group, each R³ is independently Ci-₆ alkyl, R⁴ is hydrogen, Ci-₆ alkyl, or phenyl optionally substituted with 1-5 Ci-₆ alkyl groups, each R⁶ is independently C1-3 alkyl, or phenyl, preferably methyl, X^a is a C6-12 polycyclic aryl, C3-18 mono- or polycycloalkylene, C3-18 mono- or polycycloalkylidene, -C(R^h)(R^g)- wherein R^h is hydrogen, Ci-12 alkyl, or C6-12 aryl and R^g is C6-10 alkyl, C_6-8 cycloalkyl, or C6-12 aryl, or - (Q¹)_x-G-(Q²)y wherein Q¹ and Q² are each independently a C1-3 alkylene, G is a C3-10 cycloalkylene, x is 0 or 1, and y is 1, and j, m and n are each independently 0-4, or 0 or 1. A combination of high heat bisphenol groups may be used.

[0025] In an aspect in formulas (6)-(12), R^c and R^d are each independently a C1-3 alkyl, or Ci-₃ alkoxy, each R⁶ is methyl, each R³ is independently C1-3 alkyl, R⁴ is methyl, or phenyl, each R⁶ is independently C1-3 alkyl or phenyl, preferably methyl, X^a is a C6-12 polycyclic aryl, C3- 18 mono- or polycycloalkylene, C3-18 mono- or polycycloalkylidene, -C(R^f)(R^g)- wherein R^f is hydrogen, Ci-12 alkyl, or C6-12 aryl and R^g is C6-10 alkyl, C₆-8 cycloalkyl, or C6-12 aryl, or -(Q^x- G-(Q²)_y- group, wherein Q¹ and Q² are each independently a C1-3 alkylene and G is a C3-10 cycloalkylene, x is 0 or 1, and y is 0 or 1, and j, m, and n are each independently 0 or 1.

[0026] Exemplary high heat bisphenol groups are shown below wherein R^c and R^d are the same as defined for formulas (6) to (12), each R² is independently C1-4 alkyl, m and n are each independently 0-4, each R³ is independently C1-4 alkyl or hydrogen, R⁴ is Ci-₆ alkyl or phenyl optionally substituted with 1-5 Ci-₆ alkyl groups, and g is 0-10. In a specific aspect each bond of the bisphenol group is located para to the linking group that is X^a. In an aspect, R^c and R^d are each independently a C1-3 alkyl, or C1-3 alkoxy, each R² is methyl, x is 0 or 1, y is 1, and m and n are each independently 0 or 1.

[0027] The high heat bisphenol group is preferably of formula (1 la-2) or (12a-2) wherein R⁴ is methyl or phenyl, each R² is methyl, and g is 1-4. Preferably, the high heat bisphenol group is derived from N-phenyl phenolphthalein bisphenol (PPPBP, also known as 2- phenyl-3,3’-bis(4-hydroxyphenyl)) or from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl- cyclohexane (BP-TMC). group)

[0028] This high heat copolycarbonate may include 0-90 mol%, or 10-80 mol% of low heat aromatic carbonate units, preferably bisphenol A carbonate units; and 10-100 mol%, preferably 20-90 mol% of high heat aromatic carbonate units, even more preferably wherein the high heat carbonate units are derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl- cyclohexane, , 4,4'-(l-phenylethylidene)bisphenol, 4, 4 '-(3, 3-dimethyl-2, 2-dihydro- lH-indene- 1 , 1 -diy Ijdiphenol, 1 , 1 -bis(4-hydroxyphenyl)cyclododecane, 3 , 8-dihydroxy-5a, 1 Ob-diphenyl- coumarano-2^,,3’,2,3-coumarane, or a combination thereof, wherein each amount is based on the total moles of the carbonate units, which sums to 100 mol%.

[0029] In certain aspects, the high heat copolycarbonate includes 60-80 mol% of bisphenol A carbonate units and 20-40 mol% of high heat aromatic carbonate units derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, or a combination thereof, wherein each amount is based on the total moles of the carbonate units, which sums to 100 mol%.

[0030] The high heat copolycarbonates comprising high heat carbonate units may have, for example, an Mw of 10,000-50,000 g/mol, or 16,000-300,000 g/mol, as measured by gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column and calibrated to bisphenol A homopolycarbonate references. GPC samples are prepared at a concentration of 1 mg per ml and are eluted at a flow rate of 1.5 ml per minute.

[0031] The high heat copolycarbonates may be present, for example, from 2.5-60 wt%, 2.5-55 wt%, 2.5-51 wt%, 10-69 wt%, 10-59 wt%, 10-50 wt%, or 40-60 wt%, each based on the total weight of the composition. [0032] The transparent compositions may include a homopolycarbonate (wherein each R¹ in the polymer is the same). In an aspect, the homopolycarbonate in the transparent composition is derived from a bisphenol of formula (2), preferably bisphenol A, in which each of A¹ and A² is p-phenylene and Y¹ is isopropylidene in formula (2). The homopolycarbonate may have, for example, an intrinsic viscosity, as determined in chloroform at 25°C, of 0.3-1.5 deciliters per gram (dl/gm), preferably 0.45-1.0 dl/gm. The homopolycarbonate may have, for example, a weight average molecular weight (Mw) of 10,000-200,000 grams per mol (g/mol), preferably 20,000-100,000 g/mol, as measured by gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column and calibrated to bisphenol A homopolycarbonate references. GPC samples are prepared at a concentration of 1 mg per ml and are eluted at a flow rate of 1.5 ml per minute. In some aspects, the homopolycarbonate is a bisphenol A homopolycarbonate having an Mw of 18,000-35,000 grams/mole, preferably 20,000-25,000 g/mol; or a bisphenol A homopolycarbonate having a weight average molecular weight of 25,000-35,000 g/mol, preferably 27,000-32,000 g/mol; or a combination thereof, each as measured as described above.

[0033] The polycarbonates may be manufactured by processes such as interfacial polymerization and melt polymerization, which are known, and are described, for example, in WO 2013/175448 A1 and WO 2014/072923 Al. An end-capping agent (also referred to as a chain stopper agent or chain terminating agent) may be included during polymerization to provide end groups, for example monocyclic phenols such as phenol, p-cyanophenol, and Ci-22 alkyl-substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p-and tertiary- butyl phenol, monoethers of diphenols, such as p-methoxyphenol, monoesters of diphenols such as resorcinol monobenzoate, functionalized chlorides of aliphatic monocarboxylic acids such as acryloyl chloride and methacryloyl chloride, and mono-chloroformates such as phenyl chloroformate, alkyl-substituted phenyl chloroformates, p-cumyl phenyl chloroformate, and toluene chloroformate. Combinations of different end groups may be used. Branched polycarbonate blocks may be prepared by adding a branching agent during polymerization, for example trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p- hydroxyphenylethane, isatin-bis-phenol, tris-phenol TC (1,3,5 -tri s((p- hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1, l-bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid. The branching agents may be added at a level of 0.05-2.0 wt%. Combinations comprising linear polycarbonates and branched polycarbonates may be used. [0034] The transparent compositions include Ci-i₆ alkyl sulfonate salt flame retardants. Examples include potassium perfluorobutane sulfonate (Rimar salt), potassium perfluoroctane sulfonate, and tetraethylammonium perfluorohexane sulfonate. The Ci-i₆ alkyl sulfonate salt flame retardant may be present, for example, from 0.1-0.5 wt%, 0.1-0.3 wt%, 0.2-0.5 wt%, or 0.2-0.4 wt% of the transparent composition. In certain aspects, potassium diphenyl sulfone sulfonate or salts such as NaiCC , K2CO3, MgCCE, CaCCE, and BaCCE, or fluoro-anion complexes such as L13AIF6, BaSiF₆, KBF4, K3AIF6, KAIF4, K2S1F6, or Na3AlF₆ may also be used in addition to the C1-16 alkyl sulfonate salt flame retardants.

[0035] An additional flame retardant different from the C1-16 alkyl sulfonate salt flame retardants may be present. In some aspects, the flame retardant different from the C1-16 alkyl sulfonate salt flame retardant is an organophosphorus flame retardant. In the organophosphorus flame retardants that have at least one organic aromatic group, the aromatic group may be a substituted or unsubstituted C3-30 group containing one or more of a monocyclic or polycyclic aromatic moiety (which may optionally contain with up to three heteroatoms (N, O, P, S, or Si)) and optionally further containing one or more nonaromatic moieties, for example alkyl, alkenyl, alkynyl, or cycloalkyl. The aromatic moiety of the aromatic group may be directly bonded to the organophosphorus flame retardant, or bonded via another moiety, for example an alkylene group. The aromatic moiety of the aromatic group may be directly bonded to the organophosphorus flame retardant, or bonded via another moiety, for example an alkylene group. In an aspect the aromatic group is the same as an aromatic group of the polycarbonate backbone, such as a bisphenol group (e.g., bisphenol A), a monoarylene group (e.g., a 1,3- phenylene or a 1,4-phenylene), or a combination comprising at least one of the foregoing.

[0036] The organophosphorus flame retardant may include a phosphate (P(=0)(OR)₃), phosphite (P(OR)3), phosphonate (RP(=0)(OR)2), phosphinate (R2P(=0)(OR)), phosphine oxide (R₃P(=0)), or phosphine (R3P), wherein each R in the foregoing organophosphorus flame retardants may be the same or different, provided that at least one R is an aromatic group. A combination of different organophosphorus flame retardants may be used. The aromatic group may be directly or indirectly bonded to the phosphorus, or to an oxygen of the organophosphorus flame retardant (i.e., an ester).

[0037] In an aspect, the organophosphorus flame retardant is a monomeric phosphate. Representative monomeric aromatic phosphates are of the formula (GO)₃P=0, wherein each G is independently an alkyl, cycloalkyl, aryl, alkylarylene, or arylalkylene group having up to 30 carbon atoms, provided that at least one G is an aromatic group. Two of the G groups may be joined together to provide a cyclic group. In some aspects G corresponds to a monomer used to form the polycarbonate, e.g., resorcinol. Exemplary phosphates include phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, and the like. A specific aromatic phosphate is one in which each G is aromatic, for example, triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, and the like.

[0038] Di- or polyfunctional organophosphorus flame retardants are also useful, for example, compounds of the formulas o wherein each G¹ is independently a Ci-30 hydrocarbyl; each G² is independently a Ci-30 hydrocarbyl or hydrocarbyloxy; X^a is as defined in formula (3) or formula (4); each X is independently a bromine or chlorine; m is 0 to 4, and n is 1 to 30. In a specific aspect, X^a is a single bond, methylene, isopropylidene, or 3,3,5-trimethylcyclohexylidene.

[0039] Specific organophosphorus flame retardants are inclusive of acid esters of formula (9) wherein each R¹⁶ is independently Ci-s alkyl, C_5-6 cycloalkyl, C_6-20 aryl, or C_7-12 arylalkylene, each optionally substituted by Ci-₁₂ alkyl, specifically by C_1-4 alkyl and X is a mono- or poly nuclear aromatic C_6-30 moiety or a linear or branched C_2-30 aliphatic radical, which may be OH- substituted and may contain up to 8 ether bonds, provided that at least one R¹⁶ or X is an aromatic group; each n is independently 0 or 1; and q is from 0.5 to 30. In some aspects each R¹⁶ is independently C_1-4 alkyl, naphthyl, phenyl(Ci-₄)alkylene, aryl groups optionally substituted by Ci-₄ alkyl; each X is a mono- or poly-nuclear aromatic C_6-30 moiety, each n is 1; and q is from 0.5 to 30. In some aspects each R¹⁶ is aromatic, e.g., phenyl; each X is a mono- or poly-nuclear aromatic C_6-30 moiety, including a moiety derived from formula (2); n is one; and q is from 0.8 to 15. In other aspects, each R¹⁶ is phenyl; X is cresyl, xylenyl, propylphenyl, or butylphenyl, one of the following divalent groups or a combination comprising one or more of the foregoing; n is 1; and q is from 1 to 5, or from 1 to 2. In some aspects at least one R¹⁶ or X corresponds to a monomer used to form the polycarbonate, e.g., bisphenol A, resorcinol, or the like. Organophosphorus flame retardants of this type include the bis(diphenyl) phosphate of hydroquinone, resorcinol bis(diphenyl phosphate) (RDP), and bisphenol A bis(diphenyl) phosphate (BPADP), and their oligomeric and polymeric counterparts.

[0040] The organophosphorus flame retardants containing a phosphorus-nitrogen bond may be a phosphazene, phosphonitrilic chloride, phosphorus ester amide, phosphoric acid amide, phosphonic acid amide, phosphinic acid amide, or tris(aziridinyl) phosphine oxide. These flame- retardant additives are commercially available. In an aspect, the organophosphorus flame retardant containing a phosphorus-nitrogen bond is a phosphazene or cyclic phosphazene of the formulas wherein wl is 3 to 10,000; w2 is 3 to 25, or 3 to 7; and each R^w is independently a Ci-12 alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkylene group. In the foregoing groups at least one hydrogen atom of these groups may be substituted with a group having an N, S, O, or F atom, or an amino group. For example, each R^w may be a substituted or unsubstituted phenoxy, an amino, or a polyoxyalkylene group. Any given R^w may further be a crosslink to another phosphazene group. Exemplary crosslinks include bisphenol groups, for example bisphenol A groups. Examples include phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene decaphenoxy cyclopentaphosphazene, and the like. In an aspect, the phosphazene has a structure represented by the formula

Commercially available phenoxyphosphazenes having the aforementioned structures are LY202 manufactured and distributed by Lanyin Chemical Co., Ltd, FP-110 manufactured and distributed by Fushimi Pharmaceutical Co., Ltd, and SPB-100 manufactured and distributed by Otsuka Chemical Co., Ltd.

[0041] When present, the organosulfonic stabilizer may be an aryl or aliphatic sulfonic acid, including a polymer thereof, an aryl or an aliphatic sulfonic acid anhydride, or an aryl or aliphatic ester of an aryl or aliphatic sulfonic acid, or a polymer thereof. In particular, the organosulfonic stabilizer is a Ci-30 alkyl sulfonic acid, a C6-30 aryl sulfonic acid, a C7-30 alkylarylene sulfonic acid, a C7-30 arylalkylene sulfonic acid, or an aromatic sulfonic acid polymer; an anhydride of a Ci-30 alkyl sulfonic acid, a C6-30 aryl sulfonic acid, a C7-30 alkylarylene sulfonic acid, or a C7-30 arylalkylene sulfonic acid; or a C6-30 aryl ester of a Ci-30 alkyl sulfonic acid, a C6-30 aryl sulfonic acid, a C7-30 alkylarylene sulfonic acid, a C7-30 arylalkylene sulfonic acid, or an aromatic sulfonic acid polymer; or a Ci-30 aliphatic ester of a Ci- 30 alkyl sulfonic acid, a C6-30 aryl sulfonic acid, a C7-30 alkylarylene sulfonic acid, a C7-30 arylalkylene sulfonic acid, an aromatic sulfonic acid polymer, or a combination thereof.

[0042] When present, the organosulfonic stabilizers are preferably represented by formula (14)

[0043] In formula (14), R⁷ is each independently a Ci-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 corresponding Ci-₃₂ alkyl ester. The C_2-32 ethylenically unsaturated aromatic sulfonic acid may be of the formula wherein R⁹ is hydrogen or methyl, and R⁸ is as defined in formula (14). Preferably the ethylenically unsaturated group and the sulfonic acid or ester group are located para on the phenyl ring.

[0044] Further in formula (14), R⁸ is hydrogen; or R⁸ is Ci-30 alkyl; or R⁸ is a group of the formula -S(=0)_2-R⁷. When R⁸ is a group of the formula -S(=0)_2-R⁷, each R⁷ in the compound of formula (8) may be the same or different, but preferably each R⁷ is the same.

[0045] In an aspect in formula (14), R⁷ is a C6-12 aryl, C7-24 alkylarylene, or a polymer unit derived from a C2-14 ethylenically unsaturated aromatic sulfonic acid or its ester; and R⁸ is hydrogen, Ci-24 alkyl, or a group of the formula -S(=0)_2-R⁷ wherein R⁷ is a C6-12 aryl or C7-24 alkylarylene.

[0046] In a preferred aspect, R⁷ is a C7-10 alkylarylene or a polymer unit derived from a C2-14 ethylenically unsaturated aromatic sulfonic acid, and R⁸ is a hydrogen, Ci-25 alkyl, or a group of the formula -S(=0)2-R⁷ wherein R⁷ is a C7-10 alkylarylene. In an aspect, R⁷ is a C7-10 alkylarylene and R⁸ is a hydrogen or Ci-₆ alkyl. In still another aspect, R⁷ is a C7-10 alkylarylene and R⁸ is a hydrogen or C12-25 alkyl, or R⁸ is a C14-20 alkyl.

[0047] In an aspect, R⁷ is a polymer unit derived from a C2-14 ethylenically unsaturated aromatic sulfonic acid, preferably p-styrene sulfonic acid or para-methyl styrene sulfonic acid, such that in formula (14) R⁸ is hydrogen.

[0048] In an aspect, the organosulfonic stabilizer is a Ci-10 alkyl ester of a C7-12 alkylarylene sulfonic acid, preferably of p-toluene sulfonic acid. More preferably the stabilizer is a Ci-₆ alkyl ester of p-toluene sulfonic acid, and even more preferably is butyl tosylate.

[0049] In another aspect, the organosulfonic stabilizer is an anhydride of a C7-12 alkylarylene sulfonic acid, preferably para-toluene sulfonic anhydride as shown in Table 13.

[0050] In still another aspect, R⁷ is a Cn-24 alkylarylene sulfonic acid, and R⁸ is hydrogen. Alternatively, R⁷ is a C16-22 alkylarylene sulfonic acid, and R⁸ is hydrogen.

[0051] The organosulfonic stabilizer may be used in an amount of 2 to 40 ppm, more preferably 2 to 20 ppm, still more preferably 4 to 15 ppm, or 4 to 10 ppm, or 4 to 8 ppm by weight based on the total weight composition.

[0052] The transparent compositions may further comprise an additive composition that includes various additives ordinarily incorporated into polymer compositions of this type, with the proviso that the additive(s) are selected so as to not significantly adversely affect the desired properties of the transparent composition, in particular heat resistance, transparency, and flame retardance. Combinations of additives may be used. The additive composition may include an impact modifier, flow modifier, particulate filler (e.g., a particulate polytetrafluoroethylene (PTFE), glass, carbon, mineral, or metal), antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) light stabilizer, UV absorbing additive, plasticizer, lubricant, release agent (such as a mold release agent), antistatic agent, anti-fog agent, antimicrobial agent, colorant (e.g., a dye or pigment), surface effect additive, radiation stabilizer, a flame retardant different from the C1-16 alkyl sulfonate salt flame retardant, or a combination thereof.

[0053] There is considerable overlap among plasticizers, lubricants, and mold release agents, which include, for example, phthalic acid esters (e.g., octyl-4, 5-epoxy- hexahydrophthalate), tris-(octoxycarbonylethyl)isocyanurate, di- or polyfunctional aromatic phosphates (e.g., resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol A); poly-alpha-olefins; epoxidized soybean oil; silicones, including silicone oils (e.g., poly(dimethyl diphenyl siloxanes); fatty acid esters (e.g., Ci-32alkyl stearyl esters, such as methyl stearate and stearyl stearate and esters of stearic acid such as pentaerythritol tetrastearate, glycerol tristearate (GTS), and the like), waxes (e.g., beeswax, montan wax, paraffin wax, or the like), or combinations comprising at least one of the foregoing plasticizers, lubricants, and mold release agents. These are generally used in amounts of 0.01-5 wt%, based on the total weight of total weight of the transparent composition, which sums to 100 wt%.

[0054] Antioxidant additives include organophosphites such as tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert- butyl-4-hydroxyhydrocinnamate)] methane; butylated reaction products of para-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene- bisphenols; benzyl compounds; esters of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of beta-(5-tert-butyl-4-hydroxy-3- methylphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl compounds such as distearylthiopropionate, dilaurylthiopropionate, ditridecylthiodipropionate, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate; amides of beta-(3,5-di- tert-butyl-4-hydroxyphenyl)-propionic acid, or combinations comprising at least one of the foregoing antioxidants. Antioxidants are used in amounts of 0.01-0.2, or 0.01-0.1 parts by weight, based on the total weight of the transparent composition, which sums to 100 wt%.

[0055] The transparent composition is essentially free of chlorine and bromine. “Essentially free of chlorine and bromine” refers to materials produced without the intentional addition of chlorine or bromine or chlorine or bromine containing materials. It is understood however that in facilities that process multiple products a certain amount of cross contamination may occur resulting in bromine or chlorine levels typically on the parts per million by weight scale. With this understanding it may be readily appreciated that “essentially free of bromine and chlorine” may be defined as having a bromine or chlorine content of less than or equal to 100 parts per million by weight (ppm), less than or equal to 75 ppm, or less than or equal to 50 ppm. In some aspects, “essentially free of bromine and chlorine” means a total bromine and chlorine content of less than or equal to 100 parts per million by weight, or less than or equal to 75 ppm, or less than or equal to 50 ppm. When this definition is applied to the flame retardant it is based on the total weight of the flame retardant. When this definition is applied to the transparent composition it is based on the total parts by weight of the transparent composition.

[0056] The transparent compositions may be manufactured by various methods. For example, powdered polycarbonates, flame retardant, or other optional components are first blended, optionally with fillers in a HENSCHEL-Mixer high speed mixer. Other low shear processes, including but not limited to hand mixing, may also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components, for example the reinforcing filler, may be incorporated into the composition by feeding directly into the extruder at the throat or downstream through a sidestuffer. Additives may also be compounded into a masterbatch with a desired polymeric polymer and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water bath and pelletized. The pellets so prepared may be one-fourth inch long or less as desired. Such pellets may be used for subsequent molding, shaping, or forming.

[0057] Transparent compositions may be produced by manipulation of the process used to manufacture the polycarbonate composition. One example of such a process to produce transparent polycarbonate compositions is described in U.S. Patent Application No. 2003/0032725.

[0058] A molded sample of the transparent composition may have a UL 94 rating of V0 at a thickness of 1.5 millimeter.

[0059] A molded sample of the transparent composition may have a UL 94 rating of V0 at a thickness of 1.2 millimeter.

[0060] A molded sample of the transparent composition may have a UL 94 rating of V0 at a thickness of 1.0 millimeter.

[0061] A molded sample of the transparent composition may have a UL 94 rating of V0 at a thickness of 0.8 millimeter.

[0062] A molded sample of the transparent composition may have a Vicat B120 softening temperature of at least 160°C as measured according to ISO 306.

[0063] A molded sample of the transparent composition may have a heat deflection temperature a heat deformation temperature of at least 145°C measured according to the ISO-75 standard with a 5.5 Joule hammer on 4 millimeter-thick bars and a load of 1.8 megapascals.

[0064] A molded sample of the transparent composition may have a flame test rating of V0, as measured according to UL-94 at a thickness of 0.8 millimeter or at a thickness of 0.6 millimeter.

[0065] A molded sample of the transparent composition may have a percent transmission of greater than 80%, or greater than 85%, as determined according to ASTM D1003, and a haze of less than 5%, or less than 2%, or less than 1% determined according to ASTM D1003 at a thickness of 2.5 millimeter. [0066] The transparent compositions may be used in articles including a molded article, a thermoformed article, an extruded film, an extruded sheet, one or more layers of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article. Optionally, the article has no significant part distortion or discoloration when the article is subjected to a secondary operation such as over-molding, lead-free soldering, wave soldering, low temperature soldering, or coating, or a combination thereof. The articles may be partially or completely coated with, e.g., a hard coat, a UV protective coat, an anti-refractive coat, an anti -reflective coat, a scratch resistant coat, or a combination thereof, or metallized.

[0067] Exemplary articles include 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.

[0068] This disclosure is further illustrated by the following examples, which are non limiting.

EXAMPLES

[0069] The following components are used in the examples. Unless specifically indicated otherwise, the amount of each component is in weight percent (wt%), based on the total weight of the composition.

[0070] The materials shown in Table 1 were used.

Table 1. [0071] The testing samples were prepared as described below and the following test methods were used.

[0072] All powder additives were combined together with the polycarbonate powder(s), using a paint shaker, and fed through one feeder to an extruder. Extrusion for all combinations was performed on a 25 mm twin screw extruder, using a melt temperature of 270-320°C and 300 revolutions per minute (rpm), then pelleted. The pellets were dried for 4-6 hours at 135°C. Dried pellets were injection molded at temperatures of 270-320°C to form specimens for most of the tests below.

[0073] Heat distortion temperatures were measured in accordance with the ISO-75 standard with a 5.5 J hammer, using the flat side of 4 mm-thick ISO bars and a load of 1.8 MPa

(A/f).

[0074] Melt volume rates were measured in accordance with the ISO-1133 standard at 300°C, using 1.2 kg of force for 300 seconds (s). The pellets were dried for 3 hours at 120°C before testing.

[0075] Vicat softening temperatures were measured on 4 mm-thick ISO bars in accordance with the ISO-306 standard at a load of 50 N and a speed of 120°C per hour (B120).

[0076] The percent transmission was acquired on 1.0 or 2.5 mm-thick parts on a HAZE- GUARD plus from BYK-Gardner instruments according to ASTM D1003.

[0077] The percent haze was acquired on 1.0 mm- and 2.5 mm-thick parts on a HAZE- GUARD plus from BYK-Gardner instruments according to ASTM D1003.

[0078] ASTM Izod notched impact (“ASTM INI”) values were determined according to ASTM D256-2010 on a 3.2 mm-thick bar at room temperature.

[0079] ISO Izod notched impact (“ISO INI”) values were determined according to ISO 180/1 A at room temperature using a 5.5 J hammer on a multi-purpose ISO 3167 type A sample having a thickness of 4 mm.

[0080] Flammability tests were performed at a thickness of 0.8 mm, 1 mm, 1.2 mm, or 1.5 mm, in accordance with the Underwriter’s Laboratory (UL) UL 94 standard. In some cases, a second set of 5 bars was tested to give an indication of the robustness of the rating. In this report the following definitions are used as shown in Table 2. Total flame-out-times for all 5 bars (FOT = tl + 12) were determined. V-ratings were obtained for every set of 5 bars.

Table 2 Examples 1-9

[0081] The formulations and properties of Examples 1-9 are shown in Table 3.

Table 3.

* Comparative Examples

Examples 10-17

[0082] The formulations and properties of Examples 10-17 are shown in Table 4.

Table 4.

* Comparative Examples

[0083] Comparative Examples 1-3 and 6 in Table 3 show that the inclusion of Rimar salt in poly(phthalate-carbonate) (PPC) compositions resulted in molded samples that were opaque (haze greater than 1%) at 2.5 mm. Comparative Examples 3-4 in Table 3 show that the addition of KSS instead of Rimar salt to PPC resulted in an adverse affect on the flammability, (i.e.,V2 at thicknesses of 1.5 mm and 1.2 mm).

[0084] As shown by Comparative Examples 7-10 in Table 4, the addition of Rimar salt to the high heat copolycarbonate PPPBP-BPA resulted in a transparent sample having a UL 94 rating of V2 at a thickness of 1.5 mm.

[0085] Increasing the Rimar loading above 0.2 wt% to a mixture of PPC and PPPBP- BPA (Examples 10-13, see Table 4), allowed to reach V0 rating at 1.2 mm and 1.0 mm while maintaining transparency having a haze less than 1%.

[0086] At 0.2 w% Rimar loading, compositions that contain 0 to 5 wt% of PPPBP-BPA (Comparative Examples 16-17, Table 4) are opaque.

Examples 18-26

[0087] The formulations and properties of Examples 18-26 are shown in Table 5.

Table 5.

* Comparative Examples

[0088] Surprisingly, when 0.2 wt% Rimar salt was added to a mixture of PPC and PPPBP-BPA (Example 17 of Table 4 and Examples 18-20 of Table 5), a transparent sample was obtained, having a haze of less than 1% at 2.5 mm and a UL 94 rating of V0 at a thickness of 1.0 mm.

[0089] Increasing the Rimar loading above 0.2 wt% (i.e., 0.4 wt%) to a mixture of PPC and PPPBP-BPA, wherein the PPPBP-BPA was present from 5-30 wt% (Comparative Examples 21-25), achieved a UL 94 flame test rating of V0 at 1.0 mm, but the transparency was adversely affected (haze greater than 1%).

Examples 27-36

[0090] The formulations and properties of Examples 27-36 are shown in Table 6.

Table 6.

* Comparative Examples

[0091] Examples 28-36 show that haze lower than 1% was maintained for all PPPBP- BPA/PPC compositions within the range 10/90 to 90/10. However, a loading of PPPBP-BPA that was equal to or higher than about 69 wt% (see Comparative Examples 34 and 36) adversely affected the flammability properties (e.g., UL 94 flame test rating of V2 at 1.0 mm thickness and significant number of flaming drips).

[0092] This disclosure further encompasses the following aspects.

[0093] Aspect 1: A transparent composition comprising: 40-97.5 weight percent of a poly(carbonate-bisphenol phthalate ester) comprising 1-50 weight percent of aromatic carbonate units and 50-99 weight percent of bisphenol phthalate ester units, each based on the sum of the weight of the carbonate units and the bisphenol phthalate ester units; 2.5-60 weight percent of a high heat copolycarbonate derived from high heat carbonate units derived from l,l-bis(4- hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, 4,4'-(l- phenylethylidene)bisphenol, 4,4'-(3,3-dimetliyl-2,2-dihydro-lH-indene-l,l-diyl)diphenol, 1,1- bis(4-hydroxyphenyl)cyclododecane, 3,8-dihydroxy-5a,10b-diphenyl-coumarano-2’,3’,2,3- coumarane, or a combination thereof, and optionally, low heat carbonate units, preferably bisphenol A carbonate units; 0.1-0.5 weight percent of a Ci-i₆ alkyl sulfonate salt flame retardant; optionally, 1-30 weight percent of a homopolycarbonate, optionally, 2-40 parts per million of an organosulfonic stabilizer of the formula wherein R⁷ is a Ci-30 alkyl, C6-30 aryl, C7-30 alkylarylene, C7-30 arylalkylene, or a polymer unit derived from a C2-32 ethylenically unsaturated aromatic sulfonic acid or its ester, R⁸ is hydrogen, Ci-30 alkyl; or a group of the formula -S(=0)_2-R⁷; optionally, 0.1-5 weight percent of an additive composition, wherein the amount of the poly(carbonate-bisphenol phthalate ester), the high heat copolycarbonate, the sulfonate salt flame retardant, the optional bisphenol A homopolycarbonate, the optional organosulfonic stabilizer, and the optional additive composition is based on the total weight of the transparent composition, which sums to 100 weight percent; wherein the transparent composition has a bromine or chlorine content, or a combined bromine and chlorine content of less than or equal to 100 parts per million by weight, less than or equal to 75 parts per million by weight, or less than or equal to 50 parts per million by weight, each based on the total parts by weight of the composition; and wherein a molded sample of the transparent composition has a UL 94 rating of VO at a thickness of 0.8 millimeter or 0.6 millimeter, a percent transmission of greater than 80% as determined according to ASTM D1003, and a haze of less than 5%, or less than 2%, or less than 1% determined according to ASTM D1003 at a thickness of 2.5 millimeter.

[0094] Aspect 2: The transparent composition of aspect 1, comprising greater than 40 to 60 weight percent, preferably 45-55 weight percent, of the poly(carbonate-bisphenol phthalate ester); 40-60 weight percent, preferably 45-55 weight percent, of the high heat copolycarbonate, optionally, 1-20 weight percent of bisphenol A homopolycarbonate as the homopolycarbonate;

0.1-0.5 weight percent of potassium perfluorobutane sulfonate; and 0.1-5.0 weight percent of the additive composition.

[0095] Aspect 3: The transparent composition of any one of the preceding aspects, wherein the poly(carbonate-bisphenol phthalate ester) has the formula wherein the weight ratio of carbonate units x to ester units y is 10:90-45:55, and the ester units have a molar ratio of isophthalate to terephthalate from 98:2-88:12.

[0096] Aspect 4: The transparent composition of any one of the preceding aspects, wherein the weight ratio of carbonate units to ester units is 75:25-85: 15.

[0097] Aspect 5: The transparent composition of any one of the preceding aspects, wherein the high heat aromatic carbonate units of the high heat copolycarbonate are derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, or a combination thereof.

[0098] Aspect 6: The transparent composition of any one of the preceding aspects, wherein low heat aromatic carbonate units are present and comprise bisphenol A carbonate units.

[0099] Aspect 7: The transparent composition of any one of the preceding aspects, wherein the C_M6 alkyl sulfonate salt flame retardant comprises potassium perfluorobutane sulfonate, potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, or a combination thereof, preferably potassium perfluorobutane sulfonate.

[00100] Aspect 8: The transparent composition of any one of the preceding aspects comprising 0.1-0.3 weight percent of the Ci-i₆ alkyl sulfonate salt flame retardant.

[00101] Aspect 9: The transparent composition of any one of the preceding aspects, wherein a molded sample has a heat deformation temperature of at least 145°C measured according to the ISO-75 standard with a 5.5 Joule hammer on 4 millimeter-thick bars and a load of 1.8 megapascals; a Vicat softening temperature of at least 160°C as measured according to the ISO-306 standard at a load of 50 newtons and a speed of 120°C per hour on 4 millimeter bars; or a combination thereof.

[00102] Aspect 10: The transparent composition of any one of the preceding aspects, wherein the additive composition is present and comprises an impact modifier, a flow modifier, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, an ultraviolet absorbing additive, a plasticizer, a lubricant, a release agent, an antistatic agent, an anti-fog agent, an antimicrobial agent, a colorant, a surface effect additive, a radiation stabilizer, optionally, a flame retardant different from the Ci-i₆ alkyl sulfonate salt flame retardant, or a combination thereof.

[00103] Aspect 11: The transparent composition of aspect 10, wherein flame retardant different from the C_M6 alkyl sulfonate salt flame retardant is an organophosphorus flame retardant comprising a phosphazene, phosphate, phosphite, phosphonate, phosphinate, phosphine oxide, phosphine, or a combination thereof, preferably comprising an aromatic group.

[00104] Aspect 12: The transparent composition of any one of the preceding aspects comprising greater than 40 to 60 weight percent of a poly(bisphenol A carbonate-bisphenol A phthalate ester) as the poly(carbonate-bisphenol phthalate ester), wherein the weight ratio of carbonate units to ester units is 10:90-45:55, and the ester units have a molar ratio of isophthalate to terephthalate from 98:2-88:12; 40-60 weight percent of the high heat copolycarbonate, wherein the high heat carbonate units of the copolycarbonate comprise units derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5 -trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, or a combination thereof; optionally, 1-20 weight percent of bisphenol A homopolycarbonate as the homopolycarbonate;

0.1-0.5 weight percent of potassium perfluorobutane sulfonate; 0.1-2.0 weight percent of the additive composition; and optionally, 1-20 weight percent of a bisphenol A homopolycarbonate.

[00105] Aspect 13: The transparent composition of any one of the preceding aspects, wherein the organosulfonic stabilizer is present and comprises a Ci-io alkyl ester of a C7-12 alkylarylene sulfonic acid, preferably of p-toluene sulfonic acid, more preferably a Ci-₆ alkyl ester of p-toluene sulfonic acid, even more preferably butyl tosylate; or a bisphenol A homopolycarbonate as the homopolycarbonate is present and has a weight average molecular weight from 18,000-35,000 grams/mole, preferably 20,000-25,000 grams/mole; or a weight average molecular weight from 25,000-35,000 grams/mole, preferably 27,000-32,000 grams/mole; or a combination thereof, each as measured via gel permeation chromatography using bisphenol A homopolycarbonate standards; or a combination thereof. [00106] Aspect 14: An article comprising the transparent composition of any one of the preceding aspects, preferably 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.

[00107] Aspect 15: A method for forming the article according to aspect 14, comprising molding, casting, or extruding the transparent composition to provide the article.

[00108] The compositions, methods, and articles may alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[00109] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt%, or, more specifically, 5 wt% to 20 wt%”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “some aspects,” “an aspect,” and so forth, means that a particular element described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects. A “combination thereof’ is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed.

[00110] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[00111] Unless defined otherwise, technical, and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[00112] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, -CHO is attached through carbon of the carbonyl group.

[0100] The term "alkyl" means a branched or straight chain, unsaturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s- pentyl, and n- and s-hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH₂)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl-O-), for example methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" means a straight or branched chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH₂-) or, propylene (-(CH₂)₃- )). “Cycloalkylene” means a divalent cyclic alkylene group, -CiTHn-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing the specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. “Arylene” means a divalent aryl group. “Alkylarylene” means an arylene group substituted with an alkyl group. “Arylalkylene” means an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" means a group or compound including one more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo groups (e.g., bromo and fluoro), or only chloro groups may be present. The prefix “hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents that may each independently be a C_1-9 alkoxy, a C_1-9 haloalkoxy, a nitro (-NO₂), a cyano (-CN), a Ci-6 alkyl sulfonyl (-S(=0)₂-alkyl), a C_6-12 aryl sulfonyl (-S(=0)₂-aryl)a thiol (-SH), a thiocyano (-SCN), a tosyl (CH3C6H4SO2-), a C3-12 cycloalkyl, a C2-12 alkenyl, a C5-12 cycloalkenyl, a C6-12 aryl, a C7-13 arylalkylene, a C_4-12 heterocycloalkyl, and a C_3-12 heteroaryl instead of hydrogen, provided that the substituted atom’s normal valence is not exceeded. The number of carbon atoms indicated in a group is exclusive of any substituents. For example -CH₂CH₂CN is a C₂ alkyl group substituted with a nitrile. [0101] While particular aspects have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

CLAIMS What is claimed is:

1. A transparent composition comprising: greater than 40 to 97.5 weight percent of a poly(carbonate-bisphenol phthalate ester) comprising 1-50 weight percent of aromatic carbonate units and 50-99 weight percent of bisphenol phthalate ester units, each based on the sum of the weight of the carbonate units and the bisphenol phthalate ester units;

2.5-60 weight percent of a high heat copolycarbonate derived from high heat carbonate units derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, 4,4'-(l-phenylethylidene)bisphenol, 4,4'~(3,3~dimethyl-2,2~dihydro- 1 H-indene- 1 , 1 -diyl)diphenol, 1 , 1 -bis(4-hydroxyphenyl)cyclododecane, 3 , 8-dihydroxy-5a, 10b- diphenyl-coumarano-2’,3’,2,3-coumarane, or a combination thereof, and optionally, low heat carbonate units, preferably bisphenol A carbonate units;

0.1-0.5 weight percent of a C_M6 alkyl sulfonate salt flame retardant; optionally, 1-30 weight percent of a homopolycarbonate, optionally, 2-40 parts per million of an organosulfonic stabilizer of the formula wherein

R⁷ is a Ci-30 alkyl, C6-30 aryl, C7-30 alkylarylene, C7-30 arylalkylene, or a polymer unit derived from a C2-32 ethylenically unsaturated aromatic sulfonic acid or its ester, R⁸ is hydrogen, Ci-30 alkyl; or a group of the formula -S(=0)_2-R⁷; optionally, 0.1-5 weight percent of an additive composition, wherein the amount of the poly(carbonate-bisphenol phthalate ester), the high heat copolycarbonate, the sulfonate salt flame retardant, the optional bisphenol A homopolycarbonate, the optional organosulfonic stabilizer, and the optional additive composition is based on the total weight of the transparent composition, which sums to 100 weight percent; wherein the transparent composition has a bromine or chlorine content, or a combined bromine and chlorine content of less than or equal to 100 parts per million by weight, less than or equal to 75 parts per million by weight, or less than or equal to 50 parts per million by weight, each based on the total parts by weight of the composition; and wherein a molded sample of the transparent composition has a UL 94 rating of V0 at a thickness of 1.5 millimeter, a UL 94 rating of VO at a thickness of 1.2 millimeter, a UL 94 rating of VO at a thickness of 1.0 millimeter, a UL 94 rating of VO at a thickness of 0.8 millimeter, or a combination thereof, and a percent transmission of greater than 80% as determined according to ASTM

D1003, a haze of less than 5%, or less than 2%, or less than 1% determined according to ASTM D1003 at a thickness of 2.5 millimeter, or a combination thereof.

2. The transparent composition of claim 1, comprising greater than 40 to 60 weight percent, preferably 45-55 weight percent, of the poly(carbonate-bisphenol phthalate ester);

40-60 weight percent, preferably 45-55 weight percent, of the high heat copolycarbonate, optionally, 1-20 weight percent of bisphenol A homopolycarbonate as the homopolycarbonate;

0.1-0.5 weight percent of potassium perfluorobutane sulfonate; and 0.1-5.0 weight percent of the additive composition.

3. The transparent composition of any one of the preceding claims, wherein the poly(carbonate-bisphenol phthalate ester) has the formula wherein the weight ratio of carbonate units x to ester units y is 10:90-45:55, and the ester units have a molar ratio of isophthalate to terephthalate from 98:2-88: 12.

4. The transparent composition of any one of the preceding claims, wherein the weight ratio of carbonate units to ester units is 75:25-85: 15.

5. The transparent composition of any one of the preceding claims, wherein the high heat aromatic carbonate units of the high heat copolycarbonate are derived from l,l-bis(4-hydroxyphenyl)-3, 3, 5-trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, or a combination thereof.

6. The transparent composition of any one of the preceding claims, wherein low heat aromatic carbonate units are present and comprise bisphenol A carbonate units.

7. The transparent composition of any one of the preceding claims, wherein the Ci-i₆ alkyl sulfonate salt flame retardant comprises potassium perfluorobutane sulfonate, potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, or a combination thereof, preferably potassium perfluorobutane sulfonate.

8. The transparent composition of any one of the preceding claims comprising 0.1- 0.3 weight percent of the C_M6 alkyl sulfonate salt flame retardant.

9. The transparent composition of any one of the preceding claims, wherein a molded sample has a heat deformation temperature of at least 145°C measured according to the ISO-75 standard with a 5.5 Joule hammer on 4 millimeter-thick bars and a load of 1.8 megapascals; a Vicat softening temperature of at least 160°C as measured according to the ISO-306 standard at a load of 50 newtons and a speed of 120°C per hour on 4 millimeter bars; or a combination thereof.

10. The transparent composition of any one of the preceding claims, wherein the additive composition is present and comprises an impact modifier, a flow modifier, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, an ultraviolet absorbing additive, a plasticizer, a lubricant, a release agent, an antistatic agent, an anti-fog agent, an antimicrobial agent, a colorant, a surface effect additive, a radiation stabilizer, optionally, a flame retardant different from the Ci-i₆ alkyl sulfonate salt flame retardant, or a combination thereof.

11. The transparent composition of claim 10, wherein flame retardant different from the Ci-16 alkyl sulfonate salt flame retardant is an organophosphorus flame retardant comprising a phosphazene, phosphate, phosphite, phosphonate, phosphinate, phosphine oxide, phosphine, or a combination thereof, preferably comprising an aromatic group.

12. The transparent composition of any one of the preceding claims comprising greater than 40 to 60 weight percent of a poly(bisphenol A carbonate-bisphenol A phthalate ester) as the poly(carbonate-bisphenol phthalate ester), wherein the weight ratio of carbonate units to ester units is 10:90-45:55, and the ester units have a molar ratio of isophthalate to terephthalate from 98:2-88:12;

40-60 weight percent of the high heat copolycarbonate, wherein the high heat carbonate units of the copolycarbonate comprise units derived from l,l-bis(4-hydroxyphenyl)-3,3,5- trimethyl-cyclohexane, N-phenyl phenolphthalein bisphenol, or a combination thereof; optionally, 1-20 weight percent of bisphenol A homopolycarbonate as the homopolycarbonate;

0.1-0.5 weight percent of potassium perfluorobutane sulfonate;

0.1-2.0 weight percent of the additive composition; and optionally, 1-20 weight percent of a bisphenol A homopolycarbonate.

13. The transparent composition of any one of the preceding claims, wherein the organosulfonic stabilizer is present and comprises a Ci-io alkyl ester of a C7-12 alkylarylene sulfonic acid, preferably of p- toluene sulfonic acid, more preferably a Ci-₆ alkyl ester of p-toluene sulfonic acid, even more preferably butyl tosylate; or a bisphenol A homopolycarbonate as the homopolycarbonate is present and has a weight average molecular weight from 18,000-35,000 grams/mole, preferably 20,000-25,000 grams/mole; or a weight average molecular weight from 25,000-35,000 grams/mole, preferably 27,000-32,000 grams/mole; or a combination thereof, each as measured via gel permeation chromatography using bisphenol A homopolycarbonate standards; or a combination thereof.

14. An article comprising the transparent composition of any one of the preceding claims, preferably 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.

15. A method for forming the article according to claim 14, comprising molding, casting, or extruding the transparent composition to provide the article.