Patent Description:
Polycarbonate is used in many applications because of its excellent balance of good impact performance, heat properties, flowability and aesthetics. Polycarbonate (PC) compositions can be formulated for high flow (e.g. via molecular weight reduction or flow promotors) and/or high impact (e.g. impact modifiers such as methacrylate-butadiene-styrene (MBS) or siloxane copolymers). The addition of siloxane copolymers to polycarbonate resin not only improves the impact performance at low temperatures, but also other properties such as flow and release performance. Trends in part design in several markets are driving towards parts that are thinner, more complex and have advanced styling features. In general, this requires materials that flow even better to fill large and complex parts, still have good enough impact properties and have sufficient release to ensure proper de-molding of the part in general, but especially in case of decreased draft core angle.

Release additives, such as pentaerythritol stearate, glycerol monostearate and poly-alpha-olefin as examples, are commonly added to improve the demolding of the piece once it's molded.

Therefore, materials are desired that offer an improved balance of flow (as indicated by a melt flow volume rate (MVR) of <NUM> cubic centimeters (cm<NUM>)/<NUM> minutes (min) and higher, measured at <NUM> degrees Celsius (°C) and <NUM> kilogram (Kg) load), good impact (as indicated by ductile Izod notched impact strength), preferably at low temperatures below <NUM>, and sufficient release to allow very sharp draft angles for applications like automotive bezels or reflectors and mobile phone housings.

These and other shortcomings are addressed by aspects of the present disclosure.

<CIT> discloses a polycarbonate composition that comprises a polycarbonate polymer formed by a melt process; a hexamethylene-bis[<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyphenyl) propionate] antioxidant; and optionally a phosphite stabilizer, indicated as maintaining its color and transparency for long time periods.

<CIT> discloses a thermoplastic composition comprising a polycarbonate, a polysiloxane-polycarbonate, and a gel-type low gloss additive, wherein the <NUM>° gloss is measured to be less than or equal to <NUM> GU according to ASTM D2457. The thermoplastic composition is indicated as having excellent impact strength and color capability. A method of making the thermoplastic composition, and an article comprising the thermoplastic composition are also disclosed.

Blended polycarbonate compositions comprising one or more polycarbonate polymer, polycarbonate/ siloxane copolymer(s), a mineral filler, and an alkyl sulfonate salt having improved mold release properties are known from <CIT>.

The invention provides a polycarbonate blend comprising:.

The invention also provides a molded article comprising the polycarbonate blend of the invention, preferably having an ejection force of less than <NUM> N when ejection force of the molded article comprising the polycarbonate blend is evaluated by injection molding a sleeve comprising the polycarbonate blend in a core and determining the force necessary to remove the sleeve from the core.

The release agent may be present in an amount of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate blend or of the molded article, preferably the release agent comprising one or more of pentaerythritol stearate, glycerol monostearate and poly-alpha-olefin.

The poly(carbonate-siloxane) copolymer may comprise bisphenol carbonate units of the formula
<CHM>
wherein.

The blend may have a Fries number of about <NUM> ppm or higher based on the total blend.

The polycarbonate blend or molded article may further comprise a processing aid, a heat stabilizer, an antioxidant, an ultra violet light absorber, or a combination comprising at least one of the foregoing.

The polycarbonate blend may have a melt volume rate ("MVR"), determined in accordance with ISO <NUM> under a load of <NUM> at <NUM>, higher than <NUM><NUM>/<NUM>.

The polycarbonate blend may have a ductile/brittle transition temperature of less than or equal to <NUM> as determined in accordance with ISO <NUM>-1A on a molded part having a thickness of <NUM>.

The polycarbonate blend or article may further comprise at least one impact modifier.

The polycarbonate blend or molded article may further comprise a flame retardant, an anti-drip agent, or a combination comprising at least one of the foregoing, wherein optionally the flame retardant comprises an alkali metal salt of a perfluorinated C<NUM>-C<NUM> alkyl sulfonate, an inorganic acid complex salt, or a combination comprising at least one of the foregoing.

The polycarbonate blend or molded article may further comprise a filler composition.

The molded article can be a housing component of a consumer electronic device or an automotive bezel or reflector.

The invention also provides a method of forming a molded article comprising:
injecting a composition into a mold, the composition comprising:.

For some applications in the market that required low temperature impact performance, blends of polycarbonate/polysiloxanes are used because compositions including these blends may have good flow, high impact and good aesthetics values in addition to very good release properties compared with normal polycarbonate. Current commercial products are based on a blend of interfacial polycarbonate and a polysiloxane copolymer in different ratios; depending on these ratios the properties of the final product, such as release performance, can vary.

It has been surprisingly found that blends including (i) a polycarbonate-siloxane copolymer having a siloxane content of <NUM> wt% to <NUM> wt% (or about <NUM> wt% to about <NUM> wt%) based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% (or about <NUM> wt% to about <NUM> wt%) based on the total weight of the composition and (ii) melt polycarbonate have improved release properties, as measured via (a) ejection force or (b) release from mold coefficient of friction over substantially similar reference compositions including interfacial polycarbonate instead of melt polycarbonate.

As used herein, a "substantially similar reference composition" is a composition consisting essentially of the same amounts of the same components as the subject composition prepared under the same conditions within tolerance. However, the substantially similar reference composition may explicitly substitute certain components (e.g., interfacial polycarbonate in place of melt polycarbonate) as a demonstration of the comparative performance between the compared compositions.

The terms "polycarbonate" or "polycarbonates" as used herein include copolycarbonates, homopolycarbonates, (co)polyester carbonates and combinations thereof.

The term polycarbonate can be further defined as compositions have repeating structural units of the formula (<NUM>):
<CHM>
in which at least <NUM> percent of the total number of R<NUM> groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic, or aromatic radicals. In a further aspect, each R<NUM> is an aromatic organic radical and, in particular, a radical of the formula (<NUM>):.

wherein each of A<NUM> and A<NUM> is a monocyclic divalent aryl radical and Y<NUM> is a bridging radical having one or two atoms that separate A<NUM> from A<NUM>. In various aspects, one atom separates A<NUM> from A<NUM>. For example, radicals of this type include, but are not limited to, radicals such as -O-, -S-, -S(O) -, -S(O<NUM>) -, -C(O) -, methylene, cyclohexyl-methylene, <NUM>-[<NUM>. <NUM>]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene, and adamantylidene. The bridging radical Y<NUM> may be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene, or isopropylidene. Polycarbonate materials include materials disclosed and described in <CIT>, which is cited for the specific purpose of disclosing various polycarbonate compositions and methods for manufacture of same. Polycarbonate polymers can be manufactured by means known to those skilled in the art.

Some polycarbonates are linear bisphenol-A polycarbonates produced by melt polymerization. The melt polycarbonate process is based on continuous reaction of a dihydroxy compound and a carbonate source in a molten stage. The reaction can occur in a series of reactors where the combined effect of catalyst, temperature, vacuum, and agitation allows for monomer reaction and removal of reaction by-products to displace the reaction equilibrium and effect polymer chain growth. A common polycarbonate made in melt polymerization reactions is derived from bisphenol A (BPA) via reaction with diphenyl carbonate (DPC). This reaction can be catalyzed by, for example, tetra methyl ammonium hydroxide (TMAOH) or tetrabutyl phosphonium acetate (TBPA), which can be added in to a monomer mixture prior to being introduced to a first polymerization unit and sodium hydroxide (NaOH), which can be added to the first reactor or upstream of the first reactor and after a monomer mixer.

The polycarbonates may be linear bisphenol-A polycarbonates produced by melt polymerization. The melt polycarbonate process is based on continuous reaction of a dihydroxy compound and a carbonate source in a molten stage. The reaction can occur in a series of reactors where the combined effect of catalyst, temperature, vacuum, and agitation allows for monomer reaction and removal of reaction by-products to displace the reaction equilibrium and effect polymer chain growth. A common polycarbonate made in melt polymerization reactions is derived from bisphenol A (BPA) via reaction with diphenyl carbonate (DPC). This reaction can be catalyzed by, for example, tetra methyl ammonium hydroxide (TMAOH) or tetrabutyl phosphonium acetate (TBPA), which can be added in to a monomer mixture prior to being introduced to a first polymerization unit and sodium hydroxide (NaOH), which can be added to the first reactor or upstream of the first reactor and after a monomer mixer.

The melt polycarbonate in some aspects may have a molecular weight (Mw) of about <NUM>,<NUM> to about <NUM>,<NUM> Dalton when measured using gel permeation chromatography (GPC) methods on a polycarbonate basis. The melt polycarbonate product may have an endcap level of about <NUM>% to about <NUM>% or <NUM> % to <NUM> %. Some polycarbonates have an endcap level of about <NUM>% to about <NUM>%, about <NUM> % to about <NUM>%, about <NUM>% to about <NUM>% or about <NUM>% to about <NUM>%. In further examples, some polycarbonates have an endcap level of <NUM>% to <NUM>%, <NUM> % to <NUM>%, <NUM>% to <NUM>% or <NUM>% to <NUM>%. Certain polycarbonates have at least <NUM> parts per million (ppm) of hydroxide groups. Certain polycarbonates have <NUM> ppm -<NUM> ppm or <NUM> ppm to <NUM> ppm hydroxide groups.

The polycarbonate polymer may contain endcapping agents. Any suitable endcapping agents can be used provided that such agents do not significantly adversely impact the desired properties of the polycarbonate composition (transparency, for example). Endcapping agents include mono-phenolic compounds, mono-carboxylic acid chlorides, and/or mono-chloroformates. Mono-phenolic endcapping agents are exemplified by monocyclic phenols such as phenol and C<NUM>-C<NUM> alkyl-substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p- and tertiary-butyl phenol; and monoethers of diphenols, such as p-methoxyphenol.

Additionally, some polycarbonates include from about <NUM> ppm to about <NUM> ppm, or from about <NUM> ppm to about <NUM> ppm Fries products. Fries products include ester type of structures A, B, and C.

Apart from the main polymerization reaction in polycarbonate production, there is a series of side reactions consisting of chain rearrangements of the polymer backbone that lead to branching that are often referred to as Fries rearrangement. The Fries species specifically found in bisphenol A melt polycarbonates include the ester type of structures A, B, and C.

The Fries reaction is induced by the combined effect of basic catalysts, temperature, and residence time, which generally result in melt-produced polycarbonates being branched as compared with the interfacial polycarbonates since their manufacturing temperatures are lower. Because high branching levels in the resin can have a negative effect on the mechanical properties of the polycarbonate (for example, on impact strength), a product with lower branched Fries product may be desirable.

In some aspects the polycarbonate polymer is a linear bisphenol-A polycarbonate produced by a melt polymerization process. In other aspects the polycarbonate polymer is a linear bisphenol-A polycarbonate produced by an interfacial polymerization process.

In some compositions, the polycarbonate polymer comprises at least one polycarbonate polymer having a molecular weight (Mw) of at least <NUM>,<NUM> grams per mole (g/mol) and a second polycarbonate polymer have a molecular weight (Mw) of less than <NUM>,<NUM>/mol. In some compositions, the molar ratio of said first polycarbonate polymer to said second polycarbonate polymer is about <NUM>:<NUM> to about <NUM>:<NUM>. In other compositions, the molar ratio of said first polycarbonate polymer to said second polycarbonate polymer is about <NUM>:<NUM> to about <NUM>:<NUM>.

In some compositions, an amount of polycarbonate made by an interfacial process may be used in addition to the polycarbonate made by a melt process. In some aspects, <NUM> wt% to <NUM> wt% or <NUM> wt% to <NUM> wt% or <NUM> to <NUM> wt% (or <NUM> wt% to about <NUM> wt% or about <NUM> wt% to about <NUM> wt% or about <NUM> to about <NUM> wt%) of one or more polycarbonates produced by an interfacial polymerization process may be present in an amount based on the total amount of polycarbonate.

As used herein, the term "polycarbonate-polysiloxane copolymer" is equivalent to polysiloxane-polycarbonate copolymer, polycarbonate-polysiloxane polymer, or polysiloxane-polycarbonate polymer. In various aspects, the polycarbonate-polysiloxane copolymer can be a block copolymer comprising one or more polycarbonate blocks and one or more polysiloxane blocks. In some aspects, the polysiloxane-polycarbonate copolymer comprises polydiorganosiloxane blocks comprising structural units of the general formula (<NUM>) below:
<CHM>
wherein the polydiorganosiloxane block length (E) is from <NUM> to <NUM>, preferably <NUM> to <NUM>, more preferably <NUM> to <NUM>; wherein each R group can be the same or different, and is selected from a C<NUM>-<NUM> monovalent organic group; wherein each M can be the same or different, and is selected from a halogen, cyano, nitro, C<NUM>-C<NUM> alkylthio, C<NUM>-C<NUM> alkyl, C<NUM>-C<NUM> alkoxy, C<NUM>-C<NUM> alkenyl, C<NUM>-C<NUM> alkenyloxy group, C<NUM>-C<NUM> cycloalkyl, C<NUM>-C<NUM> cycloalkoxy, C<NUM>-C<NUM> aryl, C<NUM>-C<NUM> aryloxy, C<NUM>-C<NUM> aralkyl, C<NUM>- C<NUM>aralkoxy, C<NUM>- C<NUM> alkylaryl, or C<NUM>- C<NUM> alkylaryloxy, and where each n is independently <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. The polysiloxane-polycarbonate copolymer also comprises polycarbonate blocks comprising structural units of the general formula (<NUM>) below:
<CHM>
wherein at least <NUM> percent of the total number of R<NUM> groups comprise aromatic moieties and the balance thereof comprise aliphatic, alicyclic, or aromatic moieties.

Certain polycarbonate-polysiloxane resins comprise allylphenol capped siloxanes. Such resins comprise the structure of the general formula (<NUM>) below:
<CHM>
where R is an alkyl group having <NUM>-<NUM> carbon atoms, n1 is an integer of from <NUM> to <NUM> and n2 is an integer of from <NUM> to <NUM>. Polycarbonate-polysiloxane copolymers comprising such structures can be found in <CIT>.

Certain polysiloxane-polycarbonates materials include materials disclosed and described in <CIT>.

The polycarbonate-siloxane copolymer comprises about <NUM> wt% to about <NUM> wt% (or <NUM> wt% to <NUM> wt%) siloxane. In particular aspects, the polycarbonate-siloxane copolymer comprises about <NUM> to about <NUM> wt% siloxane. Certain polycarbonate-polysiloxane copolymers have a polydiorganosiloxane block having from about <NUM> to about <NUM> diorganosiloxane units. The polycarbonate-siloxane copolymer is present in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% or of about <NUM> wt% to about <NUM> wt. % based on the total weight of the composition.

Examples of mold release agents include both aliphatic and aromatic carboxylic acids and their alkyl esters, for example, stearic acid, behenic acid, pentaerythritol stearate, glycerin tristearate, and ethylene glycol distearate. Polyolefins such as high-density polyethylene, linear low-density polyethylene, low-density polyethylene, and similar polyolefin homopolymers and copolymers can also be used a mold release agents.

Some compositions use pentaerythritol stearate, glycerol monostearate, a wax or a poly-alpha-olefin.

Mold release agents are optional but are often used to facilitate release of the article from the mold. Mold release agents are typically present in the composition at <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, based on total weight of the composition, and in particular aspects from <NUM> wt% to <NUM> wt% or about <NUM> to about <NUM> wt%, from <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, or from <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%. Particular aspects have less than <NUM> wt%, or even less than <NUM> wt% release agent.

In some aspects the mold release agents will have high molecular weight, typically greater than <NUM>, to prevent loss of the release agent from the molten polymer mixture during melt processing.

The additive composition can include an impact modifier, flow modifier, antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) light stabilizer, UV absorbing additive, plasticizer, lubricant, antistatic agent, anti-fog agent, antimicrobial agent, colorant (e.g., a dye or pigment), surface effect additive, radiation stabilizer, anti-drip agent (e.g., a PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or a combination comprising one or more of the foregoing. For example, a combination of a heat stabilizer and ultraviolet light stabilizer can be used. In general, the additives are used in the amounts generally known to be effective. For example, the total amount of the additive composition can be from <NUM> wt% to <NUM> wt% or about <NUM> to about <NUM> wt%, or from <NUM> wt% to <NUM> wt% or about <NUM> to about <NUM> wt%, each based on the total weight of all ingredients in the composition.

The composition can include 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 thermoplastic composition (good compatibility for example). Such additives can be mixed at a suitable time during the mixing of the components for forming the composition.

Examples of impact modifiers include natural rubber, fluoroelastomers, ethylene-propylene rubber (EPR), ethylene-butene rubber, ethylene-propylene-diene monomer rubber (EPDM), acrylate rubbers, hydrogenated nitrile rubber (HNBR), silicone elastomers, styrene-butadiene-styrene (SBS), styrene-butadiene rubber (SBR), styrene-(ethylene-butene)-styrene (SEBS), acrylonitrile-butadiene-styrene (ABS), acrylonitrile-ethylene-propylene-diene-styrene (AES), styrene-isoprene-styrene (SIS), styrene-(ethylene-propylene)-styrene (SEPS), methyl methacrylate-butadiene-styrene (MBS), high rubber graft (HRG), and the like. Some suitable impact modifies include PC(polycarbonate)/ABS (such as Cycoloy PC/ABS) and MBS type formulations.

Heat stabilizer additives include organophosphites (e.g. triphenyl phosphite, tris-(<NUM>,<NUM>-dimethylphenyl)phosphite, tris-(mixed mono-and di-nonylphenyl)phosphite or the like), phosphonates (e.g., dimethylbenzene phosphonate or the like), phosphates (e.g., trimethyl phosphate, or the like), or combinations comprising at least one of the foregoing heat stabilizers. The heat stabilizer can be tris(<NUM>,<NUM>-di-t-butylphenyl) phosphate available as Irgafos™ <NUM>. Heat stabilizers are generally used in amounts of from <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, based on the total weight of polymer in the composition.

There is considerable overlap among plasticizers, lubricants, and mold release agents, which include, for example, glycerol tristearate (GTS), phthalic acid esters (e.g., octyl-<NUM>,<NUM>-epoxy-hexahydrophthalate), tris-(octoxycarbonylethyl)isocyanurate, tristearin, 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); esters, for example, fatty acid esters (e.g., alkyl stearyl esters, such as, methyl stearate, stearyl stearate, and the like), polyethylene, 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 from about <NUM> to about <NUM> wt%, based on the total weight of the polymer in the composition.

Light stabilizers, in particular ultraviolet light (UV) absorbing additives, also referred to as UV stabilizers, include hydroxybenzophenones (e.g., <NUM>-hydroxy-<NUM>-n-octoxy benzophenone), hydroxybenzotriazines, cyanoacrylates, oxanilides, benzoxazinones (e.g., <NUM>,<NUM>'-(<NUM>,<NUM>- phenylene)bis(<NUM>-<NUM>,<NUM>-benzoxazin-<NUM>-one, commercially available under the trade name CYASORB UV-<NUM> from Cytec), aryl salicylates, hydroxybenzotriazoles (e.g., <NUM>-(<NUM>-hydroxy-<NUM>-methylphenyl)benzotriazole, <NUM>-(<NUM>-hydroxy-<NUM>-tert-octylphenyl)benzotriazole, and <NUM>-(<NUM>-benzotriazol-<NUM>-yl)-<NUM>-(<NUM>,<NUM>,<NUM>,<NUM>-tetramethylbutyl)-phenol, commercially available under the trade name CYASORB <NUM> from Cytec) or combinations comprising at least one of the foregoing light stabilizers. The UV stabilizers can be present in an amount of from about <NUM> to about <NUM> wt%, specifically, from <NUM> wt% to <NUM> wt% or about <NUM> to about <NUM> wt%, and more specifically, from <NUM> wt% to <NUM> wt% or about <NUM> to about <NUM> wt%, based upon the total weight of polymer in the composition.

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

Anti-drip agents can also be used in the composition, for example a fibril forming or non-fibril forming fluoropolymer such as polytetrafluoroethylene (PTFE). The anti-drip agent can be encapsulated by a rigid copolymer, for example styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is known as TSAN. A TSAN comprises about <NUM> wt% PTFE and about <NUM> wt% SAN, based on the total weight of the encapsulated fluoropolymer. The SAN can comprise, for example, about <NUM> wt% styrene and about <NUM> wt% acrylonitrile based on the total weight of the copolymer. Antidrip agents can be used in amounts of <NUM> parts by weight to <NUM> parts by weight or about <NUM> to about <NUM> parts by weight, based on <NUM> parts by weight of the total composition, excluding any filler.

The polycarbonate compositions may optionally include flame retardants. Various types of flame retardants can be utilized. In one aspect, the flame retardant additives include, for example, flame retardant salts such as alkali metal salts of perfluorinated C1-C16 alkyl sulfonates such as potassium perfluorobutane sulfonate (Rimar salt), potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate (KSS), and the like, sodium benzene sulfonate, sodium toluene sulfonate (NATS) and the like; and salts formed by reacting for example an alkali metal or alkaline earth metal (for example lithium, sodium, potassium, magnesium, calcium and barium salts) and an inorganic acid complex salt, for example, an oxo-anion, such as alkali metal and alkaline-earth metal salts of carbonic acid, such as sodium carbonate Na<NUM>CO<NUM>, potassium carbonate K<NUM>CO<NUM>, magnesium carbonate MgCO<NUM>, calcium carbonate CaCO<NUM>, and barium carbonate BaCO<NUM> or fluoro-anion complex such as lithium hexafluoroaluminate Li<NUM>AlF<NUM>, barium hexafluorosilicate BaSiF<NUM>, potassium tetrafluoroborate KBF<NUM>, potassium hexafluoroaluminate K<NUM>AlF<NUM>, potassium tetrafluoroaluminate KAlF<NUM>, potassium hexafluorosilicate K<NUM>SiF<NUM>, and/or sodium hexafluoroaluminate Na<NUM>AlF<NUM> or the like. Rimar salt and KSS and NATS, alone or in combination with other flame retardants, are particularly useful in the compositions disclosed herein.

The polycarbonate compositions can optionally include a colorant composition containing pigment and/or dye additives. Useful pigments can include, for example, inorganic pigments such as metal oxides and mixed metal oxides such as zinc oxide, titanium dioxides, iron oxides, or the like; sulfides such as zinc sulfides, or the like; aluminates; sodium sulfo-silicates sulfates, chromates, or the like; carbon blacks; zinc ferrites; ultramarine blue; organic pigments such as azos, di-azos, quinacridones, perylenes, naphthalene tetracarboxylic acids, flavanthrones, isoindolinones, tetrachloroisoindolinones, anthraquinones, enthrones, dioxazines, phthalocyanines, and azo lakes; Pigment Red <NUM>, Pigment Red <NUM>, Pigment Red <NUM>, Pigment Red <NUM>, Pigment Red <NUM>, Pigment Red <NUM>, Pigment Violet <NUM>, Pigment Blue <NUM>, Pigment Blue <NUM>, Pigment Green <NUM>, Pigment Yellow <NUM>, Pigment Yellow <NUM>, Pigment Yellow <NUM>, and Pigment Brown <NUM>; or combinations comprising at least one of the foregoing pigments.

Dyes are generally organic materials and include coumarin dyes such as coumarin <NUM> (blue), coumarin <NUM> (green), nile red or the like; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hydrocarbon dyes; scintillation dyes such as oxazole or oxadiazole dyes; aryl- or heteroaryl-substituted poly (C2-<NUM>) olefin dyes; carbocyanine dyes; indanthrone dyes; phthalocyanine dyes; oxazine dyes; carbostyryl dyes; napthalenetetracarboxylic acid dyes; porphyrin dyes; bis(styryl)biphenyl dyes; acridine dyes; anthraquinone dyes; cyanine dyes; methine dyes; arylmethane dyes; azo dyes; indigoid dyes, thioindigoid dyes, diazonium dyes; nitro dyes; quinone imine dyes; aminoketone dyes; tetrazolium dyes; thiazole dyes; perylene dyes, perinone dyes; bis-benzoxazolylthiophene (BBOT); triarylmethane dyes; xanthene dyes; thioxanthene dyes; naphthalimide dyes; lactone dyes; fluorophores such as anti-stokes shift dyes which absorb in the near infrared wavelength and emit in the visible wavelength, or the like; luminescent dyes such as <NUM>-amino-<NUM>-methylcoumarin; <NUM>-(<NUM>'-benzothiazolyl)-<NUM>-diethylaminocoumarin; <NUM>-(<NUM>-biphenylyl)-<NUM>-(<NUM>-t-butylphenyl)-<NUM>,<NUM>,<NUM>-oxadiazole; <NUM>,<NUM>-bis-(<NUM>-biphenylyl)-oxazole; <NUM>,<NUM>'-dimethyl-p-quaterphenyl; <NUM>,<NUM>-dimethyl-p-terphenyl; <NUM>,<NUM>,<NUM>"",<NUM>""-tetra-t-butyl-p-quinquephenyl; <NUM>,<NUM>-diphenylfuran; <NUM>,<NUM>-diphenyloxazole; <NUM>,<NUM>'-diphenylstilbene; <NUM>-dicyanomethylene-<NUM>-methyl-<NUM>-(p-dimethylaminostyryl)-<NUM>-pyran; <NUM>,<NUM>'-diethyl-<NUM>,<NUM>'-carbocyanine iodide; <NUM>,<NUM>'-diethyl-<NUM>,<NUM>',<NUM>,<NUM>'-dibenzothiatricarbocyanine iodide; <NUM>-dimethylamino-<NUM>-methyl-<NUM>-methoxy-<NUM>-azaquinolone-<NUM>; <NUM>-dimethylamino-<NUM>-methylquinolone-<NUM>; <NUM>-(<NUM>-(<NUM>-dimethylaminophenyl)-<NUM>,<NUM>-butadienyl)-<NUM>-ethylbenzothiazolium perchlorate; <NUM>-diethylamino-<NUM>-diethyliminophenoxazonium perchlorate; <NUM>-(<NUM>-naphthyl)-<NUM>-phenyloxazole; <NUM>,<NUM>'-p-phenylen-bis(<NUM>-phenyloxazole); rhodamine <NUM>; rhodamine <NUM>; pyrene, chrysene, rubrene, coronene, or the like; or combinations comprising at least one of the foregoing dyes.

The composition can have any suitable color including white, gray, light gray, black, and the like. The white or light gray color can exhibit an L* value greater than or equal to <NUM>. A composition having a white or light gray color can comprise an amount of titanium dioxide in amounts of <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, or <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt%, each based on the total weight of the polycarbonate composition.

The gray or black color can exhibit an L* value of below <NUM>. A composition having a gray or black color can comprise an amount of carbon black of greater than zero and less than <NUM> wt% based on the total weight of the colorant composition. In an aspect, a molded sample having a thickness of <NUM> and comprising the composition has an average L* value of <NUM> or less as measure by the CIE Lab method, <NUM> degree observer, D65 illuminant, specular component included, measured in reflectance mode.

The polymer compositions can be formed by techniques known to those skilled in the art. Extrusion and mixing techniques, for example, may be utilized to combine the components of the polymer composition.

The polymer composition may comprise (i) about <NUM> wt% to about <NUM> wt% of polycarbonate, (ii) about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition, and <NUM> to about <NUM> wt% or about <NUM> wt% to about <NUM> wt% of at least one release agent. Some polymer compositions may comprise (i) about <NUM> wt% to about <NUM> wt% of polycarbonate, (ii) about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer, and about <NUM> wt% to about <NUM> wt% of at least one release agent. Certain polymer compositions comprise about (i) <NUM> wt% to about <NUM> wt% polycarbonate; (ii) about <NUM> wt% to about <NUM> wt% polycarbonate-polysiloxane copolymer; and (iii) about <NUM> wt% to about <NUM> wt% release agent.

In some aspects, the composition has a siloxane content of about <NUM> to about <NUM> wt% based on the total composition. In other aspects, the composition has a siloxane content of <NUM> wt% to <NUM> wt% or about <NUM> wt% to about <NUM> wt % based on the total composition.

The polymer mixtures of the instant disclosure may have a melt flow volume rate (MVR) of at least <NUM> or <NUM> or <NUM> or <NUM> or <NUM><NUM>/<NUM> or at least <NUM><NUM>/<NUM> when measured according to ISO <NUM> at <NUM> and <NUM>.

Polymer compositions/molded articles formed according to the present disclosure may be used in any number of applications. Suitable applications include, but are not limited to:.

It is to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the aspects "consisting of" and "consisting essentially of. " Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

As used in the specification and the appended claims, the singular forms "a," "an" and "the" include plural equivalents unless the context clearly dictates otherwise. Thus, for example, reference to "a polycarbonate polymer" includes mixtures of two or more polycarbonate polymers.

Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent 'about,' it will be understood that the particular value forms another aspect. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself. When more than one range for a particular value is disclosed, the ranges are combinable to form additional aspects.

As used herein, the terms "about" and "at or about" mean that the amount or value in question can be the designated value, approximately the designated value, or about the same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ±<NUM>% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is "about" or "approximate" whether or not expressly stated to be such. It is understood that where "about" is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

Disclosed are the components to be used to prepare the compositions of the disclosure as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited each is individually and collectively contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.

References in the specification and concluding claims to parts by weight, of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a compound containing <NUM> parts by weight of component X and <NUM> parts by weight component Y, X and Y are present at a weight ratio of <NUM>:<NUM>, and are present in such ratio regardless of whether additional components are contained in the compound.

As used herein the terms "weight percent," "weight %," and "wt%" of a component, which can be used interchangeably, unless specifically stated to the contrary, are based on the total weight of the formulation or composition in which the component is included. For example if a particular element or component in a composition or article is said to have <NUM>% by weight, it is understood that this percentage is relative to a total compositional percentage of <NUM>% by weight.

As used herein, the terms "weight average molecular weight" or "Mw" can be used interchangeably, and are defined by the formula: <MAT> where Mi is the molecular weight of a chain and Ni is the number of chains of that molecular weight. Mw can be determined for polymers, e.g., polycarbonate polymers, by methods well known to a person having ordinary skill in the art using molecular weight standards, e.g. polycarbonate standards or polystyrene standards, and in particular certified or traceable molecular weight standards. Polystyrene basis refers to measurements using a polystyrene standard.

The term "siloxane" refers to a segment having a Si-O-Si linkage.

The term "flowable" means capable of flowing or being flowed. Typically a polymer is heated such that it is in a melted state to become flowable.

"Interfacial polycarbonate" is produced by a process where typically the disodium salt of bisphenol A (BPA) is dissolved in water and reacted with phosgene which is typically dissolved in a solvent that not miscible with water.

"Melt polycarbonate" is produced by a process where BPA reacts with diphenyl carbonate (DPC) in a molten state without the solvent.

Melt Volume Flow Rate (MVR) is measured according to ISO <NUM> at <NUM> and <NUM>.

Izod Notched Impact tests are performed according to ISO <NUM>-1A.

Ejection force may be measured by injection molding sleeves in a core and then measuring the force necessary to remove the sleeve from the core. For example, ejection force of a molded article comprising the polycarbonate blend may be evaluated by injection molding a sleeve in a core and determining the force necessary to remove the sleeve from the core. At the opening of the mold, the sleeve remains on the core due to the material contraction. At the end of the opening stroke, the ejector pins detach the sleeve from the core. The force applied to the sleeve for demolding is measured as the ejection force. The surface temperature of the sleeve is kept constant so that an accurate comparison of ejection forces can be made. A mold <NUM> comprising a sleeve <NUM> and sprue <NUM> suitable for use in determining ejection force is shown in <FIG>. The sleeve <NUM> is presented with the core <NUM> disposed therein. Ejection force, or mold release force (FR), for demolding may be determined according to equation (<NUM>): <MAT> where Cf is the coefficient of friction between the sleeve and the core while FN refers to the normal force applied on the core due to shrinkage.

Dimensions of the sleeve shown in <FIG> are in millimeters (mm) for the sleeve <NUM> configured to the sprue <NUM>. Ejection force can be measured with a composition formed into the exemplary sleeve/mold of <FIG>. It should be noted that other sleeves/molds with other dimensions could be used for comparing the compositions of the disclosure to the reference compositions. In further aspects, ejection force may be measured according to UL410.

Measurement process parameters are as follows.

The term "metalized" means that the article or molded part is partially or fully coated with a metal. The coating may be made by any means known in the art.

The present disclosure comprises at least the following aspects.

Aspect <NUM>. A polycarbonate blend comprising: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend comprising: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend having a release from mold coefficient of friction that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend comprising: <NUM> wt% to <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; <NUM> wt% to <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend comprising: <NUM> wt% to <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; <NUM> wt% to <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to <NUM> wt% release agent; wherein the polycarbonate blend having a release from mold coefficient of friction that is at least <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend consisting essentially of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend consisting essentially of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend having a release from mold coefficient of friction that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend consisting of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A polycarbonate blend consisting of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend having a release from mold coefficient of friction that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process.

Aspect <NUM>. A molded article comprising the polycarbonate blend of any one of aspects <NUM>-<NUM>.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM> having a siloxane content of about <NUM> to <NUM> wt% based on the total weight of the polycarbonate blend or molded article.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM> having a siloxane content of <NUM> to <NUM> wt% based on the total weight of the polycarbonate blend or molded article.

Aspect <NUM>. The molded article of any one of Aspects <NUM>-<NUM> having an ejection force of less than <NUM> N, when ejection force of a molded article comprising the polycarbonate blend is evaluated by injection molding a sleeve in a core and determining the force necessary to remove the sleeve from the core.

Aspect <NUM>. The molded article of any one of Aspects <NUM>-12having (i) an ejection force of less than <NUM> Newton (N), preferably less than <NUM> N, more preferably less than <NUM> N and (ii) a release from mold coefficient of friction of less than <NUM>, preferably less than <NUM> and more preferably less than <NUM>, as measured by UL410.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the poly(carbonate-siloxane) copolymer comprises bisphenol carbonate units of the formula
<CHM>
wherein.

or a combination comprising at least one of the foregoing, wherein.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend has a Fries number of about <NUM> ppm or higher or <NUM> ppm or higher or <NUM> ppm or higher or <NUM> ppm or higher based on the total composition.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend has a Fries number of <NUM> ppm or higher or <NUM> ppm or higher or <NUM> ppm or higher or <NUM> ppm or higher based on the total composition.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend or article comprises: about <NUM> wt% to about <NUM> wt% polycarbonate; about <NUM> wt% to about <NUM> wt% polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition; and about <NUM> wt% to about <NUM> wt% release agent.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend or article comprises: <NUM> wt% to <NUM> wt% polycarbonate; <NUM> wt% to <NUM> wt% polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the composition; and <NUM> wt% to <NUM> wt% release agent.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, additionally comprising a processing aid, a heat stabilizer, an antioxidant, an ultra violet light absorber, or a combination comprising at least one of the foregoing.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the release agent is present in an amount of about <NUM> wt% or less or about <NUM> wt% or less.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend or article has a siloxane content of about <NUM> to about <NUM> wt%, or of about <NUM> to about <NUM> wt% based on the total weight of the composition.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend or article has a siloxane content of <NUM> to <NUM> wt%, or of <NUM> to <NUM> wt% based on the total weight of the composition.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the polycarbonate blend has a melt volume rate ("MVR"), determined in accordance with ISO <NUM> under a load of <NUM> at <NUM>, higher than <NUM> or higher than <NUM> or higher than <NUM> or higher than <NUM>.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the polycarbonate blend has a ductile/brittle transition temperature of less than or equal to <NUM> or less than or equal to <NUM>, or less than or equal to -<NUM>, or less than or equal to -<NUM> as determined in accordance with ISO <NUM>-1A on a molded part having a thickness of <NUM>.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the release agent comprises one or more of pentaerythritol stearate, glycerol monostearate and poly-alpha-olefin.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, wherein the blend or article additionally comprises at least one impact modifier.

Aspect <NUM>. The polycarbonate blend or molded article of any one or more of Aspects <NUM>-<NUM>, further comprising a flame retardant, an anti-drip agent, or a combination comprising at least one of the foregoing, wherein optionally the flame retardant comprising an alkali metal salt of a perfluorinated C<NUM>-C<NUM> alkyl sulfonate, an inorganic acid complex salt, or a combination comprising at least one of the foregoing.

Aspect <NUM>. The polycarbonate blend or molded article of any one or more of Aspects <NUM>-<NUM>, further comprising a filler composition.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, additionally comprising <NUM> wt% to <NUM> wt% of one or more polycarbonates produced by an interfacial polymerization process present in a ratio of <NUM>% or less based on the total amount of polycarbonate.

Aspect <NUM>. The polycarbonate blend or molded article of any one of Aspects <NUM>-<NUM>, additionally comprising <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by an interfacial polymerization process present in a ratio of <NUM>% or less based on the total amount of polycarbonate.

Aspect <NUM>. The molded article of any one of Aspects <NUM>-<NUM>-<NUM> wherein the molded 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 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,.

Aspect <NUM>. The molded article of any one of Aspects <NUM>-<NUM>, wherein the article is a housing of a consumer electronic device or an automotive bezel or automotive reflector.

Aspect <NUM>. The molded article of any one of Aspects <NUM>-<NUM>, wherein the article is metallized.

Aspect <NUM>. A method of forming a molded article comprising: injecting a composition into a mold, the composition comprising: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process, and releasing the composition from the mold.

Aspect <NUM>. A method of forming a molded article comprising: injecting a composition into a mold, the composition comprising: <NUM> wt% to <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; <NUM> wt% to <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the composition; <NUM> wt% to <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process, and releasing the composition from the mold.

Aspect <NUM>. A method of forming a molded article comprising: injecting a composition into a mold, the composition consisting essentially of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process, and releasing the composition from the mold.

Aspect <NUM>. A method of forming a molded article comprising: injecting a composition into a mold, the composition consisting of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition; <NUM> wt% to about <NUM> wt% release agent; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference composition including only polycarbonates produced by an interfacial polymerization process, and releasing the composition from the mold.

Aspect <NUM>. The method of any one of aspects34-<NUM>, wherein the composition comprises: about <NUM> wt% to about <NUM> wt% polycarbonate; about <NUM> wt% to about <NUM> wt% polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the composition; and about <NUM> wt% to about <NUM> wt% release agent.

Aspect <NUM>. The method of any one of aspects <NUM>-<NUM>, wherein the composition comprises: <NUM> wt% to <NUM> wt% polycarbonate; <NUM> wt% to <NUM> wt% polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the composition; and <NUM> wt% to <NUM> wt% release agent.

Aspect <NUM>. The method of any one of aspects <NUM>-<NUM>, wherein the release agent is present in an amount of <NUM> wt% or less.

Aspect <NUM>. The method of any one of <NUM>-<NUM>, wherein the polycarbonate has a molecular weight (Mw) of about <NUM>,<NUM> to about <NUM>,<NUM>/mol.

Aspect <NUM>. The method of any one of Aspects <NUM>-<NUM>, wherein the polycarbonate has a molecular weight (Mw) of <NUM>,<NUM> to <NUM>,<NUM>/mol.

Aspect <NUM>. The method of any one of Aspects <NUM>-<NUM>, wherein the polycarbonate-polysiloxane copolymer has a molecular weight (Mw) of about <NUM>,<NUM> to about <NUM>,<NUM>/mol.

Aspect <NUM>. The method of any one of Aspects <NUM>-<NUM>, wherein the polycarbonate-polysiloxane copolymer has a molecular weight (Mw) of <NUM>,<NUM> to <NUM>,<NUM>/mol.

Aspect <NUM>. A polycarbonate blend comprising: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process when ejection force is evaluated by injection molding a sleeve formed from the polycarbonate blend in a core and determining the force necessary to remove the sleeve from the core.

Aspect <NUM>. A polycarbonate blend comprising: <NUM> wt% to <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; <NUM> wt% to <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate blend; wherein the polycarbonate blend has a release from mold ejection force that is at least <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process when ejection force is evaluated by injection molding a sleeve formed from the polycarbonate blend in a core and determining the force necessary to remove the sleeve from the core.

Aspect <NUM>. A polycarbonate blend consisting essentially of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process when ejection force is evaluated by injection molding a sleeve formed from the polycarbonate blend in a core and determining the force necessary to remove the sleeve from the core.

Aspect <NUM>. A polycarbonate blend consisting of: about <NUM> wt% to about <NUM> wt% of one or more polycarbonates produced by a melt polymerization process; about <NUM> wt% to about <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of about <NUM> wt% to about <NUM> wt% based on the total weight of the polycarbonate blend; wherein the polycarbonate blend has a release from mold ejection force that is at least about <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process when ejection force is evaluated by injection molding a sleeve formed from the polycarbonate blend in a core and determining the force necessary to remove the sleeve from the core.

The following non-limited examples illustrate certain aspects of the disclosure.

Formulations were prepared using the components presented in Table <NUM>:.

Tables 2A and 2B present ejection force and impact strength testing values.

This demonstrates that the compositions give unexpected benefits in ejection force when using polycarbonate made by melt polymerization process in combination with particular PC-Si types. Effects are significantly positive for Si-PC copolymers containing relatively high siloxane content (PC-Si1, having <NUM>%), but not for Si-PC copolymers containing relatively low siloxane content (Si-PC2, having <NUM>% siloxane). This demonstrates that optimization of the composition is possible when using polycarbonate made by melt polymerization process in combination with PC-Si having a relatively high siloxane loading.

The results in the table show that the improvement in ejection force for compositions containing PC-Si1 and polycarbonate made by melt polymerization process compared to the same composition with polycarbonate made by interfacial polymerization process (CE15) are achieved for different Fries levels for the melt polycarbonate with Fries levels for the composition ranging from <NUM> to <NUM> ppm (E16-E19).

Thus, melt polycarbonate compositions including a PC-siloxane copolymer and release agent consistently had better release performance than substantially similar reference compositions including interfacial PC instead of melt PC.

Additional formulations are presented in Tables 4A and 4B. The samples include varying amounts of the PC-Si1 component with varying polycarbonate compositions and ratios.

This data further demonstrates that the compositions give unexpected benefits in ejection force when using polycarbonate made by melt polymerization process in combination with particular PC-Si types. Furthermore, a lower Fries content (higher molecular weight) of the melt polycarbonate by increase the ejection force observed.

Claim 1:
A polycarbonate blend comprising:
<NUM> wt% to <NUM> wt% of one or more polycarbonates produced by a melt polymerization process;
<NUM> wt% to <NUM> wt% of a polycarbonate-polysiloxane copolymer with a siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate-polysiloxane copolymer, in an amount effective to provide a total siloxane content of <NUM> wt% to <NUM> wt% based on the total weight of the polycarbonate blend; and optionally, <NUM> wt% to <NUM> wt% release agent;
wherein the blend has a Fries number of <NUM> ppm or higher based on the total blend; and wherein
the polycarbonate blend has a release from mold ejection force that is at least <NUM>% less than a substantially similar reference blend including only polycarbonates produced by an interfacial polymerization process; or
the polycarbonate blend has a release from mold coefficient of friction that is at least <NUM>% less than a substantially similar reference blend including polycarbonates produced by an interfacial polymerization process.