Patent ID: 8314181

Claim:
A method of forming a resin composition, comprising the steps of: blending 50 to 99 wt. % of a polycarbonate resin with 1 to 50 wt. % of a polyolefin that has been modified with at least one functional group selected from a carboxyl, an acid anhydride, an epoxy groups or mixtures containing at least one of the foregoing functional groups to form a blended mixture; wherein the blended mixture further comprises an unmodified polyolefin selected from crystalline polypropylene, crystalline propylene-ethylene block or random copolymer, low density polyethylene, high density polyethylene, linear low density polyethylene, ultra-high molecular weight polyethylene, ethylene-propylene random copolymer, ethylene-propylene-diene copolymer, or a mixture comprising at least one of the foregoing polyolefins and a bi-functional monomer wherein the bi-functional monomer comprises a monomer represented formula (6): wherein Z is an alkylene group, an alkylidene, an oligomethylene group, a phenylene group, or a naphthylene group containing at least 5 carbon atoms, the phenylene group and the naphthylene group being optionally substituted with a substituent, a monomer represented formula (7): HO—R—OH (7) wherein R is an alkylene group, an alkylidene, an oligomethylene group, a phenylene group, or a naphthylene group containing at least 5 carbon atoms, the phenylene group and the naphthylene group being optionally substituted with a substituent; a monomer represented formula (8): HOOC—R—COOH (8) wherein R is an alkylene group, an alkylidene, an oligomethylene group, a phenylene group, or a naphthylene group containing at least 5 carbon atoms, the phenylene group and the naphthylene group being optionally substituted with a substituent, or combinations of one or more of the foregoing; and extruding the blended mixture to form the resin composition; wherein the blended mixture is extruded in an extruder having a melt residence time of 20 seconds or greater and wherein the extruder is operated at a temperature of 240° C. to 340° C.; and wherein the resin composition has a Notched Izod Impact of 500J/m to 900J/m as measured at room temperature using 3.18 mm (+3%) bars in accordance with a standard selected from ASTM D256.