Abstract: The present invention relates to an aromatic polycarbonate obtained via the melt transesterification of a diaryl carbonate, a bisphenol and an endcapping agent selected from paracumyl phenol, dicumyl phenol, p-tert-butyl phenol and mixtures of at least two of said endcapping agents, said polycarbonate having a melt volume rate of at least 20 cm3/10 min (ISO 1133, 300° C., 1.2 kg), a terminal hydroxyl group content of at most 800 ppm by weight, a Fries branching content of at most 1300 ppm by weight and a content of bulky end groups of at least 20 mol % defined as the sum of the mol % of end-groups based on said bisphenol and the mol % of end-groups based on said endcapping agent.

Abstract: In an embodiment, a reactor for carrying out a melt transesterification reaction at a reactor temperature of 160 to 300° C. and a reactor pressure of 5 to 200 mbar, comprises a cylindrical tank comprising a top, a side, and a bottom, wherein the bottom is convex, extending away from the top; a stirring shaft disposed within the cylindrical tank along an axis thereof so that it is rotatable from outside of the cylindrical tank; a stirring blade extending from the stirring shaft in the cylindrical tank; a reactant solution inlet located on the bottom; and a reaction solution outlet located on the bottom. The reactor can be used for the polymerization of a polycarbonate oligomer.

Abstract: In an embodiment, a reactor for carrying out a melt transesterification reaction at a reactor temperature of 160 to 300° C. and a reactor pressure of 5 to 200 mbar, comprises a cylindrical tank comprising a top, a side, and a bottom, wherein the bottom is convex, extending away from the top; a stirring shaft disposed within the cylindrical tank along an axis thereof so that it is rotatable from outside of the cylindrical tank; a stirring blade extending from the stirring shaft in the cylindrical tank; a reactant solution inlet located on the bottom; and a reaction solution outlet located on the bottom. The reactor can be used for the polymerization of a polycarbonate oligomer.

Abstract: A method of preparing a polycarbonate composition in a polymerization system that comprises a monomer mixing unit, an oligomerization section, and a polymerization section. The method includes melt polymerizing a dihydroxy compound with a diaryl carbonate compound in the presence of a quaternary phosphonium catalyst to produce the polycarbonate composition having a phosphorus-containing byproduct of at least one of the quaternary phosphonium catalyst or of the diaryl carbonate compound. The method further includes recycling the phosphorus-containing byproduct into the monomer mixing unit of the polymerization system and removing the polycarbonate composition from the polymerization system. The recycle stream has a phosphorus concentration of greater than or equal to 40 ppm.

Abstract: The present invention relates to an aromatic polycarbonate obtained via the melt transesterification of a diaryl carbonate, a bisphenol and an endcapping agent selected from paracumyl phenol, dicumyl phenol, p-tert-butyl phenol and mixtures of at least two of said endcapping agents, said polycarbonate having a melt volume rate of at least 20 cm3/10 min (ISO 1133, 300° C., 1.2 kg), a terminal hydroxyl group content of at most 800 ppm by weight, a Fries branching content of at most 1300 ppm by weight and a content of bulky end groups of at least 20 mol % defined as the sum of the mol % of end-groups based on said bisphenol and the mol % of end-groups based on said endcapping agent.

Abstract: The present invention relates to a method for the continuous multi-stage manufacture of an end-capped polycarbonate comprising, i) preparing a monomer mixture in a monomer mixing stage by mixing a bisphenol, a diaryl carbonate and optionally a transesterification catalyst in at least one monomer mixing device, ii) preparing a carbonate oligomer in an oligomerisation stage by reacting said monomer mixture in at least one oligomerisation reactor, iii) preparing the polycarbonate in a polymerisation stage by further reacting the carbonate oligomer of the oligomerisation stage in at least one polymerisation reactor, wherein an end-capping agent different from phenol and having a single phenolic hydroxy group is added to the monomer mixture in the monomer mixing stage and/or to at least one oligomerisation reactor in the oligomerisation stage.

Abstract: A molded article includes a polycarbonate resin, an ultraviolet (UV) absorbing component, a heat stabilizer component and an acid stabilizer component. The polycarbonate resin is produced by an interfacial polymerization process and has an end-cap level of at least about 98%, and includes a ratio of bound UV absorbing component to free UV absorbing component of less than about 1.0 when molded under abusive molding conditions. The polycarbonate resin may include high purity polycarbonate. The acid stabilizer component may include a sulfonic acid ester. Methods of forming molded articles are also described.

Abstract: In an embodiment, a reactor for carrying out a melt transesterification reaction at a reactor temperature of 160 to 300° C. and a reactor pressure of 5 to 200 mbar, comprises a cylindrical tank comprising a top, a side, and a bottom, wherein the bottom is convex, extending away from the top; a stirring shaft disposed within the cylindrical tank along an axis thereof so that it is rotatable from outside of the cylindrical tank; a stirring blade extending from the stirring shaft in the cylindrical tank; a reactant solution inlet located on the bottom; and a reaction solution outlet located on the bottom. The reactor can be used for the polymerization of a polycarbonate oligomer.

Abstract: The disclosure concerns a polymer blend derived from transesterification of (i) 69.9 to 95 weight percent polycarbonate; and (ii) 4.9 to 30 weight percent liquid crystal polymer; in the presence of 0.01 to 0.1 weight percent catalyst; wherein the polymer is transparent.

Abstract: A molded article includes a polycarbonate resin, an ultraviolet (UV) absorbing component, a heat stabilizer component and an acid stabilizer component. The polycarbonate resin is produced by an interfacial polymerization process and has an end-cap level of at least about 98%, and includes a ratio of bound UV absorbing component to free UV absorbing component of less than about 1.0 when molded under abusive molding conditions. The polycarbonate resin may include high purity polycarbonate. The acid stabilizer component may include a sulfonic acid ester. Methods of forming molded articles are also described.

Abstract: A process for manufacturing a polycarbonate composition includes melt polymerizing a dihydroxy compound and a carbonate compound in the presence of a catalyst to form a polycarbonate; and adding 1 to 400 ppm of glycerol tristearate to form the polycarbonate composition, wherein the polycarbonate composition is unquenched.

Abstract: The disclosure concerns a polymer derived from melt extrusion of (i) 80 to 95 wt % polycarbonate; said polycarbonate having and endcap level of 45% to 80% and a branching level of 300-5,000 m comprising the following branching structures: (ii) 4.9 to 20 wt % polymethyl methacrylate; and (iii) 0.1 to 1.5 wt % of catalyst; wherein the polymer is transparent, and wherein transesterification occurs with at least a portion of the polycarbonate and the polymethyl methacrylate during melt extrusion.

Abstract: In an embodiment, a method for making a thermoplastic composition, comprising: melt polymerizing a polycarbonate, extruding and melt filtering the polycarbonate to form a melt filtered polycarbonate; forming the thermoplastic composition comprising the melt filtered polycarbonate, 0.03 to 0.05 wt % of a triacylglyceride release agent; and 0.10 to 0.14 wt % of a UV stabilizer; wherein the weight percentages are based on the total weight of the composition; and extruding the thermoplastic composition.

Abstract: Melt polymerization processes for producing photoactive additives are disclosed. The photoactive additives are cross-linkable polycarbonate resins formed from a benzophenone, a dihydroxy chain extender, a carbonate precursor, and a catalyst. The additives can be produced without the use of phosgene or dichloromethane, and can be cross-linked with other polymers upon exposure to UV radiation.

Abstract: In an embodiment, a melt polymerization process comprises melt polymerizing a carbonate compound and a dihydroxy compound in the presence of a catalyst composition to form a polycarbonate; and adding an end-capping agent comprising a mono-phenolic compound to the polycarbonate, wherein the adding of the end-capping agent comprises at least one of adding the end-capping agent just upstream of a final polymerization unit, adding the end-capping agent directly into the final polymerization unit, and adding the end-capping agent downstream of the final polymerization unit; wherein a molecular weight of the polycarbonate increases by less than 10% downstream of the final polymerization unit.

Abstract: The disclosure concerns a polymer derived from melt extrusion of (i) 80 to 95 wt % polycarbonate; said polycarbonate having and endcap level of 45% to 80% and a branching level of 300-5,000 m comprising the following branching structures: (ii) 4.9 to 20 wt % polymethyl methacrylate; and (iii) 0.1 to 1.5 wt % of catalyst; wherein the polymer is transparent, and wherein transesterification occurs with at least a portion of the polycarbonate and the polymethyl methacrylate during melt extrusion.

Abstract: The disclosure concerns a polymer blend derived from transesterification of (i) 69.9 to 95 weight percent polycarbonate; and (ii) 4.9 to 30 weight percent liquid crystal polymer; in the presence of 0.01 to 0.1 weight percent catalyst; wherein the polymer is transparent.

Abstract: In an embodiment, a process for forming a quenched composition comprises mixing an unquenched melt polycarbonate and a quenched melt polycarbonate to form the quenched composition; wherein the quenched polycarbonate was formed from a first melt polymerization, wherein the first melt polymerization comprises adding a quencher to form the quenched polycarbonate, wherein the unquenched polycarbonate was formed from a second melt polymerization, wherein the unquenched melt polycarbonate comprises an active catalyst used during the second melt polymerization, and wherein the second melt polymerization is free of a quencher addition.

Abstract: In an embodiment, a polycarbonate polymerization process comprises interfacially polymerizing a carbonate compound and dihydroxy compound in the presence of an interfacial catalyst to form a polycarbonate and adding a viscosity reducing agent and a transesterification catalyst to polycarbonate upstream of a first filter to form an adjusted polycarbonate. The first filter can be replaced with a replacement filter and the adjusted polycarbonate can be introduced to the replacement filter. The flow can be diverted to a replacement filter. The process further comprises reducing the addition rate of the viscosity reducing agent and the transesterification catalyst until the addition rate is 0 mol/hr.

Abstract: In an embodiment, a melt polymerization process comprises melt polymerizing a carbonate compound and a dihydroxy compound in the presence of a catalyst composition to form a polycarbonate; and adding an end-capping agent comprising a mono-phenolic compound to the polycarbonate, wherein the adding of the end-capping agent comprises at least one of adding the end-capping agent just upstream of a final polymerization unit, adding the end-capping agent directly into the final polymerization unit, and adding the end-capping agent downstream of the final polymerization unit; wherein a molecular weight of the polycarbonate increases by less than 10% downstream of the final polymerization unit.