Synergistic effect of multiple mold release additives in polycarbonate based compositions

A thermoplastic composition comprising:

• (a) from about 10 wt % to about 40 wt % of a first polycarbonate;
• (b) an impact modifier composition from about 1 wt % to about 30 wt %;
• (c) a second polycarbonate in an amount in the range from about 20 wt % to about 60 wt %;
• (d) from greater than 0 to about 10 wt % of a third polycarbonate comprising a polycarbonate polysiloxane copolymer;
• wherein the combined weight percent of components (a) through (d) does not exceed 100 wt %, wherein all weight percent values are based on the total weight of the thermoplastic composition;
• and
• (e) a mold release composition comprising at least two different mold release additives from about 0.01 parts by weight to about 1.5 parts by weight added to 100 parts of the thermoplastic composition excluding the mold release composition, wherein the mold release composition has a pentaerythritol tetrastearate ratio of greater than about 4:1 to about 10:1 than a second one of the at least two different mold release additives;
• and
• wherein a molded sample of the thermoplastic composition has better mold release performance compared to a substantially identical reference composition in the absence of the mold release composition, and wherein the presence of the mold release composition has substantially no impact on the mechanical and physical properties.

A method of making a thermoplastic composition comprising the steps:

• (a) providing:
• (i) a first polycarbonate in an amount in the range from about 10 wt % to about 80 wt %;
• (ii) an impact modifier composition in an amount in the range from about 1 wt % to about 30 wt %;
• (b) mixing all components to create a mixture that does not exceed 100 wt %, and wherein all weight percent value are based on the total weight of the thermoplastic composition;
• (c) blending a mold release composition in an amount in the range from about 0.01 parts by weight to about 1.5 parts by weight into 100 parts of the mixture excluding the mold release composition to form a thermoplastic composition;
• wherein the mold release composition comprises one or more of at least two different mold release additives, wherein the at least two different mold release additives comprises pentaerythritol tetrastearate in combination with glycerol monostearate, glycerol tristearate, poly(alfa) olefin, poly(ethylene oxide-propylene oxide-ethylene oxide), or any combination thereof;
• wherein the at least two different mold release additives comprise pentaerythritol tetrastearate in a ratio of greater than about 4:1 to about 10:1 to a second one of the at least two mold release additives;
• and wherein a molded sample of the thermoplastic composition has better mold release performance compared to a substantially identical reference composition in the absence of the mold release composition, and wherein the presence of the mold release composition has substantially no impact on the mechanical and physical properties;
• and wherein the molded sample of the thermoplastic composition has lower ejection pressure compared to a substantially identical reference composition in the absence of the mold release composition, and wherein the presence of the mold release composition has substantially no impact on the mechanical and physical properties.

A method of making a thermoplastic composition comprising the steps:

• (a) providing:
• (i) a first polycarbonate in an amount in the range from about 10 wt % to about 40 wt %;
• (ii) a second polycarbonate in an amount in the range from about 20 wt % to about 60 wt %, wherein the second polycarbonate is different from the first polycarbonate;
• (iii) an impact modifier composition in an amount in the range from about 1 wt % to about 30 wt %;
• (iv) a third polycarbonate composition comprising a polycarbonate-polysiloxane copolymer in an amount in the range from greater than 0 to about 10 wt %;
• (b) mixing all components to create a mixture that does not exceed 100 wt %, and wherein all weight percent value are based on the total weight of the thermoplastic composition;
• (c) blending a mold release composition in an amount in the range from about 0.01 parts by weight to about 1.5 parts by weight into 100 parts of the mixture excluding the mold release composition to form a thermoplastic composition;
• wherein the mold release composition comprises at least two mold release agents and wherein the mold release composition has a pentaerythritol tetrastearate ratio of greater than 4:1 to about 10:1 than a second one of the at least two mold release agents;
• and
• wherein a molded sample of the thermoplastic composition has better mold release performance compared to a substantially identical reference composition in the absence of the mold release composition, and wherein the presence of the mold release composition has substantially no impact on the mechanical and physical properties.