Method of making poly(arylene ether) compositions

1. A method of making a thermoplastic composition comprising melt mixing a concentrate comprising a first thermoplastic, a second thermoplastic and an additive with a component selected from the group consisting of a third thermoplastic, fire retardant additive, reinforcing agent, electrically conductive filler, non-electrically conductive filler, and combinations of two or more of the foregoing,

wherein the first thermoplastic comprises poly(arylene ether),

wherein the second thermoplastic and third thermoplastic are selected from the group consisting of poly(alkenyl aromatic) homopolymer resin, rubber modified poly(alkenyl aromatic) homopolymer resin, polyamide, polyolefin and combinations of two or more of the foregoing,

wherein the concentrate is solid prior to melt mixing,

wherein the concentrate comprises 50 to 99 weight percent poly(arylene ether) based on the total weight of the concentrate, and

wherein the composition comprises greater than or equal to 34 weight percent poly(arylene ether), based on the total weight of the composition.

2. The method of claim 1 , wherein the second and third thermoplastics are the same.

3. The method of claim 1 , wherein the second and third thermoplastics are different.

4. The method of claim 1 , wherein the second and third thermoplastics comprise rubber modified polystyrene.

5. The method of claim 1 , wherein the composition further comprises an impact modifier.

6. The method of claim 5 , wherein the concentrate further comprises an impact modifier.

7. The method of claim 6 wherein the impact modifier is present in an amount of about 1 to about 10 weight percent based on the total weight of the concentrate.

8. The method of claim 1 , wherein the concentrate is in the form of a dry blend.

9. The method of claim 1 , wherein the concentrate is pelletized.

10. The method of claim 1 wherein the second thermoplastic comprises a poly(alkenyl aromatic) resin and the poly(alkenyl aromatic) resin is present in an amount of about 3 to about 50 weight percent based on the total weight of the concentrate.

11. The method of claim 1 wherein the second thermoplastic comprises a polyamide and the polyamide is present in an amount of about 5 to about 50 weight percent based on the total weight of the concentrate.

12. The method of claim 1 wherein the second thermoplastic comprises a polyolefin and the polyolefin is present in an amount of about 5 to about 80 weight percent based on the total weight of the concentrate.

13. The method of claim 1 wherein the additive is present in an amount of about 1 to about 25 weight percent based on the total weight of the concentrate.

14. The method of claim 1 wherein the concentrate comprises a combination of additives and the combination of additives is present in an amount of about 1 to about 25 weight percent based on the total weight of the concentrate.

15. The method of claim 1 wherein the component comprises a third thermoplastic and the composition further comprises a blowing agent.

16. The method of claim 1 wherein the additive is selected from the group consisting of coupling agents, antioxidants, mold release agents, UV absorbers, light stabilizers, heat stabilizers, lubricants, plasticizers, pigments, dyes, colorants, anti-static agents, nucleating agents, anti-drip agents, acid scavengers, and combinations of two or more of the foregoing.

17. A method of making a thermoplastic composition comprising:

dry blending a first thermoplastic, a second thermoplastic and an additive to form a concentrate; and

melt mixing the concentrate with a component selected from the group consisting of a third thermoplastic, fire retardant additive, reinforcing agent, electrically conductive filler, non-electrically conductive filler, and combinations of two or more of the foregoing,

wherein the first thermoplastic comprises poly(arylene ether), and

wherein the second thermoplastic and third thermoplastic are selected from the group consisting of poly(alkenyl aromatic) homopolymer resin, rubber modified poly(alkenyl aromatic) homopolymer resin, polyamide, polyolefin and combinations of two or more of the foregoing,

wherein the concentrate comprises 50 to 99 weight percent poly(arylene ether) based on the total weight of the concentrate, and

wherein the composition comprises greater than or equal to 34 weight percent poly(arylene ether), based on the total weight of the composition.

18. A method of making a thermoplastic composition comprising

melt-mixing a first thermoplastic, a second thermoplastic and an additive to form a molten concentrate;

pelletizing the molten concentrate to form a pelletized concentrate;

melt mixing the pelletized concentrate with a component selected from the group consisting of a third thermoplastic, fire retardant additive, reinforcing agent, electrically conductive filler, non-electrically conductive filler, and combinations of two or more of the foregoing,

wherein the first thermoplastic comprises poly(arylene ether), and

wherein the second thermoplastic and third thermoplastic are selected from the group consisting of poly(alkenyl aromatic) homopolymer resin, rubber modified poly(alkenyl aromatic) homopolymer resin, polyamide, polyolefin and combinations of two or more of the foregoing,

wherein the concentrate comprises 50 to 99 weight percent poly(arylene ether) based on the total weight of the concentrate, and

wherein the composition comprises greater than or equal to 34 weight percent poly(arylene ether), based on the total weight of the composition.

19. The method of claim 18 wherein the thermoplastic composition has a butyraldehyde level less than or equal to about 800 parts per million by weight, based on the total weight of the poly(arylene ether).

20. The method of claim 18 wherein the thermoplastic composition has a trimethylanisole level less than or equal to about 30 parts per million based on the total weight of the poly(arylene ether).

21. The method of claim 18 wherein the thermoplastic composition has a toluene level less than or equal to about 100 parts per million by weight based on the total weight of the poly(arylene ether).

22. A method of injection molding a thermoplastic composition comprising

melt-mixing a first thermoplastic, a second thermoplastic and an additive to form a molten concentrate;

pelletizing the molten concentrate to form a pelletized concentrate;

blending the pelletized concentrate with a component selected from the group consisting of a third thermoplastic, fire retardant additive, reinforcing agent, electrically conductive filler, non-electrically conductive filler, and combinations of two or more of the foregoing to form a blend and

injection molding the blend,

wherein the first thermoplastic comprises poly(arylene ether),

wherein the second thermoplastic and third thermoplastic are selected from the group consisting of poly(alkenyl aromatic) homopolymer resin, rubber modified poly(alkenyl aromatic) homopolymer resin, polyamide, polyolefin and combinations of two or more of the foregoing,

wherein the concentrate comprises 50 to 99 weight percent poly(arylene ether) based on the total weight of the concentrate, and

wherein the composition comprises greater than or equal to 34 weight percent poly(arylene ether), based on the total weight of the composition.

23. A method of making a thermoplastic composition comprising melt mixing a concentrate comprising a poly(arylene ether), a second thermoplastic and an additive with a component selected from the group consisting of a third thermoplastic, fire retardant additive, reinforcing agent, electrically conductive filler, non-electrically conductive filler, and combinations of two or more of the foregoing,

wherein the second thermoplastic and third thermoplastic are selected from the group consisting of polystyrene, rubber modified polystyrene and combinations thereof,

wherein the concentrate is solid prior to melt mixing,

wherein the concentrate comprises 50 to 99 weight percent poly(arylene ether) based on the total weight of the concentrate, and

wherein the composition comprises greater than or equal to 34 weight percent poly(arylene ether), based on the total weight of the composition.