Impact modified poly(arylene ether)/polyester blends and method

1 . A resin composition comprising:

a poly(arylene ether) resin;

a polyester resin;

a first impact modifier;

a second impact modifier comprising less than or equal to 5.5 wt % structural units comprising a pendant epoxy group; and

a polymeric compatibilizer comprising greater than or equal to 6.0 wt % structural units comprising a pendant epoxy group wherein a portion of the poly(arylene ether) is functionalized poly(arylene ether).

2 . The composition of claim 1 , wherein the functionalized poly(arylene ether) is the reaction product of poly(arylene ether) and a functionalizing agent selected from the group consisting of carboxylic acids, anhydrides, imides, amines, hydroxyls, and salts thereof.

3 . The composition of claim 2 wherein the functionalizing agent is selected from the group consisting of maleic anhydride, citric acid, malic acid, and fumaric acid.

4 . The composition of claim 1 wherein the polyester resin is a poly(alkylene dicarboxylate).

5 . The composition of claim 4 , wherein the poly(alkylene dicarboxylate) comprises at least one member selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate), poly(butylene-2,6-naphthalate), poly(ethylene-2,6-naphthalate), poly(cyclohexanedimethanol terephthalate), poly(ethylene-co-cyclohexanedimethanol terephthalate), polytrimethylene terephthalate, poly(dimethanol-1,4-cyclohexanedicarboxylate), and polyxylene terephthalate.

6 . The composition of claim 1 , wherein the first impact modifier is a block copolymer.

7 . The composition of claim 6 , wherein the copolymer is at least one member selected from the group consisting of polystyrene-polybutadiene; polystyrene-poly(ethylene-butylene); polystyrene-polyisoprene; polystyrene-poly(ethylene-propylene); poly(alpha-methylstyrene)-polybutadiene; poly(alpha-methylstyrene)-poly(ethylene-butylene); polystyrene-polybutadiene-polystyrene; polystyrene-poly(ethylene-butylene)-polystyrene; polystyrene-polyisoprene-polystyrene; polystyrene-poly(ethylene-propylene)-polystyrene; poly(alpha-methylstyrene)-polybutadiene-poly(alpha-methylstyrene); and combinations comprising at least one of the foregoing impact modifiers.

8 . The composition of claim 1 , wherein the second impact modifier comprising less than or equal to 3 wt % structural units comprising a pendant epoxy group.

9 . The composition of claim 1 , wherein the second impact modifier further comprises structural units derived from at least one olefinic monomer.

10 . The composition of claim 9 , wherein the second impact modifier comprises a copolymer comprising structural units derived from ethylene and glycidyl methacrylate; ethylene, alkyl acrylate, and glycidyl acrylate; ethylene, methyl acrylate, and glycidyl acrylate; ethylene, butyl acrylate, and glycidyl acrylate; or ethylene, vinyl acetate, and glycidyl acrylate.

11 . The composition of claim 1 , wherein the compatibilizer comprises greater than or equal to 8 wt % structural units comprising a pendant epoxy group.

12 . The composition of claim 1 , wherein the compatibilizer comprises greater than or equal to 10 wt % structural units comprising a pendant epoxy group.

13 . The composition of claim 1 , wherein the compatibilizer further comprises structural units derived from at least one olefinic monomer.

14 . The composition of claim 1 , wherein the compatibilizer comprises a copolymer comprising structural units derived from ethylene and glycidyl methacrylate; ethylene, alkyl acrylate, and glycidyl acrylate; ethylene, methyl acrylate, and glycidyl acrylate; ethylene, butyl acrylate, and glycidyl acrylate; or ethylene, vinyl acetate, and glycidyl acrylate.

15 . The composition of claim 1 , further comprising at least one additive selected from the group consisting of reinforcing fillers, metal salts, flow promoters, flame retardants, drip retardants, colorants, dyes, pigments, stabilizers, crystallization nucleators, plasticizers, non-reinforcing fillers and lubricants.

16 . The composition of claim 1 , further comprising a conductive filler.

17 . The composition of claim 16 , having a specific volume resistivity value of less than 100 kilo ohm-cm.

18 . A resin composition comprising:

a poly(2,6-dimethyl-1,4-phenylene ether) resin;

a poly(cyclohexanedimethanol terephthalate) resin;

a first impact modifier selected from the group consisting of polystyrene-polybutadiene; polystyrene-poly(ethylene-butylene); polystyrene-polyisoprene; polystyrene-poly(ethylene-propylene); poly(alpha-methylstyrene)-polybutadiene; poly(alpha-methylstyrene)-poly(ethylene-butylene); polystyrene-polybutadiene-polystyrene; polystyrene-poly(ethylene-butylene)-polystyrene; polystyrene-polyisoprene-polystyrene; polystyrene-poly(ethylene-propylene)-polystyrene; poly(alpha-methylstyrene)-polybutadiene-poly(alpha-methylstyrene); and combinations comprising at least one of the foregoing impact modifiers;

a second impact modifier derived from ethylene and less than or equal to 5.5 wt % glycidyl methacrylate; and

a polymeric compatibilizer comprising derived from ethylene and greater than or equal to 6 wt % glycidyl methacrylate wherein a portion of the poly(2,6-dimethyl-1,4-phenylene ether) resin is functionalized poly(2,6-dimethyl-1,4-phenylene ether) resin.

19 . The composition of claim 18 , further comprising a conductive filler.

20 . An article made from the composition of claim 1 .

21 . An article made from the composition of claim 16 .

22 . A method to prepare the composition of claim I comprising the steps of

a) melt mixing a composition comprising a poly(arylene ether), a first impact modifier and a functionalizing agent to form a first blend; and

b) melt mixing the said first blend with a mixture comprising a polyester, second impact modifier, compatibilizer, and optionally a conductive filler to form a final blend.

23 . The method according to claim 22 wherein the melt mixing is performed in an extruder and said first blend is produced by upstream addition and the remaining components are added at a downstream feeding section.

24 . The method according to claim 23 wherein a vacuum is applied to the extruder at a location after the upstream addition of said first blend and prior to the addition of remaining components to form said final blend.