Forming concentrate of poly(arylene ether), thermosetting resin and compatibilizer

1. A method of forming a poly(arylene ether)-containing solid concentrate, comprising:

blending about 30 to about 86 parts by weight of a poly(arylene ether), about 10 to about 70 parts by weight of a thermosetting resin, and about 4 to about 8 parts by weight of a compatibilizing agent in the presence of a solvent to form a homogeneous solution; and

substantially removing the solvent to yield a solid concentrate;

wherein the solid concentrate consists of the poly(arylene ether), the thermosetting resin, the compatibilizing agent, and any residual solvent;

wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.

2. The method of claim 1 , wherein the poly(arylene ether) comprises a plurality of structural units of the formula

wherein for each structural unit, each Q 1 is independently halogen, primary or secondary C 1 -C 7 alkyl, phenyl, C 1 -C 7 haloalkyl, C 1 -C 7 aminoalkyl, C 1 -C 7 hydrocarbonoxy, or C 2 -C 7 halohydrocarbonoxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each Q 2 is independently hydrogen, halogen, primary or secondary C 1 -C 7 alkyl, phenyl, C 1 -C 7 haloalkyl, C 1 -C 7 aminoalkyl, C 1 -C 7 hydrocarbonoxy, or C 2 -C 7 halohydrocarbonoxy wherein at least two carbon atoms separate the halogen and oxygen atoms.

3. The method of claim 1 wherein the poly(arylene ether) is a homopolyrner comprising 2,6-dimethyiphenylene ether units, or a random copolymer comprising 2,6-dimethyiphenylene ether units in combination with 2,3,6-trimethyl-1,4-phenylene ether units.

4. The method of claim 1 , wherein the poly(arylene ether) comprises a redistributed poly(arylene ether).

5. The method of claim 1 , wherein the poly(arylene ether) has an intrinsic viscosity of about 0.20 to about 0.40 deciliter/gram as measured at 25° C. in chloroform.

6. The method of claim 1 , wherein the poly(arylene ether) has a number average molecular weight of about 15,000 to 25,000 atomic mass units.

7. The method of claim 1 , wherein the poly(arylene ether) has a number average molecular weight of about 8,000 to 13,000 atomic mass units.

8. The method of claim 1 , wherein the thermosetting resin is selected from the group consisting of epoxy resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, and mixtures comprising at least one of the foregoing thermosetting resins.

9. The method of claim 1 , wherein the thermosetting resin comprises an epoxy resin.

10. The method of claim 1 , wherein the thermo setting resin comprises a reaction product of 2,2-bis(4-hydroxyphenyl)propane and epichlorohydrin.

11. The method of claim 1 , wherein the solvent is selected from the group consisting of alcohols, ketones, aliphatic hydrocarbons, aromatic hydrocarbons, chlorohydrocarbons, nitrohydrocarbons, ethers, esters, amides, mixed ether-esters, sulfoxides, and mixtures thereof.

12. The method of claim 1 , wherein the solvent is selected from the group consisting of benzene, toluene, and xylenes.

13. The method of claim 1 , wherein said substantially removing the suitable solvent comprises removing at least 95 weight percent of the solvent.

14. The method of claim 1 , wherein the compatibilizing agent is selected from the group consisting of polyvinyl acetal resins, styrene-butadiene-styrene block copolymers, styrene ethylene styrene block copolymers, styrene-ethylene-butylene-styrene block copolymers, functionalized butadiene-acrylonitrile copolymers, styrene-butadiene core shell rubbers, styrene-butadiene-styrene core shell rubbers, and mixtures thereof.

15. The method of claim 14 , wherein the compatibilizing agent comprises a polyvinyl acetal.

16. The method of claim 1 , wherein the homogeneous solution consists of the poly(arylene ether), the thermosetting resin, the compatibilizing agent, and the solvent.

17. A method of forming a poly(arylene ether)-containing solid concentrate, comprising:

blending about 30 to about 76 parts by weight of a poly(arylene ether), about 20 to about 70 parts by weight of a thermosetting resin, and about 4 to about 6 parts by weight of a compatibilizing agent in the presence of a solvent to form a homogeneous solution; and

removing at least 95 weight percent of the solvent to yield a solid concentrate;

wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100;

wherein the poly(arylene ether) is a homopolymer comprising 2,6-dimethylphenylene ether units, or a random copolymer comprising 2,6-dimethylphenylene ether units in combination with 2,3,6-trimethyl-1,4-phenylene ether units;

wherein the thermosetting resin comprises an epoxy resin;

wherein the compatibilizing agent comprises a polyvinyl acetal;

wherein the homogeneous solution consists of the poly(arylene ether), the thermosetting resin, the compatibilizing agent, and the solvent; and

wherein the solid concentrate consists of the poly(arylene ether), the thermosetting resin, the compatibilizing agent, and any residual solvent.