Poly(arylene ether) composition, method, and article
View Patent ↗A composition includes specific amounts of a virgin poly(arylene ether) resin and a rubber-modified polystyrene that is preferably derived from post-consumer recycling. The composition includes about 0.2 to about 1.5 weight percent of polymerized acrylonitrile residue that can originate as a contaminant in the recycled rubber-modified polystyrene. The composition avoids the need for compatibilizing agents required by related compositions.
1. A composition comprising:
about 30 to about 60 weight percent of a poly(arylene ether) consisting of virgin poly(arylene ether);
about 20 to about 55 weight percent of a rubber-modified polystyrene; and
about 0.2 to about 1.5 weight percent of polymerized acrylonitrile residue;
wherein the composition comprises 0 to 3 weight percent of a copolymer of an ethylenically unsaturated epoxy compound and an olefin; and
wherein all weight percents are based on the total weight of the composition, unless a different basis is specified.
2. The composition of claim 1 , wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene comprising styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, or a mixture thereof.
3. The composition of claim 1 , further comprising about 1 to about 25 weight percent of a flame retardant.
4. The composition of claim 3 , wherein the flame retardant comprises an organophosphate ester.
5. The composition of claim 1 , excluding polyamides.
6. A method of forming a composition, comprising:
melt blending components comprising
about 30 to about 60 weight percent of a poly(arylene ether) consisting of virgin poly(arylene ether),
about 20 to about 55 weight percent of a rubber-modified polystyrene, and
about 0.2 to about 1.5 weight percent of polymerized acrylonitrile residue to form the composition;
wherein the composition comprises 0 to 3 weight percent of a copolymer of an ethylenically unsaturated epoxy compound and an olefin; and
wherein all weight percents are based on the total weight of the composition, unless a different basis is specified.
7. The method of claim 6 , wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene comprising styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, or a mixture thereof.
8. The method of claim 6 , wherein the composition further comprises about 1 to about 25 weight percent of a flame retardant.
9. The method of claim 8 , wherein the flame retardant comprises an organophosphate ester.
10. The method of claim 6 , wherein the composition excludes polyamides.
11. The method of claim 6 ,
wherein the composition comprises
about 40 to about 50 weight percent of the poly(arylene ether),
about 32 to about 40 weight percent of the rubber-modified polystyrene, and
about 0.25 to about 1 weight percent of the polymerized acrylonitrile residue;
wherein the composition further comprises about 10 to about 20 weight percent of an organophosphate ester;
wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene; and
wherein the composition excludes polyamides.
12. The method of claim 11 , wherein the composition consists of the virgin poly(arylene ether), the post-consumer recycled rubber-modified polystyrene, the organophosphate ester, and, optionally, up to 5 weight percent of additives selected from the group consisting of stabilizers, antioxidants, mold release agents, processing aids, drip retardants, nucleating agents, UV blockers, fragrances, anti-static agents, mineral oil, metal deactivators, antiblocking agents, and combinations thereof.
13. A composition formed by the method of claim 6 .
14. The composition of claim 13 , wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene comprising styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, or a mixture thereof.
15. The composition of claim 13 , further comprising about 1 to about 25 weight percent of a flame retardant.
16. The composition of claim 15 , wherein the flame retardant comprises an organophosphate ester.
17. The composition of claim 13 , excluding polyamides.
18. The composition of claim 13 ,
wherein the composition comprises
about 40 to about 50 weight percent of the poly(arylene ether),
about 32 to about 40 weight percent of the rubber-modified polystyrene, and
about 0.25 to about 1 weight percent of the polymerized acrylonitrile residue;
wherein the composition further comprises about 10 to about 20 weight percent of an organophosphate ester;
wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene; and
wherein the composition excludes polyamides.
19. The composition of claim 18 , consisting of the virgin poly(arylene ether), the post-consumer recycled rubber-modified polystyrene, the organophosphate ester, and, optionally, up to 5 weight percent of additives selected from the group consisting of stabilizers, antioxidants, mold release agents, processing aids, drip retardants, nucleating agents, UV blockers, fragrances, anti-static agents, mineral oil, metal deactivators, antiblocking agents, and combinations thereof.
20. An injection molded article comprising the composition of claim 1 .
21. The injection molded article of claim 20 , wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene comprising styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, or a mixture thereof.
22. The injection molded article of claim 20 , further comprising about 1 to about 25 weight percent of a flame retardant.
23. The injection molded article of claim 22 , wherein the flame retardant comprises an organophosphate ester.
24. The injection molded article of claim 20 , excluding polyamides.
25. The injection molded article of claim 20 ,
wherein the composition comprises
about 40 to about 50 weight percent of the poly(arylene ether),
about 32 to about 40 weight percent of the rubber-modified polystyrene, and
about 0.25 to about 1 weight percent of polymerized acrylonitrile residue;
wherein the composition further comprises about 10 to about 20 weight percent of an organophosphate ester;
wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene; and
wherein the composition excludes polyamides.
26. The injection molded article of claim 25 , wherein the composition consists of the virgin poly(arylene ether), the post-consumer recycled rubber-modified polystyrene, the organophosphate ester, and, optionally, up to 5 weight percent of additives selected from the group consisting of stabilizers, antioxidants, mold release agents, processing aids, drip retardants, nucleating agents, UV blockers, fragrances, anti-static agents, mineral oil, metal deactivators, antiblocking agents, and combinations thereof.
27. The composition of claim 1 ,
wherein the composition comprises
about 40 to about 50 weight percent of the poly(arylene ether),
about 32 to about 40 weight percent of the rubber-modified polystyrene, and
about 0.25 to about 1 weight percent of the polymerized acrylonitrile residue;
wherein the composition further comprises about 10 to about 20 weight percent of an organophosphate ester;
wherein the rubber-modified polystyrene and the polymerized acrylonitrile residue are provided in the form of a post-consumer recycled rubber-modified polystyrene; and
wherein the composition excludes polyamides.
28. The composition of claim 27 , consisting of the virgin poly(arylene ether), the post-consumer recycled rubber-modified polystyrene, the organophosphate ester, and, optionally, up to 5 weight percent of additives selected from the group consisting of stabilizers, antioxidants, mold release agents, processing aids, drip retardants, nucleating agents, UV blockers, fragrances, anti-static agents, mineral oil, metal deactivators, antiblocking agents, and combinations thereof.
29. The composition of claim 1 , excluding the copolymer of an ethylenically unsaturated epoxy compound and an olefin.