Blends of polyphenylene sulfones and polyphenylene sulfide resins

1. A compatibilized blend of polyphenylene sulfone (PPSU) and polyphenylene sulfide (PPS) comprising:

a) 20-77 wt % of a polyphenylene sulfone (PPSU);

b) 20-77 wt % of a polyphenylene sulfide (PPS);

c) 2.5-22.5 wt % a polyetherimide compatibilizer; and

d) 0.5-1.5 wt % an epoxy compatibilizer;

wherein the amounts of a), b), c), and d) are based on the overall weight of the compatibilized blend and together account for 100 wt % of the compatibilized blend.

2. The compatibilized blend of claim 1 , wherein the compatibilized blend possesses a tensile strength greater than 75 MPa, an impact strength of at least 40 J/m, and an elongation at break of at least 70%.

3. The compatibilized blend of claim 1 , wherein the epoxy compatibilizer is an epoxy cresol novolac resin.

4. The compatibilized blend of claim 1 , wherein the polyphenylene sulfide (PPS) is a linear poly(phenylene) sulfide.

5. The compatibilized blend of claim 1 , wherein the morphology of the compatibilized blend comprises fine, well-dispersed domains of polyphenylene sulfone (PPSU) and polyphenylene sulfide (PPS).

6. The compatibilized blend of claim 1 , wherein the compatibilized blend exhibits a heat distortion temperature (HDT) of at least 87° C.

7. The compatibilized blend of claim 1 comprising:

a) 24.5-74.5 wt % of the polyphenylene sulfone (PPSU);

b) 24.5-74.5 wt % of the polyphenylene sulfide (PPS);

c) 2.5-22.5 wt % of the polyetherimide compatibilizer; and

d) 0.5-1.5 wt % of the epoxy compatibilizer;

wherein the amounts of a), b), c), and d) are based on the overall weight of the compatibilized blend and together account for 100 wt % of the compatibilized bend.

8. An extrudate of the compatibilized blend of claim 1 .

9. A molded product of the compatibilized blend of claim 1 .

10. A method of preparing the compatibilized blend of claim 1 , comprising:

melt mixing the polyphenylene sulfone (PPSU), the polyphenylene sulfide (PPS), the polyetherimide compatibilizer, and the epoxy compatibilizer in a single pass through an extruder.

11. The method of claim 10 , wherein the extruder is a twin screw, vented extruder.

12. The method of claim 11 , wherein melt mixing is performed at a temperature of 300 to 350° C.

13. The method of claim 11 , wherein melt mixing is performed at a screw speed of about 250 rotations per minute (rpm) and vented under vacuum.

14. A method of preparing the compatibilized blend of claim 1 , comprising:

(a) melt mixing the polyphenylene sulfone (PPSU) and the polyetherimide compatibilizer in a first pass through an extruder to form an initial mixture; and

(b) melt mixing the initial mixture with the polyphenylene sulfide (PPS) and the epoxy compatibilizer in a second pass through the extruder.

15. The method of claim 14 , wherein the extruder is a twin screw, vented extruder.

16. The method of claim 15 , wherein melt mixing of step a) is performed at a temperature of 350 to 360° C., and melt mixing of step b) is performed at a temperature of 330 to 340° C.

17. The method of claim 15 , wherein melt mixing of step a) and melt mixing of step b) are performed at a screw speed of about 250 rotations per minute (rpm) and vented under vacuum.

18. A method of preparing the compatibilized blend of claim 1 , comprising:

a) melt mixing the polyphenylene sulfide (PPS), the polyetherimide compatibilizer, and the epoxy compatibilizer in a first pass through an extruder to form an initial mixture; and

b) melt mixing the initial mixture with the polyphenylene sulfone (PPSU) in a second pass through the extruder.

19. The method of claim 18 , wherein the extruder is a vented, twin screw extruder.

20. The method of claim 19 , wherein melt mixing of step a) and melt mixing of step b) are performed at a temperature of 340 to 350° C.

21. The method of claim 19 , wherein melt mixing of step a) and melt mixing of step b) are performed at a screw speed of about 250 rotations per minute (rpm) and vented under vacuum.