NON-DUSTING POLY(PHENYLENE ETHER) PARTICLES
Disclosed herein are non-dusting poly(phenylene ether) particles comprising 80 to 96 weight percent of poly(phenylene ether) particles having a mean particle size of 1 to 40 micrometers; and 4 to 20 weight percent of a liquid reactive diluent. Poly(alkenyl aromatic) resins, rubber-modified poly(alkenyl aromatic) resins, and hydrogenated, partially hydrogenated, and non-hydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene are all excluded from the particles. The liquid reactive diluent is selected from a first polyol having at least two hydroxyl groups per molecule, a first epoxy resin, a first ethylenically unsaturated monomer, a polyether-modified polysiloxane, and combinations thereof. Also disclosed are compositions comprising the non-dusting poly(phenylene ether) particles and a thermoset composition, wherein the liquid reactive diluent is reactive with the components of the thermoset composition.
1 . Non-dusting poly(phenylene ether) particles, comprising:
80 to 96 weight percent of poly(phenylene ether) particles having a mean particle size of 1 to 40 micrometers; and
4 to 20 weight percent of a liquid reactive diluent;
wherein all amounts are based on the combined weight of the poly(phenylene ether) particles and the liquid reactive diluent; and
wherein poly(alkenyl aromatic) resins, rubber-modified poly(alkenyl aromatic) resins, and hydrogenated, partially hydrogenated, and non-hydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene are all excluded from the non-dusting poly(phenylene ether) particles.
2 . The non-dusting poly(phenylene ether) particles of claim 1 , further comprising 0 to less than 0.1 parts of liquid polyglycols, mineral oil, silicone fluid, and hydroxyl-terminated polybutadiene combined, per 100 parts poly(phenylene ether) particles.
3 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the liquid reactive diluent is selected from a first polyol having at least two hydroxyl groups per molecule, a first epoxy resin, a first ethylenically unsaturated monomer, a polyether-modified polysiloxane, and combinations thereof.
4 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the non-dusting poly(phenylene ether) particles comprise poly(2,6-dimethyl-4-phenylene ether).
5 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the liquid reactive diluent comprises a first polyol having at least two hydroxyl groups per molecule.
6 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the liquid reactive diluent comprises a first polyol having 2 to 10 hydroxyl groups per molecule.
7 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the liquid reactive diluent comprises a polyether polyol prepared by reacting a monomeric polyol containing 2 to 8 hydroxyl groups per molecule with an alkoxylating agent selected from ethylene oxide, propylene oxide, 1,2-butylene oxide, and combinations thereof.
8 . The non-dusting poly(phenylene ether) particles of claim 2 , wherein the liquid reactive diluent comprises an ethylene oxide capped polyether triol having a hydroxyl equivalent weight of 100 to 3,000 grams per equivalent.
9 . The non-dusting poly(phenylene ether) particles of claim 1 , wherein the liquid reactive diluent comprises a first epoxy resin.
10 . The non-dusting poly(phenylene ether) particles of claim 1 , wherein the liquid reactive diluent comprises a glycidyl ether group.
11 . The non-dusting poly(phenylene ether) particles of claim 1 , wherein the liquid reactive diluent comprises an epoxy resin selected from reaction products of bisphenol A and epichlorohydrin having an epoxy equivalent weight of 100 to 500 grams per equivalent, 1,4-butanediol diglycidyl ether, 2-ethylhexyl glycidyl ether, and combinations thereof.
12 . The non-dusting poly(phenylene ether) particles of claim 1 , wherein the liquid reactive diluent comprises a first ethylenically unsaturated monomer.
13 . The non-dusting poly(phenylene ether) particles of claim 1 , wherein the liquid reactive diluent comprises a hydroxyl-functional polyether-modified polysiloxane.
14 . A composition comprising the non-dusting poly(phenylene ether) particles of claim 1 and a second polyol, wherein the liquid reactive diluent comprises a first polyol having at least 2 hydroxyl groups per molecule.
15 . A composition comprising the non-dusting poly(phenylene ether) particles of claim 1 and a polyurethane or polyisocyanurate, wherein the liquid reactive diluent comprises a first polyol having at least 2 hydroxyl groups per molecule.
16 . The composition of claim 15 , wherein the polyurethane or polyisocyanurate comprises the reaction product of a polyisocyanate, a second polyol, and the first polyol.
17 . A composition comprising the non-dusting poly(phenylene ether) particles of claim 1 and a second epoxy resin, wherein the liquid reactive diluent comprises a first epoxy resin.
18 . A composition comprising the poly(phenylene ether) particles of claim 1 and a cured epoxy resin, wherein the reactive diluent comprises a first epoxy resin.
19 . The composition of claim 18 , wherein the cured epoxy resin comprises the reaction product of a curing agent, a second epoxy resin, and the first epoxy resin.
20 . A composition comprising the non-dusting poly(phenylene ether) particles of claim 1 and a second ethylenically unsaturated monomer, wherein the reactive diluent comprises a first ethylenically unsaturated monomer.
21 . A cured composition comprising the non-dusting poly(phenylene ether) particles of claim 1 and a thermoset resin, wherein the liquid reactive diluent comprises a first ethylenically unsaturated monomer, and the thermoset resin comprises a second ethylenically unsaturated monomer.
22 . The cured composition of claim 21 , wherein the cured composition comprises the reaction product of an unsaturated polyester resin or vinyl ester resin, a second ethylenically unsaturated monomer, and the first ethylenically unsaturated monomer.
23 . A method of preventing the dusting of poly(phenylene ether) particles having a particle size of 1 to 40 micrometers, comprising combining the poly(phenylene ether) particles and an amount of liquid reactive diluent sufficient to provide non-dusting poly(phenylene ether) particles.
24 . The method of claim 23 , wherein 80 to 96 weight percent of the poly(phenylene ether) particles are combined with 4 to 20 weight percent of the liquid reactive diluent, based on the total weight of the non-dusting poly(phenylene ether) particles.
25 . The method of claim 23 , wherein the non-dusting poly(phenylene ether) particles comprise 0 to 0.1 weight percent of liquid polyglycols, mineral oil, silicone fluid, and hydroxyl-terminated polybutadiene combined, per 100 parts poly(phenylene ether) particles.