Reinforced poly(phenylene ether)-polysiloxane block copolymer composition, and article comprising same

1. A composition, comprising:

5 to 91 weight percent of a poly(phenylene ether)-polysiloxane block copolymer reaction product comprising a first poly(phenylene ether) and a poly(phenylene ether)-polysiloxane block copolymer;

4 to 25 weight percent of a flame retardant comprising an organophosphate ester, a phosphazene, or a combination thereof;

5 to 40 weight percent of a reinforcing filler; and

3 to 6 weight percent of an impact modifier selected from the group consisting of rubber-modified polystyrenes, unhydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene, hydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene, acrylate core-shell impact modifiers, and combinations thereof;

wherein all weight percents are based on the total weight of the composition.

2. The composition of claim 1 , exhibiting

a flammability rating of V-0 at a sample thickness less than or equal to 1.5 millimeters in the 20 millimeter Vertical Burning Flame Test of Underwriter's Laboratory Bulletin 94 “Tests for Flammability of Plastic Materials, UL 94”,

a heat deflection temperature of at least 110° C. determined according to ASTM D 648-07 using a stress of 1.82 megapascals (MPa) and a sample thickness of 6.4 millimeters, and

a flexural modulus of at least 3,500 megapascals measured at 23° C. according to ASTM D 790-07e1 using a sample thickness of 6.4 millimeters.

3. The composition of claim 1 , further comprising 5 to 86 weight percent of a second poly(phenylene ether).

4. The composition of claim 1 , wherein the poly(phenylene ether)-polysiloxane block copolymer comprises a poly(phenylene ether) block comprising phenylene ether repeating units having the structure

and

a polysiloxane block having the structure

wherein n is 30 to 60.

5. The composition of claim 1 , wherein the poly(phenylene ether)-polysiloxane block copolymer contributes 0.25 to 5 weight percent of polysiloxane to the composition.

6. The composition of claim 1 , wherein the flame retardant comprises an organophosphate ester.

7. The composition of claim 1 , wherein the flame retardant comprises a phosphazene.

8. The composition of claim 1 , wherein the reinforcing filler is selected from the group consisting of glass fibers, carbon fibers, wollastonite, halloysite, clays, talcs, micas, glass flakes, solid glass beads, hollow glass beads, solid ceramic beads, hollow ceramic beads, and combinations thereof.

9. The composition of claim 1 , wherein the reinforcing filler comprises glass fibers.

10. The composition of claim 1 , wherein the reinforcing filler consists of glass fibers.

11. The composition of claim 1 , comprising the impact modifier; wherein the impact modifier is selected from the group consisting of rubber-modified polystyrenes, unhydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene, acrylate core-shell impact modifiers, and combinations thereof.

12. The composition of claim 1 , comprising 0 to 1 weight percent of each of polyamides and polyesters.

13. The composition of claim 1 ,

wherein the poly(phenylene ether)-polysiloxane block copolymer comprises a poly(phenylene ether) block comprising phenylene ether repeating units having the structure

and

a polysiloxane block having the structure

wherein n is 30 to 60;

wherein the composition comprises 5 to 15 weight percent of the poly(phenylene ether)-polysiloxane block copolymer reaction product;

wherein the composition further comprises 47 to 67 weight percent of a second poly(phenylene ether) comprising a homopolymer of 2,6-dimethylphenol;

wherein the flame retardant comprises an organophosphate ester;

wherein the composition comprises 6 to 14 weight percent of the flame retardant;

wherein the reinforcing filler comprises glass fibers;

wherein the composition comprises 10 to 30 weight percent of the reinforcing filler;

wherein the composition comprises the impact modifier, and the impact modifier is a polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer; and

wherein the composition comprises 0 to 1 weight percent of each of polyamides and polyesters.

14. The composition of claim 13 , wherein the composition comprises 15 to 25 weight percent of the reinforcing filler.

15. An article comprising a composition, comprising:

5 to 91 weight percent of a poly(phenylene ether)-polysiloxane block copolymer reaction product comprising a first poly(phenylene ether) and a poly(phenylene ether)-polysiloxane block copolymer;

4 to 25 weight percent of a flame retardant comprising an organophosphate ester, a phosphazene, or a combination thereof;

5 to 40 weight percent of a reinforcing filler; and

3 to 6 weight percent of an impact modifier selected from the group consisting of rubber-modified polystyrenes, unhydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene, hydrogenated block copolymers of an alkenyl aromatic monomer and a conjugated diene, acrylate core-shell impact modifiers, and combinations thereof;

wherein all weight percents are based on the total weight of the composition.

16. The article of claim 15 , wherein the article is selected from the group consisting of electrophotographic copier parts, photovoltaic junction boxes and connectors, inverter housings, automotive electrical connectors, electrical relays, and charge couplers.

17. The article of claim 15 , wherein the article is a fuser holder for an electrophotographic copier.

18. The article of claim 15 ,

wherein the poly(phenylene ether)-polysiloxane block copolymer comprises a poly(phenylene ether) block comprising phenylene ether repeating units having the structure

and

a polysiloxane block having the structure

wherein n is 30 to 60;

wherein the composition comprises 5 to 15 weight percent of the poly(phenylene ether)-polysiloxane block copolymer reaction product;

wherein the composition further comprises 47 to 67 weight percent of a second poly(phenylene ether) comprising a homopolymer of 2,6-dimethylphenol;

wherein the flame retardant comprises an organophosphate ester;

wherein the composition comprises 6 to 14 weight percent of the flame retardant;

wherein the reinforcing filler comprises glass fibers;

wherein the composition comprises 10 to 30 weight percent of the reinforcing filler;

wherein the composition comprises the impact modifier, and the impact modifier is a polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer; and

wherein the composition comprises 0 to 1 weight percent of each of polyamides and polyesters.

19. The article of claim 18 , wherein the composition comprises 15 to 25 weight percent of the reinforcing filler.