Thermoplastic poly(arylene ether)/polyamide blends and method of making

Abstract

A thermoplastic composition comprises: a compatibilized blend of a poly(arylene ether), an aliphatic-aromatic polyamide and a polymeric compatibilizer; and an impact modifier; wherein the aliphatic-aromatic polyamide is composed of units derived from a dicarboxylic acid and units derived from a diamine and the units derived from a dicarboxylic acid comprise 60 to 100 mol % of units derived from terephthalic acid and the units derived from a diamine comprise 60 to 100 mol % of units derived from 1,9-nonanediamine, 2-methyl-1,8-octanediamine, or a combination of 1,9-nonanediamine and 2-methyl-1,8-octanediamine.

1 . A thermoplastic composition comprising:
 a compatibilized blend of a poly(arylene ether), an aliphatic-aromatic polyamide and a polymeric compatibilizer; and   an impact modifier;   wherein the aliphatic-aromatic polyamide is composed of units derived from a dicarboxylic acid and units derived from a diamine and the units derived from a dicarboxylic acid comprise 60 to 100 mol % of units derived from terephthalic acid and the units derived from a diamine comprise 60 to 100 mol % of units derived from 1,9-nonanediamine, 2-methyl-1,8-octanediamine, or a combination of 1,9-nonanediamine and 2-methyl-1,8-octanediamine.   
   
   
       2 . The thermoplastic composition of  claim 1 , wherein the composition comprises a dispersed phase and a continuous phase and the dispersed phase comprises poly(arylene ether) and has a mean domain size of 0.5-3 micrometers. 
   
   
       3 . The thermoplastic composition of  claim 1 , wherein the aliphatic-aromatic polyamide, prior to forming the composition, has an amine end group less than 45 micromoles per gram of polyamide. 
   
   
       4 . The thermoplastic composition of  claim 1 , wherein the poly(arylene ether) is present in an amount of 5 to 60 weight percent, the aliphatic-aromatic polyamide is present in an amount of 35 to 80 weight percent, the impact modifier is present in an amount of 5 to 22 weight percent, and the polymeric compatibilizer is present in an amount of 0.1 to 20 weight percent, based on the total weight of the composition. 
   
   
       5 . The thermoplastic composition of  claim 1 , wherein the polymeric compatibilizer comprises an epoxy functionalized polyolefin, an epoxy functionalized poly(alkenyl aromatic) resin or a combination thereof. 
   
   
       6 . The thermoplastic composition of  claim 1 , wherein the composition has a notched Izod impact strength at 23° C. that is greater than or equal to 5 kilojoules per square meter as determined by ISO 180/A and an elongation at break greater than or equal to 9% as determined by ISO 527. 
   
   
       7 . The thermoplastic composition of  claim 1 , wherein the composition further comprises reinforcing filler, electrically conductive filler or a combination thereof. 
   
   
       8 . A thermoplastic composition produced by melt blending:
 an aliphatic-aromatic polyamide;   a poly(arylene ether) wherein a portion of the poly(arylene ether) is functionalized poly(arylene ether);   an impact modifier; and   a polymeric compatibilizer having an average of greater than or equal to 3 epoxy groups per molecule;   wherein the aliphatic-aromatic polyamide is composed of units derived from a dicarboxylic acid and units derived from a diamine and the units derived from a dicarboxylic acid comprise 60 to 100 mol % of units derived from terephthalic acid and the units derived from a diamine comprise 60 to 100 mol % of units derived from 1,9-nonanediamine, 2-methyl-1,8-octanediamine, or a combination of 1,9-nonanediamine and 2-methyl-1,8-octanediamine.   
   
   
       9 . The thermoplastic composition of  claim 8 , wherein the composition comprises a dispersed phase and a continuous phase and the dispersed phase comprises poly(arylene ether) and has a mean domain size of 0.5-3 micrometers. 
   
   
       10 . The thermoplastic composition of  claim 8 , wherein the aliphatic-aromatic polyamide, prior to forming the composition, has an amine end group less than 45 micromoles per gram of polyamide. 
   
   
       11 . The thermoplastic composition of  claim 8 , wherein the poly(arylene ether) is present in an amount of 5 to 60 weight percent, the aliphatic-aromatic polyamide is present in an amount of 35 to 80 weight percent, the impact modifier is present in an amount of 5 to 22 weight percent, and the polymeric compatibilizer is present in an amount of 0.1 to 20 weight percent, based on the total weight of the composition. 
   
   
       12 . The thermoplastic composition of  claim 8 , wherein the polymeric compatibilizer comprises an epoxy functionalized polyolefin, an epoxy functionalized poly(alkenyl aromatic) resin or a combination thereof. 
   
   
       13 . The thermoplastic composition of  claim 8 , wherein the composition has a notched Izod impact strength at 23° C. that is greater than or equal to 5 kilojoules per square meter as determined by ISO 180/A and an elongation at break greater than or equal to 9% as determined by ISO 527. 
   
   
       14 . The thermoplastic composition of  claim 8 , wherein the composition further comprises reinforcing filler, electrically conductive filler or a combination thereof. 
   
   
       15 . A thermoplastic composition produced by melt blending:
 an aliphatic-aromatic polyamide;   a poly(arylene ether);   an impact modifier;   a functionalizing agent; and   a polymeric compatibilizer having an average of greater than or equal to 3 epoxy groups per molecule,   wherein the aliphatic-aromatic polyamide is composed of units derived from a dicarboxylic acid and units derived from a diamine and the units derived from a dicarboxylic acid comprise 60 to 100 mol % of units derived from terephthalic acid and the units derived from a diamine comprise 60 to 100 mol % of units derived from 1 ,9-nonanediamine, 2-methyl-1,8-octanediamine, or a combination of 1,9-nonanediamine and 2-methyl-1,8-octanediamine.   
   
   
       16 . The thermoplastic composition of  claim 15 , wherein the composition comprises a dispersed phase and a continuous phase and the dispersed phase comprises poly(arylene ether) and has a mean domain size of 0.5-3 micrometers. 
   
   
       17 . The thermoplastic composition of  claim 15 , wherein the aliphatic-aromatic polyamide, prior to forming the composition, has an amine end group less than 45 micromoles per gram of polyamide. 
   
   
       18 . The thermoplastic composition of  claim 15 , wherein the poly(arylene ether) is present in an amount of 5 to 60 weight percent, the aliphatic-aromatic polyamide is present in an amount of 35 to 80 weight percent, the impact modifier is present in an amount of 5 to 22 weight percent, and the polymeric compatibilizer is present in an amount of 0.1 to 20 weight percent, based on the total weight of the composition. 
   
   
       19 . The thermoplastic composition of  claim 15 , wherein the functionalizing agent comprises fumaric acid, maleic anhydride, citric acid or a combination of two or more of the foregoing. 
   
   
       20 . The thermoplastic composition of  claim 15 , wherein the polymeric compatibilizer comprises an epoxy functionalized polyolefin, an epoxy functionalized poly(alkenyl aromatic) resin or a combination thereof. 
   
   
       21 . The thermoplastic composition of  claim 15 , wherein the composition further comprises reinforcing filler, electrically conductive filler or a combination thereof.