Polyphenylene ether-polyamide composition

Claim 2

1) A thermoplastic composition comprising: A) about 20% by weight to about 80% by weight of polyphenylene ether; B) about 80% by weight to about 20% by weight of a polyamide; C) about 0.05% to about 4% by weight, based on the weight of the entire composition, of a compatibilizing compound for components (A) and (B); and D) about 0.05% to about 2% by weight, based on the weight of the entire composition, of an additive combination which itself comprises (i) at least one metal stearate, and (ii) at least one amide selected from the group consisting of primary amides, secondary amides, and aklylenebisamides.

Claim 3

2) The composition of claim 1 wherein the polyphenylene ether comprises a plurality of structural units having the formula and in each of said units independently, each Q¹ is independently halogen, primary or secondary lower alkyl, phenyl, haloalkyl, aminoalkyl, hydrocarbonoxy, or halohydrocarbonoxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each Q² is independently hydrogen, halogen, primary or secondary lower alkyl, phenyl, haloalkyl, hydrocarbonoxy or halohydrocarbonoxy as defined for Q₁.

Claim 4

3) The composition of claim 2 wherein the polyphenylene ether is poly(2,6-dimethyl-1,4-phenylene ether).

Claim 5

4) The composition of claim 2 wherein the polyamide is selected from the group consisting of polyamide 6; polyamide 6,6; polyamide 12; and polyamide 6/10.

Claim 6

5) The composition of claim 2 wherein the weight ratio of polyphenylene ether to polyamide is in the range of about 40:60 to about 60:40.

Claim 7

6) The composition of claim 1 wherein compatibilizing compound (C) is selected from the group consisting of (a) compounds which contain both (i) an ethylenic carbon-carbon double bond or a carbon-carbon triple bond and (ii) a carboxylic acid, acid anhydride, acid amide, imido, carboxylic ester, amino, or hydroxyl group; (b) liquid diene polymers; (c) epoxy compounds; (d) polycarboxylic acids or derivatives thereof; (e) an oxidized polyolefin wax; (f) a compound containing an acyl functional group; (g) a polyphenylene ether modified with a compound containing an acyl functional group; and (h) a chloroepoxytriazine compound

Claim 8

7) The composition of claim 6 wherein the compatibilizing agent is selected from the group consisting of maleic anhydride, maleic acid, fumaric acid, maleimide, and maleic hydrazide.

Claim 9

8) The composition of claim 6 wherein the compatibilizing agent is trimellitic anhydride acid chloride or polyphenylene ether modified with trimellitic anhydride acid chloride.

Claim 10

9) The composition of claim 6, wherein the polycarboxylic acid or derivative thereof is selected from the group consisting of citric acid, malic acid, and salts and hydrates thereof.

Claim 11

10) The composition of claim 1, further comprising a styrene resin selected from the group consisting of styrene homopolymers, styrene copolymers, rubber-modified polystyrene, and blends thereof.

Claim 12

11) The composition of claim 10 wherein the styrene resin is present in the composition at a level of about 1%-30% by weight, based on the weight of the entire composition.

Claim 13

12) The composition of claim 1, further comprising an elastomeric block copolymer.

Claim 14

13) The composition of claim 12, wherein the elastomeric block copolymer is a diblock or triblock copolymer of styrene and at least one olefin or conjugated diene, any conjugated diene block being non-hydrogenated or partially or entirely hydrogenated.

Claim 15

14) The composition of claim 13, wherein the block copolymer is present in the composition at a level of about 5%-20% by weight, based on the weight of the entire composition.

Claim 16

15) The composition of claim 14 wherein the block copolymer is a styrene-butadiene diblock or styrene-butadiene-styrene triblock copolymer.

Claim 17

16) The composition of claim 1, further comprising about 1% by weight to about 40% by weight glass fibers, based on the weight of the entire composition.

Claim 18

17) The composition of claim 1, further comprising effective amounts of a stabilizer which inhibits oxidation or thermal degradation of the composition.

Claim 19

18) The composition of claim 17 wherein the stabilizer is a hindered polyphenol.

Claim 20

19) The composition of claim 1 wherein the metal stearate is selected from the group consisting of zinc stearate, calcium stearate, aluminum stearate, cerium stearate, and magnesium stearate.

Claim 21

20) The composition of claim 1 wherein the amide is selected from the group consisting of stearamide, behenamide, oleamide, erucamide, stearyl erucamide, erucyl erucamide, oleyl palmitamide, stearyl stearamide, erucyl stearamide, N,N′-ethylene­bisstearamide, and N,N′-ethylenebisoleamide.

Claim 22

21) The composition of claim 1 wherein the amide of component D(ii) is stearyl erucamide.

Claim 23

22) The composition of claim 21 wherein the metal stearate is zinc stearate.

Claim 24

23) The composition of claim 1 wherein the weight ratio of metal stearate to amide ranges from about 80:20 to about 60:40.

Claim 25

24) A thermoplastic composition comprising: a) about 20%-50% polyphenylene ether resin; b) about 20%-50% polyamide resin; c) about 5%-20% elastmeric block copolymer; d) about 0.1%-1.5% aliphatic polycarboxylic acid; e) about 1%-20% styrene resin; and f) about 0.05%-2.0% of an additive combination which consists essentially of at least one metal stearate and at least one amide selected from the group consisting of primary amides, secondary amides, and alkylenebisamides, each component in the composition measured in terms of percent-by-weight, based on the weight of the entire composition.

Claim 26

24) A thermoplastic composition comprising: a) about 20%-50% polyphenylene ether resin; b) about 20%-50% polyamide resin; c) about 5%-20% elastmeric block copolymer; d) about 0.1%-1.5% aliphatic polycarboxylic acid; e) about 1%-20% styrene resin; and f) about 0.05%-2.0% of an additive combination which consists essentially of at least one metal stearate and at least one amide selected from the group consisting of primary amides, secondary amides, and alkylenebisamides, each component in the composition measured in terms of percent-by-weight, based on the weight of the entire composition.

Claim 27

25) An improved method for extruding polyphenylene ether-polyamide compositions, comprising: a) admixing, in a molten state, at least one polyphenylene ether resin with at least one compatibilizing compound for polyphenylene ethers and polyamides; and b) adding to the extruder at least one polyamide resin along with an additive combination which itself comprises i) at least one metal stearate, and ii) at least one amide selected from the group consisting of primary amides, secondary amides, and alkylenebisamides; said composition while in the extruder being subjected to a temperature in the range of about 250 degrees Centigrade to about 350 degrees Centigrade for a time period of about 10 seconds to about 30 seconds.

Claim 28

25) An improved method for extruding polyphenylene ether-polyamide compositions, comprising: a) admixing, in a molten state, at least one polyphenylene ether resin with at least one compatibilizing compound for polyphenylene ethers and polyamides; and b) adding to the extruder at least one polyamide resin along with an additive combination which itself comprises i) at least one metal stearate, and ii) at least one amide selected from the group consisting of primary amides, secondary amides, and alkylenebisamides; said composition while in the extruder being subjected to a temperature in the range of about 250 degrees Centigrade to about 350 degrees Centigrade for a time period of about 10 seconds to about 30 seconds.