High impact compositions of a polyphenylene ether resin and alkenyl aromatic resins modified with EPDM rubber

Claim 2

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin and (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer of a mixture of mono-olefins and a polyene by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns, wherein the improvement comprises the modified alkenyl aromatic resin containing at least 8% by weight of rubbery interpolymer.

Claim 3

The molding composition of claim 1 wherein the alkenyl aromatic resin is modified with a rubbery interpolymer of ethylene, an alpha-olefin, and a polyene.

Claim 4

The molding composition of claim 2 wherein the alpha-olefin is propylene.

Claim 5

The molding composition of claim 1 wherein said rubbery interpolymer comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-16 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-20 carbon atoms.

Claim 6

The molding composition of claim 4 wherein the alpha-olefin is propylene.

Claim 7

The molding composition of claim 4 wherein the polyphenylene ether resin is selected from compounds of the formula ##STR7## wherein the oxygen ether atom of one unit is connected to the benzene nucleus of the next adjoining unit, n is a positive integer and is at least 50, and each Q is a monovalent substituent selected from the group consisting of hydrogen, halogen, hydrocarbon radicals free of a tertiary alpha-carbon atom, halohydrocarbon radicals having at least two carbon atoms between the halogen atom and the phenyl nucleus, hydrocarbonoxy radicals, and halohydrocarbonoxy radicals having at least two carbon atoms between the halogen atom and the phenyl nucleus.

Claim 8

The molding composition of claim 4 wherein the alkenyl aromatic resin is prepared from a monomer selected from the group consisting of styrene, α-methylstyrene bromostyrene, chlorostyrene, divinylbenzene, and vinyltoluene.

Claim 9

The molding composition of claim 1 wherein said composition includes a reinforcing amount of an inorganic reinforcing filler.

Claim 10

The molding composition of claim 8 wherein said composition includes 10-80% by weight of fibrous glass filaments, based on the total weight of the composition.

Claim 11

The molding composition of claim 1 wherein said composition includes a flame-retardant amount of a flame-retardant additive.

Claim 12

The molding composition of claim 10 wherein said flame-retardant is a halogenated organic compound, a halogenated organic compound in admixture with an antimony compound, elemental phosphorus, a phosphorus compound, compounds containing phosphorus-nitrogen bonds, or a mixture of two or more of the foregoing.

Claim 13

The molding composition of claim 1 wherein the rubbery interpolymer is comprised of particles having a median diameter in the range of about 0.5 to 1.5 microns.

Claim 14

The molding composition of claim 1 wherein the modified alkenyl aromatic resin contains from about 8 to 18% by weight of rubbery polymer.

Claim 15

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin and (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 16

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin and (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 17

The molding composition of claim 14 wherein said polyphenylene ether resin is poly(2,6-dimethyl-1,4-phenylene) ether.

Claim 18

The molding composition of claim 14 wherein the alpha-olefin is propylene.

Claim 19

The molding composition of claim 14 wherein said alkenyl aromatic resin is styrene.

Claim 20

The molding composition of claim 14 wherein said rubbery interpolymer comprises 10-90 mole percent of ethylene, 10-90 mole percent of propylene, and 0.1-12 mole percent of 5-ethylidene-2-norbornene.

Claim 21

The molding composition of claim 14 wherein said rubbery interpolymer comprises 10-90 mole percent of ethylene, 10-90 mole percent of propylene, and 0.1-12 mole percent of 1,4-hexadiene.

Claim 22

The molding composition of claim 14 wherein said rubbery interpolymer comprises 10-90 mole percent of ethylene, 10-90 mole percent of propylene, and 0.1-12 mole percent of dicyclopentadiene.

Claim 23

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin; (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns, and (c) a reinforcing amount of an inorganic reinforcing filler, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 24

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin; (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns, and (c) a reinforcing amount of an inorganic reinforcing filler, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 25

The molding composition of claim 21 wherein said polyphenylene ether resin is poly(2,6-dimethyl-1,4-phenylene) ether.

Claim 26

The molding composition of claim 21 wherein the alpha-olefin is propylene.

Claim 27

The molding composition of claim 21 wherein said reinforcing filler comprises from 10 to 80% of fibrous glass filaments, based on the total weight of the composition.

Claim 28

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin; (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; and (c) a flame-retardant amount of a flame-retardant additive, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 29

An improved thermoplastic molding composition which comprises: (a) from 20 to 65% by weight of a polyphenylene ether resin; (b) from 35 to 80% by weight of an alkenyl aromatic resin that is modified with a rubbery interpolymer which comprises 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin having 3-10 carbon atoms, and 0.1-12 mole percent of a polyene that is a non-conjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing an alkenyl aromatic monomer in the presence of the rubbery interpolymer, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; and (c) a flame-retardant amount of a flame-retardant additive, wherein the improvement comprises the modified alkenyl aromatic resin containing from about 8 to 18% by weight of rubbery interpolymer.

Claim 30

The molding composition of claim 25 wherein the alpha-olefin is propylene.

Claim 31

The molding composition of claim 25 wherein said flame-retardant additive is a halogenated organic compound, a halogenated organic compound in admixture with an antimony compound, elemental phosphorus, a phosphorus compound, compounds containing phosphorus-nitrogen bonds, or a mixture of two or more of the foregoing.

Claim 32

The molding composition of claim 25 wherein said flame-retardant additive comprises a mixture of an organic bromine-containing compound with antimony oxide.

Claim 33

The molding composition of claim 25 wherein said flame-retardant additive is triphenylphosphate.

Claim 34

The molding composition of claim 25 wherein said flame-retardant additive is comprised of a mixture of triaryl phosphates wherein one or more aryl groups are substituted by one or more isopropyl groups.