Plated polyphenylene ether resin compositions containing EPDM rubber-modified alkenyl aromatic resins and hydrogenated elastomeric block copolymers

Claim 2

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) a polyphenylene ether resin; (b) an alkenyl aromatic resin that is modified with a rubbery interpolymer of a mixture of mono-olefins and a polyene by polymerizing alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; and (c) a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are a polymerized vinyl aromatic hydrocarbon and center block B is a polymerized conjugated diene, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 3

The substrate of claim 1 wherein the polyphenylene ether resin is selected from the 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 the halohydrocarbonoxy radicals having at least two carbon atoms between the halogen atom and the phenyl nucleus.

Claim 4

The substrate of claim 1 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 5

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

Claim 6

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

Claim 7

The substrate of claim 1 wherein the 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 8

The substrate of claim 1 wherein the rubbery interpolymer comprises 10-90 mole percent of ethylene, 10-90 mole percent of propylene, and 0.1-12 mole percent of a polyene selected from 5-ethylidene-2-norbornene, 1,4-hexadiene, and dicyclopentadiene.

Claim 9

The substrate of claim 1 wherein the alkenyl aromatic resin is styrene and said rubbery interpolymer is present between about 4% and about 25% by weight of styrene and rubbery interpolymer combined.

Claim 10

The substrate of claim 1 wherein in the A-B-A block copolymer (c), the vinyl aromatic hydrocarbon of terminal blocks A is selected from the group consisting of styrene, α-methyl styrene, vinyltoluene, vinyl xylene, and vinyl naphthalene and the conjugated diene of center block B is selected from the group consisting of butadiene, 2-methyl-1,3-butadiene, 1,-3-pentadiene, and 2,3-dimethylbutadiene.

Claim 11

The substrate of claim 1 wherein in the A-B-A block copolymer (c), each of terminal blocks A has an average molecular weight of from about 4,000 to about 115,000 and center block B has an average molecular weight of from about 20,000 to 450,000.

Claim 12

The substrate of claim 1 wherein the average unsaturation of center block B has been reduced to less than 20% of its original value.

Claim 13

The substrate of claim 1 wherein the composition includes a reinforcing amount of an inorganic reinforcing filler.

Claim 14

The substrate of claim 12 wherein the composition includes from about 10 to 50% by weight of fibrious filaments based on the total weight of the composition.

Claim 15

The substrate of claim 1 wherein the composition includes a flame-retardant amount of a flame-retardant additive.

Claim 16

The substrate of claim 14 wherein the 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 17

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; and (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 18

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; and (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 19

The substrate of claim 16 wherein the polyphenylene ether resin is poly(2,6-dimethyl-1,4-phenylene) ether.

Claim 20

The substrate of claim 16 wherein the alpha-olefin is propylene.

Claim 21

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene; and (d) a reinforcing amount of an inorganic reinforcing filler, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 22

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene; and (d) a reinforcing amount of an inorganic reinforcing filler, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 23

The substrate of claim 19 wherein the polyphenylene ether resin is poly(2,6dimethyl-1,4-phenylene) ether.

Claim 24

The substrate of claim 19 wherein the alpha-olefin is propylene.

Claim 25

The substrate of claim 19 wherein the reinforcing filler comprises from about 10 to 50% of fibrous glass filaments, based on the total weight of the composition.

Claim 26

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 stoms, and 0.1-12 mole percent of a polyene that is a nonconjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene; and (d) a flame-retardant amount of a flame-retardant additive, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 27

A substrate adapted for the electroless deposition of an adherent metal coating, comprised of a molded thermoplastic composition comprising: (a) from about 10 to about 65% by weight of a polyphenylene ether resin; (b) from about 20 to about 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 stoms, and 0.1-12 mole percent of a polyene that is a nonconjugated cyclic or open-chain diene having 5-10 carbon atoms, by polymerizing alkenyl aromatic monomer in the presence of the rubbery interpolymer until 90-100% by weight of the alkenyl aromatic monomer has reacted, the rubbery interpolymer being comprised of particles having a median diameter less than about two microns; (c) from about 1 to about 25% by weight of a selectively hydrogenated elastomeric block copolymer of the A-B-A type, wherein terminal blocks A are polymerized vinyl aromatic hydrocarbons and center block B is a polymerized conjugated diene; and (d) a flame-retardant amount of a flame-retardant additive, the surface of said substrate having been rendered microporous by treatment with an etching solution.

Claim 28

The substrate of claim 23 wherein the alpha-olefin is propylene.

Claim 29

The substrate of claim 23 wherein the 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 30

The substrate of claim 23 wherein the flame-retardant additive comprises a mixture of an organic bromine-containing compound with antimony oxide.

Claim 31

The substrate of claim 23 wherein the flame-retardant additive is triphenylphosphate.

Claim 32

The substrate of claim 23 wherein the 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.