Described herein are molding compositions comprising a blend of a poly(aryl ether), a polyester and a compatibilizing amount of an aromatic polycarbonate. These compositions are especially suited for molding articles useful in electrical applications.

BACKGROUND OF THE INVENTION 
This invention is directed to a molding composition comprising a blend of a 
poly(aryl ether), a polyester and a compatibilizing amount of an aromatic 
polycarbonate. The composition can additionally contain one or more of the 
following: fiber reinforcement, inorganic particulate filler, impact 
modifier, or a flame retardant additive. 
Filled polyester compositions, particularly fiberglass filled poly(butylene 
terephthalate) are widely used to mold electrical parts, such as 
connectors, since such parts have excellent chemical resistance and a high 
heat distortion temperature. However, the parts molded from a fiberglass 
filled poly(butylene terephthalate) composition have a tendency to warp to 
a high degree due to the uneven shrinkage resulting from crystallization 
of the poly(butylene terephthalate) during molding. 
A molded article produced from a composition containing a poly(aryl ether), 
particularly polysulfone, fiberglass, and poly(butylene terephthalate) 
exhibit lower warpage than an article molded from a fiberglass filled 
poly(butylene terephthalate) composition. However, in several 
applications, an article molded from a composition of polysulfone, 
fiberglass, and poly(butylene terephthalate) tended to be brittle. Also, 
the polysulfone, fiberglass and poly(butylene terephthalate) are 
relatively incompatible and thus difficult to process into uniform 
articles. 
A molded article produced from a composition containing a poly(aryl ether), 
particularly, polysulfone, and a polyester, particularly poly(ethylene 
terephthalate) or poly(butylene terephthalate), without fiberglass has 
improved chemical and environmental stress crack resistance. However, the 
components of this composition are also relatively incompatible and thus 
difficult to process into useful molded articles. 
Thus, since compositions containing poly(aryl ether) and polyester have 
improved properties, a need exists to compatibilize them so that they can 
easily be processed into molded articles. 
THE INVENTION 
It has now been found that when an aromatic polycarbonate is added to a 
composition containing a poly(aryl ether) and a polyester, the resulting 
composition has improved compatibility and therefore can be easily 
processed into molded articles. It has also been found that a particular 
class of impact modifiers which are not effective with a composition 
containing a poly(aryl ether) and a polyester can be made effective when 
an aromatic polycarbonate is added to the composition. 
Additionally, it has been found that when an aromatic polycarbonate is 
added to a composition containing a poly(aryl ether), a polyester and 
fiber reinforcement, an article molded from such a composition has reduced 
warpage as compared to an article molded from a composition containing 
fiber reinforcement and poly(butylene terephthalate) or poly(ethylene 
terephthalate). Thus, the compositions of this invention are especially 
suitable for molding into articles for electrical applications, such as 
electrical connectors. Further when a flame retardant is added to a 
composition containing a poly(aryl ether), a polyester, an aromatic 
polycarbonate, fiber reinforcement and optionally an impact modifier, an 
article molded from such a composition has an excellent balance of 
properties which are especially suited for molding articles for electrical 
applications. 
The composition of this invention comprises a blend of: 
(a) a poly(aryl ether), 
(b) a polyester, 
(c) a compatibilizing amount of an aromatic polycarbonate, and optionally 
one or more of the following: 
(d) an impact modifier, 
(e) fiber reinforcement, 
(f) an inorganic particulate filler, or 
(g) a flame retardant additive. 
The poly(aryl ether) resin may be described as a linear, thermoplastic 
polyarylene polyether wherein the arylene units are interspersed with 
ether, sulfone or ketone linkages. These resins may be obtained by 
reaction of an alkali metal double salt of a dihydric phenol and a 
dihalobenzenoid or dinitrobenzenoid compound, either or both of which 
contain a sulfone or a ketone linkage, i.e., --SO.sub.2 -- or --CO--, 
between arylene groupings, to provide sulfone or ketone units in the 
polymer chain in addition to arylene units and ether units. The polymer 
has a basic structure comprising recurring units of the formula 
EQU O--E--O--E'-- 
wherein E is the residuum of the dihydric phenol and E' is the residuum of 
the benzenoid compound having an inert electron withdrawing group in at 
least one of the positions ortho and para to the valence bonds; both of 
said residua are valently bonded to the ether oxygens through aromatic 
carbon atoms. Such aromatic polyethers are included within the class of 
polyarylene polyether resins described in U.S. Pat. No. 3,264,536, the 
disclosure of which is hereby incorporated herein by reference, for the 
purpose of describing and exemplifying E and E' in more detail. It is 
preferred that the dihydric phenol be a weakly acidic dinuclear phenol 
such as, for example, the dihydroxy diphenyl alkanes or the nuclear 
halogenated derivatives thereof, such as, for example, the 
2,2-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)2-phenyl ethane 
bis(4-hydroxyphenyl)methane, or their chlorinated derivatives containing 
one or two chlorines on each aromatic ring. While these halogenated 
bisphenolic alkanes are more acidic than the non-halogenated bisphenols 
and hence slower in reacting in this process, they do impart valuable 
flame resistance to these polymers. Other materials also termed 
appropriately "bisphenols" are also highly valuable and preferred. These 
materials are the bisphenols of a symmetrical or unsymmetrical joining 
group, as, for example, other oxygen (--O--), carbonyl 
##STR1## 
sulfide (--S--), sulfone 
##STR2## 
or hydrocarbon residue in which the two phenolic nuclei are joined to the 
same or different carbon atoms of the residue. 
Such dinuclear phenols can be characterized as having the structure: 
##STR3## 
wherein Ar is an aromatic group and preferably is a phenylene group, 
A.sub.1 and A.sub.2 can be the same or different inert substituent groups 
as alkyl groups having from 1 to 4 carbon atoms, halogen atoms, i.e. 
fluorine, chlorine, bromine or iodine, or alkoxy radicals having from 1 to 
4 carbon atoms, a and b are integers having a value from 0 to 4, 
inclusive, and R.sub.1 is representative of a bond between aromatic carbon 
atoms as in dihydroxy-diphenyl, or is a divalent radical, including for 
example, radicals such as 
##STR4## 
--O--, --S--, --SO--, --S--S--, --SO.sub.2 --, and divalent hydrocarbon 
radicals such as alkylene, alkylidene, cycloalkylene, cycloalkylidene, or 
the halogen, alkyl, aryl or like substituted alkylene, alkylidene and 
cycloaliphatic radicals as well as aromatic radicals and rings fused to 
both Ar groups. 
Examples of specific dihydric polynuclear phenols include among others: the 
bis-(hydroxylphenyl)alkanes such as 2,2-bis-(4-hydroxyphenyl)propane, 
2,4'-dihydroxydiphenylmethane, bis-(2-hydroxyphenyl)methane, 
bis-(4-hydroxyphenyl)methane, 
bis(4-hydroxy-2,6-dimethyl-3-methoxyphenyl)methane, 
1,1-bis-(4-hydroxyphenyl)ethane, 1,2-bis-(4-hydroxyphenyl)ethane, 
1,1-bis-(4-hydroxy-2-chlorophenyl)ethane, 
1,1-bis-(3-methyl-4-hydroxyphenyl)propane, 
1,3-bis-(3-methyl-4-hydroxyphenyl)propane, 
2,2-bis-(3-phenyl-4-hydroxyphenyl) propane, 
2,2-bis-(3-isopropyl-4-hydroxyphenyl)propane, 
2,2-bis-(2-isopropyl-4-hydroxyphenyl)propane, 
2,2-bis-(4-hydroxynaphthyl)-propane, 2,2-bis-(4-hydroxyphenyl)pentane, 
3,3-bis-(4-hydroxyphenyl)pentane 2,2-bis-(4-hydroxyphenyl) heptane, 
bis-(4-hydroxyphenyl)phenylmethane, 
2,2-bis-(4-hydroxyphenyl)-1-phenyl-propane, 
2,2-bis-(4-hydroxyphenyl)1,1,1,3,3,3,-hexafluoropropane and the like; 
di(hydroxyphenyl)sulfones such as bis-(4-hydroxyphenyl, sulfone, 
2,4'-dihydroxydiphenyl sulfone, 5-chloro2,4'-dihydroxydiphenyl sulfone, 
5'-chloro-4,4'-dihydroxydiphenyl sulfone, and the like. 
di(hydroxyphenyl)ethers such as bis-(4-hydroxyphenyl)ether, the 4,3'-, 
4,2'-2,2'- 2,3'-, dihydroxydiphenyl ethers, 
4,4'-dihydroxy-2,6-dimethyldiphenyl ether, 
bis-(4-hydroxy-3-isobutylphenyl) ether, bis-(4-hydroxy-3-isopropylphenyl) 
ether, bis-(4-hydroxy-3-chlorophenyl) ether, bis-(4-hydroxy-3-fluophenyl) 
ether, bis-(4-hydroxy-3-bromophenyl) ether, bis-(4-hydroxynaphthyl) ether, 
bis-(4-hydroxy-3-chloronaphthyl) ether, 
4,4'-dihydroxy-3,6-dimethoxydiphenyl ether. 
As herein used the E term defined as being the "residuum of the dihydric 
phenol" of course refers to the residue of the dihydric phenol after the 
removal of the two aromatic hydroxyl groups. Thus as is readily seen these 
polyarylene polyethers contain recurring groups of the residuum of the 
dihydric phenol and the residuum of the benzenoid compound bonded through 
aromatic ether oxygen atoms. 
Any dihalobenzenoid or dinitrobenzenoid compound or mixtures thereof can be 
employed in this invention which compound or compounds has the two 
halogens or nitro-groups bonded to benzene rings having an electron 
withdrawing group in at least one of the positions ortho and para to the 
halogen or nitro-group. The dihalobenzenoid or dinitrobenzenoid compound 
can be either mononuclear where the halogens or nitro-groups are attached 
to the same benzenoid ring or polynuclear where they are attached to 
different benzenoid rings, as long as there is an activating electron 
withdrawing group in the ortho or para position of that benzenoid nucleus. 
Fluorine and chlorine substituted benzenoid reactants are preferred; the 
fluorine compounds for fast reactivity and the chlorine compounds for 
their inexpensiveness. Fluorine substituted benzenoid compounds are most 
preferred, particularly when there is a trace of water present in the 
polymerization reaction system. However, this water content should be 
maintained below about 1% and preferably below 0.5% for best results. 
Any electron withdrawing group can be employed as the activator group in 
these compounds. It should be, of course, inert under the reaction 
conditions, but otherwise its structure is not critical. Preferred are the 
strong activating groups such as the sulfone group 
##STR5## 
bonding two halogen or nitro substituted benzenoid nuclei as in the 
4,4'-dichlorodiphenyl sulfone and 4,4'-difluorodiphenyl sulfone, although 
such other strong withdrawing groups hereinafter mentioned can also be 
used with equal ease. 
The more powerful of the electron withdrawing groups give the fastest 
reactions and hence are preferred. It is further preferred that the ring 
contain no electron supplying groups on the same benzenoid nucleus as the 
halogen or nitro group; however, the presence of other groups on the 
nucleus or in the residuum of the compound can be tolerated. Preferably, 
all of the substituents on the benzenoid nucleus are either hydrogen (zero 
electron withdrawing), or other groups having a positive sigma* value, as 
set forth in J. F. Bunnett in Chem. Rev. 49 273 (1951) and Quart. Rev., 
12, 1 (1958). See also Taft, Steric Effects in Organic Chemistry, John 
Wiley & Sons (1956), chapter 13; Chem. Rev., 53, 222; JACS, 74, 3120; and 
JACS, 75, 4231. 
The activating groups can be basically either of two types: 
(a) monovalent groups that activate one or more halogens or nitro-groups on 
the same ring such as another nitro or halo group, phenylsulfone, or 
alkylsulfone, cyano, trifluoromethyl, nitroso, and hetero nitrogen as in 
pyridine. 
(b) divalent group which can activate displacement of halogens on two 
different rings, such as the sulfone group 
##STR6## 
the carbonyl group 
##STR7## 
the vinylene group 
##STR8## 
the sulfoxide group 
##STR9## 
the azo-group --N.dbd.N--; the saturated fluorocarbon groups --CF.sub.2 
CF.sub.2 --; organic phosphine oxides 
##STR10## 
where R.sub.2 is a hydrocarbon group, and the ethylidene group 
##STR11## 
where X.sub.1 can be hydrogen or halogen and activating groups within the 
nucleus which can activate halogens as nitro functions on the same ring 
such as in the case with difluorobenzoquinone, 1,4- or 1,5- or 
1,8-difluoroanthraquinone, etc. 
If desired, the polymers may be made with mixtures of two or more 
dihalobenzenoid or dinitrobenzenoid compounds. Thus, the E' residuum of 
the benzenoid compounds in the polymer structure may be the same or 
different. 
It is seen also that as used herein, the E' term defined as being the 
"residuum of the benzenoid compound" refers to the aromatic or benzenoid 
residue of the compound after the removal of the halogen atom or nitro 
group on the benzenoid nucleus. 
The polyarylene polyethers of this invention are prepared by methods well 
known in the art as for instance the substantially equimolar one-step 
reaction of a double alkali metal salt of dihydric phenol with a 
dihalobenzenoid compound in the presence of specific liquid organic 
sulfoxide or sulfone solvents under substantially anhydrous conditions. 
Catalyst are not necessary for this reaction but the unique facility of 
these solvents to promote the reaction to a high molecular weight product 
has now provided the critical tool necessary to secure sufficiently high 
molecular weight aromatic ether products useful for services heretofore 
limited to such products as polyformaldehydes and polycarbonates. 
The polymers are also prepared in a two-step process in which a dihydric 
phenol is first converted in situ in the primary reaction solvent to the 
alkali metal salt by the reaction with the alkali metal, the alkali metal 
hydride, alkali metal hydroxide, alkali metal alkoxide or the alkali metal 
alkyl compounds. Preferably, the alkali metal hydroxide is employed. After 
removing the water which is present or formed, in order to secure 
substantially anhydrous conditions, the dialkali metal salts of dihydric 
phenol is admixed and reacted with about stoichiometric quantities of the 
dihalobenzenoid or dinitrobenzenoid compound. 
The polymerization reaction proceeds in the liquid phase of a sulfoxide or 
sulfone organic solvent at elevated temperatures. 
A preferred form of the polyarylene polyethers of this invention are those 
prepared using the dihydric polynuclear phenols of the following four 
types, including the derivatives thereof which are substituted with inert 
substituent groups 
##STR12## 
in which the R.sub.3 group represents independently hydrogen, lower alkyl, 
lower aryl and the halogen substituted groups thereof, which can be the 
same or different; 
##STR13## 
and substituted derivatives thereof. 
It is also contemplated in this invention to use a mixture of two or more 
different dihydric phenols to accomplish the same ends as above. Thus when 
referred to above the --E-- residuum in the polymer structure can actually 
be the same or different aromatic residua. 
In order to secure the high polymers, the system should be substantially 
anhydrous, and preferably with less than 0.5 percent by weight water in 
the reaction mixtures. 
The poly(aryl ether)s have a reduced viscosity of from about 0.4 to about 
1.5 as measured in an appropriate solvent at an appropriate temperature 
depending on the particular polyether, such as in methylene chloride at 
25.degree. C. 
The preferred poly(aryl ether)s have repeating units of the formula: 
##STR14## 
The polyesters which are suitable for use herein are derived from an 
aliphatic or cycloaliphatic diol, or mixtures thereof, containing from 2 
to about 10 carbon atoms and at least one aromatic dicarboxylic acid. The 
polyesters which are derived from an aliphatic diol and an aromatic 
dicarboxylic acid have repeating units of the following general formula: 
##STR15## 
wherein n is an integer of from 2 to 4. 
The preferred polyesters are poly(ethylene terephthalate) and poly(butylene 
terephthalate). 
Also contemplated herein are the above polyesters with minor amounts, e.g., 
from 0.5 to about 2 percent by weight, of units derived from aliphatic 
acids and/or aliphatic polyols, to form copolyesters. The aliphatic 
polyols include glycols such as poly(ethylene glycol). These can be made 
following the teachings of, for example, U.S. Pat. Nos. 2,465,319 and 
3,047,539. 
Among the units which can be present in the copolyesters are those derived 
from aliphatic dicarboxylic acids, e.g., of up to about 50 carbon atoms, 
including cycloaliphatic straight and branched chain acids, such as adipic 
acid, cyclohexanediacetic acid, dimerized C.sub.16 -C.sub.18 unsaturated 
acids (which have 32 to 36 carbon atoms), trimerized acids, and the like. 
In addition, there can be minor amounts of units derived from aliphatic 
glycols and polyols, e.g., of up to about 50 carbon atoms preferably from 
2 to about 20 carbon atoms and these include, among others, propylene 
glycol, glycerol, diethylene glycol, triethylene glycol and the like. 
The polyesters which are derived from a cycloaliphatic diol and an aromatic 
dicarboxylic acid are prepared by condensing either the cis- or 
trans-isomer (or mixtures thereof) of, for example, 
1,4-cyclohexanedimethanol with the aromatic dicarboxylic acid so as to 
produce a polyester having recurring units having the following formula: 
##STR16## 
wherein the cyclohexane ring is selected from the cis- and trans-isomers 
thereof and R represents an aryl radical containing 6 to 20 carbon atoms 
and which is the decarboxylated residue derived from an aromatic 
dicarboxylic acid. 
Examples of aromatic dicarboxylic acids indicated by R in formula II, 
include isophthalic or terephthalic acid, 1,2-di(p-carboxyphenyl) ethane, 
4,4'-dicarboxydiphenyl ether, etc., and mixtures of these. All of these 
acids contain at least one aromatic nucleus. Fused rings can also be 
present such as in 1,4- or 1,5-naphthalene-dicarboxylic acids. The 
preferred dicarboxylic acid is terephthalic acid or mixtures of 
terephthalic and isophthalic acid. 
A preferred polyester may be derived from the reaction of either the cis- 
or trans-isomer (or a mixture thereof) of 1,4-cyclohexanedimethanol with 
iso- or terephthalic acids or mixtures thereof. These polyesters have 
repeating units of the formula: 
##STR17## 
The preferred polyester would be based on terephthalic acid. 
Another preferred polyester is a copolyester derived from a cyclohexane 
dimethanol, an alkylene glycol and an aromatic dicarboxylic acid. These 
copolyesters are prepared by condensing either the cis- or trans-isomer 
(or mixtures thereof) of, for example, 1,4-cyclohexanedimethanol and an 
alkylene glycol with an aromatic dicarboxylic acid so as to produce a 
copolyester having repeating units of the following formula: 
##STR18## 
wherein the cyclohexane ring is selected from the cis- and trans-isomers 
thereof, R is as previously defined, n is an integer of 2 to 4, the x 
units comprise from about 10 to about 90 percent by weight and the y units 
comprise from about 10 to about 90 percent by weight. 
The preferred copolyester may be derived from the reaction of either the 
cis- or trans-isomer (or mixtures thereof), of 1,4-cyclohexanedimethanol 
and ethylene glycol with terephthalic acid in a molar ratio of 1:2:3. 
These copolyesters have repeating units of the following formula: 
##STR19## 
wherein x and y are as previously defined. 
The polyesters used herein have an intrinsic viscosity of at least about 
0.4 to about 2.0 dl/g. measured in a 60:40 phenol/tetrachloroethane 
mixture or similar solvent at 23.degree.-60.degree. C. 
The thermoplastic aromatic polycarbonates that can be employed herein are 
homopolymers and copolymers and mixtures thereof which have an intrinsic 
viscosity of 0.40 to 1.0 dl./g. as measured in methylene chloride at 
25.degree. C. that are prepared by reacting a dihydric phenol with a 
carbonate precursor. Typical of some of the dihydric phenols that may be 
employed in the practice of this invention are bisphenol-A 
(2,2-bis(4-hydroxyphenyl) propane), bis(4-hydroxyphenyl) methane, 
2,2-bis(4-hydroxy-3-methylphenyl) propane, 4,4-bis(4-hydroxyphenyl) 
heptane, 2,2-(3,5,3',5'-tetrachloro-4,4'-dihydroxydiphenyl) propane, 
2,2-(3,5,3',5'-tetrabromo-4,4'-dihydroxydiphenyl)-propane, 
(3,3'-dichloro-4,4'-dihydroxydiphenyl) methane. Other dihydric phenols of 
the bisphenol type are also available and are disclosed in U.S. Pat. Nos. 
2,999,835, 3,028,365 and 3,334,154. 
It is, of course, possible to employ two or more different dihydric phenols 
or a copolymer of a dihydric phenol with a glycol or with hydroxy or acid 
terminated polyester, or with a dibasic acid in the event a carbonate 
copolymer or inter-polymer rather than a homopolymer is desired for use in 
the preparation of the aromatic carbonate polymers of this invention. 
The carbonate precursor may be either a carbonyl halide, a carbonate ester 
or a haloformate. The carbonyl halides which can be employed herein are 
carbonyl bromide, carbonyl chloride and mixtures thereof. Typical of the 
carbonate esters which may be employed herein are diphenyl carbonate, 
di-(halophenyl) carbonates such as di-(chlorophenyl) carbonate, 
di-(bromophenyl) carbonate, di-(trichlorophenyl) carbonate, 
di-(tribromophenyl) carbonate, etc., di-(alkylphenyl) carbonates such as 
di(tolyl) carbonate, etc., di-(naphthyl) carbonate, di-(chloronaphthyl) 
carbonate, phenyl tolyl carbonate, chlorophenyl chloronaphthyl carbonate, 
etc. or mixtures thereof. The haloformates suitable for use herein include 
bis-haloformates of dihydric phenols (for example, bischloroformates of 
bisphenol-A, of hydroquinone, etc.) or glycols (for example, 
bishaloformates of ethylene glycol, neopentyl glycol, polyethylene glycol, 
etc.). While other carbonate precursors will occur to those skilled in the 
art, carbonyl chloride, also known as phosgene, is preferred. 
The aromatic carbonate polymers of this invention may be prepared by using 
phosgene or a haloformate and by employing a molecular weight regulator, 
an acid acceptor and a catalyst. The molecular weight regulators which can 
be employed in carrying out the process of this invention include 
monohydric phenols such as phenol, para-tertiarybutylphenol, 
para-bromophenol, primary and secondary amines, etc. Preferably, a phenol 
is employed as the molecular weight regulator. 
A suitable acid acceptor may be either an organic or an inorganic acid 
acceptor. A suitable organic acid acceptor is a tertiary amine and 
includes such materials as pyridine, triethylamine, dimethylaniline, 
tributylamine, etc. The inorganic acid acceptor may be one which can be 
either a hydroxide, a carbonate, a bicarbonate, or a phosphate of an 
alkali or alkaline earth metal. 
The catalysts which are employed herein can be any of the suitable 
catalysts that aid the polymerization of bisphenol-A with phosgene. 
Suitable catalysts include tertiary amines such as, for example, 
triethylamine, tripropylamine, N,N-dimethylaniline, quaternary ammonium 
compounds such as, for example, tetraethylammonium bromide, cetyl triethyl 
ammonium bromide, tetra-n-heptylammonium iodide, tetra-n-propyl ammonium 
bromide, tetra-methylammonium chloride, tetra-methyl ammonium hydroxide, 
tetra-n-butyl ammonium iodide, benzyltrimethyl ammonium chloride and 
quaternary phosphonium compounds such as, for example, n-butyltriphenyl 
phosphonium bromide and methyl-triphenyl phosphonium bromide. 
The polycarbonates can be prepared in a one-phase (homogeneous solution) or 
two-phase (interfacial) systems when phosgene or a haloformate are used. 
Bulk reactions are possible with the diarylcarbonate precursors. The 
preferred polycarbonate is a biphenol-A polycarbonate. 
The poly(aryl ether) is used in amounts of from about 20 to about 90, 
preferably from about 40 to about 80 weight percent. The polyester is used 
in amounts of from about 10 to about 60, preferably from about 10 to about 
45 weight percent. The polycarbonate is used in compatibilizing amounts of 
from about 1 to about 25, preferably from about 3 to about 20 weight 
percent. 
The impact modifiers which can be used in this invention are described in 
U.S. Patent Application Ser. No. 049,131 of L. M. Robeson, titled "Impact 
Modified Polyarylate Blends", filed June 18, 1979. These impact modifiers 
are a graft copolymer of a vinyl aromatic, an acrylate, an unsaturated 
nitrile, or mixtures thereof, grafted onto an unsaturated elastomeric 
backbone and having a tensile modulus (as measured by ASTM D-638, except 
that the test piece is compression molded to a 20 mil thickness) of less 
than about 100,000 psi, and preferably from about 15,000 to less than 
about 100,000 psi. 
The unsaturated elastomeric backbone may be polybutadiene, 
poly(butadiene-co-styrene), poly(butadiene-co-acrylonitrile), or 
poly(isoprene). In each of the polymers there is sufficient butadiene to 
give the polymer a rubbery character. 
Additionally impact modifiers based on acrylic elastomers may be used. 
Preferably, acrylic elastomers based on n-butyl acrylate may be used. 
The constituents which are grafted onto the unsaturated elastomeric 
backbone are selected from a vinyl aromatic, such as styrene, 
.alpha.-methylstyrene, alkylstyrene, or mixtures thereof; an acrylate such 
as the acrylic ester monomers, such as methyl acrylate, ethyl acrylate, 
butyl acrylate, methyl methacrylate, or mixtures thereof; an unsaturated 
nitrile such as acrylonitrile, methacrylonitrile, or mixtures thereof. It 
will be understood that the vinyl aromatic, acrylate and acrylonitrile may 
be used individually or in any combinations in grafting onto the 
unsaturated elastomeric backbone. 
These impact modifiers are free-flowing powders and are commercially 
available as impact modifiers for poly(vinyl chloride) as described in, 
for example, V. Shakaypal, in "Developments in PVC Technology", edited by 
J. H. L. Hensen and A. Whelan, Applied Science Publishers Ltd., New York, 
1973. 
The grafted constituents of the impact modifier will comprise from about 20 
to about 60 percent by weight of said constituents such that their tensile 
modulus does not exceed about 100,000 psi, and is preferably, between 
about 15,000 to less than about 100,000 psi. 
The impact modifier is utilized in amounts of from 0 to about 30 weight 
percent, preferably from about 3 to about 15 weight percent. 
The fiber reinforcement in this composition includes fiberglass, carbon 
fibers, and the like, and mixtures thereof. The particulate inorganic 
fillers which may be used include wollastonite, calcium carbonate, glass 
beads, and the like, or mixtures thereof. Mixtures of fiber reinforcement 
and particulate fillers may also be used. 
The fiber reinforcement, filler or combinations thereof is utilized in 
amounts of from 0 to about 50 weight percent, preferably from about 15 to 
about 30 weight percent. 
The composition of this invention may also include a flame retardant 
additive such as an organic halogen containing compound particularly, 
decabromodiphenyl ether or a triarylphosphate such as triphenylphosphate, 
or combinations thereof. 
The flame retardant additive is utilized in amounts of from 0 to about 15 
weight percent, preferably from about 2 to about 10 weight percent. 
It should, of course, be obvious to those skilled in the art that other 
additives may be included in the present compositions. These additives 
include plasticizers; pigments; thermal stabilizers; ultraviolet light 
stabilizers, processing aids, and the like. 
The compositions of this invention are prepared by any conventional mixing 
methods. For example, a preferred method comprises mixing the poly(aryl 
ether), polyester, and polycarbonate, and other optional ingredients in 
powder or granular form in an extruder and extruding the mixture into 
strands, chopping the strands into pellets and molding the pellets into 
the desired article.

EXAMPLES 
The following Examples serve to give specific illustrations of the practice 
of this invention but they are not intended in any way to limit the scope 
of this invention. 
Control A 
A blend of 50 weight percent of a polysulfone of the following formula 
##STR20## 
having a reduced viscosity of 0.49 as measured in chloroform (0.2 gram 
polymer in 100 ml at 25.degree. C.) and 50 weight percent of a 
poly(butylene terephthalate) resin (6PRO sold by Tennessee Eastman 
Company) having a reduced viscosity of 1.83 as measured in 60/40 
phenol/tetrachloroethane (0.2 g/100 ml) at 25.degree. C., was prepared by 
extrusion blending in a single screw 1-inch diameter extruder with 
L/D=36/1. The extrudate was chopped into pellets. The pelletized product 
was then injection molded into ASTM test bars (at 270.degree.-300.degree. 
C.) using a Newbury 11/4 ounce screw injection molding machine. The test 
bars were measured for the following properties: tensile strength and 
modulus according to ASTM D-638; elongation at break according to ASTM 
D-638; notched izod impact strength according to ASTM D-256; tensile 
impact strength according to ASTM D-1822. 
The results are shown in Table I. 
EXAMPLE 1 
The procedure of Control A was exactly repeated except that 34 weight 
percent of the polysulfone described in Control A was blended with 50 
weight percent of the poly(butylene terephthalate) described in Control A 
and 15 weight percent of a polycarbonate (Lexan 101 sold by General 
Electric Company) having a reduced viscosity of 0.64 as measured in 
chloroform at 25.degree. C. 
The results are shown in Table I. 
CONTROL B 
The procedure of Control A was exactly repeated except that 60 weight 
percent of the polysulfone described in Control A was blended with 40 
weight percent of the poly(butylene terephthalate) [6 PRO] described in 
Control A. 
The results are shown in Table I. 
EXAMPLE 2 
The procedure of Control A was exactly repeated except that 45 weight 
percent of the polysulfone described in Control A was blended with 40 
weight percent of the poly(butylene terephthalate) [6PRO] described in 
Control A and 15 weight percent of the polycarbonate (Lexan 101) described 
in Example 1. 
The results are shown in Table I. 
CONTROL C 
The procedure of Control A was exactly repeated except that 55 weight 
percent of the polysulfone described in Control A was blended with 35 
weight percent of the poly(butylene terephthalate) [6PRO] described in 
Control A and 10 weight percent of an impact modifier KM-611 (a 
styrene/acrylate/butadiene terpolymer having a tensile modulus of 43,600 
psi and sold by Rohm and Haas Company). 
The results are shown in Table I. 
EXAMPLE 3 
The procedure of Control A was exactly repeated except that 48.6 weight 
percent of the polysulfone described in Control A was blended with 36 
weight percent of the poly(butylene terephthalate) [6PRO], described in 
Control A, 10 weight percent of impact modifier [KM-611] described in 
Control C and 5.4 weight percent of the polycarbonate (Lexan 101) 
described in Example 1. 
The results are shown in Table I. 
The data in the Table shows that the addition of aromatic polycarbonate to 
the incompatible polysulfonepoly(butylene terephthalate) mixtures improves 
the compatibility. 
When 15 weight percent of the polysulfone of Control A is replaced by 15 
weight percent of polycarbonate (Example 1) to give the composition of 
this invention, elongation and notched izod impact strength are increased. 
When 15 weight percent of the polysulfone of Control B is replaced by 15 
weight percent of polycarbonate (Example 2) to give a composition of this 
invention, notched izod impact strength and tensile impact strength are 
increased and elongation is surprisingly increased from 23 to 132 percent. 
Also, the data in the Table shows that the addition of an aromatic 
polycarbonate (Example 3) to the polysulfone-poly(butylene terephthalate) 
mixtures containing impact modifier (Control C) results in a surprising 
increase in the notched izod impact strength, i.e., from 1.2 to 14.1 
ft.-lbs./in. of notch. 
TABLE I 
__________________________________________________________________________ 
Description of Tensile 
Tensile Notched Izod 
Tensile Impact 
the Composition.sup.1 
Modulus 
Strength 
Elongation 
Impact Strength 
Strength 
Example 
Polymer 
(wt. %) 
(psi) 
(psi) 
(percent) 
(ft.-lbs./in. of Notch) 
(ft.-lbs./in..sup.2) 
__________________________________________________________________________ 
Control A 
PS 50 374,000 
7,030 
2.1 0.33 25 
PBT 50 
1 PS 35 362,000 
7,520 
2.3 0.72 15 
PBT 50 
PC 15 
Control B 
PS 60 361,000 
9,590 
23 0.76 65 
PBT 40 
2 PS 45 334,000 
8,330 
132 1.15 117 
PBT 40 
PC 15 
Control C 
PS 55 314,000 
7,400 
23 1.2 54 
PBT 35 
KM-611 
10 
3 PS 48.6 318,000 
7,790 
92 14.1 108 
PBT 36 
KM-611 
5.4 
PC 10 
__________________________________________________________________________ 
.sup.1 PS = polysulfone 
PBT = poly(butylene terephthalate) 
PC = polycarbonate 
CONTROL D 
A blend of 51.8 weight percent of a polysulfone formed from bisphenol-A and 
4,4'-dichlorodiphenyl sulfone with a reduced viscosity of 0.43 (measured 
in chloroform 0.2 g/100 ml at 25.degree. C.), 22.2 weight percent of a 
poly(ethylene terephthalate) resin (Cleartuf 1002A sold by Goodyear Tire & 
Rubber Co.) with a reduced viscosity of 1.96 (measured in 60/40 
phenol/tetrachloroethane 0.2 g/100 ml at 25.degree. C.), 4 weight percent 
decabromodiphenyl oxide, and 22 weight percent fiberglass (1/8 inch 
chopped strand P1978--X1 sold by Owens-Corning Fiberglass Co.) was 
prepared by extrusion blending the components at about 270.degree. C. in a 
single screw 1-inch diameter extruder with L/D=36/1. The extrudate was 
chopped into pellets. The pelletized product was then injection molded 
into ASTM test specimens (at 270.degree.-300.degree. C.) using a Newbury 
11/4 ounce screw injection molding machine. 
The test specimens were measured for the following properties: tensile 
strength and modulus according to ASTM D-638; elongation at break 
according to ASTM D-638; notched izod impact strength according to ASTM 
D-256; tensile impact strength according to ASTM D-1822; heat distortion 
temperature measured at 264 psi on a 1/8 inch thick unannealed test bar 
according to ASTM D-635. 
The results are shown in Table II. 
CONTROL E 
The procedure of Control D was exactly repeated except that the ingredients 
of Control D were used in the following amounts: 42.8 weight percent 
polysulfone, 31.2 weight percent poly(ethylene terephthalate) [Cleartuf 
1002A], 4 weight percent decabromodiphenyl oxide and 22 weight percent 
fiberglass. 
The results are shown in Table II. 
EXAMPLES 4 TO 10 
The procedure of Control D was exactly repeated except that a polycarbonate 
(Lexan 101 as described in Example 1) was added, in amounts shown in Table 
II, to the ingredients of Control D which were used in the amounts shown 
in Table II. 
The results are shown in Table II. 
The data in the Table shows that the addition of small amounts i.e., from 5 
to 20 weight percent of an aromatic polycarbonate (Examples 4 to 10) to a 
mixture of polysulfone, poly(ethylene terephthalate), fiberglass and 
decabromodiphenyl oxide (Controls A and B), results in improved elongation 
at break, notched izod impact strength, and tensile impact strength. This 
demonstrates the compatibilizing effect the polycarbonate has on the 
mixture of polysulfone, poly(ethylene terephthalate), fiberglass and 
decabromodiphenyl oxide. 
TABLE II 
__________________________________________________________________________ 
Example Control D 
Control E 
4 5 6 7 8 9 10 
__________________________________________________________________________ 
Components.sup.1 (wt. %) 
PS 51.8 42.8 42.8 
42.8 40.3 38.3 38.3 37.8 32 
PET 22.2 31.2 26.2 
22 26.2 26.2 24.2 26.2 22 
DBDPO 4 4 4 4 4 6 8 4 4 
fiberglass 22 22 22 22 22 22 22 22 22 
PC -- -- 5 10 7.5 7.5 7.5 10 20 
Tensile modulus (psi) 
980,000 
1,090,000 
989,000 
973,000 
946,000 
1,020,000 
1,010,000 
989,000 
947,000 
Tensile strength (psi) 
15,300 17,400 17,500 
17,300 
17,000 
17,800 
18,000 
17,200 
17,300 
Elongation (%) 2.0 2.3 2.6 2.6 2.9 2.9 2.8 2.6 2.8 
Notched Izod Impact 
Strength (ft.-lbs./in. of Notch) 
1.4 1.5 2.0 2.0 1.8 1.7 1.7 2.0 2.1 
Tensile Impact 
Strength (ft.-lbs./in..sup.2) 
36 24 83 75 68 49 63 83 90 
Heat Distortion 
Temp. (.degree.C.) 
165 119 162 155 136 126 136 151 149 
__________________________________________________________________________ 
.sup.1 PS = polysulfone 
PET = poly(ethylene terephthalate) 
DBDPO = decabromodiphenyl oxide 
PC = polycarbonate 
The following Examples describe compositions of the instant invention 
utilizing commercially available polyester or polycarbonate resins. 
EXAMPLE 11 
The procedure of Control D was exactly repeated except that 40.3 weight 
percent of the polysulfone of Control A was blended with 7.5 weight 
percent of polycarbonate (Merlon 40F sold by Mobay Corporation), with a 
reduced viscosity of 0.52 (measured in methylene chloride 0.2 g/100 ml at 
25.degree. C.), 26.2 weight percent of the poly(ethylene terephthalate) 
(Cleartuf 1002A) of Control D, 4.0 weight percent of decabromodiphenyl 
oxide and 22 weight percent of fiberglass. 
The results are shown in Table III. 
EXAMPLE 12 
The procedure of Control D was exactly repeated except that 40.3 weight 
percent of the polysulfone of Control A was blended with 7.5 weight 
percent of the polycarbonate of Example 1 (Lexan 101), 26.2 weight percent 
of poly(ethylene terephthalate) Vituf 1001A sold by Goodyear Tire & Rubber 
Company with a melt flow of 22.8 dg/min. at 27.degree. C. (44 psig), 4.0 
weight percent of decabromodiphenyl oxide and 22 weight percent of 
fiberglass. 
The results are shown in II. 
EXAMPLE 13 
The procedure of Control D was exactly repeated except that 40.3 weight 
percent of the polysulfone of Control A was blended with 7.5 weight 
percent of the polycarbonate of Example I (Lexan 101), 26.2 weight percent 
of poly(ethylene terephthalate) (Cleartuf 72 sold by Goodyear Tire & 
Rubber Co.) having an intrinsic viscosity of 0.72 dl/g as measured in 
phenol/tetrachloroethane (60/40) at 25.degree. C., 4.0 weight percent of 
decabromodiphenyl oxide and 22 weight percent fiberglass. 
The results are shown in Table III. 
EXAMPLE 14 
The procedure of Control D was exactly repeated except that 40.3 weight 
percent of the polysulfone of Control A was blended with 7.5 weight 
percent of the polycarbonate of Example 1 (Lexan 101), 26.2 weight percent 
of poly(ethylene terephthalate) Petpac sold by Celanese Corporation, 
having an intrinsic viscosity of 0.74 dl/g as measured in 
phenol/tetrachloroethane (60/40) at 25.degree. C., 4.0 weight percent of 
decabromodiphenyl oxide and 22 weight percent fiberglass. 
The results are shown in Table III. 
EXAMPLE 15 
The procedure of Control D was exactly repeated except that 40.3 weight 
percent of the polysulfone of Control A was blended with 7.5 weight 
percent of the polycarbonate of Example 1 (Lexan 101), 26.2 weight percent 
of poly(ethylene terephthalate) Tenite 7970 sold by Tennessee Eastman Co., 
having an intrinsic viscosity of 0.70 dl/g (as measured in 
phenol/tetrachloroethane (60/40) at 25.degree. C.), 4.0 weight percent 
decabromodiphenyl oxide and 22 weight percent fiberglass. 
TABLE III 
__________________________________________________________________________ 
Example Control D 
Control E 
11 12 13 14 15 
__________________________________________________________________________ 
Components.sup.1 (wt. %) 
PS 51.8 42.8 40.3 
40.3 40.3 
40.3 40.3 
PET 22.2 31.2 26.2 
26.2 26.2 
26.2 26.2 
DBDPO 4 4 4 4 4 4 4 
Fiberglass 22 22 22 22 22 22 22 
PC -- -- 7.5 7.5 7.5 7.5 7.5 
Tensile modulus (psi) 
980,000 
1,090,000 
999,000 
1,010,000 
975,000 
1,010,000 
979,000 
Tensile strength (psi) 
15,300 
17,400 
17,600 
17,400 
17,600 
17,900 
17,600 
Elongation (%) 2.0 2.3 2.9 2.8 2.7 2.6 2.6 
Notched Izod Impact 
Strength (ft.-lbs./in. of Notch) 
1.4 1.5 1.8 1.8 1.8 1.8 1.6 
Tensile Impact 
Strength (ft.-lbs./in..sup.2) 
36 24 42 61 76 65 57 
Heat Distortion 
(.degree.C.) Temp. 
165 119 136 142 141 144 154 
__________________________________________________________________________ 
.sup.1 PS = polysulfone 
PET = poly(ethylene terephthalate) 
DBDPO = decabromodiphenyl oxide 
PC = polycarbonate 
EXAMPLE 16 
The following blend of Example 6: 40.3 weight percent polysulfone, 26.2 
weight percent poly(ethylene terephthalate), 4 weight percent 
decabromodiphenyl oxide, 22 weight percent glass, and 7.5 weight percent 
polycarbonate (prepared as in Example 6) was injection molded using an 8 
ounce HPM injection molding machine into rectangular plaques 
4.times.9.times.0.125 inches. The plaques were measured for maximum 
deviation from flatness along the nine inch side with a dial micrometer. 
The percent warpage was determined by the following formula: 
##EQU1## 
The part warpage was determined by the following formula: 
##EQU2## 
For comparison, two commercially available fiberglass reinforced, flame 
retardant poly(butylene terephthalate) resins (Valox 420 SEO contains 
about 30 weight percent fiberglass and is sold by General Electric Company 
and Gafite X-4612R sold by GAF Corporation) were also molded into plaques 
and tested for percent warpage and part warpage as described, supra. 
The results are shown in Table IV. 
TABLE IV 
______________________________________ 
Warpage Part Warpage 
Composition (%) (%/inch) 
______________________________________ 
Example 6 38 4.2 
Valox 67 7.4 
Gafite 273 30.3 
______________________________________ 
EXAMPLE 17 
The following blend of Example 6:40:3 weight percent polysulfone, 26.2 
weight percent poly(ethylene terephthalate), 4 weight percent 
decabromodiphenyl oxide, 22 weight percent glass, and 7.5 weight percent 
polycarbonate (prepared as in Example 6) was injection molded into ASTM 
test specimens (at 270.degree.-300.degree. C.) using a Newbury 1/4 ounce 
screw injection molding machine. 
The test specimens were subjected to the following tests: dielectric 
strength (volts/millimeter) according to ASTM D-149-64; volume resistivity 
(ohm-centimeters) and volume resistivity after being maintained for 96 
hours at a relative humidity of 90 percent at 35.degree. C., according to 
ASTM D-257-61; surface resistivity (ohm-centimeters) and surface 
resistivity after being maintained for 96 hours at a relative humidity of 
90 percent at 35.degree. C., according to ASTM D-257-61; dielectric 
constant, measured at 60 hertz (cycles per second) a kilohertz and a 
megahertz, and dissipation factor measured at 60 hertz, a kilohertz and a 
megahertz, according to ASTM D-150-65T. 
The results are shown in Table V. 
The data in the Table show that the compositions of this invention have 
good electrical properties. 
TABLE V 
______________________________________ 
Dielectric strength (volts/mil) 
488 
Volume resistivity (ohm-cm) 
10.sup.15 
Volume resistivity after 96 hrs. 
at 35.degree. C. and 90% relative humidity (ohm-cm) 
10.sup.14 
Surface resistivity (ohm-cm) 
10.sup.15 
Surface resistivity after 96 hrs. at 
35.degree. C. and 90% relative humidity (ohm-cm) 
10.sup.14 
Dielectric constant at 
60 hertz 3.7 
1 kilohertz 3.7 
1 megahertz 3.7 
Dissipation factor at 
60 hertz 0.002 
1 kilohertz 0.003 
1 megahertz 0.010 
______________________________________