Polymer mixture comprising a polyphenylene ether and a polyarylene sulphide

Abstract: The properties of polyphenylene ether-polyarylene sulphide mixtures are improved by the addition of an agent as it is known for the improvement of the properties of polyphenylene ether-polyamide mixtures.

Description: The invention relates to a polymer mixture comprising a polyphenylene ether, a cured polyarylene sulfide and an agent to improve homogeneity as used for polyphenylene ether-polyamide polymer mixtures, the agent being a compound having in the molecular structure a two-fold or three-fold carbon-to-carbon bond and a carboxylic acid, acid anhydride, acid amide, imido, carboxylic acid ester, amino, or hydroxyl group in a quantity of 0.01 to 30 parts by weight per 100 parts by weight of polyarylene sulphide plus polyphenylene ether, Polyphenylene ether-polyamide mixtures are described in various patent publications: US-A-4,021,596; JP-A-55/129422 (see WPI Acc. No. 80-83415 C/47); JP-A-62/065351 (see WPI Acc. No. 80-120241/17); JP-A-55/135160 (see WPI Acc. No. 80-87164C/49); JP-A-50/156,561 (see CA, Vol. 84, 1976, page 35, No. 84 : 106514 v). Polymer mixtures comprising a polyphenylene ether and a polyarylene sulfide have a combination of properties which each of the individual components does not have, for example, a combination of certain mechanical properties, a good resistance against organic solvents, a better processability and flame-retarding properties. In accordance with the desired combination of properties, the two polymers were used in a variety of mixing ratios. The disadvantage of the known polymer mixtures is that the two polymers do not form a homogeneous mixture. Products manufactured, for example, from these polymer mixtures by injection moulding, show a tendency of delamination. This often leads to a surface having pearl gloss. It also often appears that the addition of further additives, for example, agents to improve the impact strength, to non-homogeneous polymer mixtures, only results in a small improvement of the properties. The invention as claimed in claims 1-3 provides polymer mixtures which have a better homogeneity. EP-A-262901 describes polymer blends comprising as dispersing phase a polyphenylene ether, a crystalline thermoplastic resin manic phase and a mutual compatibilizer. The crystalline thermoplastic resin matrix phase can be a polyphenylene sulfide. The mutual compatibilizer can be chosen among a great number of compounds some of them having a carboxylgroup and a double bond. The type of polyphenylene sulfide has not been specified. The polymer mixture according to the invention is characterised, in that the polyarylene sulfide is a cured polyarylene sulfide. All the known agents to improve the homogeneity c.q. compatibility of polyphenylene ether-polyamide mixtures have a chemical group which most likely can react with the amine and/or amide group in the polyamide. Polyarylene sulfides, however, have a quite different structure from polyamides. The applicability of the agents known for polyphenylene ether-polyamide mixtures could not be predicted. The polymer mixture according to the invention comprises in any case the following constituents: A : a polyphenylene ether B : a cured polyarylene sulfide C : an agent to improve the homogeneity. A. Polyphenylene ether Polyphenylene ethers are compounds known per se. For this purpose reference may be made to the United States Patent Specification 3,306,874, 3,306,875; 3,257,357 and 3,257,358. Polyphenylene ethers are usually prepared by an oxidative coupling reaction - in the presence of a copper amine complex - of one or more two-fold or three-fold substituted phenols, homopolymers and copolymers, respectively, being obtained. Copper amine complexes derived from primary, secondary and/or tertiary amines may be used. Examples of suitable polyphenylene ethers are: poly(2,3-dimethyl-6-ethylphenylene-1,4-ether) poly(2,3,6-trimethylphenylene-1,4-ether) poly[2-(4'-methylphenyl)phenylene-1,4-ether] poly(2-bromo-6-phenylphenylene-1,4-ether) poly(2-methyl-6-phenylphenylene-1,4-ether) poly(2-phenylpbenylene-1,4-ether) poly(2-chlorophenylene-1,4-ether) poly(2-methylphenylene-1,4-ether) poly(2-chloro-6-ethylphenylene-1,4-ether) poly(2-chloro-6-bromophenylene-1,4-ether) poly(2,6-di-n-propylphenylene-1,4-ether) poly(2-methyl-6-isopropylphenylene-1,4-ether) poly(2-chloro-6-methylphenylene-1,4-ether) poly(2-methyl-6-ethylphenylene-1,4-ether) poly(2,6-dibromophenylene-1,4-ether) poly(2,6-dichlorophenylene-1,4-ether) poly(2,6-diethylphenylene-1,4-ether) poly(2,6-dimethylphenylene-1,4-ether) Copolymers, for example copolymers derived from two or more phenols as used in the preparation of the monopolymers mentioned hereinbefore, are also suitable. Furthermore suitable are graft copolymers and block copolymers of vinylaromatic compounds, for example, polystyrene and of polyphenylene ether as described above. B. Polyarylene sulfide Polyarylene sulfides are polymers known per se. Polyarylene sulfides prepared according to one of the known methods of preparing polyarylene sulfides, for example, as described in US-A-3,354,129. In this method, polyhaloaromatic compounds, alkali metal sulfides and organic amides are contacted with each other in polymerisation conditions. A second suitable method is described, for example, in US-A-3,919,177 in which a p-dihalobenzene, an alkali metal sulfide, an organic amide and an alkali metal carboxylate are contacted with each other in polymerisation conditions. This after-treatment is described, for example, in US-A-3,699,087; US-A-3,717,620; US-A-3,725,362 and US-A-3,793,256. C. Agent to improve the homogeneity The invention is based on the discovery that certain type of compounds as defined in claim 1 are suitable to improve the homogeneity of polyphenylene ether-polyarylene sulphide. Suitable agents are the following: Compounds having in their molecular structure a two-fold or three-fold carbon-to-carbon bond and a carboxylic acid, acid anhydride, acid amide, imido, carboxylic acid ester, amino, epoxy or hydroxyl group in a quantity from 0.01 to 30 parts by weight per 100 parts by weight of cured polyarylene sulphide plus polyphenylene ether, The polyarylene sulfide in the polymer mixture of the invention is a cured polyarylene sulfide. Such cured products are known e.g. from Encyclopedia of polymer science Vol. 11, p531-533. They have a higher molecular weight and a darker color as compared to non-cured polyarylene sulfide. The curing is usually performed by an after-treatment. In addition to the agents mentioned hereinbefore, the following agents are to be considered: The reaction product of one of the-agents mentioned above with a polyphenylene ether. This reaction product may be formed in situ in the polymer mixture according to the invention when the various constituents are mixed in the melt, for example, in an extruder. It is also possible to form this reaction product separately and to then add it to the other constituents of the polymer mixture according to the invention. The ratio of the various constituents in the polymer mixtures according to the invention may be chosen within wide limits. The polymer mixture according to the invention is preferably composed so that it comprises 1-99 parts by weight, even more preferably 10-90 parts by weight of polyarylene sulphide per 100 parts by weight of polyphenylene ether plus polyarylene sulphide. The quantities to be chosen depent on the kind of properties which it is desired to obtain. However, in all the ratios the possibility exists that delamination occurs. The said delamination can be suppressed by the addition of an agent as described hereinbefore sub C. The minimum quantity of ages C to be used depends on the nature of the agent and on the relative quantity of the constituents A and B. In general, a minimum quantity of 0.1-10 parts by weight of agent C per 100 parts by weight of A plus B will suffice. This quantity can be determined experimentally comparatively easily. In addition to the constituents mentioned hereinbefore the polymer mixture according to the invention may comprise any conventional constituent, for example: styrene homopolymers and styrene copolymers, high-impact polystyrene, agents to improve the impact strength, reinforcing fibres, for example, glass fibres, mineral fillers, agents to improve the stability, dyes and pigments, flame retardants, plasticizers. The polymer mixture according to the invention preferably also comprises one or more agents to improve the impact strength. The addition of such agents leads to a considerable improvement of the impact strength in the homogeneous polymer mixtures according to the invention; an improvement which is larger than that which can be obtained in non-homogeneous polymer mixtures. Any agent suitable for polyphenylene ethers and/or polyarylene sulphides to improve the impact strength may be used in the polymer mixtures according to the invention. Particularly suitable are the so-called core-shell copolymers with a rubbery core, and one or more shells. Further suitable agents are the vinylaromatic polydiene di- or triblock copolymers, in which the block copolymer is not hydrogenated or is partially hydrogenated. Partially hydrogenated or non-hydrogenated linear styrene-butadiene-styrene triblock copolymers and partially hydrogenated or non-partially hydrogenated radial styrene-butadiene block copolymers may be mentioned in particular. Some types of polybutadiene, notably those types which are commercially available as a crumbly product, are also suitable. The polyoctenylene rubbers described in DE-A-3,518,277 and DE-A-3,442,273 are also suitable. The polymer mixture according to the invention may comprise in addition one or more additives known for polyphenylene ethers and/or for polyarylene sulfides. In particular may be mentioned: reinforcing fibres, for example, glass fibres and fillers. The polymer mixtures according to the invention are preferably prepared by melt extrusion. In melt extrusion, the individual constituents are provided, for example, in an extruder. The constituents are heated in the extruder, usually to a temperature above the melting temperature of the constituent or one of the constituents having the highest melting-point, for example, the cured polyarylene sulphide, and are intimately mixed. The so-called extrudate, usually in form of a strand, emanates from the extruder and is then chopped up. The resulting pellets of the polymer mixtures cording to the invention can be further processed according to methods known per se for injection moulding of thermoplastic synthetic resins. It has been found in the preparation of the polymer mixtures according to the invention in an extruder that the sequence in which the various constitents are mixed is of importance. For example, polymermixtures having better properties are often obtained when the polyphenylene ether or a part of the polyphenylene ether to be used is premixed with the agent C in an extruder in a separate step. The pre-extrudate thus obtained is then mixed with the other constituents in an extruder. The invention also relates to products obtained from the polymer mixtures according to the invention. The invention will now be described in greater detail with reference to the ensuing specific examples. The following constituents are used in the examples: PPE : Poly(2,6-dimethyl-1,4-phenylene)ether with an intrinsic viscosity of 45 ml/g, measured in chloroform at 25°C. FPPE-2 : A pre-extrudate of 100 parts by weight of PPE and 1 part by weight of maleic anhydride prepared in a blade extruder adjusted at 320°C and 300 rpm. PPS : A polyarylene sulfide, namely a cured polyphenylene sulfide having a melt viscosity of 200 Pa sec., measured with a Göttfert ® capillary rheometer at 300°C and a shearing rate of 200 sec -1 . SB : (Used in some examples) a partially hydrogenated styrene-ethylene/butylene-styrene triblock copolymer having a moleculair weight of approximately 175,000. Examples I, comparative examples A,B, and C The constituents indicated in the Table A were compounded in a blade extruder adjusted at 300°C (blade speed 300 rpm). The resulting extrudate was chopped up to pellets. Test pieces to determine the impact strength according to IZOD (ASTM D 256) and to determine the tensile strength (ASTM D 638) were injection moulded from the pellets. The mechanical properties of the test pieces were determined. The composition of the various polymer mixture and the resulting properties are recorded in Table A hereinafter. Example A B C I Composition (parts by weight) PPE 32.5 32.5 - - FPPE-2 - - - 32.5 PPS 67.5 55 80 55 SB - 12.5 20 12.5 Mechanical properties Impact strength with notch (J/m) 12.5 19 14.5 28 Impact strength without notch (J/m) 165 245 180 360 Tensile strength at fracture (MPa) 25 45 35 49 Elongation at fracture (%) 0.7 2.5 1.2 2.9 Other properties Appearance (visually evaluated) - Pearl gloss - It may be seen from the results of Table A that it is possible to obtain a polymer mixture having a good impact strength on the basis of the polymer mixtures according to the invention. The impact strength of the known polymer mixtures is improved to a much smaller extent by the addition of an SB block copolymer (compare example B with example I according to the invention).

Claims: A polymer mixture comprising a polyphenylene ether, a polyarylene sulfide, an agent to improve the homogeneity as used for polyphenylene ether-polyamide polymer mixtures, the agent being a compound having in the molecular structure a two-fold or three-fold carbon-to-carbon bond and a carboxylic acid, acid anhydride, acid amide, imido, carboxylic acid ester, amino, or hydroxy group in a quantity of 0.01 to 30 parts by weight per 100 parts by weight of polyarylene sulfide plus polyphenylene ether wherein the polyarylene sulfide is a cured polyarylene sulphide. A polymer mixture as claimed in Claim 1, characterised in that the polymer mixture additionally comprises a conventional agent to improve the impact strength. Articles formed from the polymer mixture as claimed in Claim 1.

Inventors: DEKKERS MARINUS EMANUEL JOHANN, DEKKERS, MARINUS EMANUEL JOHANNES
Applicants: GEN ELECTRIC, GENERAL ELECTRIC COMPANY
Application year: 1989
Main classification: C08L71
IPC codes: C08G65, C08L65, C08K5, C08L71, C08L63, C08L53, C08L81