Compositions of a Polyphenylene Ether Resin and Alkenyl Aromatic Resins Modified With EPDM Rubber

This invention relates to improved compositions of a polyphenylene ether resin and an alkenyl aromatic resin that is modified with an EPDM rubber. Reinforced and flame-retardant compositions are also provided.

The polyphenylene ether resins are a family of engineering thermoplastics that are well known to the polymer art. These polymers may be made by a variety of catalytic and non-catalytic processes from the corresponding phenols or reactive derivatives thereof. By way of illustration, certain of the polyphenylene ethers are disclosed in Hay, U.S. Pat. Nos. 3,306,874 and 3,306,875, and in Stamatoff, U.S. Pat. No. 3,257,357 and 3,257,358. In the Hay patents, the polyphenylene ethers are prepared by an oxidative coupling reaction comprising passing an oxygen-containing gas through a reaction solution of a phenol and a metal-amine complex catalyst. Other disclosures relating to processes for preparing polyphenylene ether resins, including graft copolymers of polyphenylene ethers with styrene type compounds, are found in Fox, U.S. Pat. No. 3,356,761; Sumitomo, U.K. Pat. No. 1,291,609; Bussink et al., U.S. Pat. Nos. 3,337,499; Blanchard et al., 3,219,626; Laakso et al., 3,342,892; Borman, 3,344,166; Hori et al., 3,384,619; Faurote et al., 3,440,217; and disclosures relating to metal based catalysts which do not include amines, are known from patents such as Wieden et al., U.S. Pat. Nos. 3,442,885 (copper-amidines); Nakashio et al., 3,573,257 (metal-alcoholate or -phenolate); Kobayashi et al., 3,455,880 (cobalt chelates); and the like. In the Stamatoff patents, the polyphenylene ethers are produced by reacting the corresponding phenolate ion with an initiator, such as peroxy acid salt, an acid peroxide, a hypohalite, and the like, in the presence of a complexing agent. Disclosures relating to non-catalytic processes, such as oxidation with lead dioxide, silver oxide, etc., are described in Price et al., U.S. Pat. Nos. 3,382,212. Cizek, 3,383,435 discloses polyphenylene ether-styrene resin compositions. All of the above-mentioned disclosures are incorporated by reference.

The term "alkenyl aromatic resin" includes polymers and copolymers of styrene, alpha methyl styrene, chlorostyrene, ethylvinylbenzene, divinylbenzene, vinylnaphthalene, and the like.

The term "EPDM" includes rubbery interpolymers of a mixture of mono-olefins and a polyene. Preferred types are those rubbery interpolymers of ethylene, an alpha-olefin, and a polyene. Rubbery interpolymers of ethylene, propylene, and a polyene are especially preferred.

In the prior art, rubber-modified styrene resins have been admixed with polyphenylene ether resins to form compositions that have modified properties. The Cizek patent, U.S. Pat. No. 3,383,435, discloses rubber-modified styrene resin-polyphenylene ether resin compositions wherein the rubber component is of the unsaturated type such as polymers and copolymers of butadiene. The physical properties of these compositions are such that it appears that many of the properties of the styrene resins have been upgraded, while the moldability of the polyphenylene ethers are improved.

Nakashio et al. U.S. Pat. No. 3,658,945 discloses that from 0.5 to 15% by weight of an EPDM-modified styrene resin may be used to upgrade the impact strength of polyphenylene ether resins. In Cooper et al., U.S. Pat. No. 3,943,191 it is disclosed that when the highly unsaturated rubber used in compositions of the type disclosed by Cizek, is replaced with EPDM rubber that has a low degree of residual unsaturation, the thermal oxidative stability and color stability are improved. The EPDM rubber in the Cooper et al. compositions is comprised substantially of particles in the range of 3-8 microns. There is no teaching of EPDM rubber having smaller particle size.

The impact strength of the Cooper et al. compositions is superior to that of a polyphenylene ether resin alone or that of similar compositions comprised of unmodified polystyrene; however, the impact strength of the Cooper et al. compositions is inferior to that of similar compositions comprised of polystyrene modified with polybutadiene rubber, such as a composition known as FG-834, available from Foster-Grant Co.

As is disclosed in U.S. Pat. No. 3,981,841, the impact strength of the Cooper et al. compositions can be improved by incorporating therein impact modifiers such as an emulsion-grafted EPDM polystyrene copolymer.

It has now been found that a composition of a polyphenylene ether resin and an alkenyl aromatic resin modified with an EPDM rubber comprised of particles having a median diameter less than about two microns, is a very useful thermoplastic molding material having good thermal oxidative stability and good impact strength.

It is, therefore, a primary object of this invention to provide improved compositions that are based on polyphenylene ether resins and modified alkenyl aromatic resins.

Another object of this invention is to provide molding compositions and molded articles that are based on a polyphenylene ether resin and an EPDM modified alkenyl aromatic resin and that have improved thermal oxidative stability.

Still another object of this invention is to provide molding compositions and molded articles that are based on a polyphenylene ether resin and an EPDM modified alkenyl aromatic resin and that have improved impact strength.

It is also an object of this invention to provide the above-described, improved molding compositions in reinforced and/or flame-retardant embodiments.

The above-mentioned advantages and objects and others will be readily apparent to those skilled in the art by the following compositions.

Preferred types will include thermoplastic compositions which comprise:

(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 an EPDM rubber comprised of particles having a median diameter less than about two microns. The EPDM rubbers, that is, rubbery interpolymers comprising mixtures of mono-olefins and a polyene, include those prepared from ethylene, an alpha-olefin, and a polyene. Preferred types comprise 10-90 mole percent of ethylene, 10-90 mole percent of an alpha-olefin containing 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. Especially preferred are those alpha-olefins having 3-10 carbon atoms and non-conjugated cyclic or open-chain dienes having 5-10 carbon atoms.

Useful EPDM rubbers include the ethylene-propylene-ethylidene norbornene terpolymer and those described in Ritchie, Vinyl and Allied Polymer, Vol. 1, Page 121 (1968), which is incorporated herein by reference. The preferred EPDM rubbery interpolymers are those comprised of ethylene, propylene, and 5-ethylidene-2-norbornene; of ethylene, propylene, and 1,4-hexadiene; and of ethylene, propylene, and dicyclopentadiene. Preferred modified alkenyl aromatic resins will include from about 4 to about 25% by weight of rubbery interpolymer.

The rubber particle size can be measured by several different methods. One method is the use of a transmission electron micrograph, with appropriate corrections to allow for the fact that the photograph obtained does not show particle diameters but rather sections of particles. Making the photographs and measuring the particles are rather tedious.

Another method, commonly employed, is to estimate particle size visually by means of an optical microscope. The samples will be in a cinnamaldehyde dispersion, which may cause the EPDM rubber particles to swell slightly, so that the observed particle diameters will be those of the swollen particles. The samples are photographed under magnification. A strip of the photograph is selected at random and the sizes of a sufficiently large number, e.g., 100, of particles are estimated and a size distribution is obtained. From the distribution a median particle size is estimated. The median particle diameter is that for which the sample contains the same number of larger and of smaller particles. See the appended examples.

Particle diameter size can also be measured by means of a Coulter Counter, a well known electronic counting device for measuring the volume size distribution of fine particulate dispersions. The Coulter Counter registers a number average particle diameter which normally corresponds very closely to the median particle diameter. When the Coulter Counter is used with a 100 micron orifice, smaller particles tend not to register and the determined average number particle size will be from about 5 to 35% higher than the visually determined median particle diameter. When a 30 micron orifice is used, larger particles tend to be excluded and the determined average number particle size will be from about 10 to 30% lower than the visually determined median particle size. Additional information regarding particle size measurement with a Coulter Counter can be found in James, "Particle Size Measurement of the Dispersed Phase in Rubber Modified Polystyrene," Polymer Engineering and Science, July, 1968, Vol. 8, No. 3, pages 241-244.

The useful EPDM rubbers of this invention have a median or number average particle size less than about two microns, preferably in the range of from about 0.5 to 1.5 microns, as determined by the above-mentioned cinnamaldehyde technique, and confirmed if necessary or desirable by a Coulter Counter using a 30 micron orifice.

The alkenyl aromatic resin should have at least 25% of its units derived from an alkenyl aromatic monomer of the formula: ##STR1## wherein R.sup.1 and R.sup.2 are selected from the group consisting of hydrogen and lower alkyl or alkenyl groups of from 1 to 6 carbon atoms; R.sup.3 and R.sup.4 are selected from the group consisting of chloro, bromo, hydrogen, and lower alkyl groups of from 1 to 6 carbon atoms; and R.sup.5 and R.sup.6 are selected from the group consisting of hydrogen and lower alkyl and alkenyl groups of from 1 to 6 carbon atoms or R.sup.5 and R.sup.6 may be concatenated together with hydrocarbyl groups to form a naphthyl group.

Specific examples of alkenyl aromatic monomers include styrene, bromostryene, chlorostyrene, .alpha.-methylstyrene, vinyl-xylene, divinylbenzene, vinyl naphthalene, and vinyl-toluene.

The alkenyl aromatic monomer may be copolymerized with materials such as those having the general formula: ##STR2## wherein the dotted lines each represent a single or a double carbon to carbon bond; R.sup.7 and R.sup.8 taken together represent a ##STR3## linkage; R.sup.9 is selected from the group consisting of hydrogen, vinyl, alkyl of from 1 to 12 carbon atoms, alkenyl of from 1 to 12 carbon atoms, alkylcarboxylic of from 1 to 12 carbon atoms, and alkenylcarboxylic of from 1 to 12 carbon atoms; n is 1 or 2, depending on the position of the carbon-carbon double bond; and m is an integer of from 0 to about 10. Examples include maleic anhydride, citraconic anhydride, itaconic anhydride, aconitic anhydride, and the like.

The alkenyl aromatic resins include, by way of example, homopolymers such as homopolystyrene and monochloropolystyrene, and styrene-containing copolymers, such as styrene-chlorostyrene copolymers, styrene-bromostyrene copolymers, the styrene acrylonitrile-.alpha.-alkyl styrene copolymers, styrene-acrylonitrile copolymers, styrene butadiene copolymers, styrene-acrylonitrile butadiene copolymers, poly-.alpha.-methylstyrene, copolymers of ethylvinylbenzene, divinylbenzene, and styrene maleic anhydride copolymers, and block copolymers of styrene butadiene and styrene-butadiene styrene.

The styrene-maleic anhydride copolymers are described in U.S. Pat. Nos. 3,971,939, 3,336,267, and 2,769,804, all of which are hereby incorporated herein by reference.

The preferred polyphenylene ethers are of the formula: ##STR4## 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.

Examples of polyphenylene ethers corresponding to the above formula can be found in the above-referenced patents of Hay and Stamatoff. Especially preferred is poly (2,6-dimethyl-1,4-phenylene) ether.

The alkenyl aromatic resin modified with an EPDM rubber may be prepared by dissolving the rubbery interpolymer in the alkenyl aromatic monomer and polymerizing the mixture, preferably in the presence of a free-radical initiator, until 90-100% by weight of the alkenyl aromatic monomer has reacted to form said EPDM-modified alkenyl aromatic resin.

The compositions of the invention can also include other ingredients, such as flame retardants, extenders, processing aids, pigments, stabilizers, fillers such as mineral fillers and glass flakes and fibers, and the like. In particular, reinforcing fillers, in amounts sufficient to impart reinforcement, can be used, e.g., aluminum, iron or nickel, and the like, and non-metals, e.g., carbon filaments, silicates, such as acicular calcium silicate, asbestos, titanium dioxide, potassium titanate and titanate whiskers, glass flakes and fibers, and the like. It is to be understood that, unless the filler adds to the strength and stiffness of the composition, it is only a filler and not a reinforcing filler as contemplated herein. In particular, the reinforcing fillers increase the flexural strength, the flexural modulus, the tensile strength and the heat distortion temperature.

Although it is only necessary to have at least a reinforcing amount of the reinforcement present, in general, the combination of components (a) and (b) will comprise from about 10 to about 90 parts by weight and the filler will comprise from about 10 to about 90 parts by weight of the total composition.

In particular, the preferred reinforcing fillers are of glass, and it is preferred to use fibrous glass filaments comprised of lime-aluminum borosilicate glass that is relatively soda free. This is known as "E" glass. However, other glasses are useful where electrical properties are not so important, e.g., the low soda glass known as "C" glass. The filaments are made by standard processes, e.g., by steam or air blowing, by flame blowing, or by mechanical pulling. The preferred filaments for plastics reinforcement are made by mechanical pulling. The filament diameters range from about 0.000112 to 0.00075 inch, but this is not critical to the present invention.

In general, the best properties will be obtained if the sized filamentous glass reinforcement comprises from about 1 to about 80% by weight based on the combined weight of glass and polymers and preferably from about 10 to about 50% by weight. Especially preferably the glass will comprise from about 10 to about 40% by weight based on the combined weight of glass and resin. Generally, for direct molding use, up to about 60% of glass can be present without causing flow problems. However, it is useful also to prepare the compositions containing substantially greater quantities, e.g., up to 70-80% by weight of glass. These concentrates can then be custom blended with resin compositions that are not glass reinforced to provide any desired glass content of a lower value.

The length of the glass filaments and whether or not they are bundled into fibers and the fibers bundled in turn to yarns, ropes or rovings, or woven into mats, and the like, are also not critical to the invention. However, in preparing the present compositions it is convenient to use the filamentous glass in the form of chopped strands of from about 1/8" to about 1" long, preferably less than 1/4" long. In articles molded from the compositions, on the other hand, even shorter lengths will be encountered because, during compounding, considerable fragmentation will occur. This is desirable, however, because the best properties are exhibited by thermoplastic injection molded articles in which the filament lengths lie between about 0.000005" and 0.125".

Because it has been found that certain commonly used flammable sizings on the glass, e.g., dextrinized starch or synthetic polymers, contribute flammability often in greater proportion than expected from the amount present, it is preferred to use lightly sized or unsized glass reinforcements in those compositions of the present invention which are flame-retardant. Sizings, if present, can readily be removed by heat cleaning or other techniques well known to those skilled in the art.

It is a preferred feature of this invention also to provide flame-retardant thermoplastic compositions, as defined above, by modifying the composition to include a flame-retardant additive in a minor proportion but in an amount at least sufficient to render the composition non-burning or self-extinguishing.

A preferred feature of the invention is a flame-retardant composition as above defined, which also includes 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.

When used herein, the terms "non-burning", "self-extinguishing", and "non-dripping" are used to describe compositions which meet the standards of ASTM test method D-635 and Underwriters' Laboratories Bulletin No. 94. Another recognized procedure to determine flame resistance of resinous compositions is the Oxygen Index Test or LOI (Limiting Oxygen Index). This test is a direct measure of a product's combustibility based on the oxygen content of the combustion atmosphere. Appropriate specimens are placed in a combustion chimney, and the oxygen is reduced stepwise until the material no longer supports a flame. The LOI is defined as the percent oxygen times 100 divided by the sum of the percentages of nitrogen and oxygen in the gas used to burn the material under test. Further details of the Oxygen Index Test are found in ASTM test Method D-2863. The compositions of this invention which contain flame-retardant additives in the specified amounts have a substantially higher oxygen index and thus are much less combustible than the controls.

The flame-retardant additives useful in this invention comprise a family of chemical compounds well known to those skilled in the art. Generally speaking, the more important of these compounds contain chemical elements employed for their ability to impart flame resistance, e.g., bromine, chlorine, antimony, phosphorus, and nitrogen. It is preferred that the flame-retardant additive comprise a halogenated organic compound (brominated or chlorinated); a halogen-containing organic compound in admixture with antimony oxide; elemental phosphorus or a phosphorus compound; a halogen-containing compound in admixture with a phosphorus compound or compounds containing phosphorus-nitrogen bonds; or a mixture of two or more of the foregoing.

The amount of flame-retardant additive used is not critical to the invention, so long as it is present in a minor proportion based on the polyphenylene ether-modified alkenyl aromatic polymer composition--major proportions will detract from physical properties--but at least sufficient to render the composition non-burning or self-extinguishing. Those skilled in the art are well aware that the amount will vary with the nature of the polymers in the composition and with the efficiency of the additive. In general, however, the amount of additive will be from about 0.5 to 50 parts by weight per hundred parts of components (a) plus (b). A preferred range will be from about 1 to 25 parts, and an especially preferred range will be from about 3 to 15 parts of additive per 100 parts of (a) plus (b). Smaller amounts of compounds highly concentrated in the elements responsible for flame retardance will be sufficient, e.g., elemental red phosphorus will be preferred at about 0.5 to 10 parts by weight per hundred parts of (a) plus (b), while phosphorus in the form of triphenyl phosphate will be used at about 3 to 25 parts of phosphate per part of (a) plus (b), and so forth. Halogenated aromatics will be used at about 2 to 20 parts and synergists, e.g., antimony oxide, will be used at about 1 to 10 parts by weight per 100 parts of components (a) plus (b).

Among the useful halogen-containing compounds are those of the formula ##STR5## wherein n is 1 to 10 and R is an alkylene, alkylidene, or cycloaliphatic linkage, e.g., methylene, ethylene, propylene, isopropylene, isopropylidene, butylene, isobutylene, amylene, cyclohexylene, cyclopentylidene, and the like; or a linkage selected from the group consisting of ether; carbonyl; amine; a sulfur-containing linkage, e.g., sulfide, sulfoxide, or sulfone; carbonate; a phosphorus-containing linkage; and the like. R can also consist of two or more alkylene or alkylidene linkages connected by such groups as aromatic, amino, ether, ester, carbonyl, sulfide, sulfoxide, sulfone, a phosphorus-containing linkage, and the like. R can be dihydric phenol, e.g., bisphenol-A, carbonate linkage. Other groups which are represented by R will occur to those skilled in the art. Compounds of this type are disclosed in U.S. Pat. Nos. 3,647,747 and 3,334,154, both of which are incorporated by reference.

Ar and Ar' are mono- or polycarbocyclic aromatic groups such as phenylene, biphenylene, terphenylene, naphthylene, and the like. Ar and Ar' may be the same or different.

X is a monovalent hydrocarbon group exemplified by the following: alkyl groups, such as methyl, ethyl, propyl, isopropyl, butyl, decyl, and the like; aryl groups, such as phenyl, naphthyl, biphenyl, xylyl, tolyl, and the like; aralkyl groups, such as benzyl, ethylphenyl, and the like; cycloaliphatic groups, such as cyclopentyl, cyclohexyl, and the like; as well as monovalent hydrocarbon groups containing inert substituents therein. It will be understood that where more than one X is used, they may be alike or different.

Y is a substituent selected from the group consisting of organic, inorganic, and organometallic radicals. The substituents represented by Y include (1) halogen, e.g., chlorine, bromine, iodine, or fluorine, (2) ether groups of the general formula OE, wherein E is a monovalent hydrocarbon radical similar to X, (3) monovalent hydrocarbon groups of the type represented by R, and (4) other substituents, e.g., nitro, cyano, etc., said substituents being essentially inert provided there be at least one and preferably two halogen atoms per aryl, e.g., phenyl, nucleus.

The letter d represents a whole number ranging from 1 to a maximum equivalent to the number of replaceable hydrogens substituted on the aromatic rings comprising Ar or Ar'. The letter e represents a whole number ranging from 0 to a maximum controlled by the number of replaceable hydrogens on R. The letters a, b, and c represent whole numbers including 0. When b is not 0, neither a nor c may be 0, and when b is 0, either a or c, but not both, may be 0. Where b is 0, the aromatic groups are joined by a direct carbon-carbon bond.

The hydroxyl and Y substituents on the aromatic groups, Ar and Ar', can be varied in the ortho, meta, or para positions on the aromatic rings, and the groups can be in any possible geometric relationship with respect to one another.

Included within the scope of the above formula are di-aromatics of which the following are representative:

2,2-bis-(3,5-dichlorophenyl)propane

bis-(2-chlorophenyl)methane

bis-(2,6-dibromophenyl)methane

1,1-bis-(4-iodophenyl)ethane

1,2-bis-(2,6-dichlorophenyl)ethane

1,1-bis-(2-chloro-4-iodophenyl)ethane p0 1,1-bis-(2-chloro-4-methylphenyl)ethane

1,1-bis-(3,5-dichlorophenyl)ethane

2,2-bis-(3-phenyl-4-bromophenyl)ethane

2,3-bis-(4,6-dichloronaphthyl)propane

2,2-bis-(2,6-dichlorophenyl)pentane

2,2-bis-(3,5-dichromophenyl)hexane

bis-(4-chlorophenyl)phenylmethane

bis-(3,5-dichlorophenyl)cyclohexylmethane

bis-(3-nitro-4-bromophenyl)methane

bis-(4-hydroxy-2,6-dichloro-3-methoxyphenyl)methane

2,2-bis-(3,5-dichloro-4-hydroxyphenyl)propane

2,2-bis-(3-bromo-4-hydroxyphenyl)propane

The preparation of these and other applicable biphenyls are known in the art. In the above examples sulfide, sulfoxy, and the like may be substituted in place of the divalent aliphatic group.

Included within the above structural formula are substituted benzenes exemplified by tetrabromobenzene, hexachlorobenzene, hexabromobenzene, and biphenyls such as 2,2'-dichlorobiphenyl, 2,4'-dibromobiphenyl, 2,4'-dichlorobiphenyl, hexabromobiphenyl, octabromobiphenyl, decabromobiphenyl, and halogenated diphenyl ethers containing from 2 to 10 halogen atoms.

The preferred halogen compounds for this invention are aromatic halogen compounds such as chlorinated benzene, brominated benzene, chlorinated biphenyl, chlorinated terphenyl, brominated biphenyl, brominated terphenyl, or a compound comprising two phenyl radicals separated by a divalent alkylene group and having at least two chlorine or bromine atoms per phenyl nucleus, or mixtures of at least two of the foregoing.

Especially preferred are hexabromobenzene and chlorinated biphenyls or terphenyls, alone, or mixed with antimony oxide.

In general, the preferred phosphate compounds are selected from the group of elemental phosphorus and organic phosphonic acids, phosphonates, phosphinates, phosphonites, phosphinites, phosphine oxides, phosphines, phosphites, and phosphates. Illustrative is triphenyl phosphine oxide. These can be used alone or mixed with hexabromobenzene or a chlorinated biphenyl and, optionally, antimony oxide.

Typical of the preferred phosphorus compounds to be employed in this invention would be those having the general formula ##STR6## and nitrogen analogs thereof where each Q represents the same or different radicals including hydrocarbon radicals such as alkyl, cycloalkyl, aryl, alkyl substituted aryl, and aryl substituted alkyl; halogen; hydrogen; and combinations thereof provided that at least one of said Q's is aryl. Typical examples of suitable phosphates include, phenylbisdodecyl phosphate, phenylbisneopentyl phosphate, phenylethylene hydrogen phosphate, phenylbis-(3,5,5'-trimethylhexyl phosphate), ethyldiphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, diphenyl hydrogen phosphate, bis(2-ethylhexyl) p-tolylphosphate, tritolyl phosphate, bis-(2-ethylhexyl)-phenyl phosphate, tri(nonylphenyl) phosphate, phenylmethyl hydrogen phosphate, di(dodecyl) p-tolyl phosphate, tricresyl phosphate, triphenyl phosphate, halogenated triphenyl phosphate, dibutylphenyl phosphate, 2-chloroethyldiphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyldiphenyl phosphate, diphenyl hydrogen phosphate, and the like. The preferred phosphates are those where each Q is aryl. The most preferred phosphate is triphenyl phosphate. It is also preferred to use triphenyl phosphate in combination with hexabromobenzene and, optionally, antimony oxide. Especially preferred is a composition comprised of mixed triaryl phosphates, with one or more isopropyl groups on some or all of the aryl rings, such as Kronitex 50 supplied by Food Machinery Corporation.

Also suitable as flame-retardant additives for this invention are compounds containing phosphorus-nitrogen bonds, such as phosphonitrilic chloride, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, tris(aziridinyl)phosphine oxide, or tetrakis (hydroxymethyl) phosphonium chloride. These flame-retardant additives are commercially available.

The compositions of the invention may be formed by conventional techniques, that is, by first dry mixing the components to form a premix, and then passing the premix through an extruder at an elevated temperature, e.g., 425.degree. to 640.degree. F.

By way of illustration, glass roving (a bundle of strands of filaments) is chopped into small pieces, e.g., 1/8" to 1" in length, and preferably less than 1/4" in length and put into an extrusion compounder with (a) the polyphenylene ether resin, (b) the alkenyl aromatic resin that is modified with a rubbery interpolymer of a mixture of mono-olefins and a polyene, being comprised substantially of small particles, and (c) the flame-retardant additive(s), to produce molding pellets. The fibers are shortened and predispersed in the process, coming out at less than 1/16" long. In another procedure, glass filaments are ground or milled to short lengths, are mixed with the polyphenylene ether resin, the modified alkenyl aromatic polymer and, optionally, flame-retardant additive, by dry blending, and then are either fluxed on a mill and ground, or are extruded and chopped.

In addition, compounding should be carried out to insure that the residence time in the machine is short; that the temperature is carefully controlled; that the frictional heat is utilized; and that an intimate mixture between the resins and the additives is obtained.

This invention is better understood by making reference to the drawings:

FIG. 1 represents the relationship between median rubber particle size and Izod impact strength in polyphenylene ether resin compositions having polystyrene modified by 10% by weight EPDM rubber.

FIG. 2 represents the relationship between median rubber particle size and Izod impact strength for EPDM-modified polystyrene.

The following examples are set forth as further illustration of the invention and are not to be construed as limiting the invention thereto.

One hundred grams of Epcar 387 (an EPDM rubber manufactured by B. F. Goodrich Chemical Co.) was cut in small pieces and dissolved, under nitrogen, in 900 g of styrene. 1.2 g of tert-butyl peracetate were added, and the solution was transferred to a one-gallon reactor and stirred at 1600 r.p.m. by a 31/2 inch.times.1/2 inch six-blade turbine. The mixture was heated to 100.degree. C. After three hours at this temperature a solution of 4.0 g of polyvinyl alcohol and 3.0 g of gelatin in 1500 ml of hot water was added, followed by 8.0 g of di-tert-butyl peroxide. The stirrer speed was reduced to 800 r.p.m., and the reactor was flushed with nitrogen and sealed. The mixture was heated for one hour at 100.degree. C., for two hours at 120.degree. C., for one hour at 140.degree. C., and, finally, for two and one-half hours at 155.degree. C. The mixture was allowed to cool, and the EPDM-modified polystyrene, which was obtained in the form of fine beads, was filtered off, washed thoroughly with hot water, and dried in a vacuum oven.

The polymer was characterized by the following procedure:

A thin slice of one of the beads was warmed on a microscope slide with a drop of cimamaldehyde and photographed at a magnification of 800X with an optical microscope. The rubber particles ranged from about 0.75 to about 2 microns in diameter. The sizes of one hundred particles from a strip of the photograph taken at random were estimated and the size distribution obtained:

0.5-1 micron--42

1-1.5 micron--31

1.5-2 micron--19

2-2.5 micron--8

From the distribution a median particle size of 1.2 microns was estimated. A photograph taken by transmission electron microscopy showed a median particle size of about 0.8 microns. Examination by means of a Coulter Counter with a 100 micron orifice showed a number average particle diameter of 1.3655 microns, and a weight average particle diameter of 1.6517 microns.

A 5.00 g sample of the polymer was stirred for five hours with 100 ml of methyl ethyl ketone, which dissolves polystyrene but does not dissolve the EPDM rubber or polystyrene-rubber graft copolymer. The suspension was centrifuged at 15000 r.p.m., and the clear liquid was poured off and saved. The residue was resuspended in methyl ethyl ketone and recentrifuged. The liquid was poured off and the insoluble material was dried to constant weight in a vacuum oven. It weighed 1.108 g, or 22.2% of the polymer. The graft index, the ratio of percent insoluble in methyl ethyl ketone to percent rubber added, was (22.2/10) or 2.2.

The methyl ethyl ketone solution was concentrated under vacuum and the dissolved polymer, nearly pure polystyrene, was precipitated by addition to methanol. The intrinsic viscosity of the polystyrene, measured in chloroform at 30.degree. C., was 0.86 dl/g.

A 1.000 g sample of the polymer was stirred for eight hours with 20 ml of toluene, and the suspension was transferred to a tared centrifuge tube with an additional 25 ml of toluene. The suspension was centrifuged at 15000 r.p.m., and the liquid was poured off. The gel remaining was resuspended in toluene and again centrifuged. The liquid was poured off and the tube allowed to drain in a desiccator over toluene. The tube was weighed and dried. The weight of the dry toluene-insoluble gel was 0.117 g (11.7%); the swelling index, defined as the weight of the toluene-swollen gel divided by the weight of dried gel, was 8.8.

The EPDM-modified polystyrene was compression molded at 350.degree. F. into 1/8" test bars. It had a heat deflection temperature of 214.degree. F. and a notched Izod impact strength of 0.6 ft.lbs./inch of notch.

Three hundred grams of PPO, 300 g of the EPDM-modified polystyrene, 6 g of tridecyl phosphite, 18 g of triphenyl phosphate, 0.9 g of zinc sulfide, and 0.9 g of zinc oxide were mixed together and extruded at 575.degree. F. in a 28 mm twin-screw extruder. The extruded pellets were molded into standard test pieces at 500.degree. F. in a 3 oz. screw injection molding machine. The notched Izod impact strength was 4.0 ft.lbs./inch of notch, and Gardner impact strength was 200 in.lbs. A mixture of the same composition, but with FG-834, a polystyrene modified with polybutadiene (commercially available from Foster-Grant Co.) in place of the EPDM-modified polystyrene, had Izod impact strength of 4.5 ft.lb./inch of notch and Gardner impact strength of 175 in.lbs. Another composition, prepared in the same way with Taflite 925, an EPDM-modified polystyrene having large rubber particles (commercially available from Mitsui-Toatsu), had impact strength of 1.7 ft.lbs./in. of notch and Gardner impact strength of only 5 in.lbs.

Tensile bars from the compositions were aged in air in an oven at 115.degree. C. Compositions made from FG-834 polystyrene became brittle after 53-56 days, those from the Taflite polystyrene became brittle after 67-70 days, while the composition made with the small-particle EPDM polystyrene described above remained ductile for more than 120 days.

Polymers were prepared from 100 g of EPDM rubber and 900 g of styrene by the procedure of Example I, but with different stirring speeds between 200 and 1600 r.p.m. during the first three hours of each run to produce polymers having different average particle size. Some of the polymers were made with Epcar 387 and others with Epcar 587, a rubber also from B. F. Goodrich Chemical Co. and having the same composition as 387, but with a higher molecular weight. The impact strengths of the modified polystyrenes, measured on compression molded 1/8" bars, and of 50:50 compositions with PPO, extruded and molded as described in Example I, are shown in Table 1.

The effect of particle size on the impact strength of the 50:50 compositions is shown graphically in FIG. 1. It can be seen that the impact strength of the 50:50 compositions increases with decreasing particle size, and that compositions having good impact strength (Izod impact strength .gtoreq.3.5 ft.lbs./in. of notch) were consistently obtained when the median rubber particle diameter was less than 2.0 microns (cinnamaldehyde method).

The effect on the impact strength of the modified polystyrene alone was quite different, as shown in FIG. 2. Polymers with small particles had low impact strength; the impact strength increased with increasing particle size and reached its maximum value at a size of about three microns. Thus, small rubber particle size. i.e., below two microns, does not improve the impact strength of EPDM-modified polystyrene compositions. In view of this, the improved impact strength of PPO-EPDM modified polystyrene compositions with small rubber particle size is quite unexpected.

Polymers were prepared as described in Example I, but with 8% instead of 10% EPDM rubber (80 g rubber+920 g styrene) and with different stirring speeds. The effect of particle size on impact strength is shown in the table below:

It can be seen that the results follow the same trend as at the higher rubber concentration, with the impact strength of the 50:50 composition increasing with decreasing particle size and with the impact strength of the modified polystyrene alone seeming to reach its maximum at about three microns.

The procedure of Example I was followed, but using in addition to Epcar 387, other ethylene-propylene-ethylidine norbornene (ENB) terpolymers having different ratios of ethylene, propylene, and ENB, and a terpolymer of ethylene, propylene and 1,4-hexadiene. The median diameter of the rubber particles in the products and the impact strength of 50:50 compositions with PPO, extruded and molded as described in Example I, are shown in Table 3. Also included in Table 3 are values for extruded and molded control samples made from FG-834 polystyrene modified with polybutadiene rubber and from Taflite 925 EPDM-modified polystyrene having large rubber particles.

It can be seen that the median particle size in all cases is less than two microns and that the Izod impact strength is at least 80% of the control made from the polystyrene modified with polybutadiene rubber and much higher than that of a product of the same composition made with Taflite 925.

Two hundred grams of the polymer produced in Example I, 200 g of PPO, 4 g of tridecylphosphite, 12 g of triphenylphosphate, 0.6 g of zinc sulfide, 0.6 g of zinc oxide, and 100 g of Owens Corning 497BB 1/4" chopped glass fiber were blended, extruded, and molded as described in Example I. Properties of the composition containing the glass fiber are compared in the table below with the properties of a similar composition but without the reinforcing glass fibers:

It can be seen that the addition of glass fiber produces a small increase in heat deflection temperature, tensile strength, and flexural strength, and a large increase in the rigidity of the composition, as measured by its flexural modulus.

EPDM-modified polystyrene with a mean rubber particle size of 1.2 microns was prepared as described in Example I. 200 g of the polystyrene, 200 g of PPO, 6 g of polyethylene, 4 g of tridecylphosphite, 0.6 g of zinc sulfide, and 0.6 g of zinc oxide were mixed together and extruded and molded as described in Example I into standard 5" by 1/2.times.1/16" test bars. A second 200 g portion of the polystyrene was extruded and molded in the same way, except for the addition of 12 g (3 phr) of triphenylphosphate. A third composition was prepared in the same way, but with the addition of 48 g of decabromo diphenyl ether and 12 g of antimony oxide. Similar compositions, but with FG-834 polystyrene were prepared for comparison. The bars were tested for flammability according to the procedure of UL 94, with the results shown in Table 5.

It can be seen that the compositions made with the small-particle EPDM-modified polystyrene are superior in flame resistance to those made with FG-834 and that 3 phr of triphenylphosphate gives the blend a V-I flammability rating, while the combination of decabromo diphenyl ether and antimony oxide gives it a V-O rating.

EPDM-modified polystyrene was prepared as described in Example I from 100 g of Vistalon 6505 EPDM rubber and 900 g of styrene. The median rubber particle diameter in the product was 1.8 microns.

Three hundred twenty-five grams of the modified polystyrene, 165 g of PPO, 2.5 g of tridecyl phosphite, 35 g of triphenyl phosphate, 0.75 g of zinc sulfide, and 0.75 g of zinc oxide were mixed, extruded, and molded as described in Example I. The properties of the molded product are compared in Table 6 with those of a similar composition prepared from Taflite 925 EPDM-modified polystyrene. It can be seen that the composition prepared from polystyrene containing small-particle EPDM rubber is significantly superior in Izod impact strength, Gardner impact strength, and ductility to that made with polystyrene containing large-particle EPDM rubber.

Fifty parts of EPDM-modified polystyrene, prepared as described in Example I, and with a mean rubber particle diameter of 1.5 microns, were blended with 50 parts of PPO having an intrinsic viscosity of 0.43 dl/g and 1.5 parts of polyethylene and was extruded and molded as described in Example I. A second composition was prepared in the same way, with the addition of 3 parts of triphenyl phosphate as a flame retardant. Other compositions were prepared in the same way with a 65:35 ratio of PPO to EPDM-modified polystyrene. The molded bars were tested for flammability in 1/16" sections according to the procedure of UL 94, with the following results:

The procedure of Example I was followed, but with 100 g of Royalene 302 (a terpolymer of ethylene, propylene, and dicyclopentadiene manufactured by Uniroyal Chemical) in place of the Epcar 387. The median rubber particle diameter, estimated as described in Example I, was 1.8 microns. The polystyrene was blended, extruded, and molded with PPO as described in Example I. The molded test bars had notched Izod impact strength of 3.0 ft.lbs./inch of notch. A control composition, extruded and molded at the same time, using FG-834 polystyrene, had notched Izod impact strength of 3.5 ft.lbs./inch of notch.

EPDM-modified polystyrene was prepared as described in Example I, but with 9% rubber (100 g of Epcar 387 and 1011 g of styrene) and with 0.03 g of lecithin added. The median particle diameter, determined as described in Example I, was 0.9 microns. The number average particle diameter, determined by means of a Coulter Counter with a 30 micron sample tube, was 0.53 microns. The product was blended, extruded and molded with PPO as described in Example I; it had a notched Izod impact strength of 4.2 ft.lbs./inch of notch, compared to 4.8 ft.lbs./inch for a control sample extruded and molded at the same time with FG-834 polystyrene.

EPDM-modified polystyrene was prepared as described in Example I. The median rubber particle diameter in the product was estimated as 1.0 microns using the procedure of Example I. The product was divided into three portions, and each portion was extruded and molded with a different proportion of PPO, as described in Example I. Composition XXVa contained 35 parts of PPO, 65 parts of the EPDM-modified polystyrene, and 7 parts of triphenyl phosphate. Composition XXVb contained 50 parts of PPO, 50 parts of EPDM-modified polystyrene, and 3 parts of triphenyl phosphate. Composition XXVc contained 65 parts of PPO, 35 parts of the polystyrene, and 6 parts of triphenyl phosphate. Control blends of the same composition were prepared using FG-834 polystyrene. The Izod impact strengths of the compositions are shown below: