Electrostatically sprayable molded article and method for manufacturing the same

Abstract

The invention relates to an electrostatically sprayable molded article and a method for manufacturing the same. An article molded from a thermoplastic composition comprising specific amounts of a poly (phenylene ether), a poly (butylene terephthalate), an impact modifier, a reactive compatibilizer, and a conductive filler comprising carbon nanotubes. The article is an electrostatically coatable automotive component and exhibits a desirable combination of good electrical conductivity and thermal stability. Methods of making molded articles are also disclosed.

Description

Technical Field

[0001] The present invention discloses an electrostatically coatable molded article comprising a thermoplastic composition containing a poly(phenylene ether) and a polyester, which exhibits enhanced properties such as improved impact strength, low moisture absorption, and high heat resistance. Background Art

[0002] Poly(phenylene ether)s are commercially attractive materials because of their unique combination of properties, including, for example, high temperature resistance, dimensional and hydrolytic stability, and electrical properties. Blending poly(phenylene ether)s with polyesters to form compatibilized poly(phenylene ether) / polyester blends has been sought to obtain a desired balance of properties such as dimensional stability and impact strength. Current poly(phenylene ether) / polyester compositions do not provide an adequate balance of properties for certain applications, including, for example, in-line and in-line coatable automotive components.

[0003] Accordingly, there is a continuing need for improved poly(phenylene ether) / polyester compositions to address the above technical limitations. It would be particularly advantageous to provide compositions that exhibit good mechanical strength, low moisture absorption, good dimensional stability, and good electrical conductivity. Summary of the Invention

[0004] An aspect of the present invention is a molded article comprising a thermoplastic composition, wherein the thermoplastic composition comprises: 18 to 30 weight percent of a poly(phenylene ether); 50 to 80 weight percent of poly(butylene terephthalate); 5 to 15 weight percent of an impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition; wherein the molded article is an electrostatically coatable automotive component; and wherein the molded article exhibits: a specific volume resistivity of less than 0.5 kiloohm-centimeter (kOhm·cm); and a Vicat softening temperature of greater than 165 °C measured according to ISO 306.

[0005] Another aspect is a molded article comprising a thermoplastic composition, wherein the thermoplastic composition comprises: a poly(phenylene ether), the poly(phenylene ether) comprising poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity greater than 0.25 dL / g measured at 25 °C in chloroform using an Ubbelohde viscometer; poly(butylene terephthalate), comprising: a first poly(butylene terephthalate) having an intrinsic viscosity less than 1 dL / g, preferably 0.5 to 0.9 dL / g, measured at 30 °C in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane; and a second poly(butylene terephthalate) having an intrinsic viscosity greater than 1 dL / g, preferably 1.05 to 1.5 dL / g, measured at 30 °C in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane; an impact modifier comprising a hydrogenated block copolymer; a polymer compatibilizer having greater than or equal to 10 side chain epoxy groups per molecule; a conductive filler comprising carbon nanotubes; wherein the molded article is an electrostatically coatable automotive component; and wherein the molded article exhibits: a specific volume resistivity of less than 0.5 kOhm·cm; a Vicat softening temperature greater than 165 °C measured according to ISO 306; a notched Izod impact strength greater than or equal to 8 kJ / m 2 , preferably 8 to 12 kJ / m 2 ; and a melt volume flow rate of less than 12 cm 3 / 10 minutes measured according to ISO 1133; and a moisture absorption of less than or equal to 0.3 weight percent based on the weight of the molded article.

[0006] Another aspect of the present disclosure is a method for manufacturing an electrostatically coatable molded article, the method comprising: melt mixing 18 to 30 weight percent of a poly(phenylene ether); 50 to 80 weight percent of poly(butylene terephthalate); 5 to 15 weight percent of an impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition; providing the thermoplastic composition; and molding the thermoplastic composition to provide an electrostatically coatable molded article; wherein the electrostatically coatable molded article exhibits: a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature greater than 165 °C measured according to ISO 306.

[0007] The above and other features are illustrated by the following drawings and detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following drawings are exemplary embodiments.

[0009] Figure 1 Scanning electron microscope (SEM) images showing various embodiments of the present disclosure are presented.

[0010] Figure 2 Shows the moisture absorption amounts over time of a reference material (circles) and poly(phenylene ether) / poly(butylene terephthalate) (squares) according to one aspect of the present disclosure at 23 °C and 50% relative humidity. Detailed Description

[0011] For automotive-related articles, it is desirable to match the color of other parts of the vehicle to provide the desired aesthetic appearance for the vehicle. For certain automotive articles made of thermoplastic compositions, it is typically difficult to coat them online with the rest of the vehicle, at least in part due to the use of high temperatures or in-line (where lower temperatures can be used) and thus in both cases materials with particularly high dimensional stability are required, especially when using electrostatically applied coatings. In response to this problem, specially formulated coatings have been used to spray such components "offline" in a separate operation. The "offline" coating of the finished colored coating does not always result in sufficient color matching. In addition, before applying the final color coating, the parts of the vehicle to be coated are first primed with a primer coat. Then the entire vehicle is sprayed. In these cases, if the color of the article does not closely match the color of the primer, the coated article can appear to have a different color from the primed parts of the vehicle. Electrostatic spraying can also provide high paint transfer efficiency, reduced costs, and improved environmental performance. Therefore, there is a desire to provide an improved composition that is particularly well-suited for the preparation of electrostatically coatable molded articles, especially for automotive applications.

[0012] The inventors have unexpectedly found that a thermoplastic composition comprising a specific amount of poly(phenylene ether), poly(butylene terephthalate), impact modifier, reactive compatibilizer, and conductive filler can provide a combination of desired properties, including, for example, good mechanical strength, low moisture absorption, good dimensional stability, lower warpage, and good electrical conductivity. Thus, the compositions described herein can be particularly well-suited for providing molded articles for automotive applications, such as thermally stable automotive components suitable for in-line or in-line electrostatic coating. Accordingly, the present disclosure provides a significant improvement.

[0013] Accordingly, one aspect of the present disclosure is a molded article comprising a thermoplastic composition. The thermoplastic composition comprises poly(phenylene ether), poly(butylene terephthalate), impact modifier, reactive compatibilizer, and conductive filler.

[0014] As used herein, poly(phenylene ether) comprises repeating structural units according to formula (1):

[0015]

[0016] Wherein, each occurrence of Z 1 is independently a halogen, an unsubstituted or substituted C 1-12 hydrocarbyl group, provided that the hydrocarbyl group is not a tertiary hydrocarbyl group, C 1-12 hydrocarbylthio group, C 1-12 hydrocarbyloxy group, or C 2-12 halohydrocarbyloxy group, wherein at least two carbon atoms separate the halogen and the oxygen atom; and each occurrence of Z 2 is independently hydrogen, a halogen, an unsubstituted or substituted C 1-12 hydrocarbyl group, provided that the hydrocarbyl group is not a tertiary hydrocarbyl group, C 1-12 hydrocarbylthio group, C 1-12 hydrocarbyloxy group, or C 2-12 halohydrocarbyloxy group, wherein at least two carbon atoms separate the halogen and the oxygen atom. As used herein, the term "hydrocarbyl", whether used alone or as a prefix, suffix or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain a combination of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated and unsaturated hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it can optionally contain heteroatoms in addition to and on the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or it can contain heteroatoms within the backbone of the hydrocarbyl residue. As an example, Z 1 can be a dibutylaminomethyl group formed by the reaction of the terminal 3,5-dimethyl-1,4-phenyl group with the dibutylamine component of an oxidative polymerization catalyst.

[0017] In one aspect, the poly(phenylene ether) block contains 2,6-dimethyl-1,4-phenylene ether repeating units, i.e., repeating units according to formula (2):

[0018]

[0019] 2,3,6-trimethyl-1,4-phenylene ether repeating units, or combinations thereof.

[0020] The poly(phenylene ether) can contain molecules having aminoalkyl-containing - end groups that are typically located ortho to the hydroxyl group. Also often present are tetramethylbiphenoquinone (TMDQ) end groups, typically obtained from reaction mixtures containing 2,6-dimethylphenol in which the tetramethylbiphenoquinone by-product is present. The poly(phenylene ether) can be in the form of a homopolymer, copolymer, graft copolymer, ionomer, or block copolymer, and combinations thereof.

[0021] Poly(phenylene ether) can be prepared by an oxidative polymerization method. In this method, poly(phenylene ether) is the product of oxidative polymerization of a monomer mixture containing a monohydric phenol, which can be as described above.

[0022] In one aspect, the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer. As used herein, the term "poly(phenylene ether)-polysiloxane block copolymer" refers to a block copolymer containing at least one poly(phenylene ether) block and at least one polysiloxane block.

[0023] In one aspect, a polyphenylene ether-polysiloxane block copolymer is prepared by an oxidative copolymerization method. In this method, the poly(phenylene ether)-polysiloxane block copolymer is the product of a method comprising oxidative copolymerization of a monomer mixture containing a monohydric phenol and a hydroxyaryl-terminated polysiloxane. In one aspect, based on the total weight of the monohydric phenol and the hydroxyaryl-terminated polysiloxane, the monomer mixture contains 70 to 99 parts by weight of the monohydric phenol and 1 to 30 parts by weight of the hydroxyaryl-terminated polysiloxane. The hydroxyaryl-di-terminated polysiloxane can include a plurality of repeating units having the structure of formula (3):

[0024]

[0025] wherein each occurrence of R 8 is independently hydrogen, a C 1-12 hydrocarbyl group, or a C 1-12 halohydrocarbyl group; and two terminal units having the structure of formula (4)

[0026]

[0027] wherein Y is hydrogen, a C 1-12 hydrocarbyl group, a C 1-12 hydroxy group, or a halogen, and wherein each occurrence of R 9 is independently hydrogen, a C 1-12 hydrocarbyl group, or a C 1-12 halohydrocarbyl group. In one aspect, each occurrence of R 8 and R 9 is methyl, and Y is methoxy.

[0028] In one aspect, the monohydric phenol includes 2,6-dimethylphenol, and the hydroxyaryl-terminated polysiloxane has the structure of formula (5):

[0029]

[0030] wherein n averages from 5 to 100, specifically from 30 to 60.

[0031] The oxidative copolymerization process produces a poly(phenylene ether)-polysiloxane block copolymer as the desired product and poly(phenylene ether) (without bound polysiloxane blocks) as a byproduct. It is not necessary to separate the poly(phenylene ether) from the poly(phenylene ether)-polysiloxane block copolymer. Thus, the poly(phenylene ether)-polysiloxane block copolymer can be used as a "reaction product" that includes the poly(phenylene ether) and the poly(phenylene ether)-polysiloxane block copolymer. Certain separation procedures, such as precipitation from isopropanol, make it possible to ensure that the reaction product is substantially free of residual hydroxyaryl-terminated polysiloxane starting materials. In other words, these separation methods ensure that the polysiloxane content of the reaction product is substantially entirely in the form of the poly(phenylene ether)-polysiloxane block copolymer. Detailed methods for forming poly(phenylene ether) polysiloxane block copolymers are described in U.S. Patent Nos. 8,017,697 and 8,669,332 to Carrillo, the entire contents of which are incorporated herein by reference.

[0032] In one aspect, the poly(phenylene ether) can have an intrinsic viscosity of 0.03 to 2 deciliters per gram (dl / g). In one aspect, the poly(phenylene ether) can have an inherent viscosity greater than 0.25 dl / g, such as 0.25 to 1.7 dl / g, especially 0.25 to 0.7 dl / g, more especially 0.35 to 0.55 dl / g, even more especially 0.35 to 0.50 dl / g, or 0.4 to 0.6 dl / g, measured in chloroform at 25 °C using an Ubbelohde viscometer.

[0033] In one aspect, the poly(phenylene ether) includes a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof. In one aspect, the poly(phenylene ether) contains the poly(phenylene ether)-polysiloxane block copolymer. In one aspect, for example, the poly(phenylene ether)-polysiloxane block copolymer can contribute 0.05 to 2 weight percent, especially 0.1 to 1 weight percent, more especially 0.2 to 0.8 weight percent of siloxane groups to the composition as a whole.

[0034] Based on the total weight of the thermoplastic composition, the poly(phenylene ether) is present in the composition in an amount of 18 to 30 weight percent. Within this range, based on the total weight of the thermoplastic composition, the poly(phenylene ether) can be present in an amount of 20 to 30 weight percent, or 21 to 30 weight percent, or 20 to 28 weight percent, or 21 to 28 weight percent, or 21 to 27 weight percent, or 18 to 26 weight percent, or 19 to 26 weight percent.

[0035] In addition to the poly(phenylene ether), the thermoplastic composition comprises poly(butylene terephthalate). In one aspect, the poly(butylene terephthalate) can have an intrinsic viscosity measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30 °C of from 0.2 dl / g to 1.5 dl / g. In one aspect, at least some of the poly(butylene terephthalate) comprises nucleophilic groups such as, for example, carboxylic acid groups. In some cases, an acid-reactive substance is used and it is desirable to reduce the number of carboxylic acid end groups, typically to less than 20 microequivalents per gram (meq / g) of the poly(butylene terephthalate). In other cases, it is desirable for the poly(butylene terephthalate) to have a relatively high carboxyl end group concentration, in the range of 20 meq / g to 250 meq / g of the poly(butylene terephthalate), or more specifically, 30 meq / g to 100 meq / g per gram of the poly(butylene terephthalate).

[0036] In one aspect, at least a combination of poly(butylene terephthalates) can be included in the thermoplastic composition. In one aspect, the thermoplastic composition can comprise a first poly(butylene terephthalate) and a second poly(butylene terephthalate). The first poly(butylene terephthalate) can have an intrinsic viscosity measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30 °C of less than 1 dl / g, preferably from 0.5 to 0.9 dl / g. The second poly(butylene terephthalate) can have an intrinsic viscosity measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30 °C of greater than 1 dl / g, preferably from 1.05 to 1.5 dl / g. In one aspect, the first poly(butylene terephthalate) can have an intrinsic viscosity measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30 °C of less than 1 dl / g, preferably from 0.5 to 0.9 dl / g, and a carboxyl end group concentration of less than 20 meq / g of the poly(butylene terephthalate), or more specifically, from 10 to less than 20 meq / g of the poly(butylene terephthalate). In one aspect, the second poly(butylene terephthalate) can have an intrinsic viscosity measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30 °C of greater than 1 dl / g, preferably from 1.05 to 1.5 dl / g, and a carboxyl end group concentration of greater than 20 meq / g of the poly(butylene terephthalate), or more specifically, from 25 to 50 meq / g of the poly(butylene terephthalate).

[0037] Based on the total weight of the thermoplastic composition, poly(butylene terephthalate) is present in the thermoplastic composition in an amount of 50 to 80 weight percent. Within this range, each based on the total weight of the thermoplastic composition, poly(butylene terephthalate) can be present in an amount of 50 to 75 weight percent, or 55 to 80 weight percent, or 55 to 75 weight percent, or 57 to 80 weight percent, or 57 to 75 weight percent, or 57 to 72 weight percent, or 51 to 65 weight percent, or 51 to 60 weight percent.

[0038] In addition to poly(phenylene ether) and poly(butylene terephthalate), the thermoplastic composition comprises an impact modifier. Examples of suitable impact modifiers include block copolymers, elastomers such as polybutadiene, random copolymers such as ethylene vinyl acetate (EVA), and combinations comprising two or more of the foregoing impact modifiers.

[0039] In one aspect, the impact modifier comprises a hydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene. For the sake of brevity, this component is referred to as a "hydrogenated block copolymer". Based on the weight of the hydrogenated block copolymer, the hydrogenated block copolymer can comprise a poly(alkenyl aromatic compound) content of 10 to 90 weight percent and a hydrogenated poly(conjugated diene) content of 90 to 10 weight percent. In one aspect, the hydrogenated block copolymer is an oligomeric (alkenyl aromatic compound content) hydrogenated block copolymer, wherein the poly(alkenyl aromatic compound) content is 10 to less than 40 weight percent, or 20 to 35 weight percent, or 25 to 35 weight percent, or 30 to 35 weight percent, all based on the weight of the oligomeric (alkenyl aromatic compound) content hydrogenated block copolymer. In one aspect, the hydrogenated block copolymer is a high poly(alkenyl aromatic compound) content hydrogenated block copolymer, wherein the poly(alkenyl aromatic compound) content is 40 to 90 weight percent, or 50 to 80 weight percent, or 60 to 70 weight percent, all based on the weight of the high poly(alkenyl aromatic compound content) hydrogenated block copolymer.

[0040] In one aspect, the hydrogenated block copolymer has a weight average molecular weight of 40,000 to 400,000 grams per mole (g / mol). The number average molecular weight and the weight average molecular weight can be determined by gel permeation chromatography and based on comparison with polystyrene standards. In one aspect, the hydrogenated block copolymer has a weight average molecular weight of 200,000 to 400,000 g / mol, or 220,000 to 350,000 g / mol. In one aspect, the hydrogenated block copolymer has a weight average molecular weight of 40,000 to 200,000 g / mol, or 40,000 to 180,000 g / mol, or 40,000 to 150,000 g / mol.

[0041] The vinyl aromatic monomer for preparing the hydrogenated block copolymer may have a structure according to formula (6):

[0042]

[0043] wherein, R 5 and R 6 each independently represents a hydrogen atom, a C 1-8 alkyl group or a C 2-8 alkenyl group; R 7 and R 11 each independently represents a hydrogen atom, a C 1-8 alkyl group, a chlorine atom or a bromine atom; and R 8 , R 9 and R 10 each independently represents a hydrogen atom, a C 1-8 alkyl group or a C 2-8 alkenyl group, or R 8 and R 10 together with the central aromatic ring form a naphthyl group, or R 9 and R 10 together with the central aromatic ring form a naphthyl group. Specific vinyl aromatic monomers include, for example, styrene, chlorostyrenes such as p-chlorostyrene, methylstyrenes such as α-methylstyrene and p-methylstyrene, and tert-butylstyrenes such as 3-tert-butylstyrene and 4-tert-butylstyrene. In one aspect, the vinyl aromatic monomer is styrene.

[0044] The conjugated diene for preparing the hydrogenated block copolymer may be a C 4-20 conjugated diene. Suitable conjugated dienes include, for example, 1,3-butadiene, 2-methyl-1,3-butadiene, 2-chloro-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, etc., and combinations thereof. In an aspect, the conjugated diene is 1,3-butadiene, 2-methyl-1,3-butadiene, or a combination thereof. In one aspect, the conjugated diene is 1,3-butadiene.

[0045] A hydrogenated block copolymer is a copolymer comprising (A) at least one block derived from an alkenyl aromatic compound and (B) at least one block derived from a conjugated diene, wherein the content of aliphatic unsaturated groups in block (B) is at least partially reduced by hydrogenation. In one aspect, the aliphatic unsaturation in block (B) is reduced by at least 50%, or at least 70%. The arrangement of blocks (A) and (B) includes linear structures, graft structures, and radial teleblock structures with or without branches. Linear block copolymers include tapered linear structures and non-tapered linear structures. In one aspect, the hydrogenated block copolymer has a tapered linear structure. In one aspect, the hydrogenated block copolymer has a non-tapered linear structure. In one aspect, the hydrogenated block copolymer comprises block (B) which comprises a random incorporation of alkenyl aromatic monomers. Linear block copolymer structures include diblock (A-B block), triblock (A-B-A block or B-A-B block), tetrablock (A-B-A-B block), and pentablock (A-B-A-B-A block or B-A-B-A-B block) structures and linear structures containing a total of 6 or more blocks (A) and (B), wherein the molecular weight of each (A) block may be the same as or different from the molecular weights of the other (A) blocks, and the molecular weight of each (B) block may be the same as or different from the molecular weights of the other (B) blocks. In one aspect, the hydrogenated block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0046] In one aspect, the hydrogenated block copolymer does not include monomer residues other than alkenyl aromatic compounds and conjugated dienes. In one aspect, the hydrogenated block copolymer consists of blocks derived from alkenyl aromatic compounds and conjugated dienes. It does not contain grafts formed from these or any other monomers. It also consists of carbon and hydrogen atoms and thus does not include heteroatoms. In one aspect, the hydrogenated block copolymer contains residues of one or more acid-functionalizing reagents such as maleic anhydride. In one aspect, the hydrogenated block copolymer contains a polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer.

[0047] In one aspect, the hydrogenated block copolymer is a polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer having a polystyrene content of 10 to 50 weight percent, or 20 to 40 weight percent, or 20 to 35 weight percent, or 25 to 35 weight percent, based on the weight of the polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer. In these aspects, the polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer may optionally have a weight average molecular weight of 200,000 to 400,000 g / mol, or 250,000 to 350,000 g / mol, measured by size exclusion chromatography using polystyrene standards.

[0048] Methods for preparing hydrogenated block copolymers are known in the art and many hydrogenated block copolymers are commercially available. Exemplary commercially available hydrogenated block copolymers include polystyrene-poly(ethylene-propylene) diblock copolymers available from Kraton Performance Polymers Inc. As KRATON TM G1701 (with 37 weight percent polystyrene) and G1702 (with 28 weight percent polystyrene); from Kraton Performance Polymers Inc. as KRATON TM G1641 (with 33 weight percent polystyrene), G1650 (with 30 weight percent polystyrene), G1651 (with 33 weight percent polystyrene), and G1654 (with 31 weight percent polystyrene) available polystyrene-poly(ethylene-butene)-polystyrene triblock copolymers; and as SEPTON TM S4044, S4055, S4077, and S4099 polystyrene-poly(ethylene-ethylene / propylene)-polystyrene triblock copolymers available from Kuraray. Other commercially available hydrogenated block copolymers include as CALPRENE TM H 6140 (with 31 weight percent polystyrene), H6170 (with 33 weight percent polystyrene), H6171 (with 33 weight percent polystyrene) and H6174 (with 33 weight percent polystyrene) polystyrene-poly(ethylene-butene)-polystyrene (SEBS) triblock copolymers purchased from Dynasol; and SEPTON from Kuraray TM 8006 (with 33 weight percent polystyrene) and 8007 (with 30 weight percent polystyrene); polystyrene-poly(ethylene-propylene)-polystyrene (SEPS) copolymers, as SEPTON TM 2006 (with 35 weight percent polystyrene) and 2007 (with 30 weight percent polystyrene) available from Kuraray; and from Kraton Performance Polymers Inc. as KRATON TM G4609 (containing 45% mineral oil and the SEBS has 33 weight percent polystyrene) and G4610 (containing 31% mineral oil and the SEBS has 33 weight percent polystyrene) available oil-extended compounds of these hydrogenated block copolymers; and TUFTEC from Asahi TMH1272 (contains 36% oil, and the SEBS has 35 weight percent polystyrene). Mixtures of two or more hydrogenated block copolymers can be used. In one aspect, the hydrogenated block copolymer comprises a polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer having a weight average molecular weight of at least 100,000 g / mol, or 200,000 to 400,000 g / mol.

[0049] Based on the total weight of the thermoplastic composition, the composition comprises an impact modifier in an amount of 5 to 15 weight percent. Within this range, based on the total weight of the thermoplastic composition, the amount of the impact modifier can be 8 to 15 weight percent, or 10 to 15 weight percent, or 11 to 14 weight percent.

[0050] The thermoplastic composition further comprises a reactive compatibilizer. In one aspect, the reactive compatibilizer is preferably a polymeric compatibilizer. As used herein and throughout, a reactive compatibilizer or polymeric compatibilizer refers to a polymeric multifunctional compound that interacts with poly(phenylene ether), poly(butylene terephthalate), or both. Such interaction can be chemical (e.g., grafting) and / or physical (e.g., affecting the surface properties of the dispersed phase). When the interaction is chemical, the compatibilizer can react partially or completely with poly(phenylene ether), poly(butylene terephthalate), or both, such that the composition comprises a reaction product. For example, during melt blending, the epoxy groups of the compatibilizer can react with the acid groups present on poly(butylene terephthalate). The use of a polymeric compatibilizer can improve the compatibility between poly(phenylene ether) and poly(butylene terephthalate), as evidenced by enhanced impact strength, mold knit line strength, elongation, and / or the formation of a distinct two-phase morphology. This morphology is evidenced by the occurrence of two different phases within the molded part; a continuous phase comprising the polyester and a dispersed phase comprising poly(phenylene ether). The dispersed phase particles can have an average particle size of 0.2 to 5 micrometers (μm), or more specifically, 0.5 to 4 μm, or even more specifically, 0.5 to 3 μm. This average particle size is the average circular diameter of at least 100 particles and can be determined by scanning electron microscopy or by transmission electron microscopy. In the case of oval particles, the "circular diameter" is the average of the major and minor axes of each particle. In other words, for each oval particle, the diameters of the circumscribed circle and the incision are averaged.

[0051] Exemplary instances of suitable compatibilizers include, but are not limited to, copolymers of glycidyl methacrylate (GMA) and olefins, copolymers of GMA, olefins and acrylates, copolymers of GMA, olefins and vinyl acetate, copolymers of GMA and styrene. Suitable olefins include ethylene, propylene, and mixtures of two or more of the foregoing. Suitable acrylates include alkyl acrylate monomers, including but not limited to methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, and combinations of the foregoing alkyl acrylate monomers. When present, the acrylate may be used in an amount of 15 to 35 weight percent based on the total amount of monomers used in the copolymer. When present, vinyl acetate may be used in an amount of 4 to 10 weight percent based on the total amount of monomers used in the copolymer. Exemplary instances of suitable compatibilizers include ethylene-glycidyl methacrylate copolymer, ethylene-methylglycidyl methacrylate copolymer, ethylene-methylglycidyl methacrylate-vinyl acetate copolymer, ethylene-methylglycidyl methacrylate-alkyl acrylate copolymer, ethylene-methylglycidyl methacrylate-methyl acrylate copolymer, ethylene-methylglycidyl methacrylate-ethyl acrylate copolymer, and ethylene-methylglycidyl methacrylate-butyl acrylate copolymer.

[0052] The use of glycidyl methacrylate copolymers as polymer compatibilizers is known in the art, as illustrated by U.S. Patent Nos. 5,698,632 and 5,719,236, the contents of which are incorporated herein by reference. However, different from the prior art teachings of compatibilizers, where the compatibilizer can be a compound having two side-chain epoxy groups per molecule and some monofunctional substances, it has been found that the polymer compatibilizer must have an average of greater than or equal to 3 side-chain epoxy groups per molecule, or more specifically, an average of greater than or equal to 8 side-chain epoxy groups, or more specifically, an average of greater than or equal to 11 side-chain epoxy groups, or more specifically, an average of greater than or equal to 15 side-chain epoxy groups, or more specifically, an average of greater than or equal to 17 side-chain epoxy groups. The diglycidyl compounds do not exhibit the reactivity required to form a composition with a stable phase morphology.

[0053] In one aspect, the reactive compatibilizer is preferably a polymer compatibilizer having an average of greater than or equal to 3 side-chain epoxy groups per molecule, or an average of greater than or equal to 5 side-chain epoxy groups per molecule, or an average of greater than or equal to 8 side-chain epoxy groups per molecule, or an average of greater than or equal to 10 side-chain epoxy groups per molecule.

[0054] Based on the total weight of the thermoplastic composition, the reactive compatibilizer is present in the thermoplastic composition in an amount of 0.1 to 1.4 weight percent. Within this range, based on the total weight of the composition, the amount of the reactive compatibilizer present can be 0.2 to 1.4 weight percent, or 0.5 to 1.4 weight percent, or 0.8 to 1.4 weight percent, or 0.1 to 1.2 weight percent, or 0.2 to 1.2 weight percent, or 0.5 to 1.2 weight percent, or 0.8 to 1.2 weight percent, or 0.9 to 1.1 weight percent, or 0.95 to 1.05 weight percent.

[0055] The thermoplastic composition further comprises a conductive filler containing carbon nanotubes (e.g., the conductive filler). The carbon nanotubes can be single-walled or multi-walled. In one aspect, the carbon nanotubes can be multi-layered. In one aspect, the carbon nanotubes can have an average diameter of 2 to 100 nanometers (nm), or 2 to 50 nm, or 2 to 20 nm, or 2 to 12 nm, or 5 to 12 nm, or 8 to 11 nm, or 8.5 to 10.5 nm. In one aspect, the carbon nanotubes can have an average length of 0.1 to 10 μm, or 0.1 to 5 μm, or 0.1 to 2.5 μm, or 0.5 to 2.5 μm. In a specific aspect, the carbon nanotubes can have an average length of 0.5 to 2.5 μm and an average diameter of 8.5 to 10.5 nm.

[0056] Based on the total weight of the thermoplastic composition, the conductive filler containing carbon nanotubes is present in the thermoplastic composition in an amount of 0.2 to 10 weight percent. Within this range, the conductive filler containing carbon nanotubes can be present in an amount of 0.2 to 8 weight percent, or 0.2 to 5 weight percent, or 0.2 to 2 weight percent, or 0.2 to 1.5 weight percent, or 0.2 to 1 weight percent, or 0.2 to less than 1 weight percent, or 0.2 to 0.95 weight percent, or 0.2 to 0.75 weight percent, or 0.2 to 0.65 weight percent, or 0.25 to 0.65 weight percent, each based on the total weight of the thermoplastic composition.

[0057] In one aspect, conductive fillers other than carbon nanotubes can be excluded from the thermoplastic composition. For example, conductive fillers such as conductive carbon black or inorganic fillers (e.g., metal fibers; metal disks; metal particles; metal-coated disk-shaped fillers; etc.) can be excluded from the thermoplastic composition.

[0058] The thermoplastic composition may optionally further comprise an additive composition. The additive composition comprises one or more additives. The additives can be, for example, stabilizers, mold release agents, lubricants, processing aids, anti-dripping agents, nucleating agents, UV blockers, dyes, pigments, antioxidants, antistatic agents, foaming agents, mineral oils, metal deactivators, anti-blocking agents, or combinations thereof. In one aspect, the additive composition may comprise stabilizers, antioxidants, or combinations thereof. When present, such additives are typically used in a total amount of from 0.1 to 10 weight percent, based on the total weight of the composition. In a specific aspect, the additive composition comprises stabilizers, antioxidants, or combinations thereof, and may be present in an amount of from 0.1 to 5 weight percent, based on the total weight of the thermoplastic composition.

[0059] The composition may optionally minimize or exclude additional components not specifically described herein. For example, the composition comprises less than 5 weight percent, or less than 2 weight percent, or less than 1 weight percent or less than 0.1 weight percent of any thermoplastic polymer other than poly(phenylene ether), poly(butylene terephthalate), and the polymer reactive compatibilizer as described above. In one aspect, the composition may not include polyamides. In one aspect, the composition may exclude polyesters other than poly(butylene terephthalate). In one aspect, the composition may minimize or exclude glass fibers. In one aspect, impact modifiers other than hydrogenated block copolymers may be minimized (i.e., present in an amount less than 1 weight percent) or excluded from the thermoplastic composition. In one aspect, the composition may minimize or exclude homopolystyrene or rubber-modified polystyrene. In one aspect, the composition may minimize or exclude flame retardants, such as organophosphorus flame retardants.

[0060] It should be understood that the total amount of the components of the thermoplastic composition totals 100 weight percent.

[0061] In a specific aspect, the thermoplastic composition comprises: 20 to 28 weight percent, preferably 21 to 27 weight percent of poly(phenylene ether); 51 to 65 weight percent, preferably 51 to 60 weight percent of poly(butylene terephthalate); 10 to 15 weight percent, preferably 11 to 14 weight percent of an impact modifier; 0.8 to 1.2 weight percent of the reactive compatibilizer; 0.2 to less than 1 weight percent, preferably 0.25 to 0.65 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition. The poly(phenylene ether) may comprise poly(2,6-dimethyl-1,4-phenylene ether), preferably wherein the poly(phenylene ether) has an intrinsic viscosity greater than 0.25 deciliters / gram measured in chloroform at 25 °C using an Ubbelohde viscometer. The poly(butylene terephthalate) may have an intrinsic viscosity of 0.2 dl / g to 1.5 dl / g measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C. The poly(butylene terephthalate) may comprise a first poly(butylene terephthalate) having an intrinsic viscosity less than 1 dl / g, preferably 0.5 to 0.9 dl / g measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C; and a second poly(butylene terephthalate) having an intrinsic viscosity greater than 1 dl / g, preferably 1.05 to 1.5 dl / g measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C. The impact modifier may comprise a hydrogenated block copolymer containing polystyrene-poly(ethylene-butylene)-polystyrene. The reactive compatibilizer may include a polymeric compatibilizer having an average of greater than or equal to 10 side chain epoxy groups / molecule. The carbon nanotubes may have an average length of 0.5 to 2.5 microns and an average diameter of 8.5 to 10.5 nanometers.

[0062] For example, the compositions of the present disclosure can be made by melt blending the components of the composition. Ordinary equipment such as a ribbon blender, HENSCHEL TM mixer, BANBURY TM mixer, drum machine, etc. can be used to mix or blend the components of the composition, and then the blended composition can be melt blended or melt kneaded. Ordinary equipment such as a single-screw extruder, twin-screw extruder, multi-screw extruder, co-kneader, etc. can be used to perform the melt blending or melt kneading. For example, the compositions of the present invention can be prepared by melt blending the components in a twin-screw extruder at a temperature of 270 to 310 °C or 280 to 300 °C. The extrudate can be immediately quenched in a water bath and pelletized. Optionally, the pellets so prepared can be a quarter inch long or less. Such pellets can be used for subsequent molding, shaping, or forming.

[0063] The thermoplastic composition according to the present disclosure can exhibit a desired combination of properties. Specifically, a molded article comprising the composition exhibits a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature greater than 165 °C, or greater than 170 °C, or greater than 175 °C, or greater than 180 °C measured according to ISO 306. The molded article comprising the composition can also exhibit a notched Izod impact strength of greater than or equal to 8 kilojoules per square meter (kJ / m 2 ), preferably 8 to 12 kJ / m 2 , a melt volume flow rate of less than 12 cubic centimeters per 10 minutes (cm 3 / 10 min) according to ISO 1133, or a moisture absorption of less than or equal to 0.3 weight percent based on the weight of the molded article, or a combination of one or more of these.

[0064] The combination of properties exhibited by a molded article comprising the composition according to the present disclosure is particularly useful for electrostatically coatable molded articles, such as electrostatically coatable automotive components. Thus, a molded article according to the present disclosure can be configured to withstand an electrostatic spraying process. In other words, the molded article can be subjected to the high temperatures associated with automotive coating without suffering from undesirable degradation or deformation. Thus, a molded automotive component comprising the composition described herein can be advantageously coated online with the rest of the exterior of the vehicle. Exemplary electrostatically coatable automotive components can include, but are not limited to, automotive hoods, service covers, wiper fluid covers, fenders, side body moldings, door trim panels, door handle covers, mirror skull covers, body panels, or roof rack covers.

[0065] A method for manufacturing an electrostatically coatable molded article represents another aspect of the present disclosure. The method includes melt blending 18 to 30 weight percent of a poly(phenylene ether); 50 to 80 weight percent of a poly(butylene terephthalate); 5 to 15 weight percent of an impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes to provide a molten thermoplastic composition, wherein the weight percent of each component is based on the total weight of the molten thermoplastic composition. The method further includes molding the thermoplastic composition to provide an electrostatically coatable molded article. The molten thermoplastic composition can be molded by, for example, injection molding, extrusion, rotational molding, blow molding, and thermoforming. In one aspect, molding the molten thermoplastic composition includes extrusion molding.

[0066] All of the variations described above in the context of the molded article and the thermoplastic composition also apply to the method for manufacturing an electrostatically coatable molded article.

[0067] Advantageously, the electrostatically coatable molded article exhibits a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature of greater than 165 °C measured according to ISO 306. Accordingly, the present disclosure provides a significant improvement.

[0068] The present disclosure is further illustrated by the following examples, which are non-limiting.

[0069] Examples

[0070] The materials used in the following examples are shown in Table 1.

[0071] Table 1

[0072]

[0073]

[0074] The compositions of the following examples were prepared by extrusion on a 28 mm co-rotating intermeshing twin screw extruder. The extruder barrel temperature was set at 150 °C to 300 °C. Typically, the feed rate was 15 to 20 kg / h, where the screws rotated at 300 - 500 rpm, where the torque was between 60% and 90%. All examples were processed in a 3-leaf extruder. Samples were molded using a molding machine set at 40 - 300 °C and a mold set from 120 °C to 80 °C via injection molding.

[0075] The physical properties of the compositions were evaluated according to the following test standards and procedures. The notched Izod impact strength (INI) was measured according to ISO 180 / 1A. The specific volume resistivity (SVR) was determined as follows. Tensile bars were molded according to ISO 3167. Sharp, shallow cuts were made near each end of the narrow central portion of the bar. The bar was fractured in a brittle manner at each cut to separate the narrow central portion, now having fractured ends with dimensions of 10 x 4 mm. If necessary to obtain a brittle fracture, the tensile bar was first cooled in dry ice or liquid nitrogen in a negative 40 °C freezer. The length of the bar between the fractured ends was measured. The fractured ends of the sample were sprayed with conductive silver paint and the paint was allowed to dry. Using the Dohm resistance mode, electrodes were attached to each coated surface and the resistance was measured at an applied voltage of 500 - 1000 mV. The value of the specific volume resistivity was obtained by multiplying the measured resistance by the fractured area of one side of the bar and dividing by the length according to the equation ρ = R x A / L, where ρ is the specific volume resistivity in ohm-cm, R is the measured resistance in ohm, and A is in cm 2The broken area is in cm², and the sample length L is in cm. The specific volume resistivity value thus has the unit of ohm-cm and is expressed as kiloohm-cm (kohm-cm). The heat resistance (Vicat B) is measured according to ISO 306 (in °C). The melt volume rate (MVR) is measured according to ISO 1133 at 260 °C under a load of 5 kg with a dwell time of 300 seconds.

[0076] The composition and properties are shown in Table 2.

[0077] Table 2

[0078]

[0079] Table 2 (continued)

[0080]

[0081] As shown in Table 2, the compositions according to Examples 1, 3, and 5 show that an increasing amount of PPE can provide a higher Vicat temperature. Generally, for certain applications (including in-line coating), a Vicat temperature greater than 165 °C may be desirable. Materials with a Vicat temperature less than 165 °C may be prone to deformation at the temperatures required for in-line coating. Examples 1 - 6 also show the effect of partially replacing PBT-1 with a higher molecular weight PBT (PBT-2). It was observed that including PBT-2 enhanced the impact properties of the composition and provided a slight improvement in thermal properties.

[0082] Examples 4 and 7 of Table 2 show that even a slight increase in the amount of the impact modifier can provide a 10% increase in impact properties. However, a slight decrease in MVR, conductivity, and thermal properties was observed.

[0083] Examples 8 - 14 of Table 2 show how the loading of CNT can affect the conductive properties of the composition. An increase in CNT shows an increase in the conductivity of the composition (see Examples 8 - 12). When only PBT-1 was used in the composition, a major change was noted between CNT loadings of 0.37 and 0.45 weight percent. However, when a combination of PBT-1 and PBT-2 was used, it was observed that increasing the CNT load from 0.45 weight percent to 0.6 weight percent resulted in a significantly greater increase in conductivity compared to using PBT-1 alone (see Examples 8 - 12 versus 13 - 14).

[0084] Examples 15 - 17 of Table 2 show the effect of PPE and impact modifier loading on the thermal and mechanical properties, flow, and conductivity of the composition. For example, increasing the impact modifier up to 14% results in lower heat resistance.

[0085] Comparative Examples 1 - 3 illustrate the effect of compatibilizer loading on the composition. Figure 1Scanning electron micrographs (SEM) of these compositions are shown, in which the morphology of the dispersed phase (PPE) with different proportions of compatibilizer and without any compatibilizer at all in the continuous phase (PBT) can be visualized. As Figure 1 shown, CE2 with a compatibilizer loading of 1% gives good dispersion of PPE in the continuous phase, which is evenly distributed and very uniform. However, the composition of CE1 with half the amount of compatibilizer provides a less homogeneous dispersed phase with a random distribution. The lack of compatibilizer in CE3 hinders the formation of a proper continuous phase.

[0086] Comparative Examples 4 and 5 use conductive carbon black instead of carbon nanotubes as the conductive filler. As shown in Table 2, a higher CCB loading is required to achieve comparable conductivity to the compositions including CNT instead.

[0087] The single-sided moisture absorption experiment is carried out by directly contacting a square test specimen with wet cotton. The plate has dimensions of 17.5 x 17.5 x 3 mm. The plate is formulated from the compositions (reference materials based on polyphenylene ether and polyamide) according to Example 13 and Comparative Example 6 (CE6). The compositions of Example 13 and Comparative Example 6 are shown in Table 3.

[0088] Table 3

[0089] Component Unit E13 CE6 PPE wt% 22.8 38.8 PBT-1 wt% 56.6 PBT-2 wt% 6.5 PA 48 SEBS wt% 12 10 Comp. wt% 1 CNT wt% 0.45 CCB-1 wt% CCB-2 wt% 1.8 CA wt% 0.4 0.65 PHBPP wt% 0.3 0.6 TBPP wt% 0.15 CuI wt% 0.01 KI wt% 0.05 <![CDATA[H2O]]> wt% 0.05

[0090] After a given time (e.g., 24 hours, 5 days or 14 days) of contact with the wet cotton, 3D images of the test specimens are generated to evaluate the deformation of the materials. After 5 days of contact with the wet cotton, the composition according to Example 13 does not show any significant warping (e.g., ±0.75 mm) across the plate. In contrast, the composition according to CE6 shows significant warping. Specifically, the center of the fascia of CE6 typically shows a warping greater than 1 mm, e.g., 1 to 3 mm, while the outer edges of the fascia show a warping greater than 1 mm, e.g., 1 to 3 mm, in the opposite direction of the center of the fascia. Thus, for the compositions according to the present disclosure, an improvement in dimensional stability is observed compared to the current materials on the market.

[0091] The moisture absorption is measured after specific conditions in a climatic chamber with a temperature set at 23 °C and a relative humidity of 50%. As Figure 2 shown, under these conditions, the moisture absorption of the PBT-PPE material according to Example 13 is significantly lower than that of CE6 based on polyamide. Such behavior can have a significant impact on the dimensional stability of the material, significantly reducing warping compared to the reference as described above.

[0092] The present invention further encompasses the following aspects.

[0093] Aspect 1: A molded article comprising a thermoplastic composition, wherein the thermoplastic composition comprises: 18 to 30 weight percent of a poly(phenylene ether); 50 to 80 weight percent of a poly(butylene terephthalate); 5 to 15 weight percent of an impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition; wherein the molded article is an electrostatically coatable automotive component; and wherein the molded article exhibits: a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature of greater than 165 °C measured according to ISO 306.

[0094] Aspect 2: The molded article according to aspect 1, wherein the molded article exhibits:

[0095] a notched Izod impact strength of greater than or equal to 8 kJ / m 2 , preferably 8 to 12 kJ / m 2 measured according to ISO 180 / 1A; and a melt volume flow rate of less than 12 cm 3 / 10 min measured according to ISO 1133.

[0096] Aspect 3: The molded article according to aspect 1 or 2, wherein the molded article exhibits a moisture absorption of less than or equal to 0.3 weight percent based on the weight of the molded article.

[0097] Aspect 4: The molded article according to any one of aspects 1 to 3, wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether), preferably wherein the poly(phenylene ether) has an intrinsic viscosity of greater than 0.25 dL / g measured at 25 °C in chloroform using an Ubbelohde viscometer.

[0098] Aspect 5: The molded article according to any one of aspects 1 to 4, wherein the poly(butylene terephthalate) has an intrinsic viscosity of 0.2 dL / g to 1.5 dL / g measured at 30 °C in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane.

[0099] Aspect 6: A molded article according to any one of Aspects 1 to 5, wherein the poly(butylene terephthalate) comprises a combination of at least two poly(butylene terephthalates), preferably wherein the poly(butylene terephthalate) comprises a first poly(butylene terephthalate) having an intrinsic viscosity measured at 30 °C in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane of less than 1 dl / g, preferably 0.5 to 0.9 dl / g; and a second poly(butylene terephthalate) having an intrinsic viscosity measured at 30 °C in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane of greater than 1 dl / g, preferably 1.05 to 1.5 dl / g.

[0100] Aspect 7: A molded article according to any one of Aspects 1 to 6, wherein the impact modifier comprises a hydrogenated block copolymer of polystyrene-poly(ethylene-butene)-polystyrene.

[0101] Aspect 8: A molded article according to any one of Aspects 1 to 7, wherein the reactive compatibilizer comprises a polymeric compatibilizer having greater than or equal to 10 side chain epoxy groups per molecule.

[0102] Aspect 9: A molded article according to any one of Aspects 1 to 8, wherein the carbon nanotubes have an average length of 0.5 to 2.5 microns; and an average diameter of 8.5 to 10.5 nanometers.

[0103] Aspect 10: A molded article according to any one of Aspects 1 to 9, further comprising an additive composition, preferably wherein the additive composition comprises a stabilizer, an antioxidant, or a combination thereof, more preferably wherein the additive composition is present in an amount of 0.1 to 5 weight percent based on the total weight of the thermoplastic composition.

[0104] Aspect 11: A molded article according to Aspect 1, wherein the thermoplastic composition comprises: 20 to 28 weight percent, preferably 21 to 27 weight percent of poly(phenylene ether); 51 to 65 weight percent, preferably 51 to 60 weight percent of poly(butylene terephthalate); 10 to 15 weight percent, preferably 11 to 14 weight percent of an impact modifier; 0.8 to 1.2 weight percent of a reactive compatibilizer; 0.2 to less than 1 weight percent, preferably 0.25 to 0.65 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition.

[0105] Aspect 12: The molded article according to Aspect 11, wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether), preferably wherein the poly(phenylene ether) has an intrinsic viscosity greater than 0.25 dL / g measured in chloroform at 25 °C using an Ubbelohde viscometer; the poly(butylene terephthalate) has an intrinsic viscosity of 0.2 dL / g to 1.5 dL / g measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C, optionally wherein the poly(butylene terephthalate) comprises a first poly(butylene terephthalate) having an intrinsic viscosity less than 1 dL / g, preferably 0.5 to 0.9 dL / g, measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C; and a second poly(butylene terephthalate) having an intrinsic viscosity greater than 1 dL / g, preferably 1.05 to 1.5 dL / g, measured in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane at 30 °C; the impact modifier comprises a hydrogenated block copolymer of polystyrene-poly(ethylene-butylene)-polystyrene; the reactive compatibilizer comprises a polymeric compatibilizer having greater than or equal to 10 side-chain epoxy groups per molecule; and the carbon nanotubes have an average length of 0.5 to 2.5 micrometers and an average diameter of 8.5 to 10.5 nanometers; wherein the molded article exhibits: a notched Izod impact strength of greater than or equal to 8 kJ / m 2 , preferably 8 to 12 kJ / m 2 according to ISO 180 / 1A; a melt volume flow rate of less than 12 cm 3 / 10 min according to ISO 1133; a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature of greater than 165 °C measured according to ISO 306.

[0106] Aspect 13: The molded article according to any one of Aspects 1 to 12, wherein the automotive component is electrostatically coatable, preferably wherein the automotive component is an automotive hood, service cover, wiper fluid cover, fender, side body molding, door trim, door handle cover, mirror skull cover, body panel, or roof rack cover.

[0107] Aspect 14: A method for manufacturing an electrostatically coatable molded article, the method comprising: melt blending 18 to 30 weight percent of a poly(phenylene ether); 50 to 80 weight percent of a poly(butylene terephthalate); 5 to 15 weight percent of an impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percents are based on the total weight of the thermoplastic composition; to provide a molten thermoplastic composition; and molding the molten thermoplastic composition to provide an electrostatically coatable molded article; wherein the electrostatically coatable molded article exhibits: a specific volume resistivity of less than 0.5 kOhm·cm; and a Vicat softening temperature of greater than 165 °C measured according to ISO 306.

[0108] Aspect 15: The method according to aspect 14, wherein molding the thermoplastic composition comprises extrusion molding.

[0109] Aspect 16: A molded article comprising a thermoplastic composition, wherein the thermoplastic composition comprises: a poly(phenylene ether) comprising poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of greater than 0.25 dL / g measured at 25 °C in chloroform using an Ubbelohde viscometer; a poly(butylene terephthalate) comprising: a first poly(butylene terephthalate) having an intrinsic viscosity of less than 1 dL / g, preferably 0.5 to 0.9 dL / g, measured at 30 °C in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane; and a second poly(butylene terephthalate) having an intrinsic viscosity of greater than 1 dL / g, preferably 1.05 to 1.5 dL / g, measured at 30 °C in a 1:1 weight ratio weight mixture of phenol:1,1,2,2-tetrachloroethane; an impact modifier comprising a hydrogenated block copolymer; a polymeric compatibilizer having an average of greater than or equal to 10 side chain epoxy groups per molecule; a conductive filler comprising carbon nanotubes; wherein the molded article is an electrostatically coatable automotive component; and wherein the molded article exhibits: a specific volume resistivity of less than 0.5 kOhm·cm; a Vicat softening temperature of greater than 165 °C measured according to ISO 306; a notched Izod impact strength of greater than or equal to 8 kJ / m 2 , preferably 8 to 12 kJ / m 2 ; and a melt volume flow rate of less than 12 cm 3 / 10 min measured according to ISO 1133; and a moisture absorption of less than or equal to 0.3 weight percent based on the weight of the molded article.

[0110] Alternatively, the compositions, methods, and articles of manufacture can comprise, consist of, or consist essentially of any suitable materials, steps, or components disclosed herein. The compositions, methods, and articles of manufacture can additionally or alternatively be formulated so as to be free or substantially free of any materials (or species), steps, or components that are otherwise unnecessary to achieve the functions or objectives of the compositions, methods, and articles of manufacture.

[0111] All ranges disclosed herein include the endpoints, and the endpoints can be combined independently of each other. "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not denote any order, quantity, or importance, but are used to distinguish one element from another. Unless otherwise specified herein or clearly contradicted by the context, the terms "a" and "an" and "the" do not denote a limitation of quantity, but are to be construed as covering the singular and the plural. Unless otherwise expressly stated, "or" means "and / or". Reference throughout the specification to "one aspect" means that a particular element described in connection with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. The term "their combination" as used herein includes one or more of the listed elements and is open-ended, allowing for the presence of one or more similar elements not named. Additionally, it should be understood that the described elements can be combined in any suitable manner in the various aspects.

[0112] Unless specified to the contrary herein, all test standards are the latest standards in effect as of the filing date of this application, or, if priority is claimed, as of the filing date of the earliest priority application in which the test standard appears.

[0113] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in the incorporated reference, the term from this application prevails over the conflicting term from the incorporated reference.

[0114] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group should be understood to have its valence filled by a bond or hydrogen atom as indicated. A dash ("-") not between two letters or symbols is used to indicate the point of attachment of a substituent. For example, -CHO is attached through the carbon of the carbonyl group.

[0115] As used herein, the term "hydrocarbyl", whether used alone or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when a hydrocarbyl residue is described as substituted, it can optionally contain heteroatoms in addition to and in place of carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, a hydrocarbyl residue can also contain one or more carbonyl, amino, hydroxy, etc., or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" refers to a branched or straight-chain, saturated aliphatic hydrocarbyl group, e.g., methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, sec-pentyl, and n-hexyl and sec-hexyl. "Alkenyl" refers to a straight-chain or branched monovalent hydrocarbyl group having at least one carbon-carbon double bond (e.g., vinyl (-HC=CH2)). "Alkoxy" refers to an alkyl group attached via oxygen (i.e., alkyl-O-), e.g., methoxy, ethoxy, and sec-butoxy. "Alkylene" refers to a straight-chain or branched, saturated, divalent aliphatic hydrocarbyl group (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). "Cycloalkylene" refers to a divalent cyclic alkylene group, -C n H 2n-x , where x is the number of hydrogens replaced by cyclization. "Cycloalkenyl" refers to a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, where all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbyl group containing a specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. "Arylene" refers to a divalent aryl group. "Alkylenearylene" refers to an arylene group substituted with an alkyl group. "Arylenealkylene" refers to an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" refers to a group or compound including one or more of the fluorine, chlorine, bromine, or iodine substituents. Combinations of different halogen atoms (e.g., bromine and fluorine) or only chlorine atoms can be present. The prefix "hetero" refers to a compound or group including at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatoms), where the heteroatoms are each independently N, O, S, Si, or P. "Substituted" means that a compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents, which can each independently be C 1-9 alkoxy, C 1-9 haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 alkylsulfonyl (-S(=O)2-alkyl), C 6-12Arylsulfonyl (-S(=O)2-aryl), thiol (-SH), thiocyanate (-SCN), tosyl (CH3C6H4SO2-), C 3-12 Cycloalkyl, C 2-12 Alkenyl, C 5-12 Cycloalkenyl, C 6-12 Aryl, C 7-13 Arylalkylene, C 4-12 Heterocycloalkyl, and C 3-12 A heteroaryl group replaces a hydrogen provided that the normal valence of the substituted atom is not exceeded. The number of carbon atoms indicated in the group does not include any substituents. For example, -CH2CN is a C2 alkyl group substituted with a nitrile.

[0116] Although specific embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are not currently foreseeable or may not be foreseeable may occur to the applicant or other persons skilled in the art. Therefore, the appended claims as filed and as they may be amended are intended to cover all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. A molded article comprising a thermoplastic composition, wherein: The thermoplastic composition comprises: 18 to 30 weight percent poly(phenylene ether); 50 to 80 weight percent poly(butylene terephthalate); 5 to 15 weight percent impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percentages are based on the total weight of the thermoplastic composition; wherein the molded article is an electrostatically coatable automotive component; and Wherein, the molded article exhibits: A specific volume resistivity of less than 0.5 kOhm·cm; and Vicat softening temperature greater than 165°C measured according to ISO 306.

2. The molded article according to claim 1, wherein The molded articles exhibit: Greater than or equal to 8 kJ / m measured according to ISO 180 / 1A 2 , preferably 8kJ / m 2 Up to 12kJ / m 2 Notched Izod impact strength of Less than 12 cm according to ISO 1133 3 / 10 minutes melt volume flow rate.

3. The molded article according to claim 1 or 2, wherein The molded article exhibits a moisture absorption of less than or equal to 0.3 weight percent based on the weight of the molded article.

4. The molded article according to any one of claims 1 to 3, wherein The poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether), preferably wherein the poly(phenylene ether) has an intrinsic viscosity greater than 0.25 deciliter / gram as measured in chloroform at 25°C using an Ubbelohde viscometer.

5. The molded article according to any one of claims 1 to 4, wherein Poly(butylene terephthalate) has an intrinsic viscosity of 0.2 to 1.5 dl / g, measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30°C.

6. The molded article according to any one of claims 1 to 5, wherein The poly(butylene terephthalate) comprises a combination of at least two poly(butylene terephthalates), preferably, wherein the poly(butylene terephthalate) comprises: a first poly(butylene terephthalate) having an intrinsic viscosity of less than 1 dl / g, preferably 0.5 dl / g to 0.9 dl / g, measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30°C; and The second poly(butylene terephthalate) has an intrinsic viscosity greater than 1 dl / g, preferably 1.05 dl / g to 1.5 dl / g, measured in a 1:1 (w / w) mixture of phenol and 1,1,2,2-tetrachloroethane at 30°C.

7. The molded article according to any one of claims 1 to 6, wherein The impact modifier comprises a hydrogenated block copolymer comprising polystyrene-poly(ethylene-butylene)-polystyrene.

8. The molded article according to any one of claims 1 to 7, wherein The reactive compatibilizer comprises a polymer compatibilizer having an average of greater than or equal to 10 pendant epoxy groups per molecule.

9. The molded article according to any one of claims 1 to 8, wherein the carbon nanotubes have An average length of 0.5 microns to 2.5 microns; and Average diameter of 8.5 nm to 10.5 nm.

10. The molded article according to any one of claims 1 to 9, further comprising an additive composition, preferably wherein the additive composition comprises a stabilizer, an antioxidant or a combination thereof, more preferably wherein the additive composition is present in an amount of 0.1 to 5 weight percent based on the total weight of the thermoplastic composition.

11. The molded article according to claim 1, wherein The thermoplastic composition comprises: 20 to 28 weight percent, preferably 21 to 27 weight percent poly(phenylene ether); 51 to 65 weight percent, preferably 51 to 60 weight percent poly(butylene terephthalate); 10 to 15 weight percent, preferably 11 to 14 weight percent of said impact modifier; 0.8 to 1.2 weight percent of the reactive compatibilizer; 0.2 to less than 1 weight percent, preferably 0.25 to 0.65 weight percent of said conductive filler comprising carbon nanotubes; Herein, the weight percentages are based on the total weight of the thermoplastic composition.

12. The molded article according to claim 11, wherein The poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether), preferably wherein the poly(phenylene ether) has an intrinsic viscosity greater than 0.25 deciliter / gram as measured in chloroform at 25°C using an Ubbelohde viscometer; The poly(butylene terephthalate) has an intrinsic viscosity of 0.2 dl / g to 1.5 dl / g measured in a 1:1 weight to weight mixture of phenol: 1,1,2,2-tetrachloroethane at 30°C, optionally wherein the poly(butylene terephthalate) comprises: a first poly(butylene terephthalate) having an intrinsic viscosity of less than 1 dl / g, preferably 0.5 dl / g to 0.9 dl / g, measured in a 1:1 weight to weight mixture of phenol: 1,1,2,2-tetrachloroethane at 30°C; and a second poly(butylene terephthalate) having an intrinsic viscosity greater than 1 dl / g, preferably 1.05 dl / g to 1.5 dl / g, measured in a 1:1 weight to weight mixture of phenol: 1,1,2,2-tetrachloroethane at 30°C; The impact modifier comprises a hydrogenated block copolymer comprising polystyrene-poly(ethylene-butylene)-polystyrene; The reactive compatibilizer comprises a polymer compatibilizer having an average of greater than or equal to 10 pendant epoxy groups per molecule; and The carbon nanotubes have an average length of 0.5 micrometers to 2.5 micrometers and an average diameter of 8.5 nanometers to 10.5 nanometers; Wherein, the molded article exhibits: Greater than or equal to 8 kJ / m measured according to ISO 180 / 1A 2 , preferably 8kJ / m 2 Up to 12kJ / m 2 Notched Izod impact strength; Less than 12 cm according to ISO 1133 3 / 10min melt volume flow rate; A specific volume resistivity of less than 0.5 kOhm·cm; and Vicat softening temperature greater than 165°C measured according to ISO 306.

13. The molded article according to any one of claims 1 to 12, wherein The automotive component is electrostatically coatable, Preferably, the automotive component is a trunk lid, a service cover, a wiper fluid cover, a fender, a side body molding, a door trim, a door handle cover, a rearview mirror housing, a body panel or a roof rack cover.

14. A method for making an electrostatically coatable molded article, the method comprising: Melt Mixing 18 to 30 weight percent poly(phenylene ether); 50 to 80 weight percent poly(butylene terephthalate); 5 to 15 weight percent impact modifier; 0.1 to 1.4 weight percent of a reactive compatibilizer; 0.2 to 10 weight percent of a conductive filler comprising carbon nanotubes; wherein the weight percentages are based on the total weight of the thermoplastic composition; to provide a molten thermoplastic composition; and molding the molten thermoplastic composition to provide the electrostatically coatable molded article, preferably wherein molding the thermoplastic composition comprises extrusion molding; Wherein, the electrostatically coatable molded article exhibits: A specific volume resistivity of less than 0.5 kOhm·cm; and Vicat softening temperature greater than 165°C measured according to ISO 306.

15. A molded article comprising a thermoplastic composition, wherein: The thermoplastic composition comprises: Poly(phenylene ether) including poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity greater than 0.25 deciliter / gram as measured in chloroform at 25°C using an Ubbelohde viscometer; Poly(butylene terephthalate), comprising: The first poly(butylene terephthalate) has: An intrinsic viscosity of less than 1 dl / g, preferably 0.5 dl / g to 0.9 dl / g, measured in a 1:1 weight to weight mixture of 1,1,2,2-tetrachloroethane; and The second poly(butylene terephthalate) has: an intrinsic viscosity greater than 1 dl / g, preferably from 1.05 dl / g to 1.5 dl / g, as measured in a 1:1 weight to weight mixture of 1,1,2,2-tetrachloroethane; an impact modifier comprising a hydrogenated block copolymer; A polymeric compatibilizer having an average of greater than or equal to 10 pendant epoxy groups per molecule; a conductive filler comprising carbon nanotubes; wherein the molded article is an electrostatically coatable automotive component; and Wherein, the molded article exhibits: Specific volume resistivity less than 0.5 kOhm·cm; A Vicat softening temperature greater than 165°C measured according to ISO 306; Greater than or equal to 8 kJ / m measured according to ISO 180 / 1A 2 , preferably 8kJ / m 2 Up to 12kJ / m 2 Notched Izod impact strength of Less than 12 cm according to ISO 1133 3 / 10 minutes melt volume flow rate; and Less than or equal to 0.3 weight percent moisture absorption based on the weight of the molded article.

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