Composition, method of producing the same, and article containing the composition

Abstract

The composition contains a specific amount of polyphenylene ether, polystyrene, a block copolymer of alkenyl aromatics and conjugated dienes, and a flame retardant. The composition is foamed with a blowing agent and then filled to 0.5 g / cm³. 3 It has a density of less than [amount missing]. Methods for preparing the composition are also described.

Description

[Technical Field]

[0001] The present invention relates to a composition, a method for producing the same, and an article containing the composition.

[0002] (Cross-reference of related applications) This application claims priority to European Patent Application No. 23170656.5, filed on 28 April 2023, the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0003] Polyphenylene ether resins are known as high-performance engineering thermoplastics that are useful in many applications where high temperature resistance is desired due to their high melt viscosity and softening point, and it is well known that the properties of polyphenylene ether resins can be significantly altered by blending them with other resin materials.

[0004] Foamed articles are of interest for a variety of applications. For example, lightweight, high-strength, and flame-retardant materials are particularly desirable for use in the electric vehicle industry. Existing foamed compositions based on polyolefins, polystyrene, or other thermoplastics, for instance, cannot achieve the desired levels of flame retardancy and heat resistance, thus limiting their usefulness in certain applications. [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] It is desirable to provide foamed compositions exhibiting a specific combination of properties. Providing low-density, flame-retardant foamed articles is considered particularly advantageous. [Means for solving the problem]

[0006] The composition comprises 20% to 70% by weight of polyphenylene ether, 20% to 60% by weight of homopolystyrene in combination with optionally high-impact polystyrene, 0.1% to 15% by weight of block copolymers of alkenyl aromatics and conjugated dienes, and 1% to 25% by weight of a flame retardant, where the weight percentage of each component is based on the total weight of the composition, and the composition after foaming with a foaming agent has a weight of 0.5 g / cm³. 3 Less than 0.05 g / cm³ 3 ~0.4g / cm 3 It has a density of .

[0007] A method for producing a composition includes melt-mixing 20% ​​to 70% by weight of polyphenylene ether, 20% to 60% by weight of polystyrene in optionally combination with impact-resistant polystyrene, 0.1% to 15% by weight of block copolymers of alkenyl aromatic and conjugated dienes, and 1% to 25% by weight of a flame retardant in an extruder to obtain a first mixture (where the weight percentage of each component is based on the total weight of the first mixture), introducing a blowing agent into the extruder, mixing the blowing agent and the mixture in the extruder to obtain a second mixture, optionally cooling the second mixture in a second extruder, and foaming the second mixture through a die to obtain a composition.

[0008] Articles containing the composition constitute another aspect of this disclosure.

[0009] The above features and other features are illustrated by the following detailed explanation. [Modes for carrying out the invention]

[0010] Polyphenylene ether is a foamable thermoplastic material. Conventional methods for producing polyphenylene ether foam involve foaming polyphenylene ether beads. Materials produced by such methods generally exhibit low strength, low production efficiency, and high cost. While extrusion foaming processes can improve production efficiency in manufacturing foamed materials, specific composition and process parameters must be selected to obtain the desired foamed material. Therefore, in this art, there is a constant need for improved methods for producing lightweight, heat-resistant, and flame-retardant polyphenylene ether foam. Obtaining foamed polyphenylene ether compositions using extrusion foaming processes is considered to offer further advantages.

[0011] The inventors have advantageously found specific compositions and processes that can be used to obtain improved foamed compositions of polyphenylene ethers that address the above technical limitations. In particular, the composition (i.e., the foamable composition) comprises a specific amount of polyphenylene ether, polystyrene, a block copolymer of alkenyl aromatic and conjugated dienes, and a flame retardant. This composition is produced using an extrusion foaming process. Thus, the present disclosure brings about a significant improvement.

[0012] Therefore, the composition corresponds to one aspect of the present disclosure. The foamed composition comprises a polyphenylene ether. The polyphenylene ether has a structure [ka] (In the formula, Z 1 In each case, independently, halogen, unsubstituted or substituted C 1~12 Hydrocarbyl (however, the hydrocarbyl group is not a tertiary hydrocarbyl), C 1~12 Hydrocarbilthio, C 1~12 Hydrocarbyl oxy, or C 2~12 It is a halohydrocarbyloxy (where at least two carbon atoms separate the halogen atom and the oxygen atom), Z2 In each case, independently, is hydrogen, halogen, unsubstituted or substituted C 1~12 hydrocarbyl (provided that the hydrocarbyl group is not a tertiary hydrocarbyl), C 1~12 hydrocarbylthio, C 1~12 hydrocarbyloxy, or C 2~12 halohydrocarbyloxy (where at least two carbon atoms separate the halogen atom and the oxygen atom), and includes phenylene ether units having such. The polyphenylene ether may typically have aminoalkyl-containing end groups located ortho to the hydroxy group. As an example, Z 1 can be a di-n-butylaminomethyl group formed by the reaction of a terminal 3,5-dimethyl-1,4-phenyl group with the di-n-butylamine component of an oxidative polymerization catalyst. Also, tetramethyldiphenoquinone (TMDQ) end groups are also frequently present, which are typically obtained from a 2,6-dimethylphenol-containing reaction mixture in which a tetramethyldiphenoquinone byproduct is present. The polyphenylene ether can be in the form of a homopolymer, random copolymer, graft copolymer, or block copolymer, and combinations thereof. In one aspect, the polyphenylene ether is a homopolymer, preferably poly(2,6-dimethyl-1,4-phenylene ether).

[0013] In one aspect, the polyphenylene ether has an intrinsic viscosity of 0.1 deciliter / gram to 1 deciliter / gram, measured by an Ubbelohde viscometer at 25 °C in chloroform. Within this range, the intrinsic viscosity of the polyphenylene ether can be 0.1 deciliter / gram to 0.8 deciliter / gram, or 0.2 deciliter / gram to 0.6 deciliter / gram, or 0.3 deciliter / gram to 0.5 deciliter / gram, or 0.4 deciliter / gram to 0.5 deciliter / gram.

[0014] In a specific embodiment, the polyphenylene ether is poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.1 deciliters / gram to 1 deciliter / gram, as measured by an Ubbelohde viscometer in chloroform at 25°C. Within this range, the polyphenylene ether may have an intrinsic viscosity of 0.1 deciliters / gram to 0.8 deciliters / gram, or 0.2 deciliters / gram to 0.6 deciliters / gram, or 0.3 deciliters / gram to 0.5 deciliters / gram, or 0.4 deciliters / gram to 0.5 deciliters / gram.

[0015] Polyphenylene ether is present in the composition in an amount of 20% to 70% by weight, based on the total weight of the composition. Within this range, polyphenylene ether may be present in an amount of 25% to 65% by weight, or 30% to 60% by weight, or 30% to 50% by weight, or 35% to 45% by weight.

[0016] In addition to polyphenylene ether, the composition further comprises polystyrene. The polystyrene comprises repeating units derived from styrene. The polystyrene may be linear polystyrene or may have a branched structure. The polystyrene may be atactic, syndiotactic, or isotactic. In one embodiment, the polystyrene is atactic.

[0017] The styrene content of polystyrene may be at least 90 weight percent, at least 95 weight percent, or at least 98 weight percent, based on the total weight of the polystyrene. In one embodiment, the styrene content may be 100 percent (i.e., the polystyrene may be homopolystyrene). If the polystyrene contains less than 100 weight percent of repeating units derived from styrene, the polystyrene may be a random copolymer, block copolymer, or graft copolymer of styrene and at least one other copolymerizable monomer, such as another alkenyl aromatic monomer (e.g., alpha-methylstyrene, para-methylstyrene, divinylbenzene), acrylonitrile, conjugated dienes (e.g., butadiene, isoprene), or maleic anhydride.

[0018] Polystyrene may have melt volume flow rates of 1 g / 10 min to 35 g / 10 min, or 1.5 g / 10 min to 30 g / 10 min, or 1.5 g / 10 min to 20 g / 10 min, or 1.5 g / 10 min to 10 g / 10 min, or 1.5 g / 10 min to 5 g / 10 min, as measured at 200°C and under a load of 5 kg, respectively, according to ISO 1133. Polystyrene may have a weight-average molecular weight of 50,000 g / mol to 450,000 g / mol, as determined by gel permeation chromatography.

[0019] In one embodiment, polystyrene may be a polystyrene homopolymer (also called "homopolystyrene"). As used herein, the term "homopolystyrene" refers to a homopolymer of styrene and may also be called crystalline polystyrene. Thus, residues of any monomer other than styrene are excluded from homopolystyrene. Homopolystyrene may be atactic, syndiotactic, or isotactic. In one embodiment, homopolystyrene is atactic. In one embodiment, homopolystyrene may have a melt volume flow rate of 1 g / 10 min to 5 g / 10 min measured at 200 °C and a load of 5 kg according to ISO 1133. In one embodiment, homopolystyrene may optionally be used in combination with impact-resistant polystyrene. If present, impact-resistant polystyrene may be present in amounts up to 90% by weight, or up to 80% by weight, or up to 70% by weight, or up to 60% by weight, or up to 50% by weight, or up to 40% by weight, or up to 30% by weight, or up to 25% by weight, or up to 20% by weight, or up to 15% by weight, or up to 10% by weight, or up to 5% by weight, based on the total weight of homopolystyrene and impact-resistant polystyrene. In one embodiment, if present, impact-resistant polystyrene may be present in amounts less than 5% by weight, or less than 2% by weight, or less than 1% by weight. In some embodiments, the composition may not contain impact-resistant polystyrene.

[0020] Polystyrene is present in the composition in an amount of 20% to 60% by weight, based on the total weight of the composition. Within this range, polystyrene may be present in an amount of 25% to 65% by weight, or 30% to 60% by weight, or 30% to 50% by weight, or 35% to 45% by weight.

[0021] The composition further comprises a block copolymer of an alkenyl aromatic compound and a conjugated diene. Briefly, this component is called the “block copolymer”. The block copolymer may contain a poly(alkenyl aromatic) content of 10% to 90% by weight and a hydrogenated poly(conjugated diene) content of 90% to 10% by weight, based on the weight of the block copolymer. In one embodiment, the block copolymer is a low poly(alkenyl aromatic) content block copolymer, the poly(alkenyl aromatic) content being 10% to less than 40% by weight, specifically 20% to 35% by weight, more specifically 25% to 35% by weight, and even more specifically 30% to 35% by weight, based on the weight of the low poly(alkenyl aromatic) content block copolymer. In one embodiment, the block copolymer is a block copolymer with a high poly(alkenyl aromatic) content, where the poly(alkenyl aromatic) content is 40% to 90% by weight, specifically 50% to 80% by weight, and more specifically 60% to 70% by weight, based on the weight of the block copolymer with a high poly(alkenyl aromatic) content.

[0022] Block copolymers may have a weight-average molecular weight ranging from 40,000 g / mol to 400,000 g / mol. The number-average molecular weight and weight-average molecular weight can be determined by gel permeation chromatography based on comparison with a polystyrene standard. In one embodiment, the block copolymer has a weight-average molecular weight ranging from 200,000 g / mol to 400,000 g / mol, specifically 220,000 g / mol to 350,000 g / mol. In another embodiment, the block copolymer has a weight-average molecular weight ranging from 40,000 g / mol to 200,000 g / mol, specifically 40,000 g / mol to 180,000 g / mol, more specifically 40,000 g / mol to 150,000 g / mol.

[0023] Alkenyl aromatic monomers used to manufacture block copolymers have a structure [ka] (In the formula, R 1 and R 2 These are, independently, hydrogen atoms and C 1~8 Alkyl alkyl group, or C 2~8 Represents an alkenyl group, R 3 and R 7 These are, independently, hydrogen atoms and C 1~8 R represents an alkyl group, a chlorine atom, or a bromine atom. 4 , R 5 , and R 6 These are, independently, hydrogen atoms and C 1~8 Alkyl alkyl group, or C 2~8 Represents an alkenyl group, or R 4 and R 5 It combines with the central aromatic ring to form a naphthyl group, or R 5 and R 6 It may have a central aromatic ring that together forms a naphthyl group. Specific examples of alkenyl aromatic monomers include styrene, chlorostyrene such as p-chlorostyrene, methylstyrene such as alpha-methylstyrene and p-methylstyrene, and t-butylstyrene such as 3-t-butylstyrene and 4-t-butylstyrene. In one embodiment, the alkenyl aromatic monomer is styrene.

[0024] The conjugated dienes used to manufacture block copolymers are C 4~20 It may be a 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, and 1,3-hexadiene, as well as combinations thereof. In one embodiment, the conjugated diene is 1,3-butadiene, 2-methyl-1,3-butadiene, or a combination thereof. In one embodiment, the conjugated diene is 1,3-butadiene.

[0025] A 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. The block copolymer may be unhydrogenated or at least partially hydrogenated (referred to as a hydrogenated block copolymer). When the block copolymer is a hydrogenated block copolymer, the content of aliphatic unsaturated groups in block (B) is at least partially reduced by hydrogenation. In one embodiment, the aliphatic unsaturated groups in block (B) are reduced by at least 50 percent, specifically at least 70 percent. In one embodiment, the block copolymer is an unhydrogenated block copolymer, where the content of aliphatic unsaturated groups is not reduced by hydrogenation.

[0026] The arrangement of blocks (A) and (B) can be linear, grafted, or radial teleblock with or without branched chains. Linear block copolymers can be tapered or non-tapered. In one embodiment, the block copolymer has a tapered linear structure. In one embodiment, the block copolymer has a non-tapered linear structure. In one embodiment, the block copolymer includes a block (B) containing random incorporation of alkenyl aromatic monomers. Linear block copolymer structures can be diblock (AB block) structures, triblock (ABA block or BAB block) structures, tetrablock (ABAB block) structures, pentablock (ABABA block or BABAB block) structures, or linear structures containing a total of six or more blocks (A) and (B), where the molecular weight of each block (A) may be the same as or different from that of other blocks (A), and the molecular weight of each block (B) may be the same as or different from that of other blocks (B). In one embodiment, the block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0027] In one embodiment, the block copolymer is devoid of monomer residues other than alkenyl aromatic compounds and conjugated dienes. In one embodiment, the block copolymer consists of blocks derived from alkenyl aromatic compounds and conjugated dienes. This block copolymer does not contain grafts formed from these monomers or any other monomers. This block copolymer also consists of carbon atoms and hydrogen atoms, and therefore heteroatoms are devoid. In one embodiment, the block copolymer contains residues of one or more acid functionalizing agents, such as maleic anhydride. In one embodiment, the block copolymer is a hydrogenated block copolymer and includes polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer. In one embodiment, the block copolymer is a non-hydrogenated block copolymer and includes polystyrene-polybutadiene-polystyrene triblock copolymer.

[0028] Methods for producing block copolymers are known in the art, and many block copolymers are commercially available. Examples of commercially available block copolymers include polystyrene-poly(ethylene-propylene) diblock copolymers available from Kraton Performance Polymers Inc. as KRATON® G1701 (having 37 wt percent polystyrene) and G1702 (having 28 wt percent polystyrene); polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymers available from Kraton Performance Polymers Inc. as KRATON® G1641 (having 33 wt percent polystyrene), G1650 (having 30 wt percent polystyrene), G1651 (having 33 wt percent polystyrene), and G1654 (having 31 wt percent polystyrene); and polystyrene-poly(ethylene-ethylene / propylene)-polystyrene triblock copolymers available from Kuraray as SEPTON® S4044, S4055, S4077, and S4099. Additional commercially available block copolymers include polystyrene-poly(ethylene-butylene)-polystyrene (SEBS) triblock copolymers available from Dynasol as CALPRENE® H6140 (containing 31 wt percent polystyrene), H6170 (containing 33 wt percent polystyrene), H6171 (containing 33 wt percent polystyrene), and H6174 (containing 33 wt percent polystyrene), and from Kuraray as SEPTON® 8006 (containing 33 wt percent polystyrene) and 8007 (containing 30 wt percent polystyrene), and from Kraton Performance Polymers as KRATON® A1535 (containing 56.3 wt percent to 60 wt percent).Polystyrene-poly(ethylene-butylene-styrene)-polystyrene tapered block copolymer available as A1536 (having 3 wt percent polystyrene) and A1536 (having 37 wt percent to 44 wt percent polystyrene), polystyrene-poly(ethylene-propylene)-polystyrene (SEPS) copolymer available from Kuraray as SEPTON® 2006 (having 35 wt percent polystyrene) and 2007 (having 30 wt percent polystyrene), Kraton Performance Polymers Examples include oil-expanded compounds of these block copolymers, available from Kraton Inc. as KRATON® G4609 (containing 45% mineral oil and having 33% polystyrene by weight as SEBS) and G4610 (containing 31% mineral oil and having 33% polystyrene by weight as SEBS), and from Asahi Kasei Corporation as TUFTEC® H1272 (containing 36% oil and having 35% polystyrene by weight as SEBS); polystyrene-polybutadiene-polystyrene (SBS) copolymers available from Kraton Performance Polymers as KRATON® D1101 (having 29% to 33% polystyrene by weight); and polystyrene-polybutadiene (SBS) copolymers available from Kraton Performance Polymers as KRATON® D0243 (having 26% to 31% polystyrene by weight). Mixtures of two or more block copolymers can be used.

[0029] The block copolymer is present in the composition in an amount of 0.1% to 15% by weight based on the total weight of the composition. Within this range, the block copolymer may be present in an amount of 1% to 15% by weight, or 0.1% to 12% by weight, or 0.1% to 11% by weight, or 0.1% to 10% by weight, or 1% to 12% by weight, or 1% to 11% by weight, or less than 0.1% to 11% by weight, or less than 1% to 11% by weight, or 1% to 10% by weight.

[0030] The composition further contains a flame retardant. Preferably, the flame retardant is a non-halogenated compound. Therefore, in one embodiment, the composition may be essentially chlorine and bromine-free. "Essentially chlorine and bromine-free" is defined as having a bromine or chlorine content of parts per million by weight (ppm) or less, 75 ppm or less, or 50 ppm or less, based on the total weight of the composition excluding all fillers.

[0031] There are no particular restrictions on the types of flame retardants that may be used, however, the flame retardants must be properly stable at the elevated temperatures used during processing and must not contain chlorine or bromine. Examples of flame retardants include melamine (CAS No. 108-78-1), melamine cyanurate (CAS No. 37640-57-6), melamine phosphate (CAS No. 20208-95-1), melamine pyrophosphate (CAS No. 15541-60-3), melamine polyphosphate (CAS No. 218768-84-4), melam, melem, melon, zinc borate (CAS No. 1332-07-6), boron phosphate, red phosphorus (CAS No. 7723-1) Examples include 4-0), organic phosphate esters, monoammonium phosphate (CAS No. 7722-76-1), diammonium phosphate (CAS No. 7783-28-0), alkylphosphonates (CAS Nos. 78-38-6 and 78-40-0), phosphinates (e.g., metal dialkylphosphinates), ammonium polyphosphate (CAS No. 68333-79-9), low melting point glass, and combinations of two or more of the aforementioned flame retardants.

[0032] In one embodiment, the composition comprises a flame retardant including an organophosphate ester, a phosphinate (e.g., a metal dialkylphosphinate), or a combination thereof.

[0033] Examples of organic phosphate ester flame retardants include, but are not limited to, phosphate esters containing a phenyl group, a substituted phenyl group, or a combination of a phenyl group and a substituted phenyl group, such as resorcinol-based bis-aryl phosphate esters such as resorcinol bis-diphenyl phosphate, and bis-phenol-based bis-aryl phosphate esters such as bis-phenol A bis-diphenyl phosphate. In one embodiment, the organophosphate ester may include tris(alkylphenyl) phosphate (e.g., CAS number 89492-23-9 or CAS number 78-33-1), resorcinol bis-diphenyl phosphate (e.g., CAS number 57583-54-7), bis-phenol A bis-diphenyl phosphate (e.g., CAS number 181028-79-5), triphenyl phosphate (e.g., CAS number 115-86-6), tris(isopropylphenyl) phosphate (e.g., CAS number 68937-41-7), and a mixture of two or more of the aforementioned organophosphate esters.

[0034] In one embodiment, an organophosphate ester is given by the following formula: [ka] (In the formula, R, R 12 , and R 13 In each case, R is an alkyl group having 1 to 5 carbon atoms, 8 ~R 11 (where n is independently an alkyl group, aryl group, arylalkyl group, or alkylaryl group having 1 to 10 carbon atoms, n is an integer equal to 1 to 25, and s1 and s2 are independently integers equal to 0 to 2) comprises a bis-aryl phosphate. In one embodiment, OR 8 , OR9 , OR 10 , and OR 11 These are independently derived from phenols, monoalkylphenols, dialkylphenols, or trialkylphenols.

[0035] As will be readily apparent to those skilled in the art, bis-aryl phosphates are derived from bisphenols. Exemplary bisphenols include 2,2-bis(4-hydroxyphenyl)propane (so-called bisphenol A), 2,2-bis(4-hydroxy-3-methylphenyl)propane, bis(4-hydroxyphenyl)methane, bis(4-hydroxy-3,5-dimethylphenyl)methane, and 1,1-bis(4-hydroxyphenyl)ethane. In one embodiment, bisphenol includes bisphenol A.

[0036] In one embodiment, the flame retardant contains a phosphinate. The phosphinate is given by the following formula [ka] (In the formula, R 14 and R 15 Independently, C 1~6 It is alkyl, phenyl, or aryl, and R 16 Independently, C 1~10 Alkilen, C 6~10 Alliren, C 6~10 Alkyl arylene, or C 6~10 It is an arylalkylene, where M is calcium, magnesium, aluminum, zinc, or a combination of one or more of the above, d is 2 or 3, f is 1 or 3, x is 1 or 2, and each R 17 and R 18 These are, independently, hydrogen groups or formula -CR 19 =CHR 20 It is a vinyl group, R 19 and R 20 These are independently hydrogen, carboxyl, carboxylic acid derivatives, and C 1~10 Alkyl, phenyl, benzyl, or C 1~8It may contain one or more phosphinate salts of alkyl-substituted aromatics (where K is independently hydrogen or 1 / r atoms of a metal with a valence of r, and u is the average number of monomer units, which may have a value of 1 to 20).

[0037] R 14 and R 15 Examples of these include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, n-pentyl, and phenyl. 16 Examples, though not limited to, include methylene, ethylene, n-propylene, isopropylene, n-butylene, tert-butylene, n-pentylene, n-octylene, n-dodecylene, phenylene, naphthylene, methylphenylene, ethylphenylene, tert-butylphenylene, methylnaphthylene, ethylnaphthylene, tert-butylnaphthylene, phenylethylene, phenylpropylene, and phenylbutylene.

[0038] Monophosphinates and diphosphinates can be produced by reacting the corresponding phosphinic acid with a metal oxide and / or metal hydroxide in an aqueous medium, as taught in European Patent No. 0699708.

[0039] High molecular weight phosphinates are hypophosphorous acid and / or its alkali metal salts, and formula [ka] It can be produced by reacting acetylene with [another substance].

[0040] Next, the obtained polymer phosphinic acid or polymer phosphinate is reacted with a metal compound of Group IA, Group IIA, Group IIIA, Group IVA, Group VA, Group IIB, Group IVB, Group VIIB, or Group VIIIB of the periodic table, as taught in U.S. Patent Application Publication No. 2003 / 0216533.

[0041] Several routes, R14 and R 15 is ethyl, and M is aluminum.

[0042] In one embodiment, the phosphinate is in granular form. The phosphinate particles may have a median particle size (D50) of 40 micrometers or less, or more specifically, a D50 of 30 micrometers or less, or even more specifically, a D50 of 25 micrometers or less. Furthermore, the phosphinate may be combined with a polymer to form a masterbatch. The phosphinate masterbatch contains a larger amount of phosphinate than is present in the thermoplastic composition. Using a masterbatch to add phosphinate to other components of the composition facilitates the addition of phosphinate and can improve the distribution of phosphinate.

[0043] In specific embodiments, the flame retardant comprises a metal dialkylphosphinate. As used herein, the term "metal dialkylphosphinate" refers to a salt comprising at least one metal cation and at least one dialkylphosphinate anion. In one embodiment, the metal dialkylphosphinate is of the formula: [ka] (In the formula, R 14 and R 15 Each of them is independent of C 1~6 It is alkyl, M is calcium, magnesium, aluminum, or zinc, and d is 2 or 3. 14 and R 15 Examples include methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, n-pentyl, and phenyl. In one embodiment, R 14 and R 15 is ethyl, M is aluminum, and d is 3 (i.e., the metal dialkylphosphinate is aluminum tris(diethylphosphinate)).

[0044] In one embodiment, the metal dialkylphosphinate is in granular form. The metal dialkylphosphinate particles may have a median particle size (D50) of 40 micrometers or less, or more specifically, a D50 of 30 micrometers or less, or even more specifically, a D50 of 25 micrometers or less. Furthermore, the metal dialkylphosphinate may be combined with polymers such as poly(arylene ether), polyolefin, polyamide, block copolymer, or a combination thereof to form a masterbatch. The metal dialkylphosphinate masterbatch contains a larger amount of metal dialkylphosphinate than is present in the thermoplastic composition. Using a masterbatch to add metal dialkylphosphinate to other components of a thermoplastic composition facilitates the addition of metal dialkylphosphinate and can improve the distribution of metal dialkylphosphinate.

[0045] The flame retardant is present in the composition in an amount of 1% to 25% by weight, based on the total weight of the composition. Within this range, the flame retardant may be present in an amount of 1% to 20% by weight, or 1% to 16% by weight, or 5% to 20% by weight, or 5% to 16% by weight.

[0046] In specific embodiments, flame retardants include combinations of phosphinates (e.g., metal dialkylphosphinates) and organophosphate esters. For example, a composition may contain 1% to 8% by weight of a phosphinate and 5% to 15% by weight of an organophosphate ester, where the weight percentages are based on the total weight of the composition.

[0047] In specific embodiments, the composition may comprise 35 to 45 weight percent of polyphenylene ether, 35 to 45 weight percent of polystyrene, 1 to 10 weight percent of block copolymers of alkenyl aromatics and conjugated dienes, and 5 to 16 weight percent of flame retardant. The polyphenylene ether may be poly(2,6-dimethyl-1,4-phenylene ether), where preferably the phenylene ether has an intrinsic viscosity of 0.1 deciliters / gram to 1 deciliter / gram, or 0.1 deciliters / gram to 0.8 deciliters / gram, as determined by an Ubbelohde viscometer at 25°C in chloroform. The polystyrene may be homopolystyrene. The block copolymer may be a non-hydrogenated block copolymer and may contain repeating units derived from styrene and butadiene. The flame retardant may comprise organophosphates, phosphinates, or combinations thereof.

[0048] The composition may optionally further contain a phase solvent, a chain extender, or a combination thereof.

[0049] As used herein, the terms “compatibilizer” or “compatibilizing agent” refer to a polyfunctional compound that interacts with other components of the composition, such as polyphenylene ether, polystyrene, or both. This interaction may be chemical (e.g., grafting) and / or physical (e.g., influence on the surface properties of the dispersed phase). In either case, the resulting composition exhibits improved compatibility, particularly as evidenced by improvements in impact strength, mold knit line strength, and / or tensile elongation.

[0050] Examples of compatibilizers that can be used include liquid diene polymers, epoxy compounds, oxidized polyolefin waxes, quinones, organosilane compounds, polyfunctional compounds, functionalized poly(arylene ethers), and combinations thereof. Compatibilizers are further described in Gallucci's U.S. Patent No. 5,132,365, and in Koevoets et al.'s U.S. Patents No. 6,593,411 and No. 7,226,963.

[0051] In one embodiment, the compatibilizer includes a polyfunctional compound. There are typically three types of polyfunctional compounds that can be used as compatibilizers. The first type of polyfunctional compound has both (a) a carbon-carbon double bond or a carbon-carbon triple bond in its molecule and (b) at least one carboxylic acid group, an anhydride group, an amide group, an ester group, an imide group, an amino group, an epoxy group, an orthoester group, or a hydroxyl group. Examples of such polyfunctional compounds include maleic acid, maleic anhydride, fumaric acid, glycidyl acrylate, itaconic acid, aconitic acid, maleimide, maleic acid hydrazide, diamines and reaction products from maleic anhydride, maleic acid, fumaric acid, etc., dichloromaleic anhydride, maleic acid amide, unsaturated dicarboxylic acids (e.g., acrylic acid, butenoic acid, methacrylic acid, ethyl acrylic acid, pentenoic acid, 10-hydroxy-2-decenoic acid, un10-hydroxy-2-decenoic acid, do10-hydroxy-2-decenoic acid, linoleic acid, etc.), esters, acid amides, or anhydrides of the aforementioned unsaturated carboxylic acids, unsaturated alcohols (e.g., alkanols, clotyl alcohol, methyl vinylcarbinol, 4-penten-1-ol, 1,4-hexadiene-3-ol, 3-buten-1,4-diol, 2,5-dimethyl-3-hexen-2,5-diol, and formula C n H 2n -5OH, C n H 2n -7OH, and C n H 2nExamples include -9OH alcohols (where n is a positive integer less than or equal to 30), unsaturated amines obtained by replacing the -OH group of the above unsaturated alcohol with an -NH2 group, functionalized diene polymers and copolymers, and combinations containing one or more of the above. In one embodiment, the compatibilizer includes maleic anhydride, fumaric acid, or a combination thereof.

[0052] The second type of polyfunctional compatibilizer has both (a) a group represented by formula (OR) (where R is hydrogen, or an alkyl group, aryl group, acyl group, or carbonyldioxy group) and (b) at least two groups, which may be the same or different, selected from carboxylic acids, acid halides, anhydrides, acid halide anhydrides, esters, orthoesters, amides, imides, aminos, and various salts thereof. A typical compatibilizer of this group is formula: (R I O) m R'(COOR II ) n (CONR III R IV ) s (wherein R' is a linear or branched saturated aliphatic hydrocarbon having 2 to 20 carbon atoms, or more specifically 2 to 10 carbon atoms, R I R is a hydrogen atom, or an alkyl group, aryl group, acyl group, or carbonyldioxy group having 1 to 10, or more specifically 1 to 6, or even more specifically 1 to 4 carbon atoms, and each R II Each R is independently a hydrogen atom, or an alkyl or aryl group having 1 to 20, or more specifically, 1 to 10, carbon atoms, and each R III and R IV is independently a hydrogen atom, or an alkyl or aryl group having 1 to 10, or more specifically 1 to 6, or even more specifically 1 to 4 carbon atoms, where m is equal to 1, (n+s) is 2 or more, or more specifically 2 or 3, and n and s are each 0 or more, (OR IAliphatic polycarboxylic acids, acid esters, and acid amides represented by (where the substituent is alpha or beta relative to the carbonyl group, and at least two carbonyl groups are separated by 2 to 6 carbon atoms). Clearly, when each substituent has fewer than 6 carbon atoms, R I , R II , R III , and R IV That cannot be Ariel.

[0053] Suitable polycarboxylic acids include, for example, citric acid, malic acid, and agaric acid (including their various commercial forms such as anhydrides and hydrated acids), as well as combinations containing one or more of the above. In one embodiment, the compatibilizer includes citric acid. Examples of esters useful herein include, for example, acetyl citrate esters, monostearyl citrate esters, and / or distearyl citrate esters. Suitable amides useful herein include, for example, N,N'-diethyl citrate amide, N-phenyl citrate amide, N-dodecyl enoic acid amide, N,N'-didodecyl enoic acid amide, and N-dodecyl malic acid. Derivatives include salts with amines, as well as alkali salts and alkali metal salts thereof. Examples of suitable salts include calcium malate, calcium citrate, potassium malate, and potassium citrate.

[0054] A third type of polyfunctional compatibilizer has both (a) an acid halide group and (b) at least one carboxylic acid group, an anhydride group, an ester group, an epoxy group, an orthoester group, or an amide group, preferably a carboxylic acid group or an anhydride group, within its molecule. Examples of compatibilizers in this group include trimellitic acid anhydride salts, chloroformyl succinic anhydride, chloroformyl succinic acid, chloroformyl glutaric acid anhydride, chloroformyl glutaric acid, chloroacetyl succinic anhydride, chloroacetyl succinic acid, trimellitic acid salts, and chloroacetyl glutaric acid. In one embodiment, the compatibilizer includes trimellitic acid anhydride salts.

[0055] In a specific embodiment, the compatibilizer may include maleic acid, maleic anhydride, citric acid, fumaric acid, or a combination thereof. In one embodiment, the compatibilizer may include citric acid. Exemplary compatibilizers can include citric acid, fumaric acid, maleic anhydride, or a combination thereof.

[0056] The compatibilizer may be present in the composition in an amount of 0.2 weight percent to 1 weight percent based on the total weight of the composition. Within this range, the compatibilizer may be present in an amount of 0.4 weight percent to 0.9 weight percent.

[0057] Exemplary chain extenders can include epoxy compounds. Epoxy compounds useful as additives can include epoxy-modified acrylate oligomers or polymers (e.g., substituted or unsubstituted styrenes such as styrene or 4-methylstyrene, methyl acrylate, methyl methacrylate, ethyl acrylate, or butyl acrylate, etc., such as C 1~22Examples include styrene-acrylate-epoxy polymers produced from combinations of alkyl alcohol acrylic acid esters or methacrylic acid esters and epoxy-functionalized acrylates such as glycidyl acrylate, glycidyl methacrylate, 2-(3,4-epoxycyclohexyl)ethyl acrylate, or 2-(3,4-epoxycyclohexyl)ethyl methacrylate, or epoxy carboxylate oligomers based on cyclic aliphatic epoxides (for example, 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexylcarboxylate). Epoxy-modified polyolefins are also useful as chain extenders in this composition and can be produced, for example, from a combination of an olefin such as ethylene and an epoxy-functionalized acrylate such as glycidyl acrylate, glycidyl methacrylate, 2-(3,4-epoxycyclohexyl)ethyl acrylate, or 2-(3,4-epoxycyclohexyl)ethyl methacrylate, or an epoxy carboxylate oligomer based on a cyclic aliphatic epoxide (for example, such as 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexylcarboxylate). In a specific embodiment, the epoxy-modified polyolefin can be produced from ethylene and glycidyl methacrylate.

[0058] In one embodiment, the epoxy chain extender may include styrene groups and acrylic acid groups, for example, epoxy described in U.S. Patent Publication No. 2013 / 0131255 and U.S. Patent No. 6,984,694, or epoxy available under the trade name JONCRYL (e.g., JONCRYL ADR 4368 (styrene-acrylate copolymer with epoxy functional groups)). Other epoxy hydrostabilizers include Joncryl ADR 4300 (epoxidized soybean oil).

[0059] Typical epoxy chain extenders may have molecular weights of 2,500 g / mol to 8,500 g / mol, or 3,000 g / mol to 6,000 g / mol. Epoxy chain extenders may have epoxy equivalent weights (EEW) of 180 g / mol to 2,800 g / mol, 190 g / mol to 1,400 g / mol, or 200 g / mol to 700 g / mol.

[0060] The chain extenders may be present in the composition in amounts of 0.1% to 5% by weight, 0.5% to 3% by weight, 0.5% to 2% by weight, or 1% to 2% by weight, based on the total weight of the composition.

[0061] The composition may optionally further contain one or more additives, provided that the additives do not significantly adversely affect the desired properties of the foamed composition. The additive composition or individual additives may be mixed at appropriate times when mixing the components to form the composition. The additive composition may include flow modifiers, fillers (e.g., granular polytetrafluoroethylene (PTFE), glass, carbon, minerals, or metals), antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV) light stabilizers, UV absorbing additives, plasticizers, lubricants, nucleating agents, release agents (such as mold release agents), antistatic agents, antifogging agents, antimicrobial agents, colorants (e.g., dyes or pigments), surface effect additives, radiation stabilizers, drip inhibitors (e.g., PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), initiators, curing agents, crosslinking agents, or combinations thereof. Additives are used in amounts that are generally known to be effective. For example, the total amount of additive compositions (other than any impact modifiers, fillers, or reinforcing agents) may be 0.001% to 10% by weight, or 0.1% to 10% by weight, or 0.01% to 5% by weight, based on the total weight of polymers in the composition. In one embodiment, additives not specifically disclosed herein may be excluded from the composition.

[0062] In one embodiment, the composition may include an acid scavenger, a metal deactivator, a stabilizer, a mold release agent, a drip inhibitor, or a combination thereof.

[0063] Acid scavengers generally include alkali metal and alkaline earth metal carboxylates, carbonates, and bicarbonates. Carboxylates have the general formula M(COOR 1 ) n The formula has, where "M" is an alkali metal or alkaline earth metal, and R 1 is a monovalent C 1~6 It is an alkyl group, and "n" is 1 or 2. Examples of alkali metal and alkaline earth metal carboxylates include, but are not limited to, lithium acetate, sodium acetate, potassium acetate, lithium benzoate, sodium benzoate, potassium benzoate, lithium propionate, sodium propionate, calcium acetate, calcium propionate, and calcium benzoate. Examples of alkali metal and alkaline earth metal carbonates and bicarbonates include, but are not limited to, lithium carbonate, sodium carbonate, potassium carbonate, lithium bicarbonate, sodium bicarbonate, and potassium bicarbonate. Any combination of acid scavengers can also be used.

[0064] Examples of heat stabilizers used as additives include organic phosphites (e.g., triphenyl phosphite, tris-(2,6-dimethylphenyl) phosphite, or tris-(a mixture of mono-nonylphenyl and di-nonylphenyl) phosphite), phosphonates (e.g., dimethylbenzene phosphonate), phosphates (e.g., trimethyl phosphate), or combinations thereof. The heat stabilizer may be tris(2,4-di-t-butylphenyl) phosphate, available as IRGAPHOS 168. The heat stabilizer is generally used in amounts of 0.01% to 5% by weight based on the total weight of the polymer in the composition.

[0065] Examples of light stabilizers, particularly ultraviolet (UV) light absorbing additives (also called UV stabilizers), include hydroxybenzophenone (e.g., 2-hydroxy-4-n-octoxybenzophenone), hydroxybenzotriazine, cyanoacrylate, oxanilide, benzoxazinon (e.g., 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) commercially available from Cytec under the trade name CYASORB UV-3638), aryl salicylate, hydroxybenzotriazole (e.g., 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, and 2-(2H-benzotriazole-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol commercially available from Cytec under the trade name CYASORB 5411), or combinations thereof. The UV stabilizer may be present in an amount of 0.01% to 1% by weight, preferably 0.1% to 0.5% by weight, and more preferably 0.15% to 0.4% by weight, based on the total weight of the polymers in the composition.

[0066] There is considerable overlap among plasticizers, lubricants, and mold release agents, and these include, for example, phthalates (e.g., octyl-4,5-epoxyhexahydrophthalate), tris-(octoxycarbonylethyl)isocyanurate, bifunctional or polyfunctional aromatic phosphates (e.g., resorcinol tetraphenyl diphosphate (RDP), bis(diphenyl)phosphate of hydroquinone, and bis(diphenyl)phosphate of bisphenol A), poly-alpha-olefins, epoxidized soybean oil, silicones including silicone oil (e.g., poly(dimethyldiphenylsiloxane)), fatty acid esters (e.g., methyl stearate and stearyl stearate, etc.). 1~32These include alkyl stearyl esters, as well as esters of stearic acid such as pentaerythritol tetrastearate and glycerol tristearate (GTS), waxes (e.g., beeswax, montan wax, or paraffin wax), or combinations thereof. These are generally used in amounts ranging from 0.01% to 5% by weight based on the total weight of the polymer in the composition.

[0067] In the composition, a drip inhibitor, such as a fibril-forming or non-fibril-forming fluoropolymer, such as polytetrafluoroethylene (PTFE), may also be used. The drip inhibitor can be encapsulated by a rigid copolymer, such as styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is known as TSAN. TSAN contains 50% by weight of PTFE and 50% by weight of SAN based on the total weight of the encapsulated fluoropolymer. SAN may contain, for example, 75% by weight of styrene and 25% by weight of acrylonitrile based on the total weight of the copolymer. The drip inhibitor may be used in an amount of 0.1% to 10% by weight based on the total weight of the composition.

[0068] By adjusting the relative amounts of each component, it is possible to provide the desired combination of properties derived from this disclosure. As will be understood by those skilled in the art, the amounts of each component can be selected within the enumerated range such that they total 100 weight percent.

[0069] Optionally, components not specifically described herein may be excluded from or minimized in the composition. In one embodiment, thermoplastic polymers other than polyphenylene ethers, polystyrene, block copolymers, and any polymer chain extenders may be excluded from or minimized in the composition (e.g., including less than 5% by weight, less than 1% by weight, or less than 0.1% by weight). In one embodiment, rubber-modified polystyrene or impact-resistant polystyrene may be excluded from or minimized in the composition. In one embodiment, coupling agents (e.g., silane coupling agents, titanate coupling agents, aluminate coupling agents, or combinations thereof), dispersants (e.g., polyolefin-based ultradispersants, polyether-based ultradispersants, polyacrylate-based ultradispersants, or combinations thereof), and deodorants (e.g., hydrotalcite or silica), or combinations thereof, may be excluded from or minimized in the composition.

[0070] A foamed composition in the form of an extruded foam sheet. For example, the extruded foam sheet may be a continuous sheet. The foam sheet may have a width of, for example, 50 mm to 500 mm, for example, 100 mm to 300 mm, or 150 mm to 250 mm, and a thickness of 1 mm to 25 mm, for example, 2 mm to 15 mm, or 5 mm to 10 mm.

[0071] The foamed composition may have an open-cell content of 50% or less, for example, 0% to 50%, or 0% to 40%, or 0% to 30%, or 0% to 20%, or 0% to 10%, or 1% to 50%, or 1% to 40%, or 1% to 30%, or 1% to 20%, or 1% to 10%, or 5% to 50%, or 5% to 40%, or 5% to 30%, or 5% to 20%. In other words, the foamed composition may be a closed-cell foam having a closed-cell content of more than 50%, for example, more than 50% to 100%, or 55% to 100%, or 60% to 100%, or 70% to 100%, or 75% to 100%, or 80% to 100%, or 90% to 100%.

[0072] The extruded foam sheet is lightweight and low density. For example, the extruded foam sheet is less than 0.5 g / cm 3 , or 0.05 g / cm 3 ~0.4 g / cm 3 , or 0.05 g / cm 3 ~0.3 g / cm 3 , or 0.05 g / cm 3 ~0.25 g / cm 3 , or 0.1 g / cm 3 ~0.4 g / cm 3 , or 0.1 g / cm 3 ~0.3 g / cm 3 , or 0.1 g / cm 3 ~0.25 g / cm 3 , or 0.15 g / cm 3 ~0.4 g / cm 3 , or 0.15 g / cm 3 ~0.3 g / cm 3 , or 0.15 g / cm 3 ~0.25 g / cm 3 and may have a density of.

[0073] The compositions according to the present disclosure may exhibit a desirable combination of properties. For example, the composition may have a density of 0.05 g / cm 3 ~0.4 g / cm 3 , or 0.05 g / cm 3 ~0.25 g / cm 3 . The composition may exhibit a UL94 rating of V0 or V1 at a thickness of 5 millimeters. The composition may exhibit a compressive strength of 1 MPa to 5 MPa, or 1 MPa to 4 MPa, or 1 MPa to 3 MPa, or 1 MPa to 2 MPa, determined according to ISO 844. In one aspect, the composition may exhibit a combination of the aforementioned density, UL94 rating, and compressive strength. In one aspect, the composition may include two of the aforementioned properties. In one aspect, the composition may include each of the aforementioned properties.

[0074] The compositions of the present disclosure may advantageously be made by an extrusion foaming process. Thus, the method of making the composition corresponds to another aspect of the present disclosure.

[0075] This method comprises melting and mixing polyphenylene ether, polystyrene, a block copolymer, and a flame retardant in an extruder to obtain a first mixture. This method further comprises introducing a blowing agent into the extruder (i.e., bringing it into contact with the first mixture).

[0076] The term "blowing agent" is defined as a chemical substance used to foam a polymer. A blowing agent (also referred to herein as a foaming agent) may be a solid, a liquid, and / or a supercritical liquid. Suitable blowing agents that can be used include inorganic substances, organic substances, and other chemical substances. Exemplary inorganic blowing agents include carbon dioxide, nitrogen, argon, water, air, nitrogen, and inert gases (such as helium and argon), as well as combinations containing at least one of the aforementioned. Exemplary organic substances include aliphatic hydrocarbons having 1 to 9 carbon atoms, aliphatic alcohols having 1 to 3 carbon atoms, and fully halogenated and partially halogenated aliphatic hydrocarbons having 1 to 4 carbon atoms. Examples of aliphatic hydrocarbons include methane, ethane, propane, n-butane, isobutane, n-pentane, isopentane, and neopentane. Examples of aliphatic alcohols include methanol, ethanol, n-propanol, and isopropanol. Examples of fully halogenated and partially halogenated aliphatic hydrocarbons include fluorocarbons, chlorocarbons, and chlorofluorocarbons. Examples of fluorocarbons include methyl fluoride, perfluoromethane, ethyl fluoride, 1,1-difluoroethane (HFC-152a), 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoroethane (HFC-134a), pentafluoroethane, difluoromethane, perfluoroethane, 2,2-difluoropropane, 1,1,1-trifluoropropane, perfluoropropane, dichloropropane, difluoropropane, perfluorobutane, and perfluorocyclobutane.Examples of partially halogenated chlorocarbons and chlorofluorocarbons include methyl chloride, methylene chloride, ethyl chloride, 1,1,1-trichloroethane, 1,1-dichloro-1-fluoroethane (HCFC-141b), 1-chloro-1,1-difluoroethane (HCFC-142b), chlorodifluoromethane (HCFC-22), 1,1-dichloro-2,2,2-trifluoroethane (HCFC-123), and 1-chloro-1,2,2,2-tetrafluoroethane (HCFC-124). Examples of fully halogenated chlorofluorocarbons include trichloromonofluoromethane (CFC-11), dichlorodifluoromethane (CFC-12), trichlorotrifluoroethane (CFC-113), 1,1,1-trifluoroethane, pentafluoroethane, dichlorotetrafluoroethane (CFC-114), chloroheptafluoropropane, and dichlorohexafluoropropane. Other chemically active substances include azodicarbonamide, azodiisobutyronitrile, benzenesulfon hydrazide, 4,4-oxybenzenesulfonyl semicarbazide, p-toluenesulfonyl semicarbazide, barium azodicarboxylate, N,N'-dimethyl-N,N'-dinitrosotelephthalamide, and trihydrazinotriazine. In one embodiment, the blowing agent may be a combination of carbon dioxide, air, nitrogen, argon, gaseous hydrocarbons, and at least one of the aforementioned.

[0077] In one embodiment, the blowing agent contains carbon dioxide. The blowing agent may be solid carbon dioxide, liquid carbon dioxide, gaseous carbon dioxide, or supercritical carbon dioxide. Any inert gas can also be used, such as helium, xenon, and argon. Non-limiting examples of gaseous hydrocarbons include methane, ethane, propane, and butane.

[0078] Optionally, an auxiliary blowing agent may be used in combination with the blowing agent. Exemplary auxiliary blowing agents include, for example, fluorine-containing foaming agents (e.g., fluorinated hydrocarbons). In one embodiment, the auxiliary blowing agent may include conventional halogenated hydrocarbons, such as fluorocarbon blowing agents. Preferred hydrocarbon auxiliary blowing agents include fluorocarbon blowing agents, such as trichlorofluoromethane (CCl3F), dichlorodifluoromethane (CCl2F2), and dichlorotetrafluoroethane (CClF2CClF2). These are commercially available as FREEN 11, FREEN 12, and FREEN 114. Other halogenated hydrocarbon blowing agents include HCFCs such as methylene chloride, chloroform, carbon tetrachloride (CCl4), difluorochloromethane (CHClF2), (HCFC-22), (FORCMACEL S), dichlorotrifluoroethane (CHCl2CF3), (HCFC-123), dichlorotrifluoroethane (CHFClCClF2), (HCFC-123A), chlorotetrafluoroethane (CHClFCF3), (HCFC-124), tetrafluoroethane (CH2FCF3), (HFC-134A), dichlorofluoroethane (CCl2FCH3), (HCFC-141B), chlorodifluoroethane (CH3CClF2), (HCFC-142B), and difluoroethane (CH3CHF2), (HFC-152A).

[0079] If an auxiliary blowing agent is present, it may be included in a weight ratio of blowing agent to auxiliary blowing agent of 1:0.1 to 1:0.5, or 1:0.1 to 1:0.3, or 1:0.2 to 1:0.3.

[0080] The blowing agent is introduced into the extruded in an amount effective to obtain a total blowing agent (including any auxiliary blowing agents) of less than 0.8 weight percent, where the weight percentage of the blowing agent is based on the total weight of the polyphenylene ether, polystyrene, block copolymer, and flame retardant. For example, the blowing agent may be introduced in an amount effective to obtain a total blowing agent of 0.2 weight percent to 0.76 weight percent based on the total weight of the polyphenylene ether, polystyrene, block copolymer, and flame retardant.

[0081] A foaming agent is mixed with the first mixture in an extruder to obtain a second mixture. The method further includes cooling the second mixture. In one embodiment, the cooling of the second mixture can be carried out in a second extruder downstream of the first extruder. The second mixture is foamed through a die at the outlet of the extruder (or the second extruder, if present) to obtain a foamed composition.

[0082] In one embodiment, the outlet temperature of the extruder (or a second extruder, if present) is less than 170°C, or 160°C or less, or 130°C to 160°C. The inventors have found that such outlet temperatures can give the foamed polyphenylene ether composition according to the present disclosure a desirable combination of properties.

[0083] The compositions described herein may be useful in a variety of articles. Therefore, articles containing foamed compositions constitute another aspect of this disclosure. Examples of articles include extruded foam sheets, foam insulation boards, building materials, components for electric vehicle batteries, components for electrical boxes, automotive components, or insulating materials for wires or cables. [Examples]

[0084] The present disclosure is further illustrated by the following embodiments, but these do not limit the scope of the disclosure.

[0085] The materials used in the following examples are listed in Table 1.

[0086] [Table 1]

[0087] The foamed sample was prepared according to the procedure described below.

[0088] <Example 1> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0089] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0090] Supercritical CO2 and LBA, used as foaming agents, were injected into the first extruder in a 4:1 ratio at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 143°C and the pressure between the two extruders reached 22 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0091] <Example 2> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0092] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0093] Supercritical CO2, a foaming agent, was injected into the extruder at a supply rate of 0.16 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 160°C and the pressure between the two extruders reached 30 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0094] <Example 3> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0095] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0096] Supercritical CO2, a foaming agent, was injected into the extruder at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 152°C and the pressure between the two extruders reached 25 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0097] <Example 4> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0098] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0099] Supercritical CO2, a foaming agent, was injected into the extruder at a supply rate of 0.12 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 145°C and the pressure between the two extruders reached 23 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0100] <Comparative Example 1> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0101] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0102] Supercritical CO2 and LBA, used as foaming agents, were injected into the first extruder in a 4:1 ratio at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 143°C and the pressure between the two extruders reached 22 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0103] <Comparative Example 2> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0104] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0105] Supercritical CO2 and LBA, used as foaming agents, were injected into the first extruder in a 4:1 ratio at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 160°C and the pressure between the two extruders reached 25 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0106] <Comparative Example 3> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0107] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0108] Supercritical CO2, a foaming agent, was injected into the extruder at a supply rate of 0.2 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 142°C and the pressure between the two extruders reached 21 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0109] <Comparative Example 4> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0110] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0111] Supercritical CO2 and LBA, used as foaming agents, were injected into the first extruder in a 4:1 ratio at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 162°C and the pressure between the two extruders reached 28 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0112] <Comparative Example 5> The first twin-screw extruder had barrel temperatures set to 220°C, 230°C, 240°C, 260°C, 265°C, 260°C, 255°C, 255°C, 250°C, and 245°C from the supply port to the melt pump, respectively. The melt pump temperature was set to 250°C. The second extruder had temperatures set to 250°C, 245°C, 240°C, 240°C, 235°C, 235°C, and 230°C from the supply port to the extrusion die, respectively.

[0113] The components were supplied to the supply port of the first extruder, the material was mixed in a twin-screw extruder, and then extruded from the die via a melt pump and a single-screw extruder.

[0114] Supercritical CO2, a foaming agent, was injected into the extruder at a supply rate of 0.15 kg / hour using a syringe pump. The melt pump and the second extruder were gradually cooled until the final temperature of the single-screw extruder dropped to 142°C and the pressure between the two extruders reached 23 MPa. Foamed PPO sheets were produced from the die. The foamed sheets were cut into test specimens for density testing, flame retardancy testing, and compression testing.

[0115] Table 2 summarizes the composition and processing parameters for each example. The amount of each component is given as a weight percentage (W%) based on the total weight of the composition, except that the foaming agent content is given as a weight percentage based on the total weight of polyphenylene ether, polystyrene, block copolymer, flame retardant, and any additives (i.e., epoxy, phase solvent, acid scavenger, metal deactivator, stabilizer, mold release agent, drip inhibitor, etc.).

[0116] Table 2 also shows the results of performance tests for each example. Compression tests were performed on 50 × 50 × 15 mm plaques according to ISO 844, and the results were reported in megapascals (MPa). Density was measured according to ISO 1183 in g / cm³. 3 Report in units of [unit]. The combustion test was performed on a 125 × 13 × 5 mm test bar in accordance with the UL 94 test standard.

[0117] [Table 2]

[0118] As shown in Table 2, specific compositions according to this disclosure allowed for the acquisition of polyphenylene ether foam as desired by extrusion. The foam material had a low density (e.g., 0.25 g / cm³). 3 It exhibited compressive strengths in the range of 1.35 MPa to 1.45 MPa (less than ), and further achieved flame retardancy grades of V0 or V1 in accordance with UL 94. In contrast, the comparative composition could not be foamed. Rather, a higher density material (e.g., 0.79 g / cm³) was required. 3 ~1.01 g / cm³ 3 A range of ( ) was obtained. Comparative Examples 1, 2, and 5 each contained only impact-resistant polystyrene (i.e., rubber-modified polystyrene) and no homopolystyrene. The composition of Comparative Example 3 used a higher foaming agent content. Comparative Example 4 contained an undesirably large amount of phosphinate-based flame retardant. Thus, the comparative examples and the examples of this disclosure demonstrate that specific compositions and processing conditions are required to obtain a desired low-density foamed composition having a particular combination of good compressive strength and flame retardancy. Therefore, this disclosure brings about a significant improvement.

[0119] This disclosure further includes, but is not limited to, the following aspects:

[0120] Embodiment 1: A composition comprising 20% ​​to 70% by weight of polyphenylene ether, 20% to 60% by weight of homopolystyrene in combination with optionally impact-resistant polystyrene, 0.1% to 15% by weight of block copolymers of alkenyl aromatics and conjugated dienes, and 1% to 25% by weight of a flame retardant, wherein the weight percentage of each component is based on the total weight of the composition, and the composition is foamed with a blowing agent and then weighed 0.5 g / cm³. 3 Less than 0.05 g / cm³ 3 ~0.4g / cm 3 A composition having a density of [value].

[0121] Embodiment 2: A first mixture is obtained by melt-mixing polyphenylene ether, homopolystyrene or a combination of homopolystyrene and impact-resistant polystyrene, a block copolymer, and a flame retardant in an extruder; a blowing agent is introduced into the extruder; the blowing agent and the mixture are mixed in the extruder to obtain a second mixture; the second mixture is optionally cooled in a second extruder; and the second mixture is foamed through a die to 0.5 g / cm³. 3 Less than 0.05 g / cm³ 3 ~0.4g / cm 3 The composition according to embodiment 1, which is made by a method comprising obtaining a composition having a density of .

[0122] Embodiment 3: The composition according to Embodiment 2, wherein the foaming agent is a physical foaming agent, preferably containing carbon dioxide in an optional combination with an auxiliary foaming agent, wherein the auxiliary foaming agent preferably contains a fluorine-containing foaming agent.

[0123] Embodiment 4: The composition according to any one of Embodiments 1 to 3, wherein the polyphenylene ether is poly(2,6-dimethyl-1,4-phenylene ether), where preferably the phenylene ether has an intrinsic viscosity of 0.1 deciliters / gram to 1 deciliter / gram, or 0.1 deciliters / gram to 0.8 deciliters / gram, as determined by an Ubbelohde viscometer at 25°C in chloroform.

[0124] Embodiment 5: The composition according to any one of Embodiments 1 to 4, wherein the block copolymer is a non-hydrogenated block copolymer, preferably comprising a styrene-butadiene-styrene triblock copolymer.

[0125] Embodiment 6: The composition according to any one of Embodiments 1 to 5, wherein the flame retardant comprises an organic phosphate, a phosphinate, or a combination thereof, wherein preferably the flame retardant comprises 1% to 8% by weight of a phosphinate and 5% to 15% by weight of an organic phosphate ester, each based on the total weight of the composition.

[0126] Embodiment 7: A composition according to any one of Embodiments 1 to 6, further comprising a phase solvent, a chain extender, or a combination thereof, wherein the phase solvent preferably comprises citric acid, fumaric acid, maleic anhydride, or a combination thereof, and the chain extender preferably comprises an epoxy compound.

[0127] Embodiment 8: A composition according to any one of Embodiments 1 to 7, comprising 35 to 45 weight percent of polyphenylene ether, 35 to 45 weight percent of homopolystyrene in combination with optionally impact-resistant polystyrene, 1 to 10 weight percent of block copolymers of alkenyl aromatic and conjugated dienes, and 5 to 16 weight percent of a flame retardant.

[0128] Apparatus 9: The composition is foamed with a foaming agent, and then 0.05 g / cm³ 3 ~0.4g / cm 3 , or 0.05 g / cm³ 3 ~0.25g / cm 3 , or 0.1 g / cm³ 3 ~0.24 g / cm³ 3 A composition according to any one of embodiments 1 to 8, having one or more of the following: density, UL94 grade V0 or V1 at a thickness of 5 mm, or compressive strength of 1 MPa to 5 MPa as determined in accordance with ISO 844.

[0129] Embodiment 10: The composition according to any one of Embodiments 1 to 9, further comprising an additive composition, wherein preferably the additive composition comprises an acid scavenger, a metal deactivator, a stabilizer, a mold release agent, a drip inhibitor, a nucleating agent, or a combination thereof.

[0130] Embodiment 11: A method for producing a composition, comprising: melt-mixing 20% ​​to 70% by weight of polyphenylene ether, 20% to 60% by weight of homopolystyrene in a combination of optionally impact-resistant polystyrene (polystryene), 0.1% to 15% by weight of block copolymer of alkenyl aromatic and conjugated dienes, and 1% to 25% by weight of a flame retardant in an extruder to obtain a first mixture (where the weight percentage of each component is based on the total weight of the first mixture); introducing a blowing agent into the extruder; mixing the blowing agent and the mixture in the extruder to obtain a second mixture; optionally cooling the second mixture in a second extruder; and foaming the second mixture through a die to 0.5 g / cm³. 3 Less than 0.05 g / cm³ 3 ~0.4g / cm 3 A method comprising obtaining a composition having a density of .

[0131] Embodiment 12: The method according to Embodiment 11, wherein the foaming agent is a physical foaming agent, preferably containing carbon dioxide, and preferably containing carbon dioxide in optional combination with an auxiliary foaming agent, wherein the auxiliary foaming agent preferably contains a fluorine-containing foaming agent.

[0132] Embodiment 13: The method according to Embodiment 11 or 12, wherein the temperature at the end of the second extruder is less than 170°C, preferably 160°C or less, or 130°C to 160°C.

[0133] Embodiment 14: The method according to any one of Embodiments 11 to 13, wherein a blowing agent is introduced in an amount effective to obtain a total amount of blowing agent of less than 0.8 weight percent, or 0.2 weight percent to 0.76 weight percent, where the weight percentage of the blowing agent is based on the total weight of polyphenylene ether, polystyrene, block copolymer, and flame retardant.

[0134] Embodiment 15: An article comprising the composition described in any of Embodiments 1 to 10, preferably an extruded foam sheet.

[0135] Compositions, methods, and articles may, by substitution, consist of, or essentially consist of any suitable materials, processes, or components disclosed herein. Compositions, methods, and articles may, additionally or by substitution, be formulated to lack, or substantially not contain, any materials (or chemical species), processes, or components that are not particularly necessary for achieving the function or purpose of the composition, method, or article.

[0136] All scopes disclosed herein include endpoints, which can be combined independently of each other. “Combinations” include blends, mixtures, alloys, and reaction products, etc. Terms such as “first” and “second” do not indicate any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a,” “an,” and “the” do not indicate a limit on quantity and should be interpreted as encompassing both singular and plural forms unless otherwise indicated herein or unless the context clearly contradicts this. “Or” means “and / or” unless otherwise specified. Throughout this specification, references to “one aspect” mean that a particular element described in relation to that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. As used herein, the term “their combinations” is an open term that includes one or more of the enumerated elements and allows for the presence of one or more similar elements not specifically named. Furthermore, it should be understood that the elements described can be combined in various ways and in any appropriate manner.

[0137] Unless otherwise specified herein, all test standards are the most current standards in effect as of the filing date of this application, or, if priority is claimed, the most current standards in effect as of the filing date of the earliest priority application for which the test standards were published.

[0138] Unless otherwise specified, technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art in which this application pertains. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if any terminology in this application conflicts with or is inconsistent with any terminology in any reference, the terminology from this application shall prevail over any conflicting terminology from the reference.

[0139] The compound is described using standard nomenclature. For example, any position not substituted by any of the indicated groups is understood to have its valence filled by the indicated bond or hydrogen atom. A dash ("-") without a space between two letters or symbols is used to indicate the attachment point for a substituent. For example, -CHO is attached via the carbonyl group's carbon.

[0140] As used herein, the term "hydrocarbyl," whether used alone or as a prefix, suffix, or subword of another term, refers to a residue containing only carbon and hydrogen. This residue may be aliphatic or aromatic, linear, cyclic, bicyclic, branched, saturated, or unsaturated. It may also contain a combination of aliphatic, aromatic, linear, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, where a hydrocarbyl residue is described as substituted, the hydrocarbyl residue may optionally contain heteroatoms in addition to the carbon and hydrogen components of the substituent residue. Therefore, where specifically described as substituted, the hydrocarbyl residue may contain one or more carbonyl, amino, or hydroxyl groups, or it may contain heteroatoms within the hydrocarbyl residue's backbone. The term "alkyl" refers to branched or linear saturated aliphatic hydrocarbon groups, such as methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n-hexyl and s-hexyl. "Alkenyl" refers to a linear or branched monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). "Alkoxy" refers to an alkyl group linked via oxygen (i.e., alkyl-O-), such as a methoxy group, an ethoxy group, and a sec-butyloxy group. "Alkylene" refers to a linear or branched saturated divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). "Cycloalkylene" refers to a divalent cyclic alkylene group, i.e., -C n H 2n-x(wherein x is the number of hydrogens replaced by cyclization) "Cycloalkenyl" means a monovalent group having one or more rings and having one or more carbon-carbon double bonds within the rings, where all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing a specific number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. "Arylene" means a divalent aryl group. "Alkylarylene" means an arylene group substituted with an alkyl group. "Arylalkylene" means an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" means a group or compound containing one or more fluoro substituents, chloro substituents, bromo substituents, or iodo substituents. There may be combinations of different halo atoms (e.g., bromine and fluorine), or only chlorine atoms. The prefix "hetero" means that the compound or group contains at least one ring member that is a heteroatom (e.g., one, two, or three heteroatoms), where each heteroatom is independently N, O, S, Si, or P. "Substitution" means that the compound or group independently replaces hydrogen with C, provided that the valence does not exceed that of the principal atom of the atom being substituted. 1~9 Alkoxy, C 1~9 Haloalkoxy, nitro(-NO2), cyano(-CN), C 1~6 Alkylsulfonyl (-S(=O)2-alkyl), C 6~12 Arylsulfonyl (-S(=O)2-aryl), thiol (-SH), thiocyano (-SCN), tosyl (CH3C6H4SO2-), C 3~12 Cycloalkyl, C 2~12 Alkenil, C 5~12 Cycloalkenyl, C 6~12 Ariel, C 7~13 Arylalkylene, C 4~12 Heterocycloalkyl, and C 3~12This means that it can be a heteroaryl group and is substituted with at least one substituent (e.g., one, two, three, or four). The number of carbon atoms shown in the group is the number of carbon atoms excluding any substituents. For example, -CH2CH2CN is a nitrile-substituted C2 alkyl group.

[0141] While specific embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents may arise that are not foreseeable or currently unforeseeable to the applicant or others skilled in the art. Therefore, the attached claims are intended to encompass all such alternatives, modifications, variations, improvements, and substantial equivalents, both at the time of filing and where they may be amended.

Claims

1. 20% to 70% by weight of polyphenylene ether, Homopolystyrene in combination with impact-resistant polystyrene in an optional amount of 20% to 60% by weight, 0.1% to 15% by weight of block copolymers of alkenyl aromatics and conjugated dienes, Flame retardant in an amount of 1% to 25% by weight, A composition comprising, The weight percentage of each component is based on the total weight of the composition. The aforementioned composition was foamed with a foaming agent, and then at 0.5 g / cm³. ３ Less than 0.05 g / cm³ ３ ~0.4 g / cm ３ Having a density of, composition.

2. The aforementioned composition, The polyphenylene ether, the homopolystyrene or a combination of the homopolystyrene and the impact-resistant polystyrene, the block copolymer, and the flame retardant are melt-mixed in an extruder to obtain a first mixture. Introducing a foaming agent into the extruder, The foaming agent and the mixture are mixed in the extruder to obtain a second mixture. The second mixture is optionally cooled in a second extruder, The second mixture is foamed through a die to obtain 0.5 g / cm³. ３ Less than 0.05 g / cm³ ３ ~0.4 g / cm ３ To obtain a composition having a density, The composition according to claim 1, produced by a method comprising the following:

3. The composition according to claim 2, wherein the foaming agent is a physical foaming agent, which preferably contains carbon dioxide in an optional combination with an auxiliary foaming agent, wherein the auxiliary foaming agent preferably contains a fluorine-containing foaming agent.

4. The composition according to any one of claims 1 to 3, wherein the polyphenylene ether is poly(2,6-dimethyl-1,4-phenylene ether), where preferably the phenylene ether has an intrinsic viscosity of 0.1 deciliters / gram to 1 deciliter / gram, or 0.1 deciliters / gram to 0.8 deciliters / gram, as determined by an Ubbelohde viscometer at 25°C in chloroform.

5. The composition according to any one of claims 1 to 4, wherein the block copolymer is a non-hydrogenated block copolymer, which preferably comprises a styrene-butadiene-styrene triblock copolymer.

6. The flame retardant comprises an organophosphate, a phosphinate, or a combination thereof, wherein preferably, the flame retardant is present in amounts relative to the total weight of the composition. 1% to 8% by weight of phosphinate, 5% to 15% by weight of organic phosphate esters, A composition according to any one of claims 1 to 5, comprising:

7. Further comprising a phase solvent, a chain extender, or a combination thereof, wherein Preferably, the phase solvent includes citric acid, fumaric acid, maleic anhydride, or a combination thereof. Preferably, the chain extender comprises an epoxy compound. The composition according to any one of claims 1 to 6.

8. 35% to 45% by weight of the polyphenylene ether, Homopolystyrene in a combination of 35% to 45% by weight, optionally with the impact-resistant polystyrene, A block copolymer of the alkenyl aromatic and conjugated diene in an amount of 1% to 10% by weight, The flame retardant in an amount of 5% to 16% by weight, A composition according to any one of claims 1 to 7, comprising:

9. The above composition is foamed with a foaming agent, 0.05 g / cm ３ ~0.4 g / cm ３ 、 or 0.05 g / cm ３ ~0.25 g / cm ３ 、 or 0.1 g / cm ３ ~0.24 g / cm ３ of density, UL94 grade V0 or V1 with a thickness of 5 mm, Compressive strength of 1 MPa to 5 MPa determined in accordance with ISO 844, A composition according to any one of claims 1 to 8, having one or more of the following:

10. The composition according to any one of claims 1 to 9, further comprising an additive composition, wherein preferably the additive composition comprises an acid scavenger, a metal deactivator, a stabilizer, a mold release agent, a drip inhibitor, a nucleating agent, or a combination thereof.

11. A method for making a composition, Inside the extruder, 20% to 70% by weight of polyphenylene ether, Homopolystyrene in combination with 20% to 60% by weight of optionally impact-resistant polystyrene (polystryene), 0.1% to 15% by weight of block copolymers of alkenyl aromatics and conjugated dienes, Flame retardant in an amount of 1% to 25% by weight, The first mixture is obtained by melting and mixing the following (where the weight percentage of each component is based on the total weight of the first mixture): Introducing a foaming agent into the extruder, The foaming agent and the mixture are mixed in the extruder to obtain a second mixture, The second mixture is optionally cooled in a second extruder, The second mixture is foamed through a die to obtain 0.5 g / cm³. ３ Less than 0.05 g / cm³ ３ ~0.4 g / cm ３ To obtain a composition having a density, Methods that include...

12. The method according to claim 11, wherein the foaming agent is a physical foaming agent, which preferably contains carbon dioxide, and preferably contains carbon dioxide in an optional combination with an auxiliary foaming agent, wherein the auxiliary foaming agent preferably contains a fluorine-containing foaming agent.

13. The method according to claim 11 or 12, wherein the temperature at the end of the second extruder is less than 170°C, preferably 160°C or less, or 130°C to 160°C.

14. The method according to any one of claims 11 to 13, wherein the blowing agent is introduced in an amount effective to obtain a total amount of blowing agent of less than 0.8 weight percent, or 0.2 weight percent to 0.76 weight percent, wherein the weight percentage of the blowing agent is based on the total weight of the polyphenylene ether, the polystyrene, the block copolymer, and the flame retardant.

15. An article comprising a foamed composition according to any one of claims 1 to 10, preferably an extruded foam sheet.

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