Compatibilized polyamide-poly(arylene ether) composition and uses thereof

Abstract

A compatibilized polyamide-poly(arylene ether) composition is the product of melt-blending particular amounts of a virgin polyamide, a second polyamide, a poly(arylene ether), an impact modifier, and a compatibilizing agent. The second polyamide includes an upcycled polyamide or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, and has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide. The compositions can provide a desirable combination of properties. Methods for the manufacture of the compositions and articles comprising the compositions are also described.

Description

COMPATIBILIZED POLY AMIDE-POLY( ARYLENE ETHER) COMPOSITION AND USES THEREOFBACKGROUND

[0001] This disclosure relates to poly(arylene ether) / polyamide compositions, in particular compatibilized polyamide -poly(arylene ether) compositions including a particular upcycled or recycled polyamide, their methods of manufacture, and articles containing the compositions.

[0002] Poly(arylene ether)s have been blended with polyamides to provide compositions having a wide variety of beneficial properties such as heat resistance, chemical resistance, impact strength, hydrolytic stability, and dimensional stability. There is increasing interest in providing sustainable compositions having low carbon foot print for example by reusing or recycling polymer materials. Compositions complying with regulations such as Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH), Restriction of Hazardous Substances (RoHS), Substances of Very High Concern (SVHCs), and the like are also of interest. Providing compositions with significant portions of recycled components can lead to challenges with obtaining a desired combination of properties, for example, a balance of mechanical, rheological, thermal properties together with uniform morphology similar to that virgin plastics.

[0003] Accordingly, there remains a continuing need in the art for sustainable thermoplastic compositions including recycled polymer components. It would be especially advantageous to provide a sustainable composition having a combination of good mechanical, rheological, thermal, and morphological properties.SUMMARY

[0004] An aspect is a compatibilized polyamide-poly(arylene ether) composition, wherein the composition is the product of melt-blending: 5 to 35 weight percent of a virgin polyamide; 5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a , preferably a post-industrial mechanically recycled polyamide, polyamide; 25 to 80 weight percent of a poly(arylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25 °C by Ubbelohde viscometer; 2 to 15 weight percent of an impact modifier; and 0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end groupconcentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is less than an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

[0005] Another aspect is a method of making a compatibilized poly amide-poly (arylene ether) thermoplastic resin composition, the method comprising: melt-blending 5 to 35 weight percent of a virgin polyamide; 5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide; 25 to 80 weight percent of a poly( arylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25°C by Ubbelohde viscometer; 2 to 15 weight percent of an impact modifier; and 0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is less than an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

[0006] Another aspect is an article comprising the compatibilized polyamide-poly(arylene ether) thermoplastic resin composition.

[0007] The above described and other features are exemplified by the following detailed description.DETAILED DESCRIPTION

[0008] The present inventor has discovered that the above-described technical limitations can be addressed by a composition including particular amounts of a virgin polyamide, a second polyamide comprising an upcycled polyamide or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, a poly(arylene ether), an impact modifier, and a compatibilizing agent. The upcycled polyamide can be derived from post-consumer recycled polyamide, post-industrial recycled polyamide, preferably a postindustrial mechanically recycled polyamide, or a combination thereof. Compositions according to the present disclosure exhibit a desirable balance of mechanical, rheological, and thermalproperties, with morphologies similar to those observed for the same composition including only virgin components. A significant improvement is therefore provided by the present disclosure.

[0009] Accordingly, an aspect of the present disclosure is a compatibilized polyamide- poly(arylene ether) composition. The composition is the product of melt-blending a poly(arylene ether), a virgin polyamide, a second polyamide, an impact modifier, and a compatibilizing agent.

[0010] The composition includes a poly(arylene ether), wherein the poly( arylene ether) can be a poly(phenylene ether), a poly(phenylene ether-siloxane), or a combination thereof. The poly(phenylene ether) is a homopolymer or copolymer comprising phenylene ether units having the structurewherein each occurrence of Z1is independently halogen, unsubstituted or substituted C1-12 hydrocarbyl, provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-12 hydrocarbylthio, C1-12 hydrocarbyloxy, or C2-12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z2is independently hydrogen, halogen, unsubstituted or substituted C1-12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-12 hydrocarbylthio, C1-12 hydrocarbyloxy, or C2-12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms. The poly(phenylene ether) can have aminoalkyl-containing end group(s), typically located in a position ortho to the hydroxy group. As one example, Z1can be a di-n-butylaminomethyl group formed by reaction of a terminal 3,5-dimethyl-l,4-phenyl group with the di-n-butylamine component of an oxidative polymerization catalyst. Also frequently present are tetramethyldiphenoquinone (TMDQ) end groups, typically obtained from 2,6-dimethylphenol- containing reaction mixtures in which a tetramethyldiphenoquinone byproduct is present. The poly(phenylene ether) can be in the form of a homopolymer, a random copolymer, a graft copolymer, or a block copolymer, as well as a combination thereof. In an aspect, the poly(phenylene ether) is a homopolymer, preferably poly(2,6-dimethyl-l,4-phenylene ether).

[0011] In an aspect, the poly(phenylene ether) can be a poly(phenylene ether-siloxane) block copolymer that includes blocks containing phenylene ether units as described above and blocks containing siloxane units having the structurewherein each occurrence of R1is independently C1-12 hydrocarbyl or C1-12 hydrocarbyloxy. In an aspect, each occurrence of R1is methyl. Methods for the preparation of poly(phenylene ether)-polysiloxanes include those described in International Patent Application Publication No. WO 2010 / 008683 A2 of F. Toublan et al. In an aspect, the poly(phenylene ether-siloxane) block copolymer can be formed by oxidative copolymerization of a monohydric phenol that comprises 2,6-dimethylphenol and a hydroxyaryl-terminated polysiloxane having the structurewherein n is, on average, 5 to 100, specifically 30 to 60.

[0012] The oxidative copolymerization method produces poly(phenylene ether)-polysiloxane block copolymer as the desired product and poly(phenylene ether) (without an incorporated polysiloxane block) as a byproduct. It is not necessary to separate the poly(phenylene ether) from the poly(phenylene ether) -poly siloxane block copolymer. The poly(phenylene ether) -poly siloxane block copolymer can thus be utilized as a “reaction product” that includes both the poly(phenylene ether) and the poly(phenylene ether)-polysiloxane block copolymer. Certain isolation procedures, such as precipitation from isopropanol, make it possible to assure that the reaction product is essentially free of residual hydroxyaryl-terminated polysiloxane starting material. In other words, these isolation procedures assure that the polysiloxane content of the reaction product is essentially all in the form of 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 et al.

[0013] The poly(arylene ether) (i.e., the poly(phenylene ether) or the poly(phenylene ether-siloxane)) has an intrinsic viscosity of 0.2 to 0.6 deciliter per gram measured by Ubbelohde viscometer at 25°C in chloroform. Within this range, the poly(arylene ether) intrinsic viscosity can be 0.3 to 0.5 deciliter per gram, specifically 0.35 to 0.55 deciliter per gram.

[0014] In an aspect, the poly(arylene ether) is a poly(phenylene ether) that includes 2,6-dimethyl-l,4-phenylene ether units, 2,3,6-trimethyl-l,4-phenylene ether units, or a combination thereof. In a specific aspect, the poly(phenylene ether) is a poly(2,6-dimethyl-l,4- phenylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliter per gram, measured by Ubbelohde viscometer at 25°C in chloroform. Within the range of 0.2 to 0.6 deciliter per gram, the poly(2,6-dimethyl-l,4-phenylene ether) intrinsic viscosity can be 0.3 to 0.5 deciliter per gram, more preferably 0.35 to 0.45 deciliter per gram.

[0015] In some aspects, the poly(arylene ethers), for example, poly(phenylene ether), which optionally may be in the form of a copolymer of two or more monomers, for example a terpolymer, and the raw materials used to produce the poly(arylene ethers) may be, or may be formed from, renewable, sustainable, bio-circular, circular, lower carbon footprint feedstocks, upcycled, and / or post-consumer / post-industrial recycled materials, including pyrolysis oil (“py- oil”).

[0016] Poly(arylene ethers) made from renewable sources may include, for example, a bio-content or PCR content of up to 99.9%, or 1 to 99%, or 5 to 95%, or 55 to 99%, or 80 to 99%, or 1 to 50%, or 1 to 25%, or 1 to 15%, or 1 to 10%, or 1 to 5%, based, e.g., on the monomer source. The poly( arylene ether) can be, e.g., an oligomer with as few as two repeating units to ultra-high molecular weight poly (arylene ethers). The weight average molecular weight of the poly( arylene ethers) in one non-limiting aspect may range from 600 to 200,000 grams per mole, as determined by gel permeation chromatography. In another non-limiting aspect, the poly(arylene ethers) may have an intrinsic viscosity of up to 1.5 deciliters per gram (dl / g) as measured at 25 °C in chloroform. Poly (arylene ethers) made from renewable sources may include material made by a mass balance approach and certified by regulatory bodies such as, for example, the ISCC Plus.

[0017] In an aspect, poly( arylene ethers) can be prepared by oxidative polymerization of monomers in the presence of a polymerization catalyst in the presence of oxygen. Any of the components used in the polymerization reaction or their synthetic precursors, or the solvents used in the process, may be bio-sourced, bio-circular, or renewable raw materials. Such components and precursors include monomers (e.g., monohydric phenol, dihydric phenol and other comonomers), reagents, solvents, catalysts (e.g., a metal source, a secondary alkylene diamine ligand, a tertiary monoamine, and optionally a secondary monoamine or alternatively enzyme catalysts), gases (e.g., oxygen gas), or any combinations thereof. In some aspects, reaction components used in the polymerization of poly(arylene ethers) may be from sources as listed in the EU Renewable Energy Directive Annex IX.

[0018] Poly(arylene ethers) can be further processed, such as by redistribution, or any chemical derivatization, such as post-polymerization end-group capping or coupling, to make other materials that can transfer the sustainability characteristic to the new material. Such reagents and / or their synthetic precursors may be sustainable, bio-sourced, bio-circular, or renewable raw materials, upcycled, and / or post-consumer / post-industrial recycled materials, including pyrolysis oil (“py-oil”), to produce a poly(arylene ether).

[0019] Biosourced and sustainable materials may be derived from biomass sources or industrial sources such as waste (e.g., municipal waste). Biomass is a renewable organic material that comes from organic matter. Lignocellulosic biomass, the most abundant type of biomass and includes a wide variety of different biomass types including grasses, wood, energy crops, and agricultural and municipal wastes, is mostly composed of cellulose, hemicellulose, and lignin. Depolymerization of lignin, which is a phenolic polymer, can provide phenol. Solvents used in the production of monomers, such as methanol and acetone can be obtained from syngas, which is a product of the gasification of biomass.

[0020] The composition according to the present disclosure includes the poly(arylene ether) in an amount of 25 to 80 weight percent, based on the total weight of the composition. Within this range, the poly(arylene ether) amount can be 30 to 75 weight percent, or 35 to 50 weight percent, or 37 to 49 weight percent, each based on the total weight of the composition.

[0021] In addition to poly (arylene ether), the composition further includes a virgin polyamide. As used herein, the term “virgin polyamide” refers to a polyamide that is not postconsumer or post-industrial polyamide. A virgin polyamide may also be referred to as a new polyamide. Polyamides, also known as nylons, are polymers containing amide (i.e., -C(=O)NH-) linking groups, for example as described in U.S. Patent No. 4,970,272 to Gallucci. Suitable polyamides include polyamide-6, polyamide-6,6, polyamide-4,6, polyamide-11, polyamide-12, polyamide-6,10, polyamide-6, 12, polyamide 6 / 6,6, polyamide-6 / 6,12, polyamide MXD,6 (where MXD is m-xylylene diamine), polyamide-6, T, polyamide-6, 1, polyamide-6 / 6,T, polyamide-6 / 6,I, polyamide-6, 6 / 6, T, polyamide-6, 6 / 6, 1, polyamide-6 / 6,T / 6,I, polyamide-6, 6 / 6, T / 6, 1, polyamide- 6 / 12 / 6, T, polyamide-6, 6 / 12 / 6, T, polyamide-6 / 12 / 6,I, polyamide-6, 6 / 12 / 6, 1, or a combination thereof. In an aspect, polyamides that can be used as the virgin polyamide include polyamide-6, polyamide-6,6, or a combination thereof. Polyamide-6 and polyamide-6,6 are commercially available from a number of sources and methods for their preparation are known. For example, polyamides can be obtained by a number of well-known processes such as those described in U.S. Patent Nos. 2,071,250, 2,071,251, 2,130,523, and 2,130,948 to Carothers; 2,241,322 and 2,312,966 to Hanford; and 2,512,606 to Bolton et al.

[0022] Virgin polyamides having an intrinsic viscosity of up to 400 milliliters per gram (mL / g) can be used, or, more specifically, having a viscosity of 90 to 350 mL / g, or, even more specifically, having a viscosity of 110 to 240 mL / g, as measured in a 0.5 weight percent solution in 96 weight percent sulfuric acid in accordance with ISO 307. The virgin polyamide can have a relative viscosity of up to 6, or a relative viscosity of 1.89 to 5.43, or a relative viscosity of 2.16 to 3.93. Relative viscosity is determined according to ISO 307 in a 1 weight percent solution in 96 weight percent sulfuric acid.

[0023] In an aspect, the virgin polyamide can have a particular amine end-group concentration. For example, the virgin polyamide can have an amine end-group concentration of greater than 40 milliequivalents per kilogram (meq / kg), or greater than or equal to 45 meq / kg. In an aspect, the virgin polyamide can have an amine end-group concentration of 75 meq / kg or greater, or 95 meq / kg or greater, or 100 meq / kg or greater, for example 100 to 125 meq / kg. In a specific aspect, the virgin polyamide can comprise polyamide-6 having an amine end group concentration of 100 to 125 meq / kg. In an aspect, the virgin polyamide can have an amine end- group concentration of 45 to less than 75 meq / kg, or 45 to 65 meq / kg, or 45 to 60 meq / kg, for example 45 to 59 meq / kg. In a specific aspect, the virgin polyamide can comprise polyamide-66 having an amine end group concentration of 45 to 59 meq / kg.

[0024] Amine end group content can be determined by dissolving the polyamide in a suitable solvent and titrating with 0.01 normal hydrochloric acid (HC1) solution using a suitable indication method. The amount of amine end groups is calculated based the volume of HC1 solution added to the sample, the volume of HC1 used for the blank, the molarity of the HC1 solution, and the weight of the polyamide sample.

[0025] The virgin polyamide is present in the composition in an amount of 5 to 35 weight percent, based on the total weight of the composition. Within this range, the virgin polyamide can be present in an amount of 5 to 30 weight percent, or 8 to 27 weight percent, or 9 to 26 weight percent, or 10 to 25 weight percent, each based on the total weight of the composition.

[0026] In addition to the poly(arylene ether) and the virgin polyamide composition, the composition further comprises a recycled polyamide. Recycled polyamides differ from virgin polyamides both in terms of their average amino end groups and trace (or larger amounts) of contaminants that are retained from the recycled material.

[0027] The recycled polyamide can be an upcycled or mechanically recycled polyamide. As used herein the term “upcycled polyamide” refers to a polyamide that is prepared from a reclaimed polyamide (e.g., post-consumer recycled or post-industrial recycled) by chemicalmeans. For example, an upcycled polyamide can be a post-consumer or post-industrial polyamide that has been chemically depolymerized to provide, for example, a caprolactam monomer, and repolymerized to provide the upcycled polyamide. The term “mechanically recycled” polyamide refers to a post-consumer or post-industrial polyamide that has been by processed by mechanical, rather than chemical means, i.e., by a manufacturing process (including e.g., purification, sorting, and pretreating) and made into a product or into a component for incorporation into a product. Such mechanically recycled post-consumer polyamides can be further processed, for example, into the form of powders, fibers, ground materials, flakes, pellets, sheets, or other form.

[0028] As used herein, the term “post-consumer recycle” (PCR) when used in connection with the polyamide, refers to a polyamide collected from the end consumer of a material stream, and the term “post-industrial,” when used in connection with the polyamide, refers to a polyamide collected from the end of an industrial material stream. Thus, postconsumer recycle polyamide is a polyamide that has reached the intended user or consumer and after end-of-life has been collected or reclaimed after use by the end-user or consumer. For example, the term refers to a polyamide in whole or in part that would have otherwise been disposed of as waste but has instead been collected and recovered (reclaimed) as a material input, in lieu of a virgin material, for a recycling or manufacturing process. A post-consumer recycled polyamide (PCR-PA) can be upcycled as described above or mechanically recycled.

[0029] As used herein, the term “post-industrial recycle polyamide” (PIR-PA) refers to a recycled polyamide that has never reached the end user and that is production waste arising during polymerization reactions, during further processing, or during manufacturing the polymer or an article from the polymer, and includes materials such as sprues from injection molding, start-up material from injection molding or extrusion, extrusion scrap, molding scrap, edge trims from extruded sheets or films, fibers and the like, including materials diverted from the waste stream during a manufacturing process for an article. A PIR-PA can be upcycled as described above or mechanically recycled. In some aspects, the PIR-PA is an upcycled PIR-PA, in particular an upcycled PIR polyamide-6. Alternatively, the PIR-PA can be a mechanically recycled PIR polyamide, in particular a mechanically recycled PIR polyamide-6.

[0030] As described herein and in the examples, the second polyamide can be an upcycled polyamide (which can be an PCR-PA or a PIR-PA), a mechanically recycled PIR-PA, or a combination thereof. Thus, the term “upcycled polyamide” refers to a polyamide that is prepared from a chemically recycled polyamide (e.g., post-consumer recycle or post-industrial recycle), e.g., a post-consumer or post-industrial polyamide that has been depolymerized toprovide, for example, a monomer such as a caprolactam monomer, and repolymerized to provide the upcycled polyamide.

[0031] The upcycled polyamide can comprise an upcycled polyamide-6, polyamide-6,6, polyamide-4, polyamide-4,6, polyamide-12, polyamide-6, 10, polyamide 6,9, polyamide-6, 12, polyamide 9T, polyamide 6 / 6T and polyamide 6,6 / 6T. In an aspect, the upcycled polyamide can comprise polyamide-6, polyamide-6,6, or a combination thereof. In an aspect, the upcycled polyamide can comprise upcycled polyamide-6, polyamide-6,6, or a combination thereof derived from post-consumer recycled polyamide. In an aspect the second polyamide can be a post- industrial recycled polyamide (i.e., that has not been upcycled).

[0032] The post-industrial mechanically polyamide can comprise a post-industrial recycled preferably a post-industrial mechanically recycled, polyamide-6, polyamide-6,6, polyamide-4, polyamide-4,6, polyamide-12, polyamide-6, 10, polyamide 6,9, polyamide-6, 12, polyamide 9T, polyamide 6 / 6T and polyamide 6,6 / 6T. In an aspect, the post-industrial mechanically recycled polyamide can comprise polyamide-6, polyamide-6,6, or a combination thereof.

[0033] The upcycled or post-industrial mechanically recycled polyamides can have an intrinsic viscosity of up to 400 mL / g, or, more specifically, having a viscosity of 90 to 350 mL / g, or, even more specifically, having a viscosity of 110 to 240 mL / g, , or a viscosity of 160 mL / g to 240 mL / g, as measured in a 0.5 weight percent solution in 96 weight percent sulfuric acid in accordance with ISO 307. The upcycled or post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, can have a relative viscosity of up to 6, or, more specifically, a relative viscosity of 1.89 to 5.43, or, even more specifically, a relative viscosity of 2.16 to 3.93. Relative viscosity is determined according to ISO 307 in a 1 weight percent solution in 96 weight percent sulfuric acid.

[0034] Upcycled or post-industrial mechanically recycled polyamides can have a polydispersity index of greater than 2.5 or having a polydispersity index (also called dispersity) of 2.5 to 6.0, as measured by GPC), using a 40 mg sample dissolved in 20 mL chloroform with 1000 parts per million of toluene as a flowmarker and 250 microliters of trifluoroacetic anhydride. The upcycled or post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, can have a polydispersity index of 2.5 to 5.5, 2.5 to 4.5, and 2.6 to 4.0, as measured by GPC under the same conditions.

[0035] In an aspect, the upcycled or post-industrial mechanically recycled polyamide can have a particular amine end-group concentration. For example, the upcycled or post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, can have anamine end-group concentration of 120 milliequivalents per kilogram (meq / kg) or less, for example 30 to 100 meq / kg. In an aspect, the upcycled polyamide can have an amine end-group concentration of 120 meq / kg or less, or 90 meq / kg or less, or 30 to 45 meq / kg and can be, for example, an upcycled post-consumer recycled polyamide-6. In an aspect, the post-industrial mechanically recycled polyamide can have an amine end-group concentration of 120 meq / kg or less, or 90 meq / kg or less and can be, for example a post-industrial recycled polyamide-6 preferably a post-industrial mechanically recycled polyamide-6. In an aspect, the post-industrial recycled polyamide, preferably the post-industrial mechanically recycled polyamide, can have an amine end-group concentration of 120 meq / kg or less, or 90 meq / kg or less, or 1 to 90 meq / kg, or 30 to 50 meq / kg, or 30 to 45 meq / kg and can be, for example, a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66.

[0036] The amine end-group concentration of the second polyamide is less than or equal to the amine end-group concentration of the virgin polyamide. In an aspect, the second polyamide has an amine end group concentration that is less than the amine end group concentration of the virgin polyamide. In an aspect, the second polyamide can have an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than the amine end group concentration of the virgin polyamide. The present inventor has found that certain combinations of virgin and second (e.g., upcycled or post-industrial mechanically recycled) polyamides having particular amine end group concentrations may be particularly useful. For example, in an aspect, the virgin polyamide can be a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the upcycled polyamide can be an upcycled polyamide-6 (e.g., derived post-consumer recycled polyamide) having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg, or 30 to 45 meq / kg. In an aspect, the virgin polyamide can be a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide can be a post-industrial mechanically recycled polyamide-6 having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg, or 30 to 45 meq / kg. In an aspect, the virgin polyamide can be a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide can be a post-industrial mechanically recycled polyamide-66 having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg.

[0037] Generally, the upcycled polyamide and / or the post-industrial mechanically recycled polyamide have a lower amine end group concentration than virgin polyamide. The lower amine end group concentration is often the result of the process of producing upcycled or post-industrial mechanically recycled polyamide. A typical process for mechanical recyclingincludes cleaning the polyamide that is being recycled, melting the recycled polyamide, homogenizing recycled polyamide, compounding the recycled polyamide via a melt filtration, and pelletizing the compounded amide. In an aspect, the polyamide being mechanically recycled is a PIR-PA. Another process, a chemical (upcycle) process, includes pretreating the polyamide that is being recycled, depolymerizing the polyamide that is being recycled to produce monomers and oligomers, then purifying the monomers and oligomers before repolymerizing the monomers and oligomers to produce upcycled polyamide. In an aspect, the polyamide being upcycled is a PCR-PA, a PIR-PA, or a combination thereof. These processes generally affect the amine end group concentration. The lower amine end group concentration generally affects the mechanical properties and flow performance of the polyamides and any compositions that include the upcycled or mechanically recycled polyamides.

[0038] The second polyamide is present in the composition in an amount of 5 to 50 weight percent, based on the total weight of the composition. Within this range, the second polyamide can be present in an amount of 10 to 50 weight percent, or 15 to 50 weight percent, or 18 to 50 weight percent, or 18 to 47 weight percent, each based on the total weight of the composition. In an aspect, the second polyamide and the virgin polyamide can be present in a weight ratio of 0.5:1 to 5:1, or 0.75:1 to 4:1, or 0.8:1 to 3.5:1. Stated another way, the second polyamide can make up 40 to 80 weight percent of the total polyamide (i.e., based on the total weight of the virgin polyamide and the second polyamide).

[0039] In addition to the poly(arylene ether), the virgin polyamide, and the second polyamide, the composition comprises an impact modifier. Impact modifiers are typically high molecular weight elastomeric materials derived from olefins, monovinyl aromatic monomers, acrylic and methacrylic acids and their ester derivatives, as well as conjugated dienes. The polymers formed from conjugated dienes can be fully or partially hydrogenated.

[0040] The impact modifier can be an unhydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene. For brevity, this component is referred to as an “unhydrogenated block copolymer.” The unhydrogenated block copolymer can comprise 10 to 90 weight percent of poly (alkenyl aromatic) content and 90 to 10 weight percent of poly (conjugated diene) content, based on the weight of the unhydrogenated block copolymer. In an aspect, the unhydrogenated block copolymer is a low poly(alkenyl aromatic content) unhydrogenated block copolymer in which the poly(alkenyl aromatic) content is 10 to less than 40 weight percent, specifically 20 to 35 weight percent, more specifically 25 to 35 weight percent, yet more specifically 30 to 35 weight percent, all based on the weight of the low poly(alkenyl aromatic) content unhydrogenated block copolymer. In an aspect, theunhydrogenated block copolymer is a high poly(alkenyl aromatic) content unhydrogenated block copolymer in which the poly(alkenyl aromatic) content is 40 to 90 weight percent, specifically 50 to 80 weight percent, more specifically 60 to 70 weight percent, all based on the weight of the high poly(alkenyl aromatic) content unhydrogenated block copolymer.

[0041] In an aspect, the unhydrogenated block copolymer has a weight average molecular weight (Mw) of 40,000 to 400,000 grams per mole (g / mol). The weight average molecular weight can be determined by gel permeation chromatography (GPC) and based on comparison to polystyrene standards. In an aspect, the unhydrogenated block copolymer has a weight average molecular weight of 200,000 to 400,000 g / mol, specifically 220,000 to 350,000 g / mol. In an aspect, the unhydrogenated block copolymer has a weight average molecular weight of 40,000 to 200,000 g / mol, specifically 40,000 to 180,000 g / mol, more specifically 40,000 to 150,000 g / mol.

[0042] The alkenyl aromatic monomer used to prepare the unhydrogenated block copolymer can have the structurewherein R2and R3each independently represent a hydrogen atom, a Ci-s alkyl group, or a C2-8 alkenyl group; R4and R8each independently represent a hydrogen atom, a Ci-s alkyl group, a chlorine atom, or a bromine atom; and R5, R6, and R7each independently represent a hydrogen atom, a Ci-s alkyl group, or a C2-8 alkenyl group, or R5and R6are taken together with the central aromatic ring to form a naphthyl group, or R6and R7are taken together with the central aromatic ring to form a naphthyl group. Specific alkenyl aromatic monomers include, for example, styrene, chlorostyrenes such as p-chlorostyrene, methylstyrenes such as alpha-methylstyrene and p-methylstyrene, and t-butylstyrenes such as 3-t-butylstyrene and 4-t- butylstyrene. In an aspect, the alkenyl aromatic monomer is styrene.

[0043] The conjugated diene used to prepare the unhydrogenated block copolymer can be a C4-20 conjugated diene. Suitable conjugated dienes include, for example, 1,3-butadiene, 2-methyl-l,3-butadiene, 2-chloro- 1,3-butadiene, 2, 3-dimethyl- 1,3-butadiene, 1,3-pentadiene,1.3-hexadiene, and combinations thereof. In an aspect, the conjugated diene is 1,3-butadiene, 2-methyl- 1,3-butadiene, or a combination thereof. In an aspect, the conjugated diene consists of1.3-butadiene.

[0044] The unhydrogenated 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 arrangement of blocks (A) and (B) includes a linear structure, a grafted structure, and a radial teleblock structure with or without a branched chain. Linear block copolymers include tapered linear structures and non-tapered linear structures. In an aspect, the unhydrogenated block copolymer has a tapered linear structure. In an aspect, the unhydrogenated block copolymer has a non-tapered linear structure. In an aspect, the unhydrogenated block copolymer comprises a (B) block that comprises random incorporation of alkenyl aromatic monomer. 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 as well as linear structures containing 6 or more blocks in total of (A) and (B), wherein the molecular weight of each (A) block can be the same as or different from that of other (A) blocks, and the molecular weight of each (B) block can be the same as or different from that of other (B) blocks. In an aspect, the unhydrogenated block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0045] In an aspect, the unhydrogenated block copolymer excludes the residue of monomers other than the alkenyl aromatic compound and the conjugated diene. In an aspect, the unhydrogenated block copolymer consists of blocks derived from the alkenyl aromatic compound and the conjugated diene. It does not comprise grafts formed from these or any other monomers. It also consists of carbon and hydrogen atoms and therefore excludes heteroatoms.

[0046] In an aspect, the unhydrogenated block copolymer includes the residue of one or more acid functionalizing agents, such as maleic anhydride.

[0047] In an aspect, the unhydrogenated block copolymer comprises a polystyrene-polybutadiene-polystyrene triblock copolymer. In an aspect, the unhydrogenated block copolymer comprises a polystyrene -polybutadiene-polystyrene triblock copolymer.

[0048] Methods for preparing unhydrogenated block copolymers are known in the art and unhydrogenated block copolymers are commercially available. Illustrative commercially available unhydrogenated block copolymers include the polystyrene-polybutadiene-polystyrene triblock copolymers from Kraton Performance Polymers Inc. under the trade names DI 101 and DI 102; and the styrene-butadiene radial teleblock copolymers from Chevron Phillips Chemical Company under the trade names K-RESIN KR01, KR03, and KR-05.

[0049] The impact modifier can be a hydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene. For brevity, this component is referred to as a “hydrogenated block copolymer.” The hydrogenated block copolymer is the same as theunhydrogenated block copolymer, except that in the hydrogenated block copolymer the aliphatic unsaturated group content in the block (B) derived from a conjugated diene is at least partially reduced by hydrogenation. In an aspect, the aliphatic unsaturation in the (B) block is reduced by at least 50 percent, specifically at least 70 percent, more specifically at least 90 percent.

[0050] Illustrative commercially available hydrogenated block copolymers include the polystyrene -poly(ethylene-propylene) diblock copolymers available from Kraton Performance Polymers Inc. as KRATON G1701 and G1702; the polystyrene-poly(ethylene-butylene)- polystyrene triblock copolymers available from Kraton Performance Polymers Inc. as KRATON G1641, G1650, G1651, G1654, G1657, G1726, G4609, G4610, GRP-6598, MD-6932M, MD- 6933, and MD-6939; the polystyrene -poly(ethylene-propylene)-polystyrene triblock copolymers available from Kraton Performance Polymers Inc. as KRATON G1730; the maleic anhydride- grafted polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymers available from Kraton Performance Polymers Inc. as KRATON G1901, G1924, and MD-6684; the maleic anhydride-grafted polystyrene -poly(ethylene-butylene-styrene)-polystyrene triblock copolymer available from Kraton Performance Polymers Inc. as KRATON MD-6670; the polystyrene- poly(ethylene-butylene)-polystyrene triblock copolymer comprising 67 weight percent polystyrene available from Asahi Kasei Elastomer as TUFTEC Hl 043; the polystyrene- poly(ethylene-butylene)-polystyrene triblock copolymer comprising 42 weight percent polystyrene available from Asahi Kasei Elastomer as TUFTEC Hl 051; the polystyrene- poly(butadiene-butylene)-polystyrene triblock copolymers available from Asahi Kasei Elastomer as TUFTEC P1000 and P2000; the polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer comprising 60 weight polystyrene available from Kuraray as SEPTON S8104; the polystyrene-poly(ethylene-ethylene / propylene)-polystyrene triblock copolymers available from Kuraray as SEPTON S4044, S4055, S4077, and S4099; and the polystyrene- poly(ethylene-propylene)-polystyrene triblock copolymer comprising 65 weight percent polystyrene available from Kuraray as SEPTON S2104.

[0051] The impact modifier can be included in the composition in an amount of 1 to 15 weight percent, based on the total weight of the composition. Within this range, the impact modifier can be present in an amount of 2 to 15 weight percent, or 5 to 15 weight percent, or 8 to 15 weight percent, or 8 to 13 weight percent, or 8 to 12 weight percent.

[0052] A compatibilizing agent can be used to facilitate formation of a compatibilized blend of the polyamide and the poly(phenylene ether). As used herein, the term “compatibilizing agent” refers to a polyfunctional compound that interacts with the poly(phenylene ether), the polyamide (i.e., the virgin polyamide and the second polyamide), or both. This interaction canbe chemical (for example, grafting) and / or physical (for example, affecting the surface characteristics of the dispersed phases). In either instance the resulting polyamidepolyphenylene ether) blend exhibits improved compatibility, particularly as evidenced by enhanced impact strength, mold knit line strength, and / or tensile elongation. Such compatibilizing agents are known, and can include, for example, both a carbon-carbon double bond and at least one carboxylic acid, anhydride, epoxy, imide, amide, ester group or functional equivalent thereof. Other known compatibilizing agents include a group such as hydroxy, alkoxy, aryloxy, or acyloxy, and at least two groups, each of which may be the same or different, and can be a carboxylic acid, acid halide, anhydride, acid halide anhydride, ester, orthoester, amide, imido, amino, or a salt thereof. Examples compatibilizing agents include maleic acid; maleic anhydride; fumaric acid; maleic hydrazide; dichloro maleic anhydride; unsaturated dicarboxylic acids (e.g. acrylic acid, butenoic acid, methacrylic acid, t-ethylacrylic acid, pentenoic acid; citric acid, malic acid, agaricic acid; acetyl citrate, mono- and / or distearyl citrates, N,N'-diethyl citric acid amide; N-phenyl citric acid amide; N-dodecyl citric acid amide; N,N'-didodecyl citric acid amide and N-dodecyl malic acid. Derivates include the salts thereof, including the salts with amines and the alkali and alkaline metal salts. Exemplary suitable salts include calcium malate, calcium citrate, potassium malate, and potassium citrate. In an aspect, the compatibilizing agent comprises citric acid anhydride, fumaric acid, or a combination thereof. In an aspect, compatibilizing agents other than citric acid anhydride or fumaric acid are not present in the composition.

[0053] The compatibilizing agent can be present in an amount of 0.2 to 2 weight percent, based on the total weight of the composition. Within this range, the compatibilizer can be present in an amount of 0.2 to 1.5 weight percent, or 0.5 to 1 weight percent.

[0054] The composition can optionally further comprise an additive composition, comprising one or more additives selected to achieve a desired property, with the proviso that the additives are also selected so as to not significantly adversely affect a desired property of the composition. The additive composition or individual additives can be mixed at a suitable time during the mixing of the components for forming the composition. The additive composition can include flow modifier, filler (e.g., a particulate polytetrafluoroethylene (PTFE), glass, carbon, mineral, or metal), antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) light stabilizer, UV absorbing additive, plasticizer, lubricant, release agent (such as a mold release agent), antistatic agent, anti-fog agent, antimicrobial agent, colorant (e.g, a dye or pigment), surface effect additive, radiation stabilizer, flame retardant, anti-drip agent (e.g., a PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or a combination thereof. In an aspect, the additivecomposition comprises an antioxidant, a mold release agent, a stabilizer, a colorant, or a combination thereof. The additives are used in amounts generally known to be effective. For example, the total amount of the additive composition (other than any impact modifier, filler, or reinforcing agent) can be 0.001 to 10 weight percent, or 0.1 to 10 weight percent, or 0.01 to 5 weight percent, each based on the total weight of the polymer in the composition. In an aspect the composition can exclude additives not specifically disclosed herein. In an aspect no filler or glass fibers are present. In an aspect, no conductive fillers are present in the composition.

[0055] In an aspect, the composition can further comprise a stabilizer. Exemplary stabilizers can include potassium iodide, copper (I) iodide, or a combination thereof.

[0056] The relative amount of each component can be adjusted to provide the desired combination of properties. As is understood by one of skill in the art, the amount of each component is selected such that they total 100 weight percent.

[0057] In a specific aspect, the composition is the product of melt-blending: 8 to 27 weight percent of the virgin polyamide; 18 to 37 weight percent of the second polyamide; 35 to 50 weight percent of the poly(arylene ether); 8 to 12 weight percent of the impact modifier; and 0.5 to 1 weight percent of a compatibilizing agent, each based on the total weight of the composition. The virgin polyamide can be a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide can be an upcycled polyamide-6 having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg, or the virgin polyamide can be a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide can be a post-industrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide can be a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide can be a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg. The impact modifier can be an unhydrogenated block copolymer, preferably a polystyrene -polybutadiene-polystyrene block copolymer. The compatibilizing agent can comprise citric acid anhydride.

[0058] The compatibilized composition can comprise a continuous phase and a dispersed phase. For example, the virgin polyamide and the upcycled polyamide can be present as a continuous polyamide phase, and the poly(arylene ether) and impact modifier can be present as a dispersed phase in the continuous polyamide phase. In an aspect, the dispersed phase can have an average particle size of 6 micrometers or less.

[0059] The composition of the present disclosure can exhibit one or more advantageous properties. For example, a molded sample comprising the composition can exhibit one or more of a melt- volume flow rate of 3 to 15 cc / 10 minutes, determined according to ISO 1133; a Vicat softening temperature of 170 to 200°C, determined according to ISO 306; a Charpy notched impact strength at 23 °C of 4 to 40 kJ / m2, preferably 15 to 40 kJ / m2, determined according to ISO 179; and a Charpy notched impact strength at -40°C of 2 to 25 kJ / m2, determined according to ISO 179.

[0060] A method of making the composition represents another aspect of the present disclosure. For example, the composition can be formed by melt-blending the components of the composition. Typical melt mixing temperatures can be 200 to 315°C. Molded articles can be formed from the composition, for example, by injection molding or extrusion. An exemplary method for the manufacture of the composition is further described in the working examples below.

[0061] An article comprising the composition represents another aspect of the present disclosure. Suitable article-forming techniques include injection molding and extrusion. Articles comprising the composition may be particularly useful for automotive applications, for example in exterior automotive components such as wheel inserts or roof rails, or automotive underhood components such as power distribution boxes, relay boxes, and junction boxes.

[0062] The composition of the present disclosure therefore provides a significant advantage with regard to certain properties, for example melt flow, thermal properties, and impact strength. The composition exhibiting this desirable balance of properties can be particularly useful for forming articles for various applications such as in automotive applications. Therefore, a significant advantage is provided by the present disclosure.

[0063] This disclosure is further illustrated by the following examples, which are nonlimiting.EXAMPLES

[0064] Materials used for the following examples are described in Table 1.Table 1

[0065] The compositions of the following examples were prepared by extrusion using the conditions provided in Table 2.Table 2

[0066] Pellets from the extruder were then injection molded to provide the various mechanical testing bars needed to evaluate the properties. Molding parameters are provided in Table 3.Table 3

[0067] Compositions and molded parts were characterized using the following test standards and methods. Melt volume flow rate (MVR) was determined at 280°C under a 5- kilogram load, according to ISO 1133. Melt viscosity (MV) was determined at 282°C at a shear rate of 1500 s1according to ISO 11443. Vicat softening temperature was determined according to ISO 306. Charpy notched impact strength was determined at -40°C, -30°C, -20°C, -10°C, 0°C, 10°C, and 23°C using a force of 4 Joules, according to ISO 179. Charpy unnotched impact strength was determined at 23°C using a force of 4 Joules, according to ISO 179. Tensile properties were determined according to ISO 527. Flexural properties were determined according to ISO 178. Particle size of the PPE was determined using laser scattering.

[0068] Compositions and properties are shown in Table 4. Amounts of each component of the composition is shown in weight percent, based on the total weight of the composition.Table 4

[0069] As shown in Table 4, replacing a virgin PA66 with an upcycled PA6 or PIR PA6 material results in lower Vicat temperature, but improved flow (see CE1, El, and El 1). When a virgin polyamide is partially replaced with upcycled materials, Table 4 shows that the CNI values improve, with upcycled PA6 content of 20-25% showing impact properties essentially equivalent to the virgin material. El -4 use a combination of virgin PA6 with high amine end group and upcycled PA6 with lower amine end group. Similar effects were observed for PIR PA6 (see El 1-16). It is also seen that the particle size of PPE can affect the impact properties.

[0070] Thus, a significant improvement in poly(phenylene ether) -polyamide compositions is provided by the present disclosure, where a desirable combination of properties can be achieved with the use of upcycled materials.

[0071] This disclosure further encompasses the following aspects.

[0072] Aspect 1: A compatibilized polyamide-poly(arylene ether) composition, wherein the composition is the product of melt-blending: 5 to 35 weight percent of a virgin polyamide; 5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a postindustrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide; 25 to 80 weight percent of a poly(arylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25 °C by Ubbelohde viscometer; 2 to 15 weight percent of an impact modifier; and 0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is less than an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

[0073] Aspect 2: The composition of aspect 1, wherein the virgin polyamide comprises polyamide-6 having an amine end group concentration of 100 to 125 meq / kg, or polyamide-66 having an amine end group concentration of 45 to 59 meq / kg.

[0074] Aspect 3: The composition of aspect 1 or 2, wherein the second polyamide comprises an upcycled post-consumer recycled polyamide-6 having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less; or a post-industrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less; or a post-industrialrecycled polyamide-66 having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less.

[0075] Aspect 4: The composition of any of aspects 1 to 3, wherein the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is an upcycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is a postindustrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide is a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg.

[0076] Aspect 5: The composition of any of aspects 1 to 4, wherein the upcycled polyamide is obtained by depolymerization of post-consumer recycled polyamide, postindustrial recycled polyamide, or a combination thereof to provide a caprolactam monomer, and repolymerization of the caprolactam monomer to provide the upcycled polyamide.

[0077] Aspect 6: The composition of any of aspects 1 to 5, wherein the post-industrial recycled polyamide, in particular the post-industrial mechanically recycled polyamide, comprises titanium dioxide in an amount of 1 weight percent or less, based on the total weight of the post-industrial recycled polyamide.

[0078] Aspect 7: The composition of any of aspects 1 to 6, wherein the impact modifier comprises a hydrogenated or unhydrogenated block copolymer of an alkenyl aromatic monomer and a conjugated diene, preferably an unhydrogenated block copolymer of an alkenyl aromatic monomer and a conjugated diene, more preferably a polystyrene-polybutadiene-polystyrene block copolymer.

[0079] Aspect 8: The composition of any of aspects 1 to 7, wherein the poly(arylene ether) comprises a poly(phenylene ether) or a poly(phenylene ether)-polysiloxane block copolymer.

[0080] Aspect 9: The composition of any of aspects 1 to 8, wherein the compatibilizing agent comprises citric acid, citric acid anhydride, fumaric acid, or a combination thereof.

[0081] Aspect 10: The composition of any of aspects 1 to 9, wherein the virgin polyamide and the second polyamide are present as a continuous polyamide phase, and thepoly(arylene ether) and impact modifier are present as a dispersed phase in the continuous polyamide phase, wherein the dispersed phase has an average particle size of 6 micrometers or less.

[0082] Aspect 11: The composition of any of aspects 1 to 10, further comprising an additive composition, preferably wherein the additive composition comprises an antioxidant, a mold release agent, a stabilizer, a colorant, or a combination thereof.

[0083] Aspect 12: The composition of aspect 1, wherein the composition is the product of melt-blending: 8 to 27 weight percent of the virgin polyamide; 18 to 47 weight percent of the second polyamide; 35 to 50 weight percent of the poly(arylene ether); 8 to 12 weight percent of the impact modifier; and 0.5 to 1 weight percent of a compatibilizing agent; wherein the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is an upcycled polyamide-6 having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is a post-industrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide is a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg; the impact modifier comprises an unhydrogenated block copolymer, preferably a polystyrene- polybutadiene-polystyrene block copolymer; and the compatibilizing agent comprises citric acid anhydride.

[0084] Aspect 13: The composition of any of aspects 1 to 12, wherein a molded sample of the composition exhibits one or more of: a melt- volume flow rate of 3 to 15 cc / 10 minutes, determined according to ISO 1133; a Vicat softening temperature of 170 to 200°C, determined according to ISO 306; a Charpy notched impact strength at 23°C of 4 to 40 kJ / m2, preferably 15 to 40 kJ / m2, determined according to ISO 179; and a Charpy notched impact strength at -40°C of 2 to 25 kJ / m2, determined according to ISO 179.

[0085] Aspect 14: A method of making a compatibilized polyamide-poly(arylene ether) thermoplastic resin composition, the method comprising: melt-blending 5 to 35 weight percent of a virgin polyamide; 5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide; 25 to 80 weight percent of a poly(arylene ether) having an intrinsicviscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25°C by Ubbelohde viscometer; 2 to 15 weight percent of an impact modifier; and 0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide, preferably wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

[0086] Aspect 15: An article comprising the compatibilized polyamide-poly( arylene ether) thermoplastic resin composition of any of aspects 1 to 12.

[0087] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0088] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and / or” unless clearly stated otherwise. Reference throughout the specification to “an aspect” means that a particular element described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. The term “combination thereof’ as used herein includes one or more of the listed elements, and is open, allowing the presence of one or more like elements not named. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.

[0089] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0090] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this applicationbelongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0091] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, -CHO is attached through carbon of the carbonyl group.

[0092] As used herein, the term “hydrocarbyl,” whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains 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 the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above 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, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" means a branched or straight chain, saturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s- pentyl, and n- and s-hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl-O-), for example methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" means a straight or branched chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or propylene (-(CH2)3- )). “Cycloalkylene” means a divalent cyclic alkylene group, -CnH2n-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing the specified 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 including one more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo atoms (e.g., bromo and fluoro), oronly chloro atoms can be present. The prefix “hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents that can each independently be a C1-9 alkoxy, a C1-9 haloalkoxy, a nitro (-NO2), a cyano (-CN), a C1-6 alkyl sulfonyl (-S(=O)2-alkyl), a C6-12 aryl sulfonyl (-S(=O)2-aryl), a thiol (-SH), a thiocyano (-SCN), a tosyl (CH3C6H4SO2-), a C3-12 cycloalkyl, a C2-12 alkenyl, a C5-12 cycloalkenyl, a C6-12 aryl, a C7- 13 arylalkylene, a C4-12 heterocycloalkyl, and a C3-12 heteroaryl instead of hydrogen, provided that the substituted atom’s normal valence is not exceeded. The number of carbon atoms indicated in a group is exclusive of any substituents. For example -CH2CH2CN is a C2 alkyl group substituted with a nitrile.

[0093] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

CLAIMSWhat is claimed is:

1. A compatibilized polyamide-poly(arylene ether) composition, wherein the composition is the product of melt-blending:5 to 35 weight percent of a virgin polyamide;5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, wherein the second polyamide has a polydispersity index of greater than about 2.5 to about 6.0;25 to 80 weight percent of a poly(arylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25 °C by Ubbelohde viscometer;2 to 15 weight percent of an impact modifier; and0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is less than an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

2. The composition of claim 1, wherein the virgin polyamide comprises: polyamide-6 having an amine end group concentration of 100 to 125 meq / kg, or polyamide-66 having an amine end group concentration of 45 to 59 meq / kg.

3. The composition of claim 1 or 2, wherein the second polyamide comprises: an upcycled post-consumer recycled polyamide-6 having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less; or a post-industrial mechanically recycled polyamide-6 having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less; or a post-industrial mechanically recycled polyamide-66 having an amine end group concentration of 120 meq / kg or less, or 90 meq / kg or less; andwherein the upcycled post-consumer recycled polyamide-6 has an intrinsic viscosity of 90 mL / g to 240 mL / g.

4. The composition of any of claims 1 to 3, wherein the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is an upcycled polyamide-6 having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is a post-industrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide is a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg.

5. The composition of any of claims 1 to 4, wherein the upcycled polyamide is obtained by depolymerization of post-consumer recycled polyamide, post-industrial recycled polyamide, or a combination thereof to provide a caprolactam monomer, and repolymerization of the caprolactam monomer to provide the upcycled polyamide.

6. The composition of any of claims 1 to 5, wherein the post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide, comprises titanium dioxide in an amount of 1 weight percent or less to greater than 0 weight percent, based on the total weight of the post-industrial recycled polyamide.

7. The composition of any of claims 1 to 6, wherein the impact modifier comprises a hydrogenated or unhydrogenated block copolymer of an alkenyl aromatic monomer and a conjugated diene, preferably an unhydrogenated block copolymer of an alkenyl aromatic monomer and a conjugated diene, more preferably a polystyrene-polybutadiene-polystyrene block copolymer.

8. The composition of any of claims 1 to 7, wherein the poly (arylene ether) comprises a poly (phenylene ether) or a poly (phenylene ether) -poly siloxane block copolymer.

9. The composition of any of claims 1 to 8, wherein the compatibilizing agent comprises citric acid, citric acid anhydride, fumaric acid, or a combination thereof.

10. The composition of any of claims 1 to 9, wherein the virgin polyamide and the second polyamide are present as a continuous polyamide phase, and the poly(arylene ether) and impact modifier are present as a dispersed phase in the continuous polyamide phase, wherein the dispersed phase has an average particle size of 6 micrometers or less.

11. The composition of any of claims 1 to 10, further comprising an additive composition, preferably wherein the additive composition comprises an antioxidant, a mold release agent, a stabilizer, a colorant, or a combination thereof.

12. The composition of claim 1, wherein the composition is the product of melt-blending:8 to 27 weight percent of the virgin polyamide;18 to 47 weight percent of the second polyamide;35 to 50 weight percent of the poly(arylene ether);8 to 12 weight percent of the impact modifier; and0.5 to 1 weight percent of a compatibilizing agent; wherein the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is an upcycled polyamide-6 having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-6 having an amine end group concentration of 100 to 120 meq / kg and the second polyamide is a post-industrial recycled polyamide-6, preferably a post-industrial mechanically recycled polyamide-6, having an amine end group concentration of 90 meq / kg or less, preferably 30 to 50 meq / kg; or the virgin polyamide is a virgin polyamide-66 having an amine end group concentration of 49 to 59 meq / kg and the second polyamide is a post-industrial recycled polyamide-66, preferably a post-industrial mechanically recycled polyamide-66, having an amine end group concentration of 49 meq / kg or less, preferably 40 to 49 meg / kg; the impact modifier comprises an unhydrogenated block copolymer, preferably a polystyrene-polybutadiene-polystyrene block copolymer; and the compatibilizing agent comprises citric acid anhydride.

13. The composition of any of claims 1 to 12, wherein a molded sample of the composition exhibits one or more of: a melt-volume flow rate of 3 to 15 cc / 10 minutes, determined according to ISO 1133; a Vicat softening temperature of 170 to 200°C, determined according to ISO 306; a Charpy notched impact strength at 23°C of 4 to 40 kJ / m2, preferably 15 to 40 kJ / m2, determined according to ISO 179; or a Charpy notched impact strength at -40 °C of 2 to 25 kJ / m2, determined according to ISO 179.

14. A method of making a compatibilized polyamide-poly(arylene ether) thermoplastic resin composition, the method comprising: melt-blending5 to 35 weight percent of a virgin polyamide;5 to 50 weight percent of a second polyamide comprising an upcycled polyamide, or a post-industrial recycled polyamide, preferably a post-industrial mechanically recycled polyamide;25 to 80 weight percent of a poly(arylene ether) having an intrinsic viscosity of 0.2 to 0.6 deciliters per gram, determined in chloroform at 25°C by Ubbelohde viscometer;2 to 15 weight percent of an impact modifier; and0.2 to 2 weight percent of a compatibilizing agent; wherein weight percent of each component is based on the total weight of the composition; and wherein the second polyamide has an amine end group concentration that is less than or equal to an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is less than an amine end group concentration of the virgin polyamide, or wherein the second polyamide has an amine end group concentration that is at least 5% less, or at least 10% less, or at least 25% less than an amine end group concentration of the virgin polyamide.

15. An article comprising the compatibilized poly amide -poly(arylene ether) thermoplastic resin composition of any of claims 1 to 12.

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