Ultrafine Poly(phenylene ether) Particles and Compositions Derived Therefrom

A process for preparing a composition comprising:

• (a) 15 to 35 percent by weight of the ultrafine particulate poly(phenylene ether), wherein the mean particle size of the poly(phenylene ether) is 6 to 40 microns;
• (b) 40 to 70 percent by weight of an epoxy resin;
• and
• (c) 5 to 25 percent by weight of a hardener;
• comprising the steps of:
• (i) combining the poly(phenylene ether) and epoxy resin at ambient temperature to form a mixture;
• (ii) adding the hardener to the mixture of (i);
• (iii) heating the mixture of (ii) from ambient to 200° C.

A process for preparing a composition comprising:

• (a) 15 to 35 percent by weight of the ultrafine particulate poly(phenylene ether), wherein the mean particle size of the poly(phenylene ether) is 6 to 40 microns;
• (b) 40 to 70 percent by weight of DGEBPA;
• and
• (c) 5 to 25 percent by weight of MDA;
• comprising the steps of:
• (i) combining the poly(phenylene ether) and epoxy resin at ambient temperature to form a mixture;
• (ii) adding the hardener to the mixture of (i);
• (iii) heating the mixture of (ii) from 50 to 200° C. to produce a casting with uniform density and an impact strength is greater than or equal to 500 J/m as measured by ASTM D4812.