Moldable poly(arylene ether) thermosetting compositions, methods, and articles

A curable composition, comprising:

• shout 5 to about 50 parts by weight of a poly(arylene ether);
• about 25 to 90 parts by weight of a thermosetting resin selected from the group consisting of epoxy resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, and mixtures comprising at least one of the foregoing thermosetting resins;
• about 0.5 to about 15 parts by weight of a compatibilizing agent comprising a polyvinyl butyral;
• and
• about 3 to about 150 parts by weight per 100 parts of weight of the thermosetting resin of an amine cure agent selected from the group consisting of amidoamines, polyamides, cycloaliphatic amines, modified cycloaliphatic amines, aromatic amines, modified aromatic amine, BF3-amine adducts, imidazoles, guanidines, arylene polyamines, and mixtures comprising at least one of the foregoing amine cure agents;
• wherein the parts by weight of tho poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.

A curable composition, comprising:

• about 10 to about 40 parts by weight of a poly(arylene ether) having an intrinsic viscosity of about 0.20 dL/g to about 0.40 dL/g as measured at 25° C. in chloroform;
• about 50 to about 85 parts by weight of an epoxy resin;
• about 2 to about 10 parts by weight of a polyvinyl butyral;
• and
• about 20 to about 100 parts by weight per 100 parts of weight of the thermosetting resin of an aromatic amine cure agent;
• wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.

A method of forming a curable resin composition, comprising:

• forming an intimate blend comprising about 5 to about 50 parts by weight of a poly(arylene ether);
• about 25 to 90 parts by weight of a thermosetting resin selected from the group consisting of epoxy resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, and mixtures comprising at least one of the foregoing thermosetting resins;
• about 0.5 to about 15 parts by weight of a compatibilizing agent comprising a polyvinyl acetal;
• about 3 to about 150 parts by weight per 100 parts by weight thermosetting resin of an amine cure agent selected from the group consisting of amidoamines, polyamides, cycloaliphatic amines, modified cycloaliphatic amines, aromatic amines, modified aromatic amines, BF3-amine adducts, imidazoles, guanidines, arylene polyamines, and mixtures comprising at least one of the foregoing amine cure agents;
• and about 0.1 to about 20 parts by weight per 100 parts by weight poly(arylene ether) of a plasticizer effective for poly(arylene ether) resin;
• wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.

A method of forming a curable resin composition, comprising:

• forming a first intimate blend comprising about 5 to about 50 parts by weight of a poly(arylene ether);
• about 25 to 90 parts by weight of a thermosetting resin selected from the group consisting of epoxy resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, and mixtures comprising at least one of the foregoing thermosetting resins;
• and about 0.5 to about 15 parts by weight of a compatibilizing agent comprising a polyvinyl acetal ;
• and about 0.1 to about 20 parts by weight per 100 parts by weight poly(arylene ether) of a plasticizer effective for poly(arylene other) resins;
• and
• forming a second intimate blend comprising the first intimate blend and about 3 to about 150 parts by weight per 100 parts by weight thermosetting resin of an amine cure agent selected from the group consisting of amidoamines, polyamides, cycloaliphatic amines, modified cycloaliphatic amines, aromatic amines, modified aromatic amines, BF3-amine adducts, imidazoles, guanidines, arylene polyamines, and mixtures comprising at least one of the foregoing amine cure agents;
• wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.

A cured composition comprising the reaction product of:

• about 5 to about 50 parts by weight of a poly(arylene ether);
• about 25 to 90 parts by weight of a thermosetting resin selected from the group consisting of epoxy resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, and mixtures comprising at least one of the foregoing thermosetting resins;
• about 0.5 to about 15 parts by weight of a compatibilizing agent comprising a polyvinyl acetal;
• about 3 to about 150 parts by weight per 100 parts of weight of the thermosetting resin of an amine cure agent selected from the group consisting of amidoamines, polyamides, cycloaliphatic amines, modified cycloaliphatic amines, aromatic amines, modified aromatic amines, BF3-amine adducts, imidazoles, guanidines, arylene polyamines, and mixtures comprising at least one of the foregoing amine cure agents;
• and
• about 0.1 to about 20 parts by weight per 100 parts by weight poly(arylene ether) of a plasticizer effective for poly(arylene ether) resins;
• wherein the parts by weight of the poly(arylene ether), the thermosetting resin, and the compatibilizing agent sum to 100.