POLY(ARYLENE ETHER) COMPRESSION MOLDING BACKGROUND OF THE INVENTION
This disclosure relates to poly(arylene ether) and more particularly to methods of forming articles from poly(aryiene ether).
Poly(arylene ether) resins are commercially attractive materials because of their unique combination of physical, chemical, and electrical properties. They are a widely used class of thermoplastic engineering resins characterized by excellent hydrolytic stability, dimensional stability, toughness, heat resistance, and dielectric properties. Furthermore, the combination of poly(aiylene ether) with other resins provides blends mat result in additional overall desirable properties such as chemical resistance, high strength, and high flow.
Poly(arylene ether) is commercially available blended with other resins such as polystyrene), polypropylene and polyamide. These blends are usually made using poly(arylene ether) powder. The poly(arylene ether) powder that is used in the preparation of polymer blends may have a wide particle size distribution, which can affect processability. Moreover, the density of the poly(arylene ether) powder is generally less than or equal to 0.6 gram per cubic centimeter. Such a low density requires large volumes for storage and transportation. Moreover, due to the fluffy nature of the poly(arylene ether) powder, it is difficult to feed to an extruder at higher feed rates.
Accordingly, mere is a need hi the art for a method of forming poly(arylene ether) powder into a compressed form that has better processability and higher density.
BRIEF DESCRIPTION OF THE INVENTION
Disclosed herein is a method for compression molding poly(arylene ether) powder. The method comprises introducing a powder comprising unheated poly(arylene ether) powder to compaction equipment comprising a compression mold and subjecting the powder in

the compression mold to a pressure sufficient to produce an article having a density greater than the vmheated polyfarylene ether) powder wherein the pressure is applied at a temperature less than the glass transition temperature of the poly(arylene ether) powder.
DETAILED DESCRIPTION
A method for compression molding poly(arylene ether) powder comprises introducing an unhcated poly(arylene ether) powder to compaction equipment comprising a compression mold, and applying sufficient pressure to the powder in the compression mold to.produce an article. As used herein poly(arylene ether) powder refers to a powder consisting essentially of poly(aryiene ether) resin or a combination of two or more poly(arytene ether) resins. The compression molding method may be performed by batch or continuous processing.
All ranges disclosed herein are inclusive and combinable (e.g., ranges of "up to about 25 wt%, or, more specifically about 5 wf% to about 20 wtV is inclusive of the endpomts and all intermediate values of the ranges of "about 5 wt% to about 25 wt%," etc.)- The terms "first," "second," and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least oae of the referenced item.
Poly(arylene ether)s are known polymers comprising a plurality of structural units of the formula (I):
(FigureRemove)

wherein for each structural unit, each Q1 is independently hydrogen, halogen, primary or secondary lower alkyl (e.g., alkyl containing up to 7 carbon atoms), phenyl, haloalkyl,

aminoalkyl, hydrocarbonoxy, halohydrocarbonoxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each Q2 is independently hydrogen, halogen, primary or secondary lower alkyl, phenyl, haloalkyl, hydrocarbonoxy, halohydrocarbonoxy wherein at least two carbon atoms separate the halogen and oxygen atoms. In one embodiment each Q1 is alkyl or phenyl, especially CM alkyl, and each Q2 is hydrogen.
Bom homopolymer and copolymer poly(arylene ether)s may be included. Exemplary homopolymers include those containing 2,6-dimethyl-l,4-phenylene ether units. Suitable copolymers include random copolymers containing such units in combination with (for
>>
example) 2,3,6-trimethyl-l,4-phenylene ether units. Also included are poly(arylene ether)s containing moieties prepared by grafting vinyl monomers or polymers such as polystyrenes and elastomers, as well as coupled poly(aryiene ether)s in which coupling agents such as low molecular weight polycarbonates, quinones, heterocycles and fdnnals undergo reaction in a known manner with the hydroxy groups of two poly(ary}ene ether) chains to produce a higher molecular weight polymer. Poly(arylene ether)s further include combinations of any of the above.
The poly(aiyiene ether) generally has a number average molecular weight of about 3,000-. 40,000 atomic mass units (amu) and a weight average molecular weightof about 20,000-80,000 amu, as determined by gel permeation chromatography. The poly(arylcne ether) may have an intrinsic viscosity of about 0.08 to about 0.60 deciliters per gram (dl/g), or, more specifically, about 0.29 to about 0.48 dl/g, as measured in chloroform at 25°C. It is also possible to utilize a high intrinsic viscosity poly(arylene ether) and a low intrinsic viscosity poly(arylene ether) in combination. Determining an exact ratio, when two intrinsic viscosities are used, will depend somewhat on the exact intrinsic viscosities of the poly(arylene ether) used and the ultimate physical properties that are desired.
Poly(arylenc ether) is generally prepared by the oxidative coupling of at least one monohydroxvaromatic compound such as 2,6-xylenol or 2,3,6-trimethylphenol. Catalyst systems are generally employed'for such coupling; they generally contain at least one

heavy metal compound such as a copper, manganese or cobalt compound, usually in combination with various other materials.
Particularly useful poly(arylene ether) for many purposes are those which comprise molecules having at least one aminoalkyl-containing end group. The aminoalkyi radical is generally located in an ortho position to the hydroxy group. Products containing such end groups may be obtained by incorporating an appropriate primary or secondary monoamine such as di-n-butylamine or dimethylamine as one of the constituents of the oxidative coupling reaction mixture. Also frequently present are 4-hydroxybiphenyl end groups, generally obtained from reaction mixtures in which a by-product diphenoquinone is present, especially in a copper-halide-secondary or tertiary amine system. A substantial proportion of the polymer molecules, typically constituting as much as about 90% by weight of the polymer, may contain at least one of said aminoalkyl-containing and 4-hydroxybiphenyl end groups.
The poly(arylene ether) may be functionalized with a functionalizing agent comprising (a) at least one carbon-carbon double bond or carbon-carbon triple bond and (b) at least one functional group selected from carboxylic acid, acid anhydride, acid amide, imide, ester, amino, hydroxy, and the like. In one embodiment the functionalizing agent comprises maleic anhydride. Other nmctionalizing agents, as well as functionalizing methods, are described, for example, in U.S. Patent No. 4,888,397 to van der Meer et al., and Japanese Patent Publication No. 2003-183385 to Tokiwa et al.
It will be apparent to those skilled in the art from the foregoing that the poly(arylene ether)s include many of those presently known, irrespective of variations in structural units or ancillary chemical features.
The pol y(arylene ether) is in powder form and may have an average particle size of about 50 micrometer to about 1500 micrometers, or, more specifically about 75 micrometers to about 1250 micrometers, or, even more specifically, about 90 micrometers to about 1000 micrometers. In some embodiments the poly(arylene ether) powder has a wide particle

size distribution, ranging in size from, about 0.2 micrometers to about 5,000 micrometers. Particles, as used herein, may be individual particles or individual particles associated together as agglomerates and/or aggregates. In some embodiments the potyarylece ether) powder comprises about S to about 70, or, more specifically, about 10 to about 65, or, even more specifically about 15 to about 60 volume percent of particles having a particle size less than about 100 micrometers, based on the total volume of the poly(arylene ether). Without being bound by theory it is believed that having a combination of particle sizes allows the smaller particles to pack between the larger particles and form an article having greater compressive strength.
The density of the poly(arylene ether) powder is less than or equal to about 0.6 grams per cubic centimetreCg/cm3), or more specifically, about 0.2 to about 0.5 g/cm3, or, even more specifically about 0.4 to about 0.5 g/ctn3.
The poly(aryleae ether) powder may optionally comprise various additives, for example, anti-oxidants, flame retardants, mold release agents, ultraviolet absorbers, stabilizers such as light stabilizers and others, lubricants, plasticizers, pigments, dyes, colorants, antistatic agents, blowing agents, and mixtures thereof. Exemplary aatioxidants include organophosphhes, for example, tris(nonyl-phenyi) phosphite, tris(2,4-di-t-butylphenyl)phospbite, bis(2,4-di-t-butylplienyl) pentaerythritol diphosphite, 2,4-di-tert-butylphenyl phosphite, or distearyl pentaerythritol diphosphite, alleviated monophenols, polyphenoJs and alkviaied reaction products of polyphenols with dienes, such as, for example, tetrakis [methyl ene(3,5^-tert-butyl^hvdioxyhydrwmnamate)] methane and 3,5^-tert>butyl^hydmxyhydrodnnamate octadccyl; butylated reaction products of para-cresol and dicyclopentadiene; alkyiated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of Deta-(3,5-di-tert-butyi-4-hydroxyphenyl>prDpionic add with monoaydric or polyhydric alcohols; esters of beta-(5-tert^utyl^hydroxy-3-methyhihenyl)-propionic acid with monohydric or polyhydric alcohols; esters of thioalkyl or mioaryt compounds, such as, for example, distearylthiopropionate, dilaurylthiopropionate, ditridecylthiodiproplonate; and amides of

beta-(3,5-di-tert-butyi-4-hydroxyphenyl)-propionic acid. Fillers and reinforcing agents may also be used, such as, for example, silicates, titanium dioxide, fibers, glass fibers (includuig continuous and chopped fibers), carbon black, graphite, calcium carbonate, talc, and mica. Each of the above additives, particularly the reinforcing additives, must be of a suitable size to be compression molded.
Suitable flame retardants may be organic compounds that include phosphorus, bromine, and/or chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants may be preferred in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds.
One type of exemplary organic phosphate is an aromatic phosphate of the formula (GO)jP=O, wherein each G is independently an alkyl, cycloalkyl, aryl, alkaryi, or aralkyl group, provided that at least one G is an aromatic group. Two of the G groups may be joined together to provide a cyclic group, for example, diphenyl pentaerythritol diphosphate, which is described by Axelrod in U.S. Pat No. 4,154,775. Other suitable aromatic phosphates may be, for example, phenyl bis(dodecyl) phosphate, phenyl bis(neopentvO phosphate, phenyl bis(3,5,5'-trimethylhexvl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonyiphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-triniethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, or me like. A specific aromatic phosphate is one in which each G is aromatic, for example, triphenyi phosphate, tricresyl phosphate, isopropylated tripheoyl phosphate, and the like.
Di- or polyfimctional aromatic phosphorus-containing compounds are also useful, for example, compounds of the formulas below:
(FigureRemove)

wherein each O1 is independently 8 hydrocarbon having 1 to about 30 carbon atoms; each O2 is independently a hydrocarbon or hydrocarbonoxy having 1 to about 30 carbon atoms; each X is independently a bromine or chlorine; m 0 to 4, and n is 1 to about 30. Examples of suitable di- or polyfunctional aromatic phosphorus-containing compounds include resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol-A (, respectively, their oligomeric and polymeric counterparts, and the like. Methods for the preparation of the aforementioned di- or polyfunctional aromatic compounds are described in British Patent No. 2,043,083.
When a flame retardant is present, the mixture may comprises about I to about 40 weight percent flame retardant, or, more specifically, about 1 to about 30 weight percent, or, even more specifically, about 1 to about 20 weight percent flame retardant, based on the total weight of the mixture.
A binder may be added to the poly(arylene ether) to form a mixture having improved cohesion between the particles of the poly(arylene ether) powder. The binder provides flexibility in manufacturing articles using the compression molding method. The binder does not cause irreversible agglomeration of the particles of poly(arylene ether) powder

when combined with the poly(arylene ether) powder prior to molding. When the binder is present, the mixture may comprise about 60 about 99.99 weight percent poly(arylcne ether) powder, or, more specifically about 90 to about 99.9 weight percent, or, even more specifically, about 95 to about 99.5 weight percent, based on the total weight of the mixture. The mixture may comprise about 0.01 to about 40 weight percent binder, or, more specifically about 0.1 to about 10 weight percent, or, even more specifically, about 0.5 to about 5 weight percent binder based on the total weight of the mixture.
The binder may be a reactive binder, non-reactive binder or a combination thereof. The binder, when polymeric or oligomeric, may be crystalline or amorphous. When the. binder is crystalline, the binder has a melt temperature less than or equal to the glass transition temperature (Tg) of the poly(arylene ether). When the binder is amorphous, the binder has a Tg less fog" or equal to the poly(arylene ether) Tg. A non-reactive binder may be any polymer or oligomer that is non-reactive with the poly(arylene ether) powder and itself. Useful non-reactive binders include vinyl acetate and its derivatives including vinyl acetate oligomers and polymers, oligomers of cthylene vinyl acetate , high impact polystyrenes (HIPS), polyolefins, and polytetrafluoioethylene dispersed in a stvrene-acrylonitrile copolymer. The polytetrafluoroethylene is usually present in the dispersion in an amount of about 40 to about 60 weight percent based on the total weight of the dispersion.
Other useful non-reactive binders include elastomeric block copolymers, for example, A-B-A triblock copolymers and A-B diblock copolymers. Suitable A-B and A-B-A type block copolymers are disclosed in, for example, U.S. Patent Numbers 3,078,254, 3,402,159, 3,297,793, 3,265,765, and 3,594,452 and U.K. Patent 1,264,741. In one embodiment the elastomeric block copolymer comprises polystyrene-poly(ethyiene-butylene)-polystyrene(SEBS), polYsrvrene-polybutadiene-polvstvrene(SBS), polvsryrene-poly(ethylene-propylene) (SEP) copolymers or a combination of two or more of the. foregoing elastomeric block copolymers.

A reactive binder may be either self reactive or reactive with the poly(arylene ether) powder. The presence of a binder may improve the appearance of me compressed poly(arylene ether) powder and may enhance the flexibility in manufacturing of articles from the compressed poly(arylene ether) powder.
Useful reactive binders include functionalized oligomers wherein the functional group is selected from the group consisting of carboxyl, acyloxy, imino, imido, hydroxy, glycidyl, amine and epoxy. Exemplary reactive binders include, but are not limited to, hydroxy terminated polybutadiene, epoxidized polybutadiene, epoxidized vegetable oils, amine terminated polyethylene glycols, poly glycidyl azide oils, hydroxy terminated triethylene ' glycol succinate polyesters and combinations of two or more of the foregoing reactive binders.
One or mere volatile components may be present in the poly(aryiene ether) powder. These volatile components may act as binders when compression molding is carried out at room temperature.
A modifying agent comprising one or more polar groups may be added to the poly(arylene ether) powder. Useful modifying agents include acid halides, carbonyl containing compounds, acid anhydrides, acid amides, carboxyiates, acid azides, sulfone containing compounds, nittile containing compounds, cyano containing compounds, isocyanate esters, amine containing compounds, imide containing compounds, bydroxyl containing compounds, epoxy containing compounds, oxazoline containing compounds, and thiol containing compounds.
The compression molding method may comprise cold compaction or warm compaction of the poly(arylene ether) powder and may produce a single phase or multi phase compact. A multi-phase (or two phase) solid article may comprise a fused cover of the mixture surrounding a core of compressed poly(aryiene ether) powder mixture. Alternatively, a multi-phase article may comprise a fused binder extending throughout the article. The binder may be grafted or end capped on the poly(arylene ether) powder.

Compression molding increases the bulk density of the polyfaryiene ether) and thereby reduces volume.
Cold compaction comprises subjecting an unseated poly(aryiene ether) powder and optional components to pressure sufficient to form an article having a density of about 0.6 g/cm* to about 12 g/cmj and a compressive strength of about 5 kilograms(kg) to about 3000 kilograins(kg). Within this range, the density may be greaterthan or equal to about 0.6 g/cra3, or, more specifically, greater than or equal to about 0.65 g/cm3. Also within mis range the density may be less than or equal to about 1.2 g/wn3, or, more specifically, less than or equal to about 1.1 g/cm5. The compressive strength may be. greater man or equal to about S kg, or, more specifically, greater than or equal to about 25 kg, or, even more specifically, preferably greater man or equal to about 100 kg. The compressive strength may be less man or equal to 3000 kg, or, more specifically, less than or equal to 2500 kg, or, even more specifically, less than or equal to 2000 kg.
The poly(arylene ether) powder may be blended with the optional components prior to mtrodoctton to the compaction equipment, or if the compaction equipment comprises a means for mixing the components the poly(arylea ether) powder and optional components maybe added simultaneously or sequentially.
The applied pressure is about 0.05 tons per square centimetre (tons/cm2) to about 53.0 tons/cm3. Within this range the applied pressure may be greater than or equal to about 1 ton/cm3, or, more specifically, greater than or equal to about 2 tons/cm2, or, even more specifically, greater than or equal to about 3 tons/cm3. Also within this range the applied pressure may be less than or equal to about 20 tons/cm2, or, more specifically, less than or equal to about 15 toss/cm2, or, even more specifically, less than or equal to about 7 tons/cm2. As used herein, ton refers to a metric ton.
Pressure is applied for about 0.1 seconds to about 100 seconds. Within this range pressure may be applied for greater man or equal to about 2 seconds, or, more specifically, greater man or equal to about 5 seconds. Also within this range, pressure

may be applied for less than or equal to about 15 seconds^ or, more specifically, less than or equal to about 10 seconds.
Compression occurs at a temperature less than the Tg of the poly(arylene emer), typically at a temperature of about 0 degrees-centigrade (*C) to about 70*C. Within this range, the temperature may be greater than or equal to about 5*C, or, more specifically, greater than or equal to about 10*C, or, even more specifically, greater than or equal to about 15*C. Abo within this range, the temperature may be less than or equal to about 65*C, or, more specifically, less than, or equal to about 60*C, or, even more specifically, less than or equal to about 55*C.
Warm compaction comprises introducing unheated poly(arylene ether) and optional components to compaction equipment and subjecting the po]y(arylene ether) powder and optional components to sufficient pressure and temperature to form an article.. The compression temperature is less man the Tg of the poly(arylene ether). The poly(arylene ether) powder and optional components, once in the compaction equipment, are heated to a temperature sufficient to at least soften the binder, when present, or the poiy(aryleae ether) and the binder when the binder is present, or the poly(aryiene ether) in the absence of a binder to produce an at least softened poly(ar>iene ether) powder or poly(arylene ether) powder mixture; applying and maintaining sufficient pressure to the at least softened poly(arylene ether) powder or poly(arylene ether) powder mixture while the temperature of the at least softened poly(arylene ether) powder or polytarylene ether) powder mixture is decreased to form an article having a density of greater man or equal to about 0.95 g/cm? and a compressive strength greater than or equal to about 4000 kg. The article density may be less than or equal to about 1.2 g/ctn3. The density may be greater than, or equal to about l.Q gfcsn3, or, more specifically, greater than or equal to about 1.05 g/cmj. Within this range the density may be less than or equal to about 1.5 g/cm3, or, more specifically, less than or equal to about 1.1 g/cm3. The compressive strength may be greater than or equal to about 5000 kg, or, more specifically, greater than or equal to about 6000 kg.

After introducing the poly(arylcne ether) powder or poly(arylene ether) powder mixture to the compaction equipment, the powder or powder mixture may be processed to reduce or remove gas, such as air, trapped between, the powder particles. Useful processing includes vibration, ultrasonification, vacuum and the like. Gas, when trapped in the at least softened polyCarylene ether), may be released through, simple venting, the application of vacuum, or other method known in the art.
When warm compacting a polyfarylrae ether) mixture the individual components may be added ftmultaneously or sequentially to the compaction equipment The poly(aryletie ether) powder may be mixed with the optional components, such as a binder, in a dry. blender prior to introducing the mixture to a cavity of a confined pressure device or to the feedthroat of an extruder. Batch or quasi-continuous flow mixing may be used. In one embodiment, the bmder and some or all of the other optional components may be introduced via a first feed port of an extruder and the binder melted or softened by heating the extruder or by virtue of a shearing action of the extruder. The poly(arylene ether) powder is added via a second feed port of the extruder and mixed with the molten binder, wherein the second feed port is downstream of the first feed port
When a bmder is present, the compression usually occurs at a temperature greater than the melt temperature of the binder and less man the Tg of the poly(arylene ether) powder, when the binder is crystalline. The compression occurs at a temperature greater than the Tg of the binder and leas than Uxe Tg of the polv(aryiene ether) powder, when (he binder is amorphous.
The pressure applied is about 0.2 tons/cm2 to about 20 tons/cm2. Within this range the pressure applied may be greater than or equal to about 0.25 tons/cm3, or, more specifically, greater than or equal to about 0.5 tons/cm2 or, even more specifically, greater than or equal to about 1.0 tons/cm3. Also within mis range the pressure applied may be less than or equal to about 10.0 tons/cm2, or, more specifically, less than or equal to about 5.0 tons/cm2, or, even more specifically, less than or equal to about 2.5 tons/cm7.

hessure maybe applied forabout300 seconds to about 2000 seconds. 'Within this range pressure may be applied for greater than or equal to about 500 seconds, or, more specifically, greater than or equal to about 900 seconds. Also withia Has range, pressure may be applied for less than or equal to about 1500 seconds, or, more specifically, leas than or equal to about 1200 seconds.
In another embodiment, the oon^ressioa method comprises mixing the poiyfaryleoe ether) powder wife a solution of fee binder in a solvent, and the mixture is isolated by devolatiiizatjan of the solvent Suitable binder solutions include solutions resulting from polymerisation of the binder or a process following polymerisation, or the dissolution of the isolated binder in a solvent As used herein with regard to binder solutions tbte term solution includes both solutions and suspensions. Devolatization is the removal of solvent through the elevation of temperature, the reduction of pressure or a combination thereof. The devoladzatkm is carried out at a temperature less than the Tg of the paly(aryiene ether). The isolation of the mixture may be carried out in a devolatilizing extruder although other methods involving spray drying, wiped film evaporators, fiake evaporators, flash vessels with metal pumps and combinations of two or more of the foregoing methods may be used. The isolated mixture may then be compacted, if necessary, by cold compaction or warm compaction &s described above.
Devolatilizing extruders and processes are known in the art and typically involve a twin-screw extrude? equipped with multiple venting sections for solvent removal The devolafilizing extruders most often contain screws with numerous types of elements adapted for such operations as simple feeding, devoiatilization and liquid seal ibtmah'on. These elements include forward-flighted screw elements designed for simple transport, and reverse-flighted screw and cylindrical elements1 to provide intensive mixing and/or create a seal. Particularfy useful are aiuatemstatiag, non-iatenneahing twin screw extruders, in which one screw is usually longer than the other to facilitate efficient Sow through the die of the material bcittg extruded Suck equipment is available from various manufacturers including Welding Engineers, Inc.

Using the cold or wann compaction method, the poly(arylene ether) powder may be compacted into small pellets, small disks with varying thickness or into large sheets of varying thickness. Useful compaction equipment includes both, confined pressure devices and extrusion devices. In a confined pressure device the poly(arylene ether) powder or powder mixture is directly consolidated in a closed mold or between two opposing surfaces. Compression is done either into mold to give a final shape or into a sheet or block that is later broken up to achieve the desired shape and size. In extrusion de\ ir.es the poly(arylene ether) powder or powder mixture undergoes shear and is consolidated while being subjected to pressure in a die. Extrudates may be formed under pressure in dies having a variety of cross sections and as they leave the die they may be broken up or cut to size. Useful confined pressure devices include pistons, molding presses, tableting presses, roll compactors, pre-getting rolls, briquetting rolls, gear pclletcrs and combinations of the foregoing. It should be noted that some compression rolls, while not individually comprising a cavity, nevertheless when used in combination with a second compression roll comprise a cavity between the two compression rohs. Extrusion devices include pellet mills, ring pellet mills, double roll extruders, and&ngle screw and twin screw extruders. As used herein and throughout the specification the term "compression mold" refers to the cavity in which the poly(arylene ether) powder is compressed, including a die head attached to an extruder. In one embodiment, the pellets have a diameter of about 2 millimctres(mm) to about 25 mm, and a height of about 1 mm to about SO mm. In another embodiment, the disks have a thickness of about 1 mm to about 50 mm. In yet another embodiment, the sheets have a thickness of about 2 mm to about 50 mm.
The compression molding method may be used to prepare pellets having any arbitrary shape. Particularly useful pellet cross sectional shapes include spherical, cylindrical, cubical, elliptical right prism, ellipsoidal, cylindrical with torrispherical heads, elliptical with ellipsoidal heads, rectangular or square right prisms, rectangular or square right' prism with rounded edges.

The compression molding method is effective in manufacturing pellets having high bulk density compared to the poly(arylene ether) powder. The high bulk density of the compacted pellets reduces the volume occupied by the material during storage and transportation and thereby reduces the costs involved in the storage and transportation of the poly(arylene ether) pellets. Moreover, the compacted poly(arviene ether) pellets may be fed to an extruder at higher feed rates than can be employed with poly(arylcne ether) powder.
The compression molded poly(aryiaie ether) articles may be subjected to further processing including sanding and painting or powder coating and used in various, applications such as domestic electric appliances, electric and electronic parts, construction materials, automobile parts, communication devices and information management transmission parts. Particularly, the molded material may be used in television housing, television chassis, deflection shock, other television parts, AC adaptor, electricity source box, air conditioner parts, audio parts, radiator cover, monitor housing, monitor chassis, liquid crystal projector housing, antenna cover, printer housing, printer chassis, scanner housing, scanner chassis, terminal adaptor, modem, and electric wiring insulation parts.
Further, it may be used in bathtub parts, shower head, pump housing, parts of air purifier, parts used in kitchens, pipes, gutter, sound barrier walls, window frame, toys, gardening tools, fishing tackles, foodstuff containers and cosmetic containers.
Further automobile part examples include instrument panel, center console, meta console, glove box, airbag, defioster garnish, air duct, heater control, steering column cover, air defioster, door trim, sunshade, roof liner, pillar cover, pillar impact absorber, bonnet air scoop, radiator grill, signal lamp part^ fog lamp part, door handle, door minor, door panel, quarter panel, battery tray and battery housing.
Also, the compression molded poly(arylene ether) may find application in the aerospace industry. Applications include missile and aircraft stabilizer fins, wing ribs and panels,

fuselage wall linings, overhead storage compartments, ducting, fasteners, engine housings and helicopter fairings.
Moreover, the compression molded sheets of poly(arylene ether) may find application in mines and thermal power stations due to their high impact strength and high abrasion resistance. Compression molded sheets of poly(arylene ether) may find application in the lining for the hopper of furnaces. In such applications the linings are frequently exposed directly to the fire. Ultra-high molecular weight polymers of poly(aryiene ether) are excellent in chemical resistance and may give sheets having higher impact strength and abrasion resistance required for such critical applications.
The disclosure is further illustrated by the following non-limiting examples. EXAMPLES 1 TO 3
The raw material used in the following examples was a powder of polv(2,6-dimethyl-l,4-phenyiene) ether having a density of 0.45 grams per cubic centimetre and an intrinsic viscosity of 0.41 dl/g as measured in chloroform at 25 *C and containing about 35 to about 45 volume percent particles with a size less than 100 micrometers.
The compression mold consisted of a cavity in the form of a hollow stainless steel cylinder wim a surrounding aluminum sleeve, with the cylinder measuring 55 mm in the outside diameter, 10 mm in the inside diameter or base diameter, and 45 mm hi height. Also, the compression mold has a stainless steel piston, with the piston measuring 60 mm hi height and 10 mm in diameter.
0.38 grams of poly(arylene ether) powder was introduced to the compression mold at room temperature. The piston was fixed, and a hydraulic compression press applied a pressure for 5 seconds, after which the molded piece was taken out of the mold. These molded pellets were tested under compressive load in a Zwick Z010 machine, and the load at which (he pellet started to disintegrate was measured which hereinafter is referred as the compressive strength.

Table 1 shows the value of the temperature in *C, pressure in tons per square centimeter (tons/cm2), weight of the poly(arylene ether) powder in grams (g), density of the molded pellets in grams per cubic centimeter (g/cm3), compressive load of the molded pellets in Newton (N), compressive strength of the molded pellets in kilograms (kg) and the compressive stress of the molded pellets in megapascal (MPa). Table 1 also shows the dimension ratio of the molded pellets which is a ratio of the diameter of the molded pellets in millimeter (mm) to the height of the molded pellets in mm. The compressive load as shown in the table is the load on the sample at the yield point All the values shown in the table are an average of five tested samples.
Table 1.

Ex. Temp •tesue Hagjt Dmcnsnr Bafo Wdgt tasty Qnpcsvc Load QxnpRssivc Strength Cbofxcssnn Stress

1 25 I 627 LSOS 037 0.748 170556 17350 2L42
2 25 2 5£2 1.790 038 0858 370914 378.10 4657
3 25 3 515 1945 038 0948 4997.89 50947 6151
No separation or cracking was seen on the surface of these compression molded pellets. The density of the article produced from the compression molding of poly(arylene ether) powder was greater than the density of the poly(arylene ether) powder as can be interpreted from the above table.
EXAMPLES4TO6
The same procedure as in Example 1 was carried out, except that the mold consisted of a cylinder of 16 millimetres base diameter.
l.S grams of poly(aryiene ether) powder was filled in the compression mold at room temperature. The piston was then fixed, and a pressure was applied by a hydraulic compression for 5 seconds, after which the molded piece was taken out of the mold. These molded pellets were tested as in Examples 1-3. Data is sbown-in Table 2.
Table 2.

Ex. Tfcmpcnttic tann He&t DnicnsiDji Ratio Wrirfi Dash' Gompresive Load Gonfxcssw
SfrBlnR Oonpcssne
Sties

4 25 1 957 L663 LSI 0.768 459954 46856 2168
5 25 2 &M 1599 150 0917 11217.94 114352 5531
6 25 3 787 2043 152 0951 12792.18 1303S9 6107
No separation or cracking was seen on the surface of these compression molded pellets. The density of the article produced was greater than the density of the poly(arylene ether) powder.
EXAMPLES 7 TO 9
The same procedure as in Examples 4-6 was canied -out, except that the dimension ratio of the compression molded pellets was about 1.
3.0 grams of poly(arylene ether) powder was placed in the compression mold at room temperature. The piston was then fixed, and a pressure was applied by a hydraulic compression for 5 seconds, after which the molded piece was taken out of the mold These molded pellets were as in Examples 1-6. Data is shown in Table 3.
Table 3.

Ex. Toppoatuic fVeasui TV_*_«-^
npgnt Dbnenoor Ratio Wag* Density Cbaprcazve Load Oonpesaw SbocJh Cbopcasne Sots
7 25 1 19.68 0817 S3 0733 198256 2Q2JO . 9J7
8 25 2 1617 0994 99 0913 738922 75323 3643
9 25 3 1543 1041 3J01 0960 965325 98402 4759
No separation or cracking was seen on the surface of these compression molded pellets or tablets. The compression strength of the compression molded pellets in examples 7 to 9 is less than the compressive strength of the pellets in example 4 to 6.
EXAMPLE 10
The same procedure as in Examples 4-6 was carried out, except that the raw material used was a poly(arylene ether) powder with an intrinsic viscosity of 0.46 and containing about 35 to about 45 volume percent particles with a size less than 100 micrometers.

1.5 grams of poly(arylene ether) powder was filled in the compression mold at room temperature. The piston was then fixed, and a pressure was applied by a hydraulic compression for 5 seconds, after which the molded piece was taken out of the mold. These molded pellets were tested as in Examples 1-9. Results are shown in Table 4.
Table 4.



Hegi
Ex.
10

25


T«ri
DhwEk^Wd^ Density Ratio
765 2101 L49 0957 1811086 1S4&16

Concessive Stoat
8929

No separation or cracking was seen on the surface of these compression molded pellets.
While the disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments Ming within the scope of the appended claims.

CLAIMS
1. Ame&odfeGQaapresaooiacMBgoFp comprising:
introducing a powder comprising imheated poly(aryleae ether) powder to co&pactiaa equipment comprising a compression mold; m&
subjecting the powder ia the compression mold to a pressure sufficient to produce an article having a density greater than the unseated pbly(arylene ether) powder wherein said pressure is at a applied temperature less than the glass transition temperature of the poly(aryleue ether) powder.
2. The method of Claim 1 wherein the pressure is about 0.05 to about 50 tons -per square centimeter, the temperature is about 0 to about ?0*C and the pressure is applied for about 0.1 to sJxRit 100 seconds.
3. The method of Claim 2, wherein fee article has a compressive strength of about 5
to about 3099 kilograms.
4. The method of Claim 2, wherein the article has a density of about 0.6 to about 1.2
grams per cubic centimeter.
5. The method of Claim 1 wherein the pressure is about 3.2 to about 20 tons per
square centimetre, the pressure is applied for about 300 to about 2000 second and the
temperature ia sufficient to at least soften the poly(arylene etter) powder and/or a birtder
when present
6. The method of Claim 5 wbereia the article has a compressive strength grealer
&an about 4000 lotograins sad a density of greater tfaaa or equal to about 0.95 grams per
cubic centimeter.
?- The method of Claim 5 whereia fee poIyCaryleue dier) ts proctsst ^ » Kaaaove «r reduce gas trapped between the ps^ktss.

8. The method of claim 1, wherein the powder further comprises a binder, a flame
retardant, an additive, a modifying agent or a combination of two or more of the
foregoing.
9. The method of claim 8, wherein the binder is crystalline and has a melt
temperature less than the glass transition temperature of the poly(arylece ether) powder.
i
10. The method of claim 8, wherein the binder is amorphous and has a glass transition
temperature less than the glass transition temperature of the poly(arylene ether) powder.
11. The method of claim 8, wherein the binder is a reactive binder.
12. The method of claim 8, wherein the binder is a non-reactive binder.
13. The method of claim 8, wherein the additive is selected from the group consisting
of antioxidants, mold release agents, ultra violet absorbers, stabilizers, lubricants,
plasticizers, pigments, dyes, colorants, antistatic agents, blowing agents, and mixtures
thereof.
14. The method of claim 8, wherein the binder is present la an amount of about 0.01
to about 40 weight percent, based on the total weight of the mixture.
15. The method of claim 1, wherein the compression mold is unheated upon
introduction of the powder.
16. The method of claim 1, wherein the compression mold is healed after introduction
of the powder.
17. The method of claim 16, wherein the compression mold is not heated during
compressing.
18. The method of claim 1, wherein the compression mold is heated prior to
introduction of the powder.

19. The method of claim 18, wherein the compression mold is heated after
introduction of the powder.
20. The method of claim 18, wherein the compression mold is not heated during the
application of pressure.
21. The method of claim 1, wherein the compression mold is a die of an extruder.
22. The method of claim 1, wherein the article is a single phase compact
23. The method of claim 1, wherein the article is a multi phase compact
24. The method of claim 1, wherein the poly(arylene ether) powder comprises about 5
to about 70 volume percent, based on the total volume of poly(arylene ether) powder, of
particles having a particle size less than about 100 micrometers.
25. The method of Claim 1 wherein the poly(arylene ether) powder has an average
particle size of about SO to about 1500 micrometer.
26. The method of Claim 1 wherein the compaction equipment is a confined pressure
device.
27. The method of Claim 1 wherein the compaction equipment is an extrusion device.
28. A method for compression molding of poly(arylene ether) powder to produce an
article, comprising:
introducing a mixture comprising a binder and poly(arylene ether) powder to compaction equipment comprising a compression mold;
subjecting the mixture in the compression mold to a pressure sufficient to form an article having a density greater than the poly(arylene ether) powder wherein said pressure is applied at a temperature less than the glass transition temperature of the poly(arylene ether).

29. The method of claim 28 wherein the binder is heated prior to blending with the
poly(arylene ether) powder.
30. The method of claim 28, wherein the binder is in solution and the mixture is
subjected to devolatization prior to being subjected to pressure.
31. The method of claim 28, wherein the poly(arylene ether) powder comprises about
5 to about 70 volume percent, based on the total volume of poly(arylene ether) powder,
of particles having a particle size less than about 100 micrometers.
32. A method for compression molding of poly(arylene ether) powder, comprising:
introducing an unheated poly(aiylene ether) powder to compaction equipment comprising a compression mold;
subjecting the unheated poly(arylene ether) powder in the compression mold to a pressure sufficient to produce an article having a density greater than the unheated poly(arylenc ether) powder wherein said pressure is applied at a temperature less than the glass transition temperature of the poly(arylene ether).