POLY(PHENYLENE ETHER) BASED COMPATIBILIZING MATERIAL

Abstract

Compatibilizing materials for use with fibers and polymeric compositions are described. A compatibilizing material can include a silane (Si) modified polyphenylene ether (PPE) oligomer having a resin reactive functional group. The resin reactive functional group can be between the PPE moiety and a Si moiety. In other instances, the resin reactive functional group can be a substituent of the Si moiety.

Claims

1. A compatibilizing material comprising a silane (Si) modified polyphenylene ether (PPE) oligomer having a resin reactive functional group, wherein the resin reactive functional group is (1) a substituent of the PPE oligomer, (2) positioned between the PPE portion of the oligomer and the Si portion of the oligomer, (3) a substituent of the Si portion of the oligomer, or (4) a combination thereof.

2. The compatibilizing material of claim 1, having the structure: ##STR00088## where A is the polyphenylene ether oligomer, a is 0 to 12, b is 0 to 12, R.sup.1 is a resin reactive group, R.sup.2 is a hydrogen (H), a substituted or unsubstituted hydrocarbyl group, R.sup.3 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group, and R.sup.4 is a H, a substituted hydrocarbyl group or unsubstituted hydrocarbyl group, preferably R.sup.4 is a substituted or unsubstituted aromatic group, or R.sup.4 has the structure of: ##STR00089## where: c is 0 to 12; d is 0 to 12; R.sup.5 is a resin reactive group; R.sup.6 is a H, a substituted or unsubstituted hydrocarbyl group; and R.sup.7 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

3. The compatibilizing material of claim 1, having the structure: ##STR00090## where A is the polyphenylene ether oligomer, Y is a linking group comprising the resin reactive functional group R.sup.10; R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.8 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; and R.sup.9 is a H, a substituted hydrocarbyl group or an unsubstituted hydrocarbyl group.

4. The compatibilizing material of claim 3, wherein R.sup.9 is a substituted or unsubstituted aromatic group, or R.sup.9 has the structure of: ##STR00091## where Y is the linking group comprising a resin reactive functional group R.sup.10; R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group; and R.sup.3 and R.sup.8 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

5. The compatibilizing material of claim 3, wherein Y is ##STR00092## where: R.sup.10 is the resin reactive group, e is from 0 to 12; f is from 0 to 12; and ##STR00093## represents the bonds to A and Si, with the proviso that when R.sup.9 is H, R.sup.10 is not OH; ##STR00094## where: R.sup.10 is the resin reactive group; g is from 0 to 12; and ##STR00095## represents the bonds to A and Si; or ##STR00096## where: R.sup.10 is the resin reactive group; h is from 0 to 12; R.sup.11 is a bond, or a substituted or unsubstituted hydrocarbyl group; and ##STR00097## represents the bond to A.

6. The compatibilizing material of claim 1, wherein the resin reactive group comprises an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group.

7. (canceled)

8. The compatibilizing material of claim 7, wherein the poly(phenylene ether) has the chemical structure of ##STR00098## where Z.sup.1, Z.sup.2, Z.sup.3, and Z.sup.4 each independently is a hydrogen, a phenyl, a (bi)cyclic hydrocarbon, a unsubstituted or a substituted C.sub.1-C.sub.12 hydrocarbyl group provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, or a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen, and oxygen atoms, preferably Z.sup.1 and Z.sup.3 are methyl and Z.sup.2 and Z.sup.4 are H, and z is at least 1 or ##STR00099## where Q.sup.1, Q.sup.2, Q.sup.3, and Q.sup.4 each independently is a halogen, an unsubstituted or substituted C.sub.1-C.sub.12 primary or secondary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy where at least two carbon atoms separate the halogen and oxygen atoms, x and y are independently 0 to 30, provided that the sum of x and y is at least 2; and L has the chemical structure: ##STR00100## where R.sup.15, R.sup.16, R.sup.17, and R.sup.18 are each independently is a hydrogen, an unsubstituted or substituted C.sub.1-C.sub.12 hydrocarbyl provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen and oxygen atoms; m is 0 or 1; and X has the chemical structure selected from the group ##STR00101## where R.sup.14 is a hydrogen or C.sub.1-C.sub.12 hydrocarbyl, R.sup.12 and R.sup.13 each independently is a hydrogen, a C.sub.1-C.sub.12 hydrocarbyl, or C.sub.1-C.sub.6 hydrocarbylene where R.sup.12 and R.sup.13 collectively can form a C.sub.4-C.sub.12 alkene, or a siloxane where R.sup.19 and R.sup.20 are each independently selected from hydrogen, hydrocarbyl or halogen-substituted hydrocarbyl, D is an integer of from about 30 to about 70, preferably R.sup.19 and R.sup.20 are both methyl and D is 40 to 60, and at least one of R.sup.15-R.sup.18 is methoxy.

9. The compatibilizing material of claim 8, having the structure of ##STR00102## where: a and c are each independently 0 to 12; b and d are each independently 0 to 12; and R.sup.2 and R.sup.6 are each independently a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.7 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; and x and y are independently 0 to 30, provided that the sum of x and y is at least 2; ##STR00103## where: a and c are each independently 0 to 12; b and d are each independently 0 to 12; and R.sup.2 and R.sup.6 are each independently a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.7 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; x and z are independently 0 to 30, provided that the sum of x and z is at least 2 and y is 0 or 1; ##STR00104## where k is 1 to 10, x and, z are independently 0 to 40, y is 0 or 1, wherein when y is 0, at least one of x and z is 1 to 40, R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; ##STR00105## where k is 1 to 10, x and, z are independently 0 to 40, y is 0 or 1, wherein when y is 0, at least one of x and z is 1 to 40, R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; or ##STR00106## where R.sup.22 and R.sup.23 each independently is a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R.sup.24 and R.sup.25 each independently is an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, x and z are independently 0 to 30, provided that the sum of x and z is at least 2 and y is 0 or 1.

10. A compatibilizing material, having the structure of ##STR00107## where, and R.sup.2 is H, a substituted or unsubstituted hydrocarbyl group, R.sup.3 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group, a is 0 to 12, b is 0 to 12, and z is 1 to 30; ##STR00108## where k is 1 to 10, z is 1 to 40, R.sup.2 is H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; or ##STR00109## where R.sup.22 and R.sup.23 each independently is a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R is an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, and z is 1 to 30.

11. A surface treated material and/or a coated material comprising the compatibilizing material of claim 1.

12. A surface treated material and/or a coated material, wherein a surface of the material is treated or coated with the compatibilizing material of claim 1.

13. (canceled)

14. (canceled)

15. A thermosetting resin composition comprising the surface treated material and/or coated material of claim 11.

16. A thermosetting resin composition comprising the compatibilizing material of claim 1 and a glass fiber, alumina fiber, basalt fiber, quartz fiber, inorganic filler or metal foil.

17. A sized fiber comprising the compatibilizing material of claim 1.

18. (canceled)

19. The sized fiber of claim 18, wherein a least a portion of the compatibilizing material is attached to the polymeric resin and the sized fiber, preferably the compatibilizing material is covalently bonded to the polymeric resin and coated on at least a portion of the surface of the sized fiber, preferably, wherein the fiber is preferably an inorganic fiber or filler, more preferably glass fibers, glass cloth, or both.

20. The sized fiber of claim 17 wherein the resin comprises a thermoset polymer, a thermoplastic polymer, a fire-retardant resin composition, or any combination thereof, preferably the thermoset polymer is an epoxy resin, an epoxy vinylester, an alkyd, an amino-based polymers a diallyl phthalate, a phenolics polymer or resin, a polyester, an unsaturated polyester resin, a dicyclopentadiene, a polyimide, a silicon, a cyanate esters of polycyanurate, a thermosetting polyacrylic resin, a benzoxazine, or co-polymers thereof, triallyl isocyanaurate, triallyl cyanurate, and other mono-, di- and multifunctional vinyl monomers or crosslinking agents or blends thereof.

21. (canceled)

22. An article of manufacture comprising the sized fiber, surface treated material and/or a coated material, and/or thermosetting resin composition of claim 11.

23. A method of preparing a silane modified polyphenylene ether (PPE), the method comprising contacting a composition comprising a PPE oligomer, a silane source, and 4-dimethylaminopyridine under conditions sufficient, to react the PPE oligomer with the silane source to produce the silane modified PPE; or by contacting 2,6-dimethyl phenol and silane source under conditions sufficient, to react 2,6-dimethyl phenol with the silane source to produce a silane modified PPE.

24. A method of preparing a silane modified polyphenylene ether (PPE) according to claim 23, wherein the method comprises contacting 2,6-dimethyl phenol and silane source under conditions sufficient, to react 2,6-dimethyl phenol with the silane source to produce a silane modified PPE.

25. A method of preparing a silane modified polyphenylene ether (PPE) according to claim 23, the method comprising contacting a composition comprising a PPE oligomer, a silane source, and 4-dimethylaminopyridine under conditions sufficient, to react the PPE oligomer with the silane source to produce the silane modified PPE

Description

DETAILED DESCRIPTION OF THE INVENTION

[0035] A discovery has been made that provides a solution to at least some of the problems associated with PPE based compatibilizing materials. The discovery can include the use of a compatibilizing material that includes a silane modified PPE. The compatibilizing material can include a silane (Si) modified polyphenylene ether (PPE) oligomer having a resin reactive functional group between the PPE moiety and a Si moiety or the resin reactive functional group is a substituent of the Si moiety or the PPE moiety. In one aspect, the compatibilizing material can be used as a sizing agent for fibers to produce sized fibers. The sized fibers can be used in composite materials that includes a polymeric matrix.

[0036] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.

A. Si Modified PPE Compatibilizing Material

[0037] The silane modified PPE compounds of the present invention can include a resin reactive functional group. Non-limiting examples of resin reactive groups include an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a hydroxy group, or any combination thereof. In some embodiments, the resin reactive group can be a hydroxy group, an acrylate group, substituted acrylate group, or a siloxane. In a preferred embodiments, the resin reactive group is a methacrylate group, or a vinyl group.

[0038] PPEs of the present invention can represented by the structure:

##STR00027##

where Z.sup.1, Z.sup.2, Z.sup.3, and Z.sup.4 can each independently be a hydrogen, a unsubstituted or a substituted C.sub.1-C.sub.12 hydrocarbyl group provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, or a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen and oxygen atoms, and z is at least 1.

[0039] In some embodiments, the PPE can be represented by the structure:

##STR00028##

where Q.sup.1, Q.sup.2, Q.sup.3, and Q.sup.4 can each independently be a hydrogen, an unsubstituted or substituted C.sub.1-C.sub.12 primary or secondary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy where at least two carbon atoms separate the halogen and oxygen atoms; x and y are independently 0 to 30, provided that the sum of x and y is at least 2; and L has the structure:

##STR00029##

where R.sup.15, R.sup.16, R.sup.17, and R.sup.18 can each independently be a hydrogen, an unsubstituted or substituted C.sub.1-C.sub.12 hydrocarbyl provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen and oxygen atoms; m is 0 or 1; and X has a structure:
and X can have a structure selected from:

##STR00030##

where R.sup.14 can be a hydrogen or C.sub.1-C.sub.12 hydrocarbyl, R.sup.12 and R.sup.13 can each independently be a hydrogen, a C.sub.1-C.sub.12 hydrocarbyl, or C.sub.1-C.sub.6 hydrocarbylene where R.sup.2 and R.sup.3 collectively can form a C.sub.4-C.sub.12 alkene, a or a siloxane where R.sup.9 and R.sup.20 are each independently selected from hydrogen, hydrocarbyl or halogen-substituted hydrocarbyl, D is an integer of from about 30 to about 70, preferably R.sup.19 and R.sup.20 are both methyl and D is 40 to 60, and at least one of R.sup.15-R.sup.18 is methoxy.

[0040] In some embodiments, the PPE can have the structure:

##STR00031##

[0041] where Z.sup.1, Z.sup.2, Z.sup.3, and Z.sup.4 can each independently be a hydrogen, a unsubstituted or a substituted C.sub.1-C.sub.12 hydrocarbyl group provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, or a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen, and oxygen atoms, preferably Z.sup.1 and Z.sup.3 are methyl and Z.sup.2 and Z.sup.4 are H, and z is at least 1.

[0042] In yet another embodiment, the PPE can have the structure of

##STR00032##

[0043] where Q.sup.1, Q.sup.2, Q.sup.3, and Q.sup.4 can each independently be a halogen, an unsubstituted or substituted C.sub.1-C.sub.12 primary or secondary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy where at least two carbon atoms separate the halogen and oxygen atoms, x and y can each independently be 0 to 30, provided that the sum of x and y is at least 2, and L can have the structure:

##STR00033##

where R.sup.15 and R.sup.16 can each be methyl groups, R.sup.17, and R.sup.18 can each be hydrogen; m can be 0 or 1; and Y can be:

##STR00034##

[0044] The PPE's of the present invention can be bonded to one or more silane groups that includes the reactive resin functional group and/or a linker group that includes the reactive resin functional group. In one aspect the silane modified PPE can have the general structure of:

##STR00035##

where A can be a polyphenylene ether moiety described above. This silane portion can have a be 0 to 12, and b can be 0 to 12. R.sup.1 can be the resin reactive group. Non-limiting examples of resin reactive groups include an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a hydroxy group, or any combination thereof. In some embodiments, the resin reactive group can be a hydroxy group, an acrylate group or substituted acrylate group. In a one embodiment, the resin reactive group is a methacrylate group or an acrylate group. R.sup.2 can be a H, a substituted hydrocarbyl group, or unsubstituted hydrocarbyl group. Non-limiting examples of R.sup.2 include methyl, ethyl, and propyl. R.sup.3 can be a H, a substituted hydrocarbyl group, an unsubstituted hydrocarbyl group, a substituted alkoxy group, or an unsubstituted alkoxy group. Non-limiting examples of R.sup.3 include methoxy and ethoxy. R.sup.4 can be a H, or a substituted or unsubstituted hydrocarbyl group. In some embodiments, R.sup.4 can be a substituted or unsubstituted aromatic group. In other embodiments, R.sup.4 can have the structure of:

##STR00036##

where c can be 0 to 12, and d can be 0 to 12. R.sup.5 can be a resin reactive group that is the same or different than R.sup.1. In one instance R.sup.5 and R.sup.1 are the same. R.sup.6 can be a H or a substituted or unsubstituted hydrocarbyl group. Non-limiting examples of R.sup.6 include methyl, ethyl, and propyl. R.sup.7 can be a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group. Non-limiting examples of R.sup.7 include methoxy and ethoxy. In one instance, the silane modified PPE can include the following structure:

##STR00037##

where a and c can each be independently 0 to 12; b and d are each independently 0 to 12, x and z can each independently be 0 to 30, provided that the sum of x and z is at least 2 and y can be 0 or 1. R.sup.2 and R.sup.6 can each independently be a H, a substituted hydrocarbyl group, or unsubstituted hydrocarbyl group, or any combination thereof. Non-limiting examples of R.sup.2 and R.sup.6 include methyl, ethyl, and propyl or combinations thereof. R.sup.3 and R.sup.7 can each independently be a H, a substituted hydrocarbyl group, or unsubstituted hydrocarbyl group, a substituted alkoxy group, an unsubstituted alkoxy group, or combinations thereof. Non-limiting examples of R.sup.3 and R.sup.7 include methoxy, ethoxy, and combinations thereof.

[0045] In another instance, R.sup.5 is a vinyl group, c and d is 0, R.sup.6 is methyl, and R.sup.7 is methoxy. Such a compound can have the structure of

##STR00038##

[0046] In another instance, the silane modified PPE can have the following general structure:

##STR00039##

where A can be one of the polyphenylene ether moieties described above. Y can be a linking group that includes the resin reactive functional group. Non-limiting examples of resin reactive groups include an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a hydroxy group, or any combination thereof. In some embodiments, the resin reactive group can be a hydroxy group, an acrylate group or substituted acrylate group. In a one instance, the resin reactive group is an alcohol, an epoxy group, a vinyl group, an allyl group or the like. R.sup.2 can be a H, a substituted hydrocarbyl group, or unsubstituted hydrocarbyl group. Non-limiting examples of R.sup.2 include methyl, ethyl, and propyl. R.sup.3 and R.sup.8 can each independently be a H, a substituted hydrocarbyl group, an unsubstituted hydrocarbyl group, a substituted alkoxy group, or unsubstituted alkoxy group, or combinations thereof. Non-limiting examples of R.sup.3 and R.sup.8 include methoxy, ethoxy or combinations thereof. R.sup.9 can be a H, or a substituted or unsubstituted hydrocarbyl group. In some instances, R.sup.9 can be a substituted or unsubstituted aromatic group. In certain instances, R.sup.9 can have the structure of:

##STR00040##

where Y is linking group that includes a resin reactive functional group R.sup.10. R.sup.2, R.sup.3, and R.sup.8 are as defined above. In some instances, Y can have the structure of

##STR00041##

where R.sup.10 can be the resin reactive group, e can be from 0 to 12, f can from 0 to 12, and

##STR00042##

represents the bonds to Si and a PPE as described in the specification. In a preferred instance R.sup.10 is not OH. In another instance, a non-limiting example of R.sup.9 can be when R.sup.10 is OH, e is 0, f is 3 and the Si is Si(OEt).sub.3. This is as shown in the following structure:

##STR00043##

In another instance, Y can have the structure of

##STR00044##

where R.sup.10 can be the resin reactive group; g can be from 0 to 12, and

##STR00045##

represents the bonds to Si and PPE as described in the Specification. A non-limiting example of R.sup.9 can be when R.sup.10 is OH, g is 3, and the Si is Si(OEt).sub.3. This is as shown in the follow structure

##STR00046##

[0047] In another instance, Y can have the structure of

##STR00047##

A non-limiting example of R.sup.9 can be when R.sup.10 is a vinyl group and g is 0.

[0048] In yet another instance, Y can have the structure of

##STR00048##

where R.sup.10 can be the resin reactive group, h can be from 0 to 12, R.sup.11 can be a bond, or a substituted or unsubstituted hydrocarbyl group; and

##STR00049##

represents the bond to PPE as described in the Specification. Non-limiting examples of R.sup.9 can be when R.sup.10 is OH, R.sup.11 is a CH.sub.2, h is 0, and the Si is Si(OMe).sub.3 or Si(OEt).sub.3. This is illustrated in the following structures.

##STR00050##

[0049] Non-limiting examples of the Si-modified PPE are illustrated as follows.

##STR00051##

where x is 0 to 40, y is 1 and z is 0 to 40.

[0050] In some embodiments, the silane moiety is attached to the hydrocarbon portion (e.g., aromatic group) of the PPE oligomer. This allows for the hydroxyl group of the PPE polymer to become the resin reactive group. Non-limiting examples of silane groups that can be attached to the aromatic portion of the PPE oligomer are silane sane/or siloxanes that include secondary amines. A non-limiting example of an amine silane modified PPE can be

##STR00052##

where R.sup.22 and R.sup.23 can each independently be a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R.sup.24 and R.sup.25 can each independently be an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, x and z are independently 0 to 30, provided that the sum of x and z is at least 2 and y is 0 or 1.

[0051] In some aspects, the compatibilizing material can have the structure of:

##STR00053##

where, and R.sup.2 can be a H, a substituted or unsubstituted hydrocarbyl group, R.sup.3 can be a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group, a can be 0 to 12, b can be 0 to 12 and z can be 1 to 30.

[0052] In some embodiments, the compatibilizing material can have the structure of

##STR00054##

where k can be 1 to 10, x and, z can be independently 0 to 40, y can be 0 or 1, wherein when y is 0, at least one of x and z is 1 to 40, R.sup.2 can be a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 can each independently be a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

[0053] In some embodiments, the compatibilizing material can have the structure of

##STR00055##

[0054] where k can be 1 to 10, x and, z can be independently 0 to 40, R2 can be a H, a substituted or unsubstituted hydrocarbyl group, and R3 and R8 can each independently be a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

[0055] In some aspects, the compatibilizing material can have the structure of:

##STR00056##

where k can be 1 to 10, z can be 1 to 40, R.sup.2 can be a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 can each independently be a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

[0056] In some aspects, the compatibilizing material can have the structure of:

##STR00057##

where R.sup.22 and R.sup.23 can each independently be a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R can be an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, z can be 1 to 30.

B. Preparation of Si Modified PPE Compatibilizing Material

[0057] Si modified PPEs can be prepared using known organic synthesis methodology. Mono- and bifunctional PPE oligomers and silane precursors can be obtained from commercial sources and/or prepared using synthetic methodology. Commercial sources of PPE oligomers can include SABIC (Saudi Arabia). Silane precursors can be obtained from commercial sources such as Gelest (USA). Non-limiting examples of silane precursors include the following structures.

##STR00058##

[0058] Secondary amino functionalized silane materials can also be used. Non-limiting examples, of amine-functionalized silanes include bis(3-trimethoxysilylpropyl)amine (aminoethylaminomethyl)phenethyltrimethoxysilane, N-(2-Aminoethyl)-3-aminopropyltrimethoxysilane, N-[3-trimethoxylsilyl)propyl]ethylene diamine available from Gelest (USA), and those described in European Patent No. 1451198 to Gedon et al., preferably bis(3-trimethoxysilylpropyl)amine. A non-limiting example of an amine functionalized silane can include

##STR00059##

where R.sup.21 and R.sup.22 can each independently be a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, i is 0 to _ and j is 0 to 6. In a preferred aspect, R.sup.22 and R.sup.23 are both methyl and i and j are 3.

[0059] Preparation of the compatibilizing materials of the present invention can include preparing a solution of mono- or bifunctional PPE oligomer (PPE oligomer) and organic solvent. The PPE oligomer solution can be heated to a temperature of 40° C. to 60° C., 45° C. to 55° C., or at least one or, equal to one of, or between any two of 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 and 60° C. until the PPE oligomer dissolves.

[0060] Non-limiting examples of organic solvents include aromatic hydrocarbons (e.g., benzene, toluene, and xylene), halogenated aromatic hydrocarbons (e.g., chlorobenzene and dichlorobenzene), halogenated aliphatic hydrocarbons (e.g., chloroform, trichloroethylene, and carbon tetrachloride), and aprotic polar solvents (e.g., N-methyl-2-pyrrolidone and 1,3-dimethyl-2-imidazolidinone). Next a silane precursor material described above and a catalytic base (e.g., 4-dimethylaminopyridine (DMAP)) can be added to the solution under agitation. The reactive solution can be heated to a reaction temperature of 80 to 100° C., 85 to 95° C., or at least one or, equal to one of, or between any two of 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99 and 100° C., and then stirred at the reaction temperature until the reaction is deemed complete (e.g., 1 to 24 hours). Examples of suitable basic catalysts which can be used according to the present invention include alcoholates (e.g., sodium methoxide and sodium ethoxide); tertiary amines (e.g., benzyldimethylamine, tributylamine, and 1,8-diazabicyclo[5,4,0]-7-undecene (DBU), 4-dimethylaminopyridine (DMAP)); and alkali metal hydroxides (e.g., sodium hydroxide and potassium hydroxide). The molar ratio of silane precursor to mono- or bifunctional PPE oligomer to can be 0.5 to 2, 1.5 to 2, or 1.6 to 1.9, 1.7 to 1.8 or any value or range there between. The product can be precipitated by contact of the reaction solution with a precipitating solvent. The reaction solvent can be added to the precipitating solvent or vice-a-versa. The precipitate can isolated using known isolation techniques such as filtration, decantation, centrifugation, etc. The isolated precipitate can be dried under vacuum at room temperature (e.g., 20 to 30° C., or about 25° C.).

[0061] In some embodiments, the amine silane functional group is coupled to the PPE polymer. Amine silane functionalized PPE can be prepared in the following manner. A solution of organic solvent (e.g., toluene) and PPE precursor materials (e.g., dimethyl phenyl, tetramethyl bisphenol A), amines (e.g., N,N-dimethylbutylamine, di-tert-butylethylenediamine N,N,N′N′-didecyldimethyl ammonium chloride and catalyst solution (e.g., Cu.sub.2O and HBr) can be polymerized under an oxygen atmosphere at a temperature of 30 to 50° C. or any value there between or about 40° C. After a desired amount of time (e.g., 1 to 1.5 hours or about 1.3 hours), the temperature can be increased to 45 to 50° C. or about 48° C. and held for a desired amount of time (e.g., 10 minutes). After holding, a secondary amine silane (e.g. bis(3-trimethoxysilylpropyl)amine can be added to the reaction mixture. The reaction can be continued under an oxygen atmosphere (e.g., an oxygen flow) for a desired amount of time or until the reaction was deemed complete (e.g., 150 minutes). The oxygen source can be discontinued and a quenching agent (nitrilotriacetic acid trisodium salt) and water (e.g., de-ionized water) can be added to the reaction mixture. The resulting mixture can be heated to 60° C. and held for a desired amount of time (e.g., 120 minutes). The layered reaction mixture can be separated by centrifugation and the final oligomer can be isolated by precipitating the toluene phase into methanol followed by filtration and drying in a vacuum oven at 60° C. under nitrogen overnight.

C. Preparation of Materials that Include the Compatibilizing Material

[0062] The compatibilizing material of the present invention can be contacted with fibrous material to form a protective coating on at least a portion of the surface or the entire surface of the fibrous material. Non-limiting examples of fibrous materials include glass fibers, carbon fibers, aramid fibers, polyethylene fibers, polyester fibers, polyamide fibers, ceramic fibers, basalt fibers, steel fibers, and/or the like. Fibers can be provided in bundles (e.g., bundles of carbon, ceramic, carbon precursor, ceramic precursor, glass, and/or the like fibers). Such bundles may include any number of fibers, such as, for example, 400, 750, 800, 1,375, 1,000, 1,500, 3,000, 6,000, 12,000, 24,000, 50,000, 60,000, or more fibers. Fibers in a bundle can have an average filament diameter of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, or more microns (e.g., from 5 to 30 microns, 10 to 20 microns, 12 to 15 microns, or any range there between). The fibers can be long (e.g., have a high aspect ratio). Aspect ratios can be from 2 to 10 or 10 to 500, or any value there between. Fibers can also be provided as a woven mat or cloth. In some instances, glass fibers, glass cloth, or both, are preferred. The fibrous material can be completely or partially coated. Contacting the fibrous material can include (1) immersing the fibrous material in a solution of the Si modified PPE, (2) removing and drying the fibrous material, and (3) drying the fibrous material. The solution with which the fibers are coated can contain from about 1 to 25 percent, by weight, of the Si modified PPE. Any solvent may be employed, preferably solvents that are non-reactive with the fibers and/or polymers to which the fibers can be incorporated into to produce composite materials. Non-limiting examples of solvents include methyl ethyl ketone, tetrahydrofuran and mixtures thereof. Drying of the fibers after removal from the solution may take place in air at ambient or elevated temperatures.

[0063] The Si modified PPE coated fibrous material can be combined with one or more resins. The fibrous material can be in any shape or form. Contact of the Si modified PPE coated fibrous materials with a resin can covalently bond the polymeric resin to the Si modified PPE. Contact can include mixing the above-described components by kneading in various kneading machines (e.g., a single-screw extruder, a twin-screw extruder, a Banbury mixer, and the like), or by mixing solutions or suspensions of each component and removing the solvent (or adding a common non-solvent) to form a precipitate, followed by collection by filtration. The components can be mixed in any of known allowable orders. Where a melt-kneading method is used, components are preferably mixed successively in descending order of viscosity of each component added. During contact, the reactive group of the Si modified PPE can covalently bond to a reactive group of the resin.

[0064] Fiber-containing composites of the present invention can also be made by dispersing fibers in a polymer matrix as described in International Application Publication No. WO 2016/142786 to Prins et al., which is incorporated by reference in its entirety. In such a method, a sheet or film that includes thermoplastic polymer matrix and additive can be supplied between a first and a second spreaded fiber layers. Heat can be applied to the fiber layer/polymer composition/fiber layer material, followed by pressing the fiber layers into the polymer composition. In some embodiments, after pressing is completed, the first or second fiber layers can be rubbed. In some embodiments, the fibers are not spread prior to heating. In another embodiment, the fiber-containing composite can be made by using known impregnation techniques. For example, Miller et al. in Polymers & Polymer Composites, 1996, Vol. 4, No. 7 describes impregnation techniques for thermoplastic matrix composites, which is incorporated by reference in its entirety. One such method can include providing supplying fibers to one or more solution baths (e.g., thermoplastic polymer in one or two baths) to form resin impregnated fibers, drying the fibers, and then pressing the fibers to produce a fiber-containing composite (e.g., prepreg sheets). In another embodiment, the polymer and fibers can be stacked together, heated, and then pressed causing the resin to flow transverse to the fibers to from prepreg sheets of fiber-containing composites. In a preferred embodiment, the fiber-containing composite is a unidirectional tape.

[0065] Also disclosed are laminates including fiber-containing composites of the present disclosure. Such laminates can include 2, 3, 4, 5, 6, 7, 8, 9, 10, or more plies where at least one ply is a fiber-containing composite of the present disclosure. In some laminates, at least two plies are positioned such that their respective fibers are substantially parallel to a first axis. In some laminates, at least two plies are positioned such that their respective fibers are not parallel to each other. Fiber-containing composites and laminates of the present disclosure can be assembled or processed into two-dimensional or three-dimensional structures, such as, for example, via winding and/or lay-up techniques.

D. Articles of Manufacture

[0066] Non-limiting examples of resins include a thermoset polymer, a thermoplastic polymer, a fire-retardant resin composition, or any combination thereof. Thermoset polymers can include an epoxy resin, an epoxy vinylester, an alkyd, an amino-based polymers a diallyl phthalate, a phenolics polymer or resin, a polyester, an unsaturated polyester resin, a dicyclopentadiene, a polyimide, a silicon, a cyanate esters of polycyanurate, a thermosetting polyacrylic resin, a benzoxazine, or co-polymers thereof, or blends thereof.

[0067] Non-limiting examples of thermoplastic polymers include polyethylene terephthalate (PET), a polycarbonate (PC) family of polymers, polybutylene terephthalate (PBT), poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate) (PCCD), glycol modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine or polyetherimide (PEI) and their derivatives, thermoplastic elastomer (TPE), terephthalic acid (TPA) elastomers, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), polyamide (PA), polysulfone sulfonate (PSS), sulfonates of polysulfones, polyether ether ketone (PEEK), polyether ketone ketone (PEKK), acrylonitrile butyldiene styrene (ABS), polyphenylene sulfide (PPS), co-polymers thereof, or blends thereof.

[0068] The resin can include additives Non-limiting examples of additives include coupling agents, antioxidants, heat stabilizers, flow modifiers, colorants, slip agents, weathering agents, nucleating agents, etc., or any combinations thereof.

[0069] The composite material comprising resin and compatibilized fibrous materials can have a fiber content, based on the total weight of the composite, of 1 to 90 wt. % fibers or greater than or substantially equal to any one of, or between any two of: 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 wt. % fibers. The resin content of the composite material can be, based on the total weight of the composite, 10 to 99 wt. % resin or greater than or substantially equal to any one of, or between any two of: 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt. % fibers.

[0070] The fibers and composites having resin and the sized fibers can be used to make a variety of articles of manufacture. Non-limiting examples of such articles of manufacture include automotive parts (e.g., doors, hoods, bumpers, A-beams, B-beams, battery casings, bodies in white, reinforcements, cross beams, seat structures, suspension components, hoses, and/or the like), braided structures, woven structures, filament wound structures (e.g., pipes, pressure vessels, and/or the like), aircraft parts (e.g., wings, bodies, tails, stabilizers, and/or the like), wind turbine blades, boat hulls, boat decks, transportation components, rail cars, rail car parts, sporting goods, window lineals, pilings, docks, reinforced wood beams, retrofitted concrete structures, reinforced extrusion or injection moldings, hard disk drive (HDD) or solid state drive (SSD) casings, TV frames, smartphone mid-frames, smartphone unibody casings, tablet mid-frames, tablet unibody casings, TV stands or tables, lap-top computer casings, ropes, cables, protective apparel (e.g., cut-resistant gloves, helmets, and/or the like), armor, plates, and the like. Non-limiting examples of transportation components can include floor panels, claddings, covers, and tray tables for train interiors. Non-limiting examples of claddings include: interior vertical surfaces, such as side walls, front walls, end-walls, partitions, room dividers, flaps, boxes, hoods and louvres; interior doors and linings for internal and external doors; window insulations; kitchen interior surfaces; interior horizontal surfaces, such as ceiling paneling, flaps, boxes, hoods and louvres; luggage storage areas, such as overhead and vertical luggage racks, luggage containers and compartments; driver's desk applications, such as paneling and surfaces of driver's desk; interior surfaces of gangways, such as interior sides of gangway membranes (bellows) and interior linings; window frames (including sealants and gaskets); (folding) tables with downward facing surface; interior and exterior surface of air ducts, and devices for passenger information (such as information display screens) and the like.

[0071] The compatibilizing material described herein can be used for surface treatment and/or coating of various materials such as can be sheet, foil, fiber, film and/or fillers. The materials can include but are not limited to glass fiber, alumina fiber, basalt fiber, quartz fiber, inorganic filler or metal foil, such as Cu foil. Certain aspects of the present invention is directed to a surface treated and/or coated material containing a compatibilizing material described herein. The surface treated and/or coated material can include but are not limited to glass such as glass fiber, alumina fiber, basalt fiber, quartz fiber, inorganic filler such as silica or metal foil such as copper foil.

[0072] In the context of the present invention, at least the following 23 aspects are provided. Embodiment 1 is directed to a compatibilizing material comprising a silane (Si) modified polyphenylene ether (PPE) oligomer having a resin reactive functional group, wherein the resin reactive functional group is (1) a substituent of the PPE oligomer, (2) positioned between the PPE portion of the oligomer and the Si portion of the oligomer, (3) a substituent of the Si portion of the oligomer, or (4) a combination thereof. Embodiment 2 is directed to the compatibilizing material of embodiment 1, having the structure:

##STR00060##

where A is the polyphenylene ether oligomer, a is 0 to 12, b is 0 to 12, R.sup.1 is a resin reactive group, R.sup.2 is a hydrogen (H), a substituted or unsubstituted hydrocarbyl group, R.sup.3 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group, and R.sup.4 is a H, a substituted hydrocarbyl group or unsubstituted hydrocarbyl group, preferably R.sup.4 is a substituted or unsubstituted aromatic group, or R.sup.4 has the structure of:

##STR00061##

where: c is 0 to 12; d is 0 to 12; R.sup.5 is a resin reactive group; R.sup.6 is a H, a substituted or unsubstituted hydrocarbyl group; and R.sup.7 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

[0073] Embodiment 3 is directed to the compatibilizing material of embodiment 1, having the structure:

##STR00062##

where A is the polyphenylene ether oligomer, Y is a linking group comprising the resin reactive functional group R.sup.10; R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.8 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; and R.sup.9 is a H, a substituted hydrocarbyl group or an unsubstituted hydrocarbyl group.

[0074] Embodiment 4 is directed to the compatibilizing material of embodiment 3, wherein R.sup.9 is a substituted or unsubstituted aromatic group, or R.sup.9 has the structure of:

##STR00063##

where Y is the linking group comprising a resin reactive functional group R.sup.10; R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group; and R.sup.3 and R.sup.8 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group.

[0075] Embodiment 5 is directed to the compatibilizing material of any one of embodiments 3 to 4, wherein Y is

##STR00064##

where: R.sup.10 is the resin reactive group, e is from 0 to 12; f is from 0 to 12; and

##STR00065##

represents the bonds to A and Si, with the proviso that when R.sup.9 is H, R.sup.10 is not OH;

##STR00066##

where: R.sup.10 is the resin reactive group; g is from 0 to 12; and

##STR00067##

represents the bonds to A and Si; or

##STR00068##

where: R.sup.10 is the resin reactive group; h is from 0 to 12; R.sup.11 is a bond, or a substituted or unsubstituted hydrocarbyl group; and

##STR00069##

represents the bond to A.

[0076] Embodiment 6 is directed to the compatibilizing material of any one of embodiments 1 to 5, wherein the resin reactive group comprises an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group.

[0077] Embodiment 7 is directed to the compatibilizing material of any one of embodiments 1 to 6, wherein A comprises poly(phenylene ether).

[0078] Embodiment 8 is directed to the compatibilizing material of embodiment 7, wherein the poly(phenylene ether) has the chemical structure of

##STR00070##

where Z.sup.1, Z.sup.2, Z.sup.3, and Z.sup.4 each independently is a hydrogen, a phenyl, a (bi)cyclic hydrocarbon, a unsubstituted or a substituted C.sub.1-C.sub.12 hydrocarbyl group provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, or a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen, and oxygen atoms, preferably Z.sup.1 and Z.sup.3 are methyl and Z.sup.2 and Z.sup.4 are H, and z is at least 1 or

##STR00071##

where Q.sup.1, Q.sup.2, Q.sup.3, and Q.sup.4 each independently is a halogen, an unsubstituted or substituted C.sub.1-C.sub.12 primary or secondary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy where at least two carbon atoms separate the halogen and oxygen atoms, x and y are independently 0 to 30, provided that the sum of x and y is at least 2; and L has the chemical structure:

##STR00072##

where R.sup.15, R.sup.16, R.sup.17, and R.sup.18 are each independently is a hydrogen, an unsubstituted or substituted C.sub.1-C.sub.12 hydrocarbyl provided that the hydrocarbyl group is not a tertiary hydrocarbyl, a C.sub.1-C.sub.12 hydrocarbylthio, a C.sub.1-C.sub.12 hydrocarbyloxy, and a C.sub.2-C.sub.12 halohydrocarbyloxy with at least two carbon atoms separating the halogen and oxygen atoms; m is 0 or 1; and X has the chemical structure selected from the group

##STR00073##

where R.sup.14 is a hydrogen or C.sub.1-C.sub.12 hydrocarbyl, R.sup.12 and R.sup.13 each independently is a hydrogen, a C.sub.1-C.sub.12 hydrocarbyl, or C.sub.1-C.sub.6 hydrocarbylene where R.sup.12 and R.sup.13 collectively can form a C.sub.4-C.sub.12 alkene, or a siloxane where R.sup.19 and R.sup.20 are each independently selected from hydrogen, hydrocarbyl or halogen-substituted hydrocarbyl, D is an integer of from about 30 to about 70, preferably R.sup.19 and R.sup.20 are both methyl and D is 40 to 60, and at least one of R.sup.15-R.sup.18 is methoxy.

[0079] Embodiment 9 is directed to the compatibilizing material of embodiment 8, having the structure of

##STR00074##

where: a and c are each independently 0 to 12; b and d are each independently 0 to 12; and R.sup.2 and R.sup.6 are each independently a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.7 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; and x and y are independently 0 to 30, provided that the sum of x and y is at least 2;

##STR00075##

where: a and c are each independently 0 to 12; b and d are each independently 0 to 12; and R.sup.2 and R.sup.6 are each independently a H, a substituted or unsubstituted hydrocarbyl group; R.sup.3 and R.sup.7 are each independently a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group; x and z are independently 0 to 30, provided that the sum of x and z is at least 2 and y is 0 or 1;

##STR00076##

where k is 1 to 10, x and, z are independently 0 to 40, y is 0 or 1, wherein when y is 0, at least one of x and z is 1 to 40, R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group;

##STR00077##

where k is 1 to 10, x and, z are independently 0 to 40, y is 0 or 1, wherein when y is 0, at least one of x and z is 1 to 40, R.sup.2 is a H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group;
or

##STR00078##

where R.sup.22 and R.sup.23 each independently is a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R.sup.24 and R.sup.25 each independently is an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, x and z are independently 0 to 30, provided that the sum of x and z is at least 2 and y is 0 or 1.

[0080] Embodiment 10 is directed to a compatibilizing material, having the structure of

##STR00079##

where, and R2 is H, a substituted or unsubstituted hydrocarbyl group, R3 is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group, a is 0 to 12, bis 0 to 12 and z is 1 to 30;

##STR00080##

where k is 1 to 10, z is 1 to 40, R.sup.2 is H, a substituted or unsubstituted hydrocarbyl group, and R.sup.3 and R.sup.8 each independently is a H, a substituted or unsubstituted hydrocarbyl group, or a substituted or unsubstituted alkoxy group;
or

##STR00081##

where R.sup.22 and R.sup.23 each independently is a hydrocarbyl or substituted hydrocarbyl group, preferably methyl or ethyl groups, R is an epoxy group, a substituted epoxy group, an olefin-containing group, a substituted olefin-containing group, an acrylate group, a substituted acrylate group, a cyano group, a substituted cyano group, a cyanate group a hydroxy group, or any combination thereof, preferably a hydroxy group, an acrylate group or substituted acrylate group, more preferably a methacrylate group, a vinyl group or a hydroxy group, i is 0 to 6 and j is 0 to 6, and z is 1 to 30.

[0081] Embodiment 11 is directed a surface treated material and/or a coated material comprising the compatibilizing material of any one of embodiments 1 to 10.

[0082] Embodiment 12 is directed a surface treated material and/or a coated material wherein a surface of the material is treated or coated with the compatibilizing material of any one of claims 1 to 10.

[0083] Embodiment 13 is directed to the surface treated material and/or coated material of embodiment 11 or 12, wherein the surface treated material and/or coated material is a glass fiber, alumina fiber, basalt fiber, quartz fiber, inorganic filler or metal foil.

[0084] Embodiment 14 is directed to the surface treated material and/or a coated material of embodiment 13, wherein the metal foil is copper (Cu) foil.

[0085] Embodiment 15 is directed to a thermosetting resin composition comprising the surface treated material and/or coated material of any one embodiments 11 to 14.

[0086] Embodiment 16 is directed to a thermosetting resin composition comprising the compatibilizing material of any one of embodiments 1 to 10 and a glass fiber, alumina fiber, basalt fiber, quartz fiber, inorganic filler or metal foil.

[0087] Embodiment 17 is directed to a sized fiber comprising the compatibilizing material of any one of embodiments 1 to 10.

[0088] Embodiment 18 is directed to the sized fiber of embodiment 17, comprised in a polymeric composition comprising a polymeric resin and optional additives.

[0089] Embodiment 19 is directed to the sized fiber of embodiment 18, wherein a least a portion of the compatibilizing material is attached to the polymeric resin and the sized fiber, preferably the compatibilizing material is covalently bonded to the polymeric resin and coated on at least a portion of the surface of the sized fiber, preferably, wherein the fiber is preferably an inorganic fiber or filler, more preferably glass fibers, glass cloth, or both.

[0090] Embodiment 20 is directed to the sized fiber of any one of embodiments 17 o 19 wherein the resin comprises a thermoset polymer, a thermoplastic polymer, a fire-retardant resin composition, or any combination thereof, preferably the thermoset polymer is an epoxy resin, an epoxy vinylester, an alkyd, an amino-based polymers a diallyl phthalate, a phenolics polymer or resin, a polyester, an unsaturated polyester resin, a dicyclopentadiene, a polyimide, a silicon, a cyanate esters of polycyanurate, a thermosetting polyacrylic resin, a benzoxazine, or co-polymers thereof, triallyl isocyanaurate, triallyl cyanurate, and other mono-, di- and multifunctional vinyl monomers or crosslinking agents or blends thereof.

[0091] Embodiment 21 is directed to the sized fiber of any one of embodiments 17 to 20, wherein the sized fiber is comprised in a laminate.

[0092] Embodiment 22 is directed to an article of manufacture comprising the sized fiber surface treated material and/or a coated material, and/or thermosetting resin composition of any one of embodiments 11 to 21.

[0093] Embodiment 23 is directed to a method of preparing a silane modified polyphenylene ether (PPE), the method comprising contacting a composition comprising a PPE oligomer, a silane source, and 4-dimethylaminopyridine under conditions sufficient, preferably a temperature of 80 to 100° C., to react the PPE oligomer with the silane source to produce a silane modified PPE.

[0094] Embodiment 24 is directed to a method of preparing a silane modified polyphenylene ether (PPE), the method comprising contacting 2,6-dimethyl phenol and silane source under conditions sufficient, to react 2,6-dimethyl phenol with the silane source to produce a silane modified PPE.

EXAMPLES

[0095] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.

Example 1

Synthesis of Si Modified Bifunctional PPE-Hydroxyl

[0096] Bifunctional PPE oligomer (20, g SA90 pellets, 1720 g/mol, Compound I) was dissolved in toluene (30 g) at 50° C. in a three-necked round bottom flask equipped with a condenser. After all PPE oligomer was dissolved, 3-glycidoxypropyltrimethoxysilane (GPTMS) (Compound II, 6.12 g) and 4-dimethylaminopyridine (DMAP, 0.3 g) were added to the oligomer solution in toluene while stirring. After addition, the temperature of the solution was increased to 90° C., and then reaction mixture was stirred for 10 hours at 90° C. The compatibilizing material of the present invention (Compound III) was isolated by precipitating the toluene solution into methanol followed by filtration and drying in vacuum oven at room temperature. The Si modified PPE included a hydroxy group as the resin reactive group.

[0097] Final structure of silane functionalized PPE oligomer (PPE-AES) of the present invention was confirmed by solution .sup.1H-NMR and .sup.31P-NMR spectroscopy. All NMR spectra were acquired on an Agilent Technology instrument operating at an observe frequency of 600 MHz in d-chloroform. In the NMR spectra of PPE-AES, disappearance of peaks correspond to aromatic end group protons and terminal phenolic protons of PPE oligomer as well as formation of new peaks correspond to newly formed methylene group protons, which was attached to the end groups of PPE oligomers, and peaks correspond to methoxy silane protons confirmed structure of PPE-AES.

##STR00082##

Example 2

Synthesis of Amino-Siloxane Functionalized Modified PPE

[0098] Table I lists the names and supplier of the ingredients. Toluene (223.8 g), DMP (99.4 g), TMBPA (21.1 g), DMBA (2.24 g), and a mixture of DBEDA (0.65 g), N,N,N′N′-didecyldimethyl ammonium chloride (0.35 g), and toluene (1.17 g) were charged to a bubbling polymerization vessel (500 mL) and stirred under nitrogen. Catalyst solution (1.45 g of 0.106 g Cu.sub.2O and 1.34 g (48%) HBr) was added to the reaction mixture. After the addition of catalyst solution, oxygen flow was started. The temperature was ramped from 25° C. to 40° C. in 15 minutes, and at 80.sup.th minute of the reaction, it was increased to 48° C. At the 90.sup.th minute of the reaction, bis(3-trimethoxysilylpropyl)amine (3.62 g) was added to the reactor. Oxygen flow was maintained for 150 minutes, at which point the flow was stopped, and NTA (8.0 g) and DI water (4.0 g) were added to the reaction mixture. The resulting mixture was stirred at 60° C. for 120 minutes. The layers were then separated by centrifugation and the final oligomer was isolated by precipitating the toluene phase into methanol followed by filtration and drying in a vacuum oven at 60° C. under nitrogen overnight.

TABLE-US-00001 TABLE 1 Acronym Name CAS# Supplier DMP 2,6 Xylenol 576-26-1 Sigma-Aldrich TMBPA Tetramethyl bisphenol A 5613-46-7 Deepak Novachem TMSA Bis(3-trimethoxy- 82985-35-1 Gelest Inc. silylpropyl)amine Cu.sub.2O Cuprous oxide 1317-39-1 American Chemet Corporation HBr Hydrobromic acid 10035-10-6 Chemtura Corporation DBEDA Di-tert-butylethyl- 4062-60-6 Achiewell LCC enediamine DMBA N,N-Dimethylbutylamine 927-62-8 Achiewell LCC Maquat ® N,N,N′N′- 7173-51-5 Mason Chemical didecyldimethyl Company ammonium chloride NTA Nitrilotriacetic acid 5064-31-3 Akzo Nobel trisodium salt Functional Chemicals LLC Toluene — 108-88-3 Fisher Scientific Methanol — 67-56-1 Fisher Scientific

Example 3

Synthesis of Compound IV

[0099] Toluene (223.8 g), DMP (120.6 g), DMBA (2.24 g), and a mixture of DBEDA (0.65 g), N,N,N′N′-didecyldimethyl ammonium chloride (0.35 g), and toluene (1.17 g) can be charged to a bubbling polymerization vessel (500 mL) and stirred under nitrogen. Catalyst solution (1.45 g of 0.106 g Cu.sub.2O and 1.34 g (48%) HBr) can be added to the reaction mixture. After the addition of catalyst solution, oxygen flow can be started. The temperature can be ramped from 25° C. to 40° C. in 15 minutes, and at 80th minute of the reaction, it can be increased to 48° C. At the 90th minute of the reaction, bis(3-trimethoxysilylpropyl)amine (3.62 g) can be added to the reactor. Oxygen flow can be maintained for 150 minutes, at which point the flow can be stopped, and NTA (8.0 g) and DI water (4.0 g) can be added to the reaction mixture. The resulting mixture can be stirred at 60° C. for 120 minutes. The layers can then be separated by centrifugation and the final oligomer (compound IV) can be isolated by precipitating the toluene phase into methanol followed by filtration and drying in a vacuum oven at 60° C. under nitrogen overnight.

##STR00083##

Example 4

Synthesis of Compound V

[0100] Compatibilizing material of Example 3 (compound IV) (50 g) can be dissolved in toluene (50 g) at 80° C. To this solution dimethylamino pyridine (0.5 g) can be added followed by slow addition of methacrylic anhydride (3.47 g). After addition, the temperature of the solution can be increased to 120° C., and then reaction mixture can be stirred for 4 hours. The compatibilizing material of example 4 (compound V) can be isolated by precipitating the toluene solution into methanol followed by filtration and drying in vacuum oven at room temperature.

##STR00084##

Example 5

Synthesis of Compound VI

[0101] Monofunctional PPE oligomer (50 g, NORYL™ SA120 pellets, 2750 g/mol, SABIC) can be dissolved in toluene (70 g) at 50° C. in a three-necked round bottom flask equipped with a condenser. NORYL™ SA110A resin is a low molecular weight polymer based on polyphenylene ether (PPE). After all PPE oligomer is dissolved, 5,6-epoxyhexyltriethoxysilane (5.91 g) and 4-dimethylaminopyridine (DMAP, 0.5 g) can be added to the oligomer solution in toluene while stirring. After addition, the temperature of the solution can be increased to 90° C., and then reaction mixture can be stirred for 10 hours at 90° C. The compatibilizing material (Compound VI) can be isolated by precipitating the toluene solution into methanol followed by filtration and drying in vacuum oven at room temperature.

##STR00085##

Poly(phenylene ether)

##STR00086##

5,6-epoxyhexyltriethoxysilane

##STR00087##

[0102] Although embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the above disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.