CA2198455A1 - Engineered olefinic compositions - Google Patents
Engineered olefinic compositionsInfo
- Publication number
- CA2198455A1 CA2198455A1 CA002198455A CA2198455A CA2198455A1 CA 2198455 A1 CA2198455 A1 CA 2198455A1 CA 002198455 A CA002198455 A CA 002198455A CA 2198455 A CA2198455 A CA 2198455A CA 2198455 A1 CA2198455 A1 CA 2198455A1
- Authority
- CA
- Canada
- Prior art keywords
- component
- blend
- article
- ethylene
- combinations
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/10—Homopolymers or copolymers of propene
- C08L23/12—Polypropene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/10—Homopolymers or copolymers of propene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2314/00—Polymer mixtures characterised by way of preparation
- C08L2314/06—Metallocene or single site catalysts
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
Abstract
Thermoplastic olefinic, polymer blends which have superior physical properties and adherence for coating materials such as paints are disclosed. The blends may be formed from various combinations of thermoplastic components such as homopolymers of propylene having an isotactic index which is greater than about 0.93, and/or a crystallinity which is greater than about 56 %, and sequentially polymerized blends of polypropylene and ethylene-propylene copolymers, with elastomeric components such as copolymers of ethylene and butene produced with metallocene or Kaminsky catalysts, and copolymers of ethylene and octene produced with metallocene or Kaminsky catalysts. If desired, other components, such as copolymers of ethylene with C3-C15 alpha olefins or fillers, can be included.
Description
~ 1 9 ~
2 PCTIUS95/l0590 OLEFINIC ~ O~
FIELD OF THE INVENTION
The invention relates to thermoplastic olefinic polymer 5 compositions and products thereof which have superior physical properties including improved wear resistance, as well as ~nhAnc~d adherence for coating materials such as paints.
B~u~huuN~ OF THE ~ u~
Polymer blends can be formed or shaped into lightweight and durable articles such as automobile parts, toys, and housings for various types of equipment. Polymer blends such as those with polypropylene and ethylene-propylene 15 copolymers, however, are difficult to form into products which are simultaneously lightweight, easily processed into large parts and have surfaces which are durable and adherent to paints.
~any attempts have been made to enhance the properties 20 of products formed of polymer blends such as those formed of propylene-ethylene copolymers. Japanese patent publication Nos. 57-57049, 62-5460 and 62-5461 each attempt to do so by improving the fluidity and stiffness of blends of polypropylene with ethylene-propylene copolymer. In 25 addition, Japanese patent publication No. 61-19651 also employs blends which have a large amount of propylene.
The propylene-ethylene copolymer blends shown in the above publications suffer from relatively slow crystallization rates. As a result, longer cooling periods 30 are required to manufacture injection molded products. These blends, moreover, do not necessarily provide products which have excellent durability, such as surface smoothness and surface hardness.
Japanese patent publication ~o. 60-3420 shows a polymer 35 blend which includes polypropylene, ethylene-propylene copolymer, talc and propylene-ethylene block copolymer. This 2198~5~ ~
~Og~106132 P~-1IU~95~10590 composition is said to show adhesion for coatings as well as low temperature impact resistance.
Japanese patent Laid-Open publication No. 1-20494~ shows a composition comprising ethylene-propylene copolymer, s polyethylene, ethylene copolymer, polypropylene and talc.
This composition is said to provide products which have dimensional stability.
European patent applications EP O 519 ~52 A2 and EP 049 625 A2 each show blends which comprise ethylene copolymer, 10 propylene polymer and propylene-ethylene "block" copolymer and talc. These blends are said to have good processability for injection molding. Ease of processability is often associated with low melt viscosities (high melt flow ratesj.
These high melt flow rates are often detrimental to other 15 physical properties such as impact strength at lo~
temperatures. Injection molded products formed of these blends are said to have good appearance, low density, good surface hardness and impact resistance, as well as good adhesion.
The above ~entioned blends are 5aid to have a morphological structure comprised of crystalline domains PmhP~ded in amorphous matrix, contrary to conventional thermoplastic polyolefin blends in which elastomer domains are dispersed in a polypropylene matrix. This structure, 25 however, still has regions where the concentration of elastomers is significantly higher than in surrounding areas, thus effectively exhibiting the existence of elastomeric "macrod~--inc". These macro~ in~ have an average size of greater than 4 ~m, which may negatively effect certain 30 physical properties of the blend.
Although the compositions shown in the aforementioned references are said to possess good processability, products formed of these compositions tend to be deficient in one or more physical properties such as durability and paint-35 adhesion. A need therefore continues for thermoplasticblends which can be processed to provide products which have combined properties of superior surface hardness, impact 8 ~ ~ a WO gC/06132 PCTIUS9.51105gO
resistance, processability, flexural modulus, adhesion of coating, and which can be painted using conventional techniques.
SUMMARY OF THE INVENTION
Thermoplastic compositions formed of olefinic, polymer blends and which have superior physical properties and adherence for coating materials such as paints are disclosed.
These blends may be formed from various combinations of 10 thermoplastic and elastomeric -n~nts. The thermoplastic , ~ent can include a homopolymer of propylene having an isotactic index which is greater than about 0.93 or a crystallinity which is greater than about 56%; a sequentially polymerized blend of a semi-crystalline polypropylene and an 15 ethylene-propylene copolymer; or mixtures thereof. The elastomeric ~ -n~t can include a copolymer of ethylene and a C} to C8 olefin produced with a metallocene or Kaminsky catalyst and having a molecular weight distribution (Mw/Mn) of less than or equal to 3. These catalysts are also called 20 "single sitel' catalysts.
In this specification, the following definitions will be used to define certain components of these compositions: ~
Thermoplastic components:
C , ~~t (lA): homopolymers and random copolymers of propylene having an isotactic index of greater than about 0.93, preferably greater than about 0.96 or a crystallinity of greater than about 56%, preferably greater than about 65%. These components also have a density of greater than about 0.898 g/cc, preferably greater than about 0.906 g/cc;
Component (lB): a sequentially polymerized blend or "block" copolymer of polypropylene and a copolymer of ethylene with propylene or ethylene with another alpha-olefin; and Component (lC): a mixture of (lA) and (lB).
~1~8~
~O9~/OC132 PCTIUS~/I~9 Elastomeric Components:
As noted above, any copolymer of ethylene and a C3 to C~
olefin produced with a metallocene or Kaminsky catalyst and having a molecular weight distribution (Mw/Mn) of less than 5 or equal to 3 is contemplated for use as this component.
Specially preferred components are as follows:
C ~-nPnt (2): copolymers of ethylene and ~butene ("EB") produced with metallocene, Kaminsky or "single site" catalysts and which have Mw/Mn of less than or equal to 3;
Component (3~: copolymers of ethylene and octene produced with metallocene, Kaminsky or "single site"
catalysts and having ~w/Mn of less than or equal to 3;
and A mixture of components (2) and (3).
In addition, the present compositions may also include -~t (4), which is a copolymer of ethylene and a C~ to C~
olefin having a crystallinity of at least about 30~.
Copolymers of ethylene with C~-C~ alpha-olefins such as 20 butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene, are preferred. These olefin~ and polymers thereof can be branched or linear.
Useful blends of Group (I) include blends of any one or more of thermoplastic ~~ ~onPnts (lA)-(lC) with elastomeric 25 components (2), (3) or mixtures of (2) and (3), such as:
Blend (IaJ formed of combinations of component (lA) with component (2~;
Blend (Ib~ formed of combinations of component (lA) with _ -- t (3);
Blend (Ic) formed of combinations of component (lB~
with component (2);
Blend (Id) formed of combinations of component (lB) with component (3);
Blend (Ie) formed of combinations of component (lC) with _ -r-nt (2);
Blend (If) formed of combinations of component (lC
with ~ ~nPnt (3).
~19~4~
.
W096/06132 PCT~S95/10590 Useful blends of Group (II) include blends of any one of ~ nts (lA)-(lC) with component (2) and/or component (3) and~or cn~ponent (4). Illustrative blends of Group (II) include:
Blend (IIA) formed of combinations of component (lA) with component (2) and component (3) and EP;
Blend (IIB~ formed of combinations of _ ~nPnt (lA) with ,- j~nt (2) and component (3) and EB;
Blend (IIC) formed of combinations of component (lA) with component (2) and component (3) and component (4);
Blend (IID) formed of combinations of component (lB) with component (23 and component (3) and EP;
Blend (IIE) formed of combinations of component (lB) with c, -~~ (2) and component (3) and EB;
Blend (IIF) formed of combinations of component (lB) with component (2) and component (3) and component (4);
Blend (IIG) formed of combinations of component ( _~ with component (2) and component (3) and EP;
Blend (IIH) formed of combinations of component (lC) with ,~ znPnt (2) and ~_ -nPnt (3) and EB;
Blend (IIK) formed of combinations of component (lC) with c n~nt (2) and component (3) and component (4)-Useful blends of Group (III) can be formed of combinations of any of the blends of Groups (I) or (II) with fillers such as talc or calcium carbonate, mica, glass fibers, or other inorganic materials that are conventionally 30 utilized in the art.
Useful compositions within the scope of the invention can be formed from any of the blends of Groups (I)-(III).
These compositions have excellent paintability, a broad range of stiffness values, as well as high impact and tensile 35 strengths which make them suitable for automotive applications. Blends of any of Groups (I), (II) and (III) also have excellent processability, as exhibited by high melt ~198~5~ ~
W0 ~106132 ~ u~,31 L .).
flow rates. Thus, the blends of Groups (I~-(III) are particularly suited for injection molding into thin wall articles. Such thin wall articles are used where impact resistance is important. Typical applications include 5 automotive external parts such as bumpers and bumper covers, as well as interior and exterior automotive co.~onent trim.
The blends of the invention can be formed into articles which have a Rockwell R hardness of at least about 60 as measured according to ASTM D-785, a flexural modulus of at lO least about 80 kpsi as measured according to ASTM D-79~, a melt flow rate of at lea8t about 15 dg/min at 23~~C and 2.16 kg as measured according to ASTM D-123S, a minimum density of ~ 0.89 g/cc, and are ductile at about -30~G at a velocity of about 5 mph as measured according to AS~M D-3763. These 15 articles can be coated with paints such as t~ c~ ,onent polyurethanes, acrylics, polyesters, epoxy resins, carboimides, urea resins, and r~l~min~-formaldehyde resins.
Having briefly summarized the invention, the invention will now be des~ribed in detail by reference to the following 20 specification and non-limiting examples. Unless otherwise specified, all percentaqes are by weight and all temperatures are in degrees Celsius.
~RIBF DBo~I~,lON OP THE DRAWING5 FIG. l is a transmission electron micrograph of the core portion of oomposition of example No. 5 of the invention.
FIG. 2 is a transmission electron micrographs of the skin layer of the composition of example No. 5 of the invention.
3C FIG. 3 compares injection molding pressures of the compositions of examples l and 4 of the invention to commercially available composition.
FIG. 4 compares clamp tonnage to fill a mold with the compositions of examples l and 4 of the invention to 35 commercially available compo~ition Dl62HF.
4 ~ 5 W096/06l32 PCT~S95/10590 FIG. 5 compares the cool/fill times to fill a mold with the compositions of examples 1 and 4 of the invention to commercially available composition D162HF.
nE~TT.~n DESCRIPTION OF TUE l~h ~1~
Propylene polymers suitable for use in the invention typically have a Melt Flow Rate("MFR") at 230~C and 2.16 kg, when measured in accordance with ASTM D-1238 of about 10 to 80 dglmin, preferably about 35 to 65 dg/min, most preferably ~o about 45 to 55 dg/min. These MFRs may be attained by controlling polymerization of the propylene monomer, or by addition of an organic peroxide such as a diacyl peroxide or a dialkyl peroxide after polymerization of the propylene is completed. These techniques are well known in the art.
The propylene polymer employed may be a propylene homopolymer, or a copolymer of propylene and unsaturated -~ s such 2S maleic anhydride, acrylic acid or trimethoxy vinyl siiane. These n-n IS can be introduced to the propylene by graft copolymerization by methods known in the 20 art.
Stereospecific catalysts can be employed in well known methods to produce propylene polymers suitable for use as a thermoplastic ~ -nt according to this invention. Useful stereospecific catalysts can be prepared as disclosed in 25 Japanese Patent Laid-Open Publication Nos. 56-100806, 56-120712 and 58-104907.
Propylene homopolymers useful as component (lA~ have an isotactic index of greater than 0.93, preferably greater than 0.96, and/or a crystallinity greater than 56%, preferably 30 greater than 65~, as determined from density measurements.
These homopolymers are commercially available, and a good example is the series ELTEX P highly isotactic polypropylenes from Solvay.
Crystalline or semi-crystalline polypropylenes can be 35 employed as component (lA) in the polymer blends of this invention. These may be blended with polyethylenes.
Crystalline or semi-crystalline copolymers of propylene and 219~5~ ~
WO9G06132 PCT~S9~110590 ethylene aLso may be used, if desired. When a copolymer of propylene and ethylene is utilized, the copolymer either can be in the form of a random copolymer, a block copolymer, or a graft copolymer.
The terminology "crystalline or semi-crystalline" refers to n~nts that are characterized by a sufficient degree of crystallinity, e.g. about 70-100%, such that their behavior is substantially that of a crystalline polyolefin ("crystalline"~ or by a degree of crystallinity, e.g. about lO 30-70%, sufficient to cause their behavior to exhibit substantial but not full crystalline polyolefin behavior ("semi-crystalline"). When polypropylene is used as the crystalline or se~i-crystalline polyolefin, the polypropylene has 30-98% crystallinity, and typically between 5~ and 70 15 crystallinity, as determined by X-ray analysis or solvent extraction. The tPrmin~logy "substantially crystalline" is used to designate those polyolefins having crystallinity of between 30 and 9~%.
Ethylene-Propylene ("E~"') copolymers which have 20 differing amounts of ethylene and propylene therein may be employed in co~ponent (lB) as well as in the blends of Group (II). EP copolymers for use in the invention ~an be prepared by copolymerizing ethylene and propylene in the presence oL
free radical coordination st~eo~e~ific polymerization 25 catalysts, such as Phillips, Kaminsky or Ziegler-~atta catalysts. These preparation techniques are well known.
Generally, EP copolymers useful as component (lB) will be slightly crystalline or substantially amorphous, i.e., greater than 50~ amorphous. Preferably, these copolymers 30 will have a Nooney viscosity of about lO-5~ at lOO~C. The amount of propylene in the EP copolymer is not particularly limited provided that the Nooney viscosity is within the stated range. The EP copolymers may be completely replaced on a one-to-one basis by terpolymers of ethylene-propylene-35 ùiene ~onomers ("EPD~s"~ such as ethylidene norbornene,dicyclopentadiene, l~4-hexadlene and the like. ~seful copolymers may include mixtures of ethylene-propylene and ~-- 8 --Wo9610~13~ 219 8 ~ ~ ~ PCT~1S9~/10590 EP~Ms. The total content of ethylene in component (lB) may be between about 0~ and about 30%, preferably about 20~. EP
copolymers useful in Group (II) blends may have about 30-90% ethylene, preferably about 70% ethylene based on the 5 total weight of the specific blend of Group (II).
The ethylene-butene ("EB") copolymers of component (2) which can be employed in the blends of Groups (I)-(III) are preferably produced by use of metallocene or Kaminsky catalysts. These copolymers typically have a narrow lO molecular weight distribution, i.e., (Mw/Mn) of less than 3, where Mw = weight average molecular weight and Mn = number average molecular weight. These EB copolymers can include ethylene in an amount of 5-95%, preferably about 50-90% and more preferably about 80%.
The ethylene-octene copolymers of component (3) which can be employed in the blends of Groups (I)-(III) also have a narrow molecular weight distribution (Mw/Mn) of less than 3 where Mw and Mn are defined as above. These ethylene-octene copolymers can be produced using methods such as those which 20 employ metallocene or Kaminsky catalysts. These ethylene-octene copolymers can have 5-95% ethylene therein, preferably about 50-90% and more preferably about 80%.
Useful blends of Group (I) can include blends of any of (Ia)-(If) as defined above. In blend (Ia), component (lA) 25 can comprise about 50 to 80~, preferably 60 to 70%, remainder cn~p~nPnt (2); ~ ~nt (lA) can comprise about 50 to 80%, preferably 60 to 70~, of blend (Ib), remainder component (3);
~ onPnt (lB) can comprise about 50 to 80~, preferably 60 to 70%, of blend (Ic), rr-~in~Pr component (2); component (lB) 30 can comprise 50 to 80% of blend (Id), rr-~;n~pr component (3); component (Ic) can comprise 50 to 80~ of the blend (Ie), ro-qin~r component (2); component (lC) can comprise 50 to 80~ of blend (If), remainder component (3).
The blends of Group (II) can be formed from combinations 35 of any one of , -n~ntS (lA)-(lC~ with components (2) and (3) with c -n~nt (4). Regarding the latter, it is preferred to use any of EP, EB other than component (2), or _ g _ 21g84~
WO96~6132 PC~IUS~
copolymers o~ ethylene and C~-C,5, preferably C4-CIJ alpha olefins such as copolymers of ethylene with at least one of propylene, butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene. Illustrative Group (II) 5 blends include but are not limited to:
about 50 to 80% ~ an~1.t (lA) with about lO to 35%
_ - ~ (2), about lO to 25% component ~3) and about 0 to 20% EP copolymer;
about 50 to 80% component (lA) with about lO to 35%
c, ~onpnt (2), about lO to 25~ component (3) and about 0 to 20% EB copolymer other than component (2);
about 50 to 80% component (lA) with about lO to 35%
c, -nPnt (2), and about lO to 25% component (3~ with about 0 to 20% copolymer of ethylene with at least one of propylene, butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene;
about 50 to 80% component (lB) with about lO to 35%
component (2), about lO to 25~ c~mron~nt ~3) and about 0 to 20~ EP copolymer;
about 50 to 80% component (lB) with about lO to 35~
component ~2), about lO to 25% component (3) and about 0 to 20~ ethylene-butene copolymer other than component (2);
about 50 to 80% component (lB) with about lO to 35 component (2), about lO to 25% ~c -nP~t (3), and about 0 to 20~ o~ a copolymer of ethylene with at least one of propylene, butylene, psntylene, hexylene, septylene, octylene, nonylene, and decylene;
about 50 to 80% component (lC) with about lQ to 35%
component ~2) and about lO to 25% component (3) with about 0 to 20% EP copolymer;
about 50 to 80% component (lC) ~ith about lO to 35%
component (2) and about lO to 25% component (3) with about 0 to 20% ethylene-butene copolymer other than ~5 component ~2); and about 50 to 80% component (lC) with about lO to 35%
_ ,~nPnt (2) and about lO to 25% component (3) with ~ 21g~5~
W096/06132 PCT~S951l0590 about 0 to 20~ copolymer of ethylene with at least one of butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene.
Each of the ethylene-butene copolymers and ethylene-5 octene copolymers of ~~ntS (2) and ~3) respectively, maybe slightly crystalline, i.e., have up to about 20%
crystallinity as calculated from density measurements.
Preferably, each of the ethylene-butene and ethylene-octene copolymers are substantially amorphous. Amorphous ethylene-10 butene copolymers are available from Exxon Polymers Co. underthe tradename EXXACT. Amorphous ethylene-octene copolymers are available from Dow Chemical Co. under the tradename ENGAGE.
Any of the blends of Groups (I) and (II~ optionally may 15 be combined with fillers such as talc, glass, mica, or calcium carbonate, and the like, preferably talc, to provide blends of Group III. These fillers may be present in an amount of about 0.1 to 10% and preferably about 3-5%.
Each of blends of Groups (Ij-(III) provide products with 20 superior combinations of mechanical and surface properties.
Blends of Groups (I)-(III) can be molded into products which show a Rockwell R hardness of at ~east about 60 as measured according to ASTM D-785, a flexural modulus of at least about 80 kpsi as measured according to ASTM D-7gc, a melt flow rate 25 of at least about lO and preferably about 15 dg/min or more at 230 C and 2.16 kg as measured according to ASTM D-1238, a maximum density of 0.98 g/cc, and are ductile at -30~C at a velocity of about 5 mph as measured according to ASTM D-3763.
Talc usable in the blends of Group III has a particle 30 size less than lO microns, preferably less than 5 microns, most preferably about O.g micron, and a specific surface area of about 3.5 m2/g or more, preferably about 3.5-6.0 m2/g. The amount of talc utili~ed depends on the other component(s) employed in the specific blend of Group (IIIj. Typically, 35 about 0.1 to 10 parts of talc by weight of the component(s), preferably about 0.1 to 8 parts, and more preferably between about 3 to 5 parts, may be employed.
2198 45~
.
WO~61~132 PCT~S9~10590 The talc may be prepared by dry pulverization and subsequent dry classification. The average particle size of the talc employed is a particle size at a cumulative amount of 50~ by weight in a cumulative particle size distribution 5 curve obtained by a li~uid phase sedimentation light transmission method using, for instance, Nodel CP
manufactured by Shimadzu Corp. The specific surface area measuring apparatus Model SS-lOO is produced by Shimadzu Corp.
Talc filler employed in the invention need not be treated. However, to improve adhesion between the talc filler and the polymers employed in the blends of Group III, as well as for disperslbility of the talc in those component blends, the talc may be treated with organic titanate ~5 coupling agents, silane coupling agents, fatty acids, metal salts of fatty acids, fatty acid esters, and the like.
Various additives may be combined with any of the blends of Grou~ III) unless they substantially impair the advantsgeous properties of those component blends. Useful 20 additives include for example, process stabilizers, antioxidants, ultraviolet absorbers, soaps such as metal soaps, anti-static agents, lubricants, nucleating agents, pigments and dispersant for pigment. In addition, additives capable of imparting higher flexural modulus to the blend 25 than that imparted by talc can be included. Examples of these additives include fibrous potassium titanate, fibrous magnesium oxalate, fibrous aluminum borate, and carbon fibers.
Morphology of blends of Groups (I)-(III) shows excellent 30 dispersion of components with the biggest domains being the filler particles. Apart from the filler, the average domain size is less than 2 ~m. This indicates excellent compatibility of components as shown in FIGs l and 2. This compatibility, combined with the high melt flow rate of the 35 blend, leads to a characteristic thin layering typically less than about 0.5 ~m, near the surface of the injection molded specimens produced from the compositions of the invention.
~ ~ i 9 ~
WO g6106132 PCTIUS95/10590 This is illustrated in FIGs. 3 and 4 which show the morphology of the skin layer of specimens formed from the composition of example 5 of the invention.
The blends of Groups (I)-(III) can be molded or 5 otherwise formed to produce articles which are lightweight, durable, and have surfaces which are paint receptive. The - -n~nts also can be pelletized for storage and shipment prior to molding into shaped articles by known methods.
Products formed of any of the blends of Groups (I~
10 can be coated with paints, particularly with paints such as commercially available two-component blend polyurethanes to provide products with superior fluid resistance. The blends of Groups (I~-(III~ may be coated with paints ~hich have active functional groups such as acrylics, polyesters, epoxy 15 resins, carboimides, urea resins, melamine-formaldehyde resins, enamines, ketimines, amines, and isocyanates to provide products with improved fluid resistance. These types of paints are well known in the paint and coatings industry.
Products having superior physical properties and 20 adherence for coating materials such as paints can be prepared by mixing any of the blends of Groups (I~-(III~
with, if desired, optional additives by using extruders, Banbury mixers, rollers, brabenders and kneaders. Molded products may be prepared from any of blends of Groups (I~-25 ~ by known methods such as injection molding, extrusionmolding, and blow molding. Injection molding is preferred.
Blends of Groups (I~-(III~ present a significant advantage in injection molding compared to conventional thermoplastic polyolefin blends. A computer simulation of 30 the molding conditions for the blends of Groups (I)-(III) show lower injection pressure, lower clamp tonnage and shorter cycle time than conventional thermoplastic polyolefin blends having comparable viscosities under standard conditions.
The computer simulation, performed using the commercial software package C-Nold from AC Technologies, requires input of rheological and thermodynamic properties of the material 21~8~5 ~
WOg6/06132 ~ PCT~S951105~0 under consideration. These properties can be determined experimentally. The re~uired properties are viscosity as a function of shear rate between 5 secJ and l~,000 sec~ at temperatures of 200~C, ~30~C and 260~C; specific heat as a 5 function of temperature between room temperature and 250~C, as well as density of the material in the solid state and as melted are also required. The thermoplastic polyolefin blend which serves as a control is Dl62~F. Dl62HF, available from D&S Plastics, has the highest melt flow rate for commercially lO available thermoplastic olefin blends.
As shown in FIGs. 5-7, the computer simulation indicates that the maximum injection molding pressure, the clamp tonnage, as well as the filllcool times for the compositions of Examples l and 4 of the invention are much less than for 15 commercially available composition Dl6~HF.
Generally, processing of the components of the invention can be performed using Banbury mixers or twin screw extruders. When a Banbury mixer is employed to prepare any of blends of Groups (I)-(III), a single screw extruder can be 20 used to pelletize that component blend. The resulting pellets then are supplied to an injection molding machine for manufacture of molded articles.
During mixing of the blends of Groups (I~ with a Banbury mixer, the ram pressure in the ~anbury mixer is about 25 30-35 psi. Mixing is continued until fluxing temperature is achieved, i.e., the temperature at which the viscosity of the blend drops sharply. When fluxing temperature is achieved, mixing is terminated and the resulting batch of material is removed from the Banbury mixer. The batch then is ground 30 into chips and/or pelletized in a single screw extruder.
Pellets of the formed component blends are supplied to an injection molding machine for injection molding into shaped products.
35 F~A~P~ES
The invention will now be explained in more detail with reference to the following examples, which are given merely ~ 21g84~
W096l06~32 PCT~S9~/lU~9 to illustrate the invention and are not intended to be limiting thereof.
Examples 1-6 The compositions of examples 1-6 are given in Table 1.
Table 1 also shows the physical properties of the compositions when processed according to the conditions set forth in Table lA. In Table 1, Ductility Index is measured by using a High Rate Impact Tester machine Model No. RIT-8000 10 from Rheometrics Company, Piscataway, New Jersey. The RIT-8000 is equipped with a steel probe having a size measuring o.S" diameter by 12.25" long, and having a weight of about 0.705 lb. The probe has a spherical tip. The probe is accelerated to penetrate a specimen measuring 4" x 6" x 1/8"
15 at a constant speed of 5 mph. The temperature of the specimen is -30~C.
Ductility Index is calculated from the equation DI=(T-U)IT
where DI=Ductility Index, T represents total energy at the point at which the probe has broken through the specimen,i.e., the point at which the force applied to the sp~;r by the probe drops to zero, and U represents ultimate energy, i.e., the energy at the point at which the force exerted by the probe on the specimen is at maximum as determined from the force-position curve of force applied by the probe to the specimen vs. the position of the probe. The DI values for each of 3 - 5 30 specimens are averaged and reported as DI.
Also, in Tables 1 and 2, the peel strength is the force ~g/cm~ required to peel the paint off substra~e, is a measure of adhesive strength of the coating to the substrate.
In determining the peel strength, an injection molded 35 plaque, formed of a composition of the invention, of size 4x6 inches and 118 inch thick, is partially coated with the adhesion promoter RB899 from Morton International Co., and , . . , .. _ _ _ _ _ _ _ _ ~198~5i W096/06132 PCT~'S9.~1~1~90 entirely with a topcoat of R773 ~rom Morton, InternationalCo. to enable lifting the topcoat from that portion of the plaque which iB not coated with the adhesion promoter.
Cuts through the topcoat coating are made using a sharp 5 knife and a metal template to form two or three one cm wide strips. The one cm side strips are slowly peeled from those portions of the plaque which are free of the adhesion promoter. A piece of polyester tape is placed on the peeled off strip to form a "handle" with which the strip is peeled lO further.
The prepared plaque is placed into an Instron Tensile Tester (Instron Model ll30).
The force required to peel the strip from the plaque is recorded as a function of the length of peeled off strip 15 along the plaque. The peeling speed is two inches per minute. The average force in the entire peel is reported as the measure of adhesion strength per one cm of width of peel, i.e., in units of g/cm.
2198~5 W 096/06l32 PCTrUS~S/IOSJO
TABLE l Stand-rd Ex~mpl~ No./ TPO
e~mpon-nt ~ l 2 3 4 S 6~Cortrol) 62 62 65 65 ~
R~ -- -- -- __ __ __ __ R -- -- -- -- __ __ __ oly~ethylene- 22 ll 17.5 12 22 22 --co-b tene~
Pol~ ethylene- 11 22 17.5 23 11 11 --- nene~
_L. S S O O S S --_E AL 197 190 163 163 214 213 220 zo ULUSI~
SITY12 ~3 93 . O . 9 93 ~3 1.~2 15ACT @-30C D D
I CTILITY . 8 .36 . 4 . 6 .38 . 7 . S
INDEX
PEEL STRENGZTRlOSO1200 7S0 1200 83010851000 1. Polypro~ylene, MFR at (230 C, 2.16 kg~ = 45 dg/min, ASTM D-1238 2. Po_ypro~ilene, MFR at (230 C, 2.16 kg) = 49 dg/min, ASTM D-1238 3. Po yprop~lene, MFR at (230 C, 2.16 kg~ = 56 dg/min, ASTM D-1238 4. Po_y(etl 'lt'.~tc _u ~Lu~ylene~; C2=SO~, C3 = 50%, Mooney Viscosity at 20100~C =~i S. Po~y(ethylene-co-butene~; C2=75~, C4 = 25%; MFR at (19OC, 2. 6 kg~ = 0.8 dg/min 6. EXXACT 4033 zrom Exxon Co., produced by Kaminsky catalyst process, having C2=80~; MFR at (190 C, 2.16 kg) = 0.3 dg~min, ASTM D-1238 7. C2 80~; MFR at (190 C, 2.16 kg~ = S.O dg/min, ASTM D-1238 8. Average talc particle slze = 0.9 micron 9. Rockwell R bardness measured according to ASTM D-785 _0. Xpsi measured according to ASTM D-790 1. dg/min at (23û C, 2.16 kgj as measured according to ASTM D-1238 2. g/cc 3. D=Ductile Failure; B=Brittle Failure measured according to ASTM D-~1984~ --W 096/06132 PCT/U89~1059U
TABLE l(a) Proc~lng '~t ~.
ESAMPLE/l._ 1 2 3 4 5 6 CONDI~ION
BANBURY MISING
ROTOR SPEED ~RPK) 185 185 190 190 185 185 RAM PRESSURE tPSI) 32 32 34 34 32 32 TIME TO FLUX (SEC~ gS 95 90 90 9S 9S
FLUY. TEMP ('F) 360 360 355 355 360 360 BATCN TEHP t~~) 410 410 410 410 410 41D
p~T,~V~IZ SINGLE SCREW
ESIRUDER
END ZONES T~P (~F1 360 360 360 360 360 360 CENTRAL ZONE TEMP (~Fi 380 380 380 380 380 380 SCREW SPEE0 (RPM) 9S 9S 9S 9S 95 9S
KELT TEUP (~F) 375 375 375 375 375 375 MOLDING ' _.~I~
SCREW SPEED ~RPM) 90 90 90 90 90 90 MOLD TEMP (~F~ 50 80 80 80 80 80 INJECTION TI~E (SEC) lO 10 10 10 10 lO
COOLING TIKE (SEC) 25 25 25 25 25 25 INJECTION PRESSURE (PSI) sS0 SSO 550 SSO 550 SSO
FILLING TIKE (PSI) 10 lO 10 10 10 10 EOLDING PRESSURE ~PSI) 430 430 430 430 430 430 EOLDING TIME (SEC~ 15 lS lS lS lS lS
BACE PRESSURE (PSIi50 50 50 50 50 50 Examples 7-11 Table 2 illustrates additional compositions within the scope of the invention. Table 2 also shows the physical properties of the compositions when processed according to the conditions set forth in Table 2a.
Ductility index and peel strength are maasured as in Examples 1-6.
2 ~
EYAMPLE No./ 7 8 9 10 11 Component (95) }7Ipp2 __ __ __ __ __ HI PP3 __ _ _ _ __ _ _ _ EPR4 33 __16.5 -- --EBR5 -- 3316.5 -- --Poly(ethylene- -- -- -- 33 --co-butene)' Poly(ethylene- -- -- -- -- 33 co-octene)7 HARDNEsS945 60 55 79 74 15 MODULUSI~
MFRIl14 14 14 16 19 DvENSITYI2 0.930.93O.gO 0.89 0.93 IMPACT @-30C~5 D B B 8 B
DUCTILITY INDEX0.370.10 0.25 0.2S 0.25 1. High crystallLn.ty polypropylene, MFR at (230 C, 2.16 kg) = 45 dg/min, ASTM D-_238 2. High cry~tall.n_ty polypropylene, MFR at ~230 C, 2.16 kg) = 49 dg/min, ASTM D- 238 3. High crystall n_ty polypropylene, MFR at (230 C, 2.16 kg) = 56 dg/min, ASTM D- 238 4. Poly(ethylc.._ _~ ~ylene); C2=S0~, C3 = S0~, Mooney Viscosity at 100~C =35 S. Poly(ethyleAe _v b~ene); C2=75~, C4 = 25~; MFP. at 190C, 2.16 kg e 0.8 dg/min, prepared by conventional process, e.g., Flexomer (Union CarbLde), Tafmer (Mitsui Petrochemical) 6. EXXACT 4033 from Exxon Co., produceù from Kaminsky catalyst, and having C2=80~; MFR at (190 C, 2.16 kg) = 0.3 dg/min, A8TM D-1238 7. C2=80~; MFR at (190 C, 2.16 kg) = S.0 dg/min, ASTM D-1238 0. Talc, particle size = 0.9 micron ~ . Rockwell R hardneus moasured according to ASTM D-785 o 7Kpsi measured according to ASTM D-790 1 dg/min at 230 C and 2.16 kg as measured according to ASTM D-1238 12. g/cc 13. D=Ductile Failure; B=Brittle Failure measured according to ASTM D-2198~5~ ~
W 096~6132 PCT~g511059U
TABLE 2 la) Proc~ll;sL.g Ct~n.dit.o~
E~AMPLE~.~t~,o~ltn~ 7 8 9 10 11 CONDITION
BANBURY MI~ING
ROTOR SPEED (RPX) 185 185 185 185 185 RAU PRESSURE ~PSI) 32 32 32 32 32 T-IME TO FLUX ~SEC) 110 110 110 95 95 FLUX TEUP (F~) 380 380 380 360 360 3ATCU TEMP (~F~ 420 420 420 410 410 0 pRT.T.R'l'T5STt~~
END ZONE TE~P ~~F) 36Q 360 360 360 360 CENTRAL ZONE TBMP 1~F) 3~0 380 380 380 380 SC ~ W SPEED (RPM~ 9C 90 90 95 95 MELT TEMP ~~FI 380 380 380 375 375 MOLDING ~
CENTP~L ZONE 2 380 380 380 360 360 SCP~EW SPEED (RP~) 85 85 85 90 90 MOLD TEMP (~F) 80 80 80 80 80 INJECTION T}ME (SEC~ 10 10 10 10 10 COOLING TIME ~SEC) 25 25 25 25 25 (PSI) FILLING TIME ~SEC) 10 10 10 10 lO
~OLDING PRESSUP~ (PSI) 550 550 550 430 430 ~OLDIN& TI~B ~SEC) 15 15 15 15 15 BACK PP~SSURE ~PSI) 50 SO SO 50 SO
Examples 12-15 Table 3 illustrates additional compositions within the scope o~ this invention. Table 3 shows the durability of these compositions, as measured by the so-called SLEdge test and high speed cohesive strength test.
The SLEdge test utilizes a 15.6 lb pendulum head with a 1" wide painted strip of reaction injection molded polyurethane bolted to it. The pendulum head drops from a 90~ position to tangentially impact a 41t X 6" painted ~1~8~S
WO96~06132 PCT/U~9SIIOS90 plaque o~ the molded composition after the plaque has been preheated to 175~F for a minimum of 40 minutes. The extent of the damage is recorded as the area of paint that has been removed from the substrate in square millimeters.
The high speed cohesive strength test includes the steps of coating a 4" x 6" x 1/8" injection molded plaque of the composition with 0.1-0.2 mils of a chlorinated polyolefin adhesion promoter and then baking the coated composition for 30 minutes at 80~C. After cooling, a 1.5 cm strip of a 1/16" thick polycarbonate sheet is adhered to the primed surface using a two-component epoxy adhesive. The average force required to cohesively delaminate the sheet from the coated composition is measured in Newtons/meter at 75~F and 180~F.
As shown by the tests results, peel area values are in the range of 105-450 mm2 for conventional compositions while values of 40 mm2 or less are obtained with the compositions of the invention. When conventional Ziegler-Natta rubbers are omitted, no peel areas at all occur, as shown by Examples 14 and 15. The inventive compositions also exhibited a significantly greater cohesive strengths than those of conventional compositions.
~84~
Wo 96106132 PCI~/IIS95~10~91J
~n~. o OO O O O O O ~o,~ 00 ~, ot~o~oooo o_ os~, o~oo ooooo ~oo ooC~
~~oo~ ooo oo X~
:C~ ~ ~~, ~ ~ O O o o X ~, o ~9 ~o~,oooo oo x~, li.~50o~ Xoooo oo x~.
L~l c~Oo oooo~oq oo x~--- ~ 1cr o o o o o ~ o o o oo ~-i ~oO OO~OO oo x~
cq~OOO~~rOOO OO 00 <,~ o.oo ,o,oooo oo o~
.=
~ X _ ~ _ ~ 2 z z z ~ ~ -~-~ ~
~ ~ ~ W ~U W ~ ~
Dulability C , ' .~ Materh~ ention A B C D E F G E~ 12 13 14 15 SLEdge Test, Peeled area mm~ 460 425 321 305 105 200 150 400 40 0 20 0 High Speed Cohesive Strength at 75~F, N/m 4000 4100 4100 46005200 5000 5500 38006200 8000 8200 9000 at 180~F, N/rn 1600 1600 1750 18001950 1800 2000 16002700 3800 3700 4000 P~
Notes u:~
~N = Ziegler-Natta catalyzed o~a = ~ catalyzed SLEdge data on all c . coated with Ked-Spot 2k urethane coating Cohesive Strength data obtah~ed at a test speed of 200 inches/min
FIELD OF THE INVENTION
The invention relates to thermoplastic olefinic polymer 5 compositions and products thereof which have superior physical properties including improved wear resistance, as well as ~nhAnc~d adherence for coating materials such as paints.
B~u~huuN~ OF THE ~ u~
Polymer blends can be formed or shaped into lightweight and durable articles such as automobile parts, toys, and housings for various types of equipment. Polymer blends such as those with polypropylene and ethylene-propylene 15 copolymers, however, are difficult to form into products which are simultaneously lightweight, easily processed into large parts and have surfaces which are durable and adherent to paints.
~any attempts have been made to enhance the properties 20 of products formed of polymer blends such as those formed of propylene-ethylene copolymers. Japanese patent publication Nos. 57-57049, 62-5460 and 62-5461 each attempt to do so by improving the fluidity and stiffness of blends of polypropylene with ethylene-propylene copolymer. In 25 addition, Japanese patent publication No. 61-19651 also employs blends which have a large amount of propylene.
The propylene-ethylene copolymer blends shown in the above publications suffer from relatively slow crystallization rates. As a result, longer cooling periods 30 are required to manufacture injection molded products. These blends, moreover, do not necessarily provide products which have excellent durability, such as surface smoothness and surface hardness.
Japanese patent publication ~o. 60-3420 shows a polymer 35 blend which includes polypropylene, ethylene-propylene copolymer, talc and propylene-ethylene block copolymer. This 2198~5~ ~
~Og~106132 P~-1IU~95~10590 composition is said to show adhesion for coatings as well as low temperature impact resistance.
Japanese patent Laid-Open publication No. 1-20494~ shows a composition comprising ethylene-propylene copolymer, s polyethylene, ethylene copolymer, polypropylene and talc.
This composition is said to provide products which have dimensional stability.
European patent applications EP O 519 ~52 A2 and EP 049 625 A2 each show blends which comprise ethylene copolymer, 10 propylene polymer and propylene-ethylene "block" copolymer and talc. These blends are said to have good processability for injection molding. Ease of processability is often associated with low melt viscosities (high melt flow ratesj.
These high melt flow rates are often detrimental to other 15 physical properties such as impact strength at lo~
temperatures. Injection molded products formed of these blends are said to have good appearance, low density, good surface hardness and impact resistance, as well as good adhesion.
The above ~entioned blends are 5aid to have a morphological structure comprised of crystalline domains PmhP~ded in amorphous matrix, contrary to conventional thermoplastic polyolefin blends in which elastomer domains are dispersed in a polypropylene matrix. This structure, 25 however, still has regions where the concentration of elastomers is significantly higher than in surrounding areas, thus effectively exhibiting the existence of elastomeric "macrod~--inc". These macro~ in~ have an average size of greater than 4 ~m, which may negatively effect certain 30 physical properties of the blend.
Although the compositions shown in the aforementioned references are said to possess good processability, products formed of these compositions tend to be deficient in one or more physical properties such as durability and paint-35 adhesion. A need therefore continues for thermoplasticblends which can be processed to provide products which have combined properties of superior surface hardness, impact 8 ~ ~ a WO gC/06132 PCTIUS9.51105gO
resistance, processability, flexural modulus, adhesion of coating, and which can be painted using conventional techniques.
SUMMARY OF THE INVENTION
Thermoplastic compositions formed of olefinic, polymer blends and which have superior physical properties and adherence for coating materials such as paints are disclosed.
These blends may be formed from various combinations of 10 thermoplastic and elastomeric -n~nts. The thermoplastic , ~ent can include a homopolymer of propylene having an isotactic index which is greater than about 0.93 or a crystallinity which is greater than about 56%; a sequentially polymerized blend of a semi-crystalline polypropylene and an 15 ethylene-propylene copolymer; or mixtures thereof. The elastomeric ~ -n~t can include a copolymer of ethylene and a C} to C8 olefin produced with a metallocene or Kaminsky catalyst and having a molecular weight distribution (Mw/Mn) of less than or equal to 3. These catalysts are also called 20 "single sitel' catalysts.
In this specification, the following definitions will be used to define certain components of these compositions: ~
Thermoplastic components:
C , ~~t (lA): homopolymers and random copolymers of propylene having an isotactic index of greater than about 0.93, preferably greater than about 0.96 or a crystallinity of greater than about 56%, preferably greater than about 65%. These components also have a density of greater than about 0.898 g/cc, preferably greater than about 0.906 g/cc;
Component (lB): a sequentially polymerized blend or "block" copolymer of polypropylene and a copolymer of ethylene with propylene or ethylene with another alpha-olefin; and Component (lC): a mixture of (lA) and (lB).
~1~8~
~O9~/OC132 PCTIUS~/I~9 Elastomeric Components:
As noted above, any copolymer of ethylene and a C3 to C~
olefin produced with a metallocene or Kaminsky catalyst and having a molecular weight distribution (Mw/Mn) of less than 5 or equal to 3 is contemplated for use as this component.
Specially preferred components are as follows:
C ~-nPnt (2): copolymers of ethylene and ~butene ("EB") produced with metallocene, Kaminsky or "single site" catalysts and which have Mw/Mn of less than or equal to 3;
Component (3~: copolymers of ethylene and octene produced with metallocene, Kaminsky or "single site"
catalysts and having ~w/Mn of less than or equal to 3;
and A mixture of components (2) and (3).
In addition, the present compositions may also include -~t (4), which is a copolymer of ethylene and a C~ to C~
olefin having a crystallinity of at least about 30~.
Copolymers of ethylene with C~-C~ alpha-olefins such as 20 butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene, are preferred. These olefin~ and polymers thereof can be branched or linear.
Useful blends of Group (I) include blends of any one or more of thermoplastic ~~ ~onPnts (lA)-(lC) with elastomeric 25 components (2), (3) or mixtures of (2) and (3), such as:
Blend (IaJ formed of combinations of component (lA) with component (2~;
Blend (Ib~ formed of combinations of component (lA) with _ -- t (3);
Blend (Ic) formed of combinations of component (lB~
with component (2);
Blend (Id) formed of combinations of component (lB) with component (3);
Blend (Ie) formed of combinations of component (lC) with _ -r-nt (2);
Blend (If) formed of combinations of component (lC
with ~ ~nPnt (3).
~19~4~
.
W096/06132 PCT~S95/10590 Useful blends of Group (II) include blends of any one of ~ nts (lA)-(lC) with component (2) and/or component (3) and~or cn~ponent (4). Illustrative blends of Group (II) include:
Blend (IIA) formed of combinations of component (lA) with component (2) and component (3) and EP;
Blend (IIB~ formed of combinations of _ ~nPnt (lA) with ,- j~nt (2) and component (3) and EB;
Blend (IIC) formed of combinations of component (lA) with component (2) and component (3) and component (4);
Blend (IID) formed of combinations of component (lB) with component (23 and component (3) and EP;
Blend (IIE) formed of combinations of component (lB) with c, -~~ (2) and component (3) and EB;
Blend (IIF) formed of combinations of component (lB) with component (2) and component (3) and component (4);
Blend (IIG) formed of combinations of component ( _~ with component (2) and component (3) and EP;
Blend (IIH) formed of combinations of component (lC) with ,~ znPnt (2) and ~_ -nPnt (3) and EB;
Blend (IIK) formed of combinations of component (lC) with c n~nt (2) and component (3) and component (4)-Useful blends of Group (III) can be formed of combinations of any of the blends of Groups (I) or (II) with fillers such as talc or calcium carbonate, mica, glass fibers, or other inorganic materials that are conventionally 30 utilized in the art.
Useful compositions within the scope of the invention can be formed from any of the blends of Groups (I)-(III).
These compositions have excellent paintability, a broad range of stiffness values, as well as high impact and tensile 35 strengths which make them suitable for automotive applications. Blends of any of Groups (I), (II) and (III) also have excellent processability, as exhibited by high melt ~198~5~ ~
W0 ~106132 ~ u~,31 L .).
flow rates. Thus, the blends of Groups (I~-(III) are particularly suited for injection molding into thin wall articles. Such thin wall articles are used where impact resistance is important. Typical applications include 5 automotive external parts such as bumpers and bumper covers, as well as interior and exterior automotive co.~onent trim.
The blends of the invention can be formed into articles which have a Rockwell R hardness of at least about 60 as measured according to ASTM D-785, a flexural modulus of at lO least about 80 kpsi as measured according to ASTM D-79~, a melt flow rate of at lea8t about 15 dg/min at 23~~C and 2.16 kg as measured according to ASTM D-123S, a minimum density of ~ 0.89 g/cc, and are ductile at about -30~G at a velocity of about 5 mph as measured according to AS~M D-3763. These 15 articles can be coated with paints such as t~ c~ ,onent polyurethanes, acrylics, polyesters, epoxy resins, carboimides, urea resins, and r~l~min~-formaldehyde resins.
Having briefly summarized the invention, the invention will now be des~ribed in detail by reference to the following 20 specification and non-limiting examples. Unless otherwise specified, all percentaqes are by weight and all temperatures are in degrees Celsius.
~RIBF DBo~I~,lON OP THE DRAWING5 FIG. l is a transmission electron micrograph of the core portion of oomposition of example No. 5 of the invention.
FIG. 2 is a transmission electron micrographs of the skin layer of the composition of example No. 5 of the invention.
3C FIG. 3 compares injection molding pressures of the compositions of examples l and 4 of the invention to commercially available composition.
FIG. 4 compares clamp tonnage to fill a mold with the compositions of examples l and 4 of the invention to 35 commercially available compo~ition Dl62HF.
4 ~ 5 W096/06l32 PCT~S95/10590 FIG. 5 compares the cool/fill times to fill a mold with the compositions of examples 1 and 4 of the invention to commercially available composition D162HF.
nE~TT.~n DESCRIPTION OF TUE l~h ~1~
Propylene polymers suitable for use in the invention typically have a Melt Flow Rate("MFR") at 230~C and 2.16 kg, when measured in accordance with ASTM D-1238 of about 10 to 80 dglmin, preferably about 35 to 65 dg/min, most preferably ~o about 45 to 55 dg/min. These MFRs may be attained by controlling polymerization of the propylene monomer, or by addition of an organic peroxide such as a diacyl peroxide or a dialkyl peroxide after polymerization of the propylene is completed. These techniques are well known in the art.
The propylene polymer employed may be a propylene homopolymer, or a copolymer of propylene and unsaturated -~ s such 2S maleic anhydride, acrylic acid or trimethoxy vinyl siiane. These n-n IS can be introduced to the propylene by graft copolymerization by methods known in the 20 art.
Stereospecific catalysts can be employed in well known methods to produce propylene polymers suitable for use as a thermoplastic ~ -nt according to this invention. Useful stereospecific catalysts can be prepared as disclosed in 25 Japanese Patent Laid-Open Publication Nos. 56-100806, 56-120712 and 58-104907.
Propylene homopolymers useful as component (lA~ have an isotactic index of greater than 0.93, preferably greater than 0.96, and/or a crystallinity greater than 56%, preferably 30 greater than 65~, as determined from density measurements.
These homopolymers are commercially available, and a good example is the series ELTEX P highly isotactic polypropylenes from Solvay.
Crystalline or semi-crystalline polypropylenes can be 35 employed as component (lA) in the polymer blends of this invention. These may be blended with polyethylenes.
Crystalline or semi-crystalline copolymers of propylene and 219~5~ ~
WO9G06132 PCT~S9~110590 ethylene aLso may be used, if desired. When a copolymer of propylene and ethylene is utilized, the copolymer either can be in the form of a random copolymer, a block copolymer, or a graft copolymer.
The terminology "crystalline or semi-crystalline" refers to n~nts that are characterized by a sufficient degree of crystallinity, e.g. about 70-100%, such that their behavior is substantially that of a crystalline polyolefin ("crystalline"~ or by a degree of crystallinity, e.g. about lO 30-70%, sufficient to cause their behavior to exhibit substantial but not full crystalline polyolefin behavior ("semi-crystalline"). When polypropylene is used as the crystalline or se~i-crystalline polyolefin, the polypropylene has 30-98% crystallinity, and typically between 5~ and 70 15 crystallinity, as determined by X-ray analysis or solvent extraction. The tPrmin~logy "substantially crystalline" is used to designate those polyolefins having crystallinity of between 30 and 9~%.
Ethylene-Propylene ("E~"') copolymers which have 20 differing amounts of ethylene and propylene therein may be employed in co~ponent (lB) as well as in the blends of Group (II). EP copolymers for use in the invention ~an be prepared by copolymerizing ethylene and propylene in the presence oL
free radical coordination st~eo~e~ific polymerization 25 catalysts, such as Phillips, Kaminsky or Ziegler-~atta catalysts. These preparation techniques are well known.
Generally, EP copolymers useful as component (lB) will be slightly crystalline or substantially amorphous, i.e., greater than 50~ amorphous. Preferably, these copolymers 30 will have a Nooney viscosity of about lO-5~ at lOO~C. The amount of propylene in the EP copolymer is not particularly limited provided that the Nooney viscosity is within the stated range. The EP copolymers may be completely replaced on a one-to-one basis by terpolymers of ethylene-propylene-35 ùiene ~onomers ("EPD~s"~ such as ethylidene norbornene,dicyclopentadiene, l~4-hexadlene and the like. ~seful copolymers may include mixtures of ethylene-propylene and ~-- 8 --Wo9610~13~ 219 8 ~ ~ ~ PCT~1S9~/10590 EP~Ms. The total content of ethylene in component (lB) may be between about 0~ and about 30%, preferably about 20~. EP
copolymers useful in Group (II) blends may have about 30-90% ethylene, preferably about 70% ethylene based on the 5 total weight of the specific blend of Group (II).
The ethylene-butene ("EB") copolymers of component (2) which can be employed in the blends of Groups (I)-(III) are preferably produced by use of metallocene or Kaminsky catalysts. These copolymers typically have a narrow lO molecular weight distribution, i.e., (Mw/Mn) of less than 3, where Mw = weight average molecular weight and Mn = number average molecular weight. These EB copolymers can include ethylene in an amount of 5-95%, preferably about 50-90% and more preferably about 80%.
The ethylene-octene copolymers of component (3) which can be employed in the blends of Groups (I)-(III) also have a narrow molecular weight distribution (Mw/Mn) of less than 3 where Mw and Mn are defined as above. These ethylene-octene copolymers can be produced using methods such as those which 20 employ metallocene or Kaminsky catalysts. These ethylene-octene copolymers can have 5-95% ethylene therein, preferably about 50-90% and more preferably about 80%.
Useful blends of Group (I) can include blends of any of (Ia)-(If) as defined above. In blend (Ia), component (lA) 25 can comprise about 50 to 80~, preferably 60 to 70%, remainder cn~p~nPnt (2); ~ ~nt (lA) can comprise about 50 to 80%, preferably 60 to 70~, of blend (Ib), remainder component (3);
~ onPnt (lB) can comprise about 50 to 80~, preferably 60 to 70%, of blend (Ic), rr-~in~Pr component (2); component (lB) 30 can comprise 50 to 80% of blend (Id), rr-~;n~pr component (3); component (Ic) can comprise 50 to 80~ of the blend (Ie), ro-qin~r component (2); component (lC) can comprise 50 to 80~ of blend (If), remainder component (3).
The blends of Group (II) can be formed from combinations 35 of any one of , -n~ntS (lA)-(lC~ with components (2) and (3) with c -n~nt (4). Regarding the latter, it is preferred to use any of EP, EB other than component (2), or _ g _ 21g84~
WO96~6132 PC~IUS~
copolymers o~ ethylene and C~-C,5, preferably C4-CIJ alpha olefins such as copolymers of ethylene with at least one of propylene, butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene. Illustrative Group (II) 5 blends include but are not limited to:
about 50 to 80% ~ an~1.t (lA) with about lO to 35%
_ - ~ (2), about lO to 25% component ~3) and about 0 to 20% EP copolymer;
about 50 to 80% component (lA) with about lO to 35%
c, ~onpnt (2), about lO to 25~ component (3) and about 0 to 20% EB copolymer other than component (2);
about 50 to 80% component (lA) with about lO to 35%
c, -nPnt (2), and about lO to 25% component (3~ with about 0 to 20% copolymer of ethylene with at least one of propylene, butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene;
about 50 to 80% component (lB) with about lO to 35%
component (2), about lO to 25~ c~mron~nt ~3) and about 0 to 20~ EP copolymer;
about 50 to 80% component (lB) with about lO to 35~
component ~2), about lO to 25% component (3) and about 0 to 20~ ethylene-butene copolymer other than component (2);
about 50 to 80% component (lB) with about lO to 35 component (2), about lO to 25% ~c -nP~t (3), and about 0 to 20~ o~ a copolymer of ethylene with at least one of propylene, butylene, psntylene, hexylene, septylene, octylene, nonylene, and decylene;
about 50 to 80% component (lC) with about lQ to 35%
component ~2) and about lO to 25% component (3) with about 0 to 20% EP copolymer;
about 50 to 80% component (lC) ~ith about lO to 35%
component (2) and about lO to 25% component (3) with about 0 to 20% ethylene-butene copolymer other than ~5 component ~2); and about 50 to 80% component (lC) with about lO to 35%
_ ,~nPnt (2) and about lO to 25% component (3) with ~ 21g~5~
W096/06132 PCT~S951l0590 about 0 to 20~ copolymer of ethylene with at least one of butylene, pentylene, hexylene, septylene, octylene, nonylene, and decylene.
Each of the ethylene-butene copolymers and ethylene-5 octene copolymers of ~~ntS (2) and ~3) respectively, maybe slightly crystalline, i.e., have up to about 20%
crystallinity as calculated from density measurements.
Preferably, each of the ethylene-butene and ethylene-octene copolymers are substantially amorphous. Amorphous ethylene-10 butene copolymers are available from Exxon Polymers Co. underthe tradename EXXACT. Amorphous ethylene-octene copolymers are available from Dow Chemical Co. under the tradename ENGAGE.
Any of the blends of Groups (I) and (II~ optionally may 15 be combined with fillers such as talc, glass, mica, or calcium carbonate, and the like, preferably talc, to provide blends of Group III. These fillers may be present in an amount of about 0.1 to 10% and preferably about 3-5%.
Each of blends of Groups (Ij-(III) provide products with 20 superior combinations of mechanical and surface properties.
Blends of Groups (I)-(III) can be molded into products which show a Rockwell R hardness of at ~east about 60 as measured according to ASTM D-785, a flexural modulus of at least about 80 kpsi as measured according to ASTM D-7gc, a melt flow rate 25 of at least about lO and preferably about 15 dg/min or more at 230 C and 2.16 kg as measured according to ASTM D-1238, a maximum density of 0.98 g/cc, and are ductile at -30~C at a velocity of about 5 mph as measured according to ASTM D-3763.
Talc usable in the blends of Group III has a particle 30 size less than lO microns, preferably less than 5 microns, most preferably about O.g micron, and a specific surface area of about 3.5 m2/g or more, preferably about 3.5-6.0 m2/g. The amount of talc utili~ed depends on the other component(s) employed in the specific blend of Group (IIIj. Typically, 35 about 0.1 to 10 parts of talc by weight of the component(s), preferably about 0.1 to 8 parts, and more preferably between about 3 to 5 parts, may be employed.
2198 45~
.
WO~61~132 PCT~S9~10590 The talc may be prepared by dry pulverization and subsequent dry classification. The average particle size of the talc employed is a particle size at a cumulative amount of 50~ by weight in a cumulative particle size distribution 5 curve obtained by a li~uid phase sedimentation light transmission method using, for instance, Nodel CP
manufactured by Shimadzu Corp. The specific surface area measuring apparatus Model SS-lOO is produced by Shimadzu Corp.
Talc filler employed in the invention need not be treated. However, to improve adhesion between the talc filler and the polymers employed in the blends of Group III, as well as for disperslbility of the talc in those component blends, the talc may be treated with organic titanate ~5 coupling agents, silane coupling agents, fatty acids, metal salts of fatty acids, fatty acid esters, and the like.
Various additives may be combined with any of the blends of Grou~ III) unless they substantially impair the advantsgeous properties of those component blends. Useful 20 additives include for example, process stabilizers, antioxidants, ultraviolet absorbers, soaps such as metal soaps, anti-static agents, lubricants, nucleating agents, pigments and dispersant for pigment. In addition, additives capable of imparting higher flexural modulus to the blend 25 than that imparted by talc can be included. Examples of these additives include fibrous potassium titanate, fibrous magnesium oxalate, fibrous aluminum borate, and carbon fibers.
Morphology of blends of Groups (I)-(III) shows excellent 30 dispersion of components with the biggest domains being the filler particles. Apart from the filler, the average domain size is less than 2 ~m. This indicates excellent compatibility of components as shown in FIGs l and 2. This compatibility, combined with the high melt flow rate of the 35 blend, leads to a characteristic thin layering typically less than about 0.5 ~m, near the surface of the injection molded specimens produced from the compositions of the invention.
~ ~ i 9 ~
WO g6106132 PCTIUS95/10590 This is illustrated in FIGs. 3 and 4 which show the morphology of the skin layer of specimens formed from the composition of example 5 of the invention.
The blends of Groups (I)-(III) can be molded or 5 otherwise formed to produce articles which are lightweight, durable, and have surfaces which are paint receptive. The - -n~nts also can be pelletized for storage and shipment prior to molding into shaped articles by known methods.
Products formed of any of the blends of Groups (I~
10 can be coated with paints, particularly with paints such as commercially available two-component blend polyurethanes to provide products with superior fluid resistance. The blends of Groups (I~-(III~ may be coated with paints ~hich have active functional groups such as acrylics, polyesters, epoxy 15 resins, carboimides, urea resins, melamine-formaldehyde resins, enamines, ketimines, amines, and isocyanates to provide products with improved fluid resistance. These types of paints are well known in the paint and coatings industry.
Products having superior physical properties and 20 adherence for coating materials such as paints can be prepared by mixing any of the blends of Groups (I~-(III~
with, if desired, optional additives by using extruders, Banbury mixers, rollers, brabenders and kneaders. Molded products may be prepared from any of blends of Groups (I~-25 ~ by known methods such as injection molding, extrusionmolding, and blow molding. Injection molding is preferred.
Blends of Groups (I~-(III~ present a significant advantage in injection molding compared to conventional thermoplastic polyolefin blends. A computer simulation of 30 the molding conditions for the blends of Groups (I)-(III) show lower injection pressure, lower clamp tonnage and shorter cycle time than conventional thermoplastic polyolefin blends having comparable viscosities under standard conditions.
The computer simulation, performed using the commercial software package C-Nold from AC Technologies, requires input of rheological and thermodynamic properties of the material 21~8~5 ~
WOg6/06132 ~ PCT~S951105~0 under consideration. These properties can be determined experimentally. The re~uired properties are viscosity as a function of shear rate between 5 secJ and l~,000 sec~ at temperatures of 200~C, ~30~C and 260~C; specific heat as a 5 function of temperature between room temperature and 250~C, as well as density of the material in the solid state and as melted are also required. The thermoplastic polyolefin blend which serves as a control is Dl62~F. Dl62HF, available from D&S Plastics, has the highest melt flow rate for commercially lO available thermoplastic olefin blends.
As shown in FIGs. 5-7, the computer simulation indicates that the maximum injection molding pressure, the clamp tonnage, as well as the filllcool times for the compositions of Examples l and 4 of the invention are much less than for 15 commercially available composition Dl6~HF.
Generally, processing of the components of the invention can be performed using Banbury mixers or twin screw extruders. When a Banbury mixer is employed to prepare any of blends of Groups (I)-(III), a single screw extruder can be 20 used to pelletize that component blend. The resulting pellets then are supplied to an injection molding machine for manufacture of molded articles.
During mixing of the blends of Groups (I~ with a Banbury mixer, the ram pressure in the ~anbury mixer is about 25 30-35 psi. Mixing is continued until fluxing temperature is achieved, i.e., the temperature at which the viscosity of the blend drops sharply. When fluxing temperature is achieved, mixing is terminated and the resulting batch of material is removed from the Banbury mixer. The batch then is ground 30 into chips and/or pelletized in a single screw extruder.
Pellets of the formed component blends are supplied to an injection molding machine for injection molding into shaped products.
35 F~A~P~ES
The invention will now be explained in more detail with reference to the following examples, which are given merely ~ 21g84~
W096l06~32 PCT~S9~/lU~9 to illustrate the invention and are not intended to be limiting thereof.
Examples 1-6 The compositions of examples 1-6 are given in Table 1.
Table 1 also shows the physical properties of the compositions when processed according to the conditions set forth in Table lA. In Table 1, Ductility Index is measured by using a High Rate Impact Tester machine Model No. RIT-8000 10 from Rheometrics Company, Piscataway, New Jersey. The RIT-8000 is equipped with a steel probe having a size measuring o.S" diameter by 12.25" long, and having a weight of about 0.705 lb. The probe has a spherical tip. The probe is accelerated to penetrate a specimen measuring 4" x 6" x 1/8"
15 at a constant speed of 5 mph. The temperature of the specimen is -30~C.
Ductility Index is calculated from the equation DI=(T-U)IT
where DI=Ductility Index, T represents total energy at the point at which the probe has broken through the specimen,i.e., the point at which the force applied to the sp~;r by the probe drops to zero, and U represents ultimate energy, i.e., the energy at the point at which the force exerted by the probe on the specimen is at maximum as determined from the force-position curve of force applied by the probe to the specimen vs. the position of the probe. The DI values for each of 3 - 5 30 specimens are averaged and reported as DI.
Also, in Tables 1 and 2, the peel strength is the force ~g/cm~ required to peel the paint off substra~e, is a measure of adhesive strength of the coating to the substrate.
In determining the peel strength, an injection molded 35 plaque, formed of a composition of the invention, of size 4x6 inches and 118 inch thick, is partially coated with the adhesion promoter RB899 from Morton International Co., and , . . , .. _ _ _ _ _ _ _ _ ~198~5i W096/06132 PCT~'S9.~1~1~90 entirely with a topcoat of R773 ~rom Morton, InternationalCo. to enable lifting the topcoat from that portion of the plaque which iB not coated with the adhesion promoter.
Cuts through the topcoat coating are made using a sharp 5 knife and a metal template to form two or three one cm wide strips. The one cm side strips are slowly peeled from those portions of the plaque which are free of the adhesion promoter. A piece of polyester tape is placed on the peeled off strip to form a "handle" with which the strip is peeled lO further.
The prepared plaque is placed into an Instron Tensile Tester (Instron Model ll30).
The force required to peel the strip from the plaque is recorded as a function of the length of peeled off strip 15 along the plaque. The peeling speed is two inches per minute. The average force in the entire peel is reported as the measure of adhesion strength per one cm of width of peel, i.e., in units of g/cm.
2198~5 W 096/06l32 PCTrUS~S/IOSJO
TABLE l Stand-rd Ex~mpl~ No./ TPO
e~mpon-nt ~ l 2 3 4 S 6~Cortrol) 62 62 65 65 ~
R~ -- -- -- __ __ __ __ R -- -- -- -- __ __ __ oly~ethylene- 22 ll 17.5 12 22 22 --co-b tene~
Pol~ ethylene- 11 22 17.5 23 11 11 --- nene~
_L. S S O O S S --_E AL 197 190 163 163 214 213 220 zo ULUSI~
SITY12 ~3 93 . O . 9 93 ~3 1.~2 15ACT @-30C D D
I CTILITY . 8 .36 . 4 . 6 .38 . 7 . S
INDEX
PEEL STRENGZTRlOSO1200 7S0 1200 83010851000 1. Polypro~ylene, MFR at (230 C, 2.16 kg~ = 45 dg/min, ASTM D-1238 2. Po_ypro~ilene, MFR at (230 C, 2.16 kg) = 49 dg/min, ASTM D-1238 3. Po yprop~lene, MFR at (230 C, 2.16 kg~ = 56 dg/min, ASTM D-1238 4. Po_y(etl 'lt'.~tc _u ~Lu~ylene~; C2=SO~, C3 = 50%, Mooney Viscosity at 20100~C =~i S. Po~y(ethylene-co-butene~; C2=75~, C4 = 25%; MFR at (19OC, 2. 6 kg~ = 0.8 dg/min 6. EXXACT 4033 zrom Exxon Co., produced by Kaminsky catalyst process, having C2=80~; MFR at (190 C, 2.16 kg) = 0.3 dg~min, ASTM D-1238 7. C2 80~; MFR at (190 C, 2.16 kg~ = S.O dg/min, ASTM D-1238 8. Average talc particle slze = 0.9 micron 9. Rockwell R bardness measured according to ASTM D-785 _0. Xpsi measured according to ASTM D-790 1. dg/min at (23û C, 2.16 kgj as measured according to ASTM D-1238 2. g/cc 3. D=Ductile Failure; B=Brittle Failure measured according to ASTM D-~1984~ --W 096/06132 PCT/U89~1059U
TABLE l(a) Proc~lng '~t ~.
ESAMPLE/l._ 1 2 3 4 5 6 CONDI~ION
BANBURY MISING
ROTOR SPEED ~RPK) 185 185 190 190 185 185 RAM PRESSURE tPSI) 32 32 34 34 32 32 TIME TO FLUX (SEC~ gS 95 90 90 9S 9S
FLUY. TEMP ('F) 360 360 355 355 360 360 BATCN TEHP t~~) 410 410 410 410 410 41D
p~T,~V~IZ SINGLE SCREW
ESIRUDER
END ZONES T~P (~F1 360 360 360 360 360 360 CENTRAL ZONE TEMP (~Fi 380 380 380 380 380 380 SCREW SPEE0 (RPM) 9S 9S 9S 9S 95 9S
KELT TEUP (~F) 375 375 375 375 375 375 MOLDING ' _.~I~
SCREW SPEED ~RPM) 90 90 90 90 90 90 MOLD TEMP (~F~ 50 80 80 80 80 80 INJECTION TI~E (SEC) lO 10 10 10 10 lO
COOLING TIKE (SEC) 25 25 25 25 25 25 INJECTION PRESSURE (PSI) sS0 SSO 550 SSO 550 SSO
FILLING TIKE (PSI) 10 lO 10 10 10 10 EOLDING PRESSURE ~PSI) 430 430 430 430 430 430 EOLDING TIME (SEC~ 15 lS lS lS lS lS
BACE PRESSURE (PSIi50 50 50 50 50 50 Examples 7-11 Table 2 illustrates additional compositions within the scope of the invention. Table 2 also shows the physical properties of the compositions when processed according to the conditions set forth in Table 2a.
Ductility index and peel strength are maasured as in Examples 1-6.
2 ~
EYAMPLE No./ 7 8 9 10 11 Component (95) }7Ipp2 __ __ __ __ __ HI PP3 __ _ _ _ __ _ _ _ EPR4 33 __16.5 -- --EBR5 -- 3316.5 -- --Poly(ethylene- -- -- -- 33 --co-butene)' Poly(ethylene- -- -- -- -- 33 co-octene)7 HARDNEsS945 60 55 79 74 15 MODULUSI~
MFRIl14 14 14 16 19 DvENSITYI2 0.930.93O.gO 0.89 0.93 IMPACT @-30C~5 D B B 8 B
DUCTILITY INDEX0.370.10 0.25 0.2S 0.25 1. High crystallLn.ty polypropylene, MFR at (230 C, 2.16 kg) = 45 dg/min, ASTM D-_238 2. High cry~tall.n_ty polypropylene, MFR at ~230 C, 2.16 kg) = 49 dg/min, ASTM D- 238 3. High crystall n_ty polypropylene, MFR at (230 C, 2.16 kg) = 56 dg/min, ASTM D- 238 4. Poly(ethylc.._ _~ ~ylene); C2=S0~, C3 = S0~, Mooney Viscosity at 100~C =35 S. Poly(ethyleAe _v b~ene); C2=75~, C4 = 25~; MFP. at 190C, 2.16 kg e 0.8 dg/min, prepared by conventional process, e.g., Flexomer (Union CarbLde), Tafmer (Mitsui Petrochemical) 6. EXXACT 4033 from Exxon Co., produceù from Kaminsky catalyst, and having C2=80~; MFR at (190 C, 2.16 kg) = 0.3 dg/min, A8TM D-1238 7. C2=80~; MFR at (190 C, 2.16 kg) = S.0 dg/min, ASTM D-1238 0. Talc, particle size = 0.9 micron ~ . Rockwell R hardneus moasured according to ASTM D-785 o 7Kpsi measured according to ASTM D-790 1 dg/min at 230 C and 2.16 kg as measured according to ASTM D-1238 12. g/cc 13. D=Ductile Failure; B=Brittle Failure measured according to ASTM D-2198~5~ ~
W 096~6132 PCT~g511059U
TABLE 2 la) Proc~ll;sL.g Ct~n.dit.o~
E~AMPLE~.~t~,o~ltn~ 7 8 9 10 11 CONDITION
BANBURY MI~ING
ROTOR SPEED (RPX) 185 185 185 185 185 RAU PRESSURE ~PSI) 32 32 32 32 32 T-IME TO FLUX ~SEC) 110 110 110 95 95 FLUX TEUP (F~) 380 380 380 360 360 3ATCU TEMP (~F~ 420 420 420 410 410 0 pRT.T.R'l'T5STt~~
END ZONE TE~P ~~F) 36Q 360 360 360 360 CENTRAL ZONE TBMP 1~F) 3~0 380 380 380 380 SC ~ W SPEED (RPM~ 9C 90 90 95 95 MELT TEMP ~~FI 380 380 380 375 375 MOLDING ~
CENTP~L ZONE 2 380 380 380 360 360 SCP~EW SPEED (RP~) 85 85 85 90 90 MOLD TEMP (~F) 80 80 80 80 80 INJECTION T}ME (SEC~ 10 10 10 10 10 COOLING TIME ~SEC) 25 25 25 25 25 (PSI) FILLING TIME ~SEC) 10 10 10 10 lO
~OLDING PRESSUP~ (PSI) 550 550 550 430 430 ~OLDIN& TI~B ~SEC) 15 15 15 15 15 BACK PP~SSURE ~PSI) 50 SO SO 50 SO
Examples 12-15 Table 3 illustrates additional compositions within the scope o~ this invention. Table 3 shows the durability of these compositions, as measured by the so-called SLEdge test and high speed cohesive strength test.
The SLEdge test utilizes a 15.6 lb pendulum head with a 1" wide painted strip of reaction injection molded polyurethane bolted to it. The pendulum head drops from a 90~ position to tangentially impact a 41t X 6" painted ~1~8~S
WO96~06132 PCT/U~9SIIOS90 plaque o~ the molded composition after the plaque has been preheated to 175~F for a minimum of 40 minutes. The extent of the damage is recorded as the area of paint that has been removed from the substrate in square millimeters.
The high speed cohesive strength test includes the steps of coating a 4" x 6" x 1/8" injection molded plaque of the composition with 0.1-0.2 mils of a chlorinated polyolefin adhesion promoter and then baking the coated composition for 30 minutes at 80~C. After cooling, a 1.5 cm strip of a 1/16" thick polycarbonate sheet is adhered to the primed surface using a two-component epoxy adhesive. The average force required to cohesively delaminate the sheet from the coated composition is measured in Newtons/meter at 75~F and 180~F.
As shown by the tests results, peel area values are in the range of 105-450 mm2 for conventional compositions while values of 40 mm2 or less are obtained with the compositions of the invention. When conventional Ziegler-Natta rubbers are omitted, no peel areas at all occur, as shown by Examples 14 and 15. The inventive compositions also exhibited a significantly greater cohesive strengths than those of conventional compositions.
~84~
Wo 96106132 PCI~/IIS95~10~91J
~n~. o OO O O O O O ~o,~ 00 ~, ot~o~oooo o_ os~, o~oo ooooo ~oo ooC~
~~oo~ ooo oo X~
:C~ ~ ~~, ~ ~ O O o o X ~, o ~9 ~o~,oooo oo x~, li.~50o~ Xoooo oo x~.
L~l c~Oo oooo~oq oo x~--- ~ 1cr o o o o o ~ o o o oo ~-i ~oO OO~OO oo x~
cq~OOO~~rOOO OO 00 <,~ o.oo ,o,oooo oo o~
.=
~ X _ ~ _ ~ 2 z z z ~ ~ -~-~ ~
~ ~ ~ W ~U W ~ ~
Dulability C , ' .~ Materh~ ention A B C D E F G E~ 12 13 14 15 SLEdge Test, Peeled area mm~ 460 425 321 305 105 200 150 400 40 0 20 0 High Speed Cohesive Strength at 75~F, N/m 4000 4100 4100 46005200 5000 5500 38006200 8000 8200 9000 at 180~F, N/rn 1600 1600 1750 18001950 1800 2000 16002700 3800 3700 4000 P~
Notes u:~
~N = Ziegler-Natta catalyzed o~a = ~ catalyzed SLEdge data on all c . coated with Ked-Spot 2k urethane coating Cohesive Strength data obtah~ed at a test speed of 200 inches/min
Claims (20)
1. An automotive component of a molded thermoplastic article having enhanced wear resistance comprising a blend of a thermoplastic component comprising component (1A) which is a homopolymer of propylene having an isotactic index of greater than about 0.93 or a crystallinity of greater than about 56%; component (1B), which is a sequentially polymerized semi-crystalline blend of polypropylene and an ethylene-propylene copolymer; or a mixture of component (1A) and (1B); and an elastomeric component of a copolymer of ethylene and a C~ to C8 olefin produced with a metallocene or Kaminsky catalyst and having a molecular weight distribution (Mw/Mn) of less than or equal to 3.
2. The article of claim 1 wherein the elastomeric component is component (2), which is a copolymer of ethylene and butene; component (3), which is a copolymer of ethylene and octene; or a mixtures of components (2) and (3).
3. The article of claim 1 wherein the blend has a melt flow rate of at least about 10 dg/min and wherein the thermoplastic component is present in the blend in an amount of about 50 to 80% and the elastomeric component is present in an amount of about 20 to 50%.
4. The article of claim 1 which further comprises component (4), which a copolymer of ethylene and a C3 to C15 olefin having a crystallinity of at least about 30%.
5. The article of claim 1 which further comprises a filler.
6. The article of claim 1 wherein:
the Group (I) blends include at least one of:
blend (Ia) comprising component (1A) with component (2);
blend (Ib) comprising component (1A) with component (3);
blend (Ic) comprising component (1B) with component (2);
blend (Id) comprising component (1B) with component (3);
blend (Ie) comprising component (1C) with component (2); or blend (If) comprising component (1C) with component (3);
and the Group (II) blends include combinations of at least one of:
blend (IIA) comprising combinations of component (1A) with component (2) and component (3) and EP;
blend (IIB) comprising combinations of component (1A) with component (2) and component (3) and EB;
blend (IIC) comprising combinations of component (1A) with component (2) and component (3) and component (4);
blend (IID) comprising combinations of component (1B) with component (2) and component (3) and EP;
blend (IIE) comprising combinations of component (1B) with component (2) and component (3) and EB;
blend (IIF) comprising combinations of component (1B) with component (2) and component (3) and component (4);
blend (IIG) comprising combinations of component (1C) with component (2) and component (3) and EP;
blend (IIH) comprising combinations of component (1C) with component (2) and component (3) and EB; or blend (IIK) comprising combinations of component (1C) with component (2) and component (3) and component (4).
the Group (I) blends include at least one of:
blend (Ia) comprising component (1A) with component (2);
blend (Ib) comprising component (1A) with component (3);
blend (Ic) comprising component (1B) with component (2);
blend (Id) comprising component (1B) with component (3);
blend (Ie) comprising component (1C) with component (2); or blend (If) comprising component (1C) with component (3);
and the Group (II) blends include combinations of at least one of:
blend (IIA) comprising combinations of component (1A) with component (2) and component (3) and EP;
blend (IIB) comprising combinations of component (1A) with component (2) and component (3) and EB;
blend (IIC) comprising combinations of component (1A) with component (2) and component (3) and component (4);
blend (IID) comprising combinations of component (1B) with component (2) and component (3) and EP;
blend (IIE) comprising combinations of component (1B) with component (2) and component (3) and EB;
blend (IIF) comprising combinations of component (1B) with component (2) and component (3) and component (4);
blend (IIG) comprising combinations of component (1C) with component (2) and component (3) and EP;
blend (IIH) comprising combinations of component (1C) with component (2) and component (3) and EB; or blend (IIK) comprising combinations of component (1C) with component (2) and component (3) and component (4).
7. The article of claim 1 wherein the propylene polymer in any of components (1A)-(1C) is a polypropylene homopolymer that has a melt flow rate of about 10 to 80 dg/min.
8. The article of claim 1 wherein the propylene polymer in any of components (1A)-(1C) is a copolymer of propylene and at least one member selected from the group of maleic anhydride, acrylic acid or trimethoxyvinyl silane.
9. The article of claim 1 wherein the ethylene content of component (1B) or (1C) is about 0-30% based on the total weight of the component.
10. The article of claim 1 wherein the ethylene-propylene copolymers have a Mooney viscosity of about 10-90 at 100°C.
11. The article of claim 10 wherein the ethylene-propylene copolymers of any of components (2)-(3) have about 50-90% ethylene based on the total weight of the component.
12. The article of claim 1 wherein the ethylene-butene copolymers of component (2) or the ethylene-octene copolymers of component (3) are substantially amorphous.
13. The article of claim 4 wherein the alpha olefins of component (4) are have 4-10 carbons.
14. The article of claim 5 wherein the filler is talc or calcium carbonate, glass fibers, mica, or glass microspheres and is present in an amount of about 1-10%.
15. The article of claim 1 wherein the thermoplastic component is present in the blend in an amount of about 40 to 80% and comprises a mixture of components (1A) and (1B), and wherein the elastomeric component comprises a mixture of components (2) and (3) and is present in an amount of about 20 to 60%, wherein component (2) is present in an amount of about 10 to 35% and component (3) is present in an amount of about 10 to 25%.
16. The article of claim 4 wherein the thermoplastic component is present in the blend in an amount of about 50 to 80%, the elastomeric component comprises a mixture of components (2) and (3) is present in an amount of about 20 to 60%, wherein component (2) is present in an amount of about 10 to 35%, and component (3) is present in an amount of about 10 to 25%, component (4) is present in an amount of about 1 to 20%.
17. The article of claim 1 further comprising at least one of stabilizers, antioxidants, ultraviolet absorbers, metal soaps, anti-static agents, lubricants, nucleators, pigments, fibrous potassium titanate, fibrous magnesium oxalate, fibrous aluminum borate, carbon fibers, and mixtures thereof.
18. The articles of claim 1 further comprising:
a Rockwell R hardness of at least about 60 as measured according to ASTM D-785, a flexural modulus of at least about 80 kpsi as measured according to ASTM D-790, a melt flow rate of at least about 10 dg/min at 230°C
and 2.16 kg as measured according to ASTM D-1238, and a density of about 0.95 g/cc, and wherein the article is ductile at about -30°C when measured according to ASTM D-3763.
a Rockwell R hardness of at least about 60 as measured according to ASTM D-785, a flexural modulus of at least about 80 kpsi as measured according to ASTM D-790, a melt flow rate of at least about 10 dg/min at 230°C
and 2.16 kg as measured according to ASTM D-1238, and a density of about 0.95 g/cc, and wherein the article is ductile at about -30°C when measured according to ASTM D-3763.
19. The article of claim 1 further comprising a coating of paint thereon, said paint selected from the group of two-component polyurethanes, acrylics, polyesters, epoxy resins, carboimides, urea resins, and melamine-formaldehyde resins.
20. The article of claim 20 in the form of an bumper, bumper cover, exterior trim part, or interior trim part.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/296,293 US5773515A (en) | 1994-08-25 | 1994-08-25 | Engineered polyolefin materials |
| US296,293 | 1994-08-25 | ||
| US480,175 | 1995-06-07 | ||
| US08/480,175 US5763534A (en) | 1994-08-25 | 1995-06-07 | Thermoplastic polypropylene blends with mixtures of ethylene/butene and ethylene/octene copolymer elastomers |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2198455A1 true CA2198455A1 (en) | 1996-02-29 |
Family
ID=26969583
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002198455A Abandoned CA2198455A1 (en) | 1994-08-25 | 1995-08-21 | Engineered olefinic compositions |
Country Status (10)
| Country | Link |
|---|---|
| US (3) | US5763534A (en) |
| EP (1) | EP0777700B1 (en) |
| JP (1) | JP3771583B2 (en) |
| KR (1) | KR100345060B1 (en) |
| AT (1) | ATE214079T1 (en) |
| AU (1) | AU3409195A (en) |
| CA (1) | CA2198455A1 (en) |
| DE (1) | DE69525754T2 (en) |
| MX (1) | MX9701407A (en) |
| WO (1) | WO1996006132A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
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-
1995
- 1995-06-07 US US08/480,175 patent/US5763534A/en not_active Expired - Fee Related
- 1995-08-21 DE DE69525754T patent/DE69525754T2/en not_active Expired - Lifetime
- 1995-08-21 EP EP95930867A patent/EP0777700B1/en not_active Expired - Lifetime
- 1995-08-21 AT AT95930867T patent/ATE214079T1/en not_active IP Right Cessation
- 1995-08-21 MX MX9701407A patent/MX9701407A/en unknown
- 1995-08-21 KR KR1019970701183A patent/KR100345060B1/en not_active IP Right Cessation
- 1995-08-21 AU AU34091/95A patent/AU3409195A/en not_active Abandoned
- 1995-08-21 CA CA002198455A patent/CA2198455A1/en not_active Abandoned
- 1995-08-21 JP JP50823796A patent/JP3771583B2/en not_active Expired - Fee Related
- 1995-08-21 WO PCT/US1995/010590 patent/WO1996006132A1/en active IP Right Grant
-
1997
- 1997-10-29 US US08/960,474 patent/US5998524A/en not_active Expired - Lifetime
- 1997-10-29 US US08/959,528 patent/US5985971A/en not_active Expired - Lifetime
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|---|---|
| EP0777700A1 (en) | 1997-06-11 |
| KR100345060B1 (en) | 2002-10-11 |
| AU3409195A (en) | 1996-03-14 |
| DE69525754T2 (en) | 2002-10-24 |
| MX9701407A (en) | 1997-05-31 |
| JP3771583B2 (en) | 2006-04-26 |
| JPH10505372A (en) | 1998-05-26 |
| US5985971A (en) | 1999-11-16 |
| US5998524A (en) | 1999-12-07 |
| US5763534A (en) | 1998-06-09 |
| EP0777700A4 (en) | 1998-06-10 |
| DE69525754D1 (en) | 2002-04-11 |
| ATE214079T1 (en) | 2002-03-15 |
| WO1996006132A1 (en) | 1996-02-29 |
| EP0777700B1 (en) | 2002-03-06 |
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