Foamed polypropylene composition

Patent metadata

Field	Value
Publication number	US-11945926-B2
Application number	US-201917050550-A
Country	US
Kind code	B2
Filing date	May 14, 2019
Priority date	May 16, 2018
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

The present invention is directed to a polypropylene composition (C) a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 15 to 40 g/10 min, the use of said polypropylene composition (C) for the production of a foamed article and a foamed article comprising said polypropylene composition (C).

First claim

The invention claimed is:

1. A polypropylene composition (C) having a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 15 to 40 g/10 min, comprising
a) 35.0 to 55.0 wt.-%, based on the overall polypropylene composition (C), of a first heterophasic propylene copolymer (HECO1) having a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 60 to 160 g/10 min, said first heterophasic propylene copolymer comprising
i) a first matrix being a first propylene polymer (M1) and
ii) a first elastomeric propylene copolymer (E1) dispersed in said first matrix,

b) ≥20.0 wt.-%, based on the overall polypropylene composition (C), of a second heterophasic propylene copolymer (HECO2) having a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 3 to <50 g/10 min, said second heterophasic propylene copolymer comprising
iii) a second matrix, which is a second propylene polymer (M2) and
iv) a second elastomeric propylene copolymer (E2) dispersed in said second matrix,

c) 2.0 to 10.0 wt.-%, based on the overall polypropylene composition (C), of a high density polyethylene (HDPE) having a melt flow rate MFR 2 (190° C.) determined according to ISO 1133 in the range of 2 to 15 g/10 min,
d) 5.0 to 15.0 wt.-%, based on the overall polypropylene composition (C), of a plastomer (PL), which is a copolymer of ethylene and a C 4 to C 8 α-olefin and having a melt flow rate MFR 2 (190° C.) determined according to ISO 1133 in the range of 10 to 70 g/10 min,
e) 1.0 to 20.0 wt.-%, based on the overall polypropylene composition (C), of an inorganic filler (F),
f) 1.0 to 10.0 wt.-%, based on the overall polypropylene composition (C), of a foaming agent (FA) comprising citric acid in combination with a bicarbonate, and
g) optionally, a nucleating agent.

2. The polypropylene composition (C) according to claim 1 , wherein
i) the matrix of the first heterophasic propylene copolymer (HECO1) being the first propylene polymer (M1) has a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 50 to 200 g/10 min, and
ii) the matrix of the second heterophasic propylene copolymer (HECO2) being the second propylene polymer (M2) has a melt flow rate MFR 2 (230° C.) determined according to ISO 1133 in the range of 50 to 200 g/10 min.

3. The polypropylene composition (C) according to claim 1 , wherein the first heterophasic propylene copolymer (HECO1) has
i) a xylene soluble fraction (XCS) in the range of 15.0 to 35.0 wt.-%, and/or
ii) a xylene soluble fraction (XCS) whose intrinsic viscosity (IV) is <3.5 dl/g at 135° C., and/or
iii) a xylene soluble fraction (XCS) whose ethylene content is from 30.0 to 40.0 wt.-%, based on the total weight of the xylene soluble fraction (XCS).

4. The polypropylene composition (C) according to claim 1 , wherein the second heterophasic propylene copolymer (HECO2) has
i) a xylene soluble fraction (XCS) in the range of 10.0 to 35.0 wt.-%, and/or
ii) a xylene soluble fraction (XCS) whose intrinsic viscosity (IV) is <4.0 dl/g at 135° C., and/or
iii) a xylene soluble fraction (XCS) whose ethylene content is 35.0 to 50.0 wt.-%, based on the total weight of the xylene soluble fraction (XCS).

5. The polypropylene composition (C) according to claim 1 , wherein the first propylene polymer (M1) and/or the second propylene polymer (M2) are propylene homopolymers.

6. The polypropylene composition (C) according to claim 1 , wherein the first elastomeric propylene copolymer (E1) and/or the second elastomeric propylene copolymer (E2) are copolymers of propylene and ethylene.

7. The polypropylene composition (C) according to claim 1 , wherein the plastomer (PL)
i) is a copolymer of ethylene and 1-octene, and/or
ii) has a density of below 0.900 g/cm 3 .

8. The polypropylene composition (C) claim 1 , wherein the inorganic filler (F) is talc and/or wollastonite.

9. The polypropylene composition (C) according to claim 1 , wherein the bicarbonate is selected from the group consisting of sodium bicarbonate, potassium bicarbonate, magnesium bicarbonate, calcium bicarbonate, ammonium bicarbonate, and mixtures thereof.

10. The polypropylene composition (C) according to claim 9 , wherein the bicarbonate is sodium bicarbonate.

11. The polypropylene composition (C) according to claim 1 , wherein said polypropylene composition (C) is a foamable polypropylene composition.

12. A foamed article comprising the polypropylene composition (C) according to claim 1 .

13. The foamed article according to claim 12 , wherein said foamed article is an automotive article.

Assignees

• Borealis Ag
• Abu Dhabi Polymers Co Ltd Borouge Llc

Inventors

• Kahlen Susanne
• Mileva Daniela
• Grestenberger Georg
• Fuchs Andreas
• Engleder Stefanie
• Huber Jürgen
• Zhu Shengquan

Classifications

• C08J9/0061 Primary

  characterized by the use of several polymeric components · CPC title

• C08J9/08

  developing carbon dioxide · CPC title

• C08K3/34

  Silicon-containing compounds · CPC title

• C08L23/06

  Polyethylene · CPC title

• C08L23/0815

  with aliphatic 1-olefins containing one carbon-to-carbon double bond · CPC title