High flow fiber-reinforced propylene composition having low emissions

Patent metadata

Field	Value
Publication number	US-12209177-B2
Application number	US-202117221042-A
Country	US
Kind code	B2
Filing date	Apr 2, 2021
Priority date	Jan 10, 2017
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

Abstract

A fiber-reinforced polymer composition that contains a polymer matrix and a plurality of long reinforcing fibers that are distributed within the polymer matrix is provided. The polymer matrix contains a propylene polymer and constitutes from about 30 wt. % to about 90 wt. % of the composition. The fibers constitute from about 10 wt. % to about 70 wt. % of the composition. Further, the polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3123-09 and a volatile organic content of about 100 micrograms per gram or less as determined by VDA 277.

First claim

What is claimed is:

1. An automotive part comprising a fiber-reinforced polymer composition comprising:
a polymer matrix that contains: a propylene polymer having a melt flow index from about 150 to about 250 g/10 min, wherein melt flow index is determined in accordance with ISO 1133-1:2011 at a load of 2.16 kg and temperature of 230° C., wherein the polymer matrix constitutes from about 30 wt. % to about 90 wt. % of the composition; and
a plurality of long reinforcing fibers that are distributed within the polymer matrix, wherein the fibers constitute from about 10 wt. % to about 70 wt. % of the composition, wherein the polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3123-09, and further wherein the composition exhibits a volatile organic content of about 100 μgC/g or less as determined in accordance with VDA 277:1995.

2. The automotive part of claim 1 , wherein the composition exhibits a toluene equivalent volatile organic content of about 250 μg/g or less as determined in accordance with VDA 278:2002.

3. The automotive part of claim 1 , wherein the composition exhibits a fogging content of about 500 μg/g or less as determined in accordance with VDA 278:2002.

4. The automotive part of claim 1 , wherein the propylene polymer is a homopolymer.

5. The automotive part of claim 4 , wherein the homopolymer is metallocene-catalyzed.

6. The automotive part of claim 1 , wherein the propylene polymer is an α-olefin/propylene copolymer.

7. The automotive part of claim 4 , wherein the composition further comprises an α-olefin/propylene copolymer.

8. The automotive part of claim 7 , wherein the homopolymer is metallocene-catalyzed.

9. The automotive part of claim 1 , wherein the fibers are glass fibers.

10. The automotive part of claim 1 , wherein the fibers constitute from about 20 wt. % to about 60 wt. % of the composition.

11. The automotive part of claim 1 , wherein the fibers are oriented in a longitudinal direction of the composition.

12. The automotive part of claim 1 , wherein the part has a wall thickness of about 2.5 millimeters or less.

13. The automotive part of claim 1 , wherein the composition exhibits a toluene equivalent volatile organic content of about 150 μg/g or less as determined in accordance with VDA 278:2002.

14. The automotive part of claim 1 , wherein the composition exhibits a fogging content of about 350 μg/g or less as determined in accordance with VDA 278:2002.

15. The automotive part of claim 1 , wherein the part has a wall thickness of about 2 millimeters or less.

16. The automotive part of claim 1 , wherein the part is injection molded.

17. The automotive part of claim 1 , wherein the part is an interior automotive part.

18. The automotive part of claim 17 , wherein the part is a pedal module, instrument panel, arm rest, console, seat structure, interior module, lift gate, interior organizer, step assist, ash tray, glove box, gear shift lever, or a combination thereof.

19. The automotive part of claim 1 , wherein the automotive part is an exterior automotive part.

20. The automotive part of claim 19 , wherein the exterior automotive part is a fan shroud, sunroof system, door panel, front end module, side body panel, underbody shield, bumper panel, cladding, cowl, spray nozzle body, capturing hose assembly, pillar cover, rocker panel, or a combination thereof.

Assignees

• Celanese Int Corp
• Ticona Llc

Inventors

• Kanuteh Jimmy
• Dehe Markus
• Schoenwald-Otten Uta
• Stuermer Juergen
• Kenny Paul
• Tibor Timothy L

Classifications

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title

• B29C45/0005

  using fibre reinforcements · CPC title

• C08L2207/02

  Heterophasic composition · CPC title

• C08F2810/10

  including a reactive processing step which leads, inter alia, to morphological and/or rheological modifications, e.g. visbreaking · CPC title

• C08L2314/06

  Metallocene or single site catalysts · CPC title