Polypropylene composition for exterior automotive applications

Patent metadata

Field	Value
Publication number	US-12209178-B2
Application number	US-202218567631-A
Country	US
Kind code	B2
Filing date	Jun 7, 2022
Priority date	Jun 9, 2021
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

Abstract

A composition suitable for automotive application obtainable by blending at least components (A), (B), (C) and (D): (A) 15 wt.-% to 50 wt.-%, preferably 18 to 44 wt.-%, more preferably 20 to 40 wt.-% of a mixed-plastics polypropylene blend; (B) 20 wt.-% to 50 wt.-%, preferably 22 to 47 wt.-%, more preferably 25 to 45 wt.-% of a heterophasic propylene copolymer; (C) 5 wt.-% to 25 wt.-%, preferably 7 to 23 wt.-%, more preferably 10 to 22 wt.-% of an ethylene-based plastomer and (D) 5 wt.-% to 25 wt.-%, preferably 7 to 22 wt.-%, more preferably 10 to 20 wt.-% of an inorganic filler.

First claim

The invention claimed is:

1. A composition suitable for automotive applications:
obtained by blending at least components (A), (B), (C) and (D)
(A) 15 wt % to 50 wt % of a mixed-plastics polypropylene blend;
(B) 20 wt % to 50 wt % of a heterophasic propylene copolymer;
(C) 5 wt % to 25 wt % of an ethylene-based plastomer and
(D) 5 wt % to 25 wt % of an inorganic filler;
whereby all percentages refer to a total composition, and whereby
the mixed-plastics polypropylene blend (A) has
a crystalline fraction (CF) content determined according to CRYSTEX QC analysis in a range from 85.0 to 96.0 wt %, and
a soluble fraction (SF) content determined according to CRYSTEX QC analysis in a range from 4.0 to 15.0 wt %, whereby
said crystalline fraction (CF) has an ethylene content (C2(CF)), as determined by FT-IR spectroscopy calibrated by quantitative 13 C-NMR spectroscopy, in a range from 1.0 to 10.0 wt %; and
said soluble fraction (SF) has an intrinsic viscosity (iV(SF)) in a range from 0.9 to 2.1 dl/g;

the heterophasic propylene copolymer (B) comprises a matrix phase and an elastomer phase dispersed therein and has:
a melt flow rate MFR 2 (230° C., 2.16 kg, ISO 1133) of 85 to 250 g/10 min;
a soluble fraction (SF) content determined according to CRYSTEX QC analysis in a range from more than 20.0 wt % to 30.0 wt %; and
an intrinsic viscosity of said soluble fraction iV(SF), as measured in decalin according to DIN ISO 1628/1 at 135° C., of 2.0 dl/g to 4.5 dl/g;

the ethylene based plastomer (C) is a copolymer of ethylene with comonomer units selected from alpha-olefins having from 3 to 12 carbon atoms, and has:
a melt flow rate MFR 2 (190° C., 2.16 kg, ISO 1133) of 0.2 to 2.5 g/10 min; and
a density of 850 to 870 kg/m 3 ;

the composition has a:
a melt flow rate MFR 2 (230° C., 2.16 kg, ISO 1133) of 8 to 50 g/10 min.

2. The composition according to claim 1 , obtained by blending components (A), (B), (C), (D) and one or more of the following components:
(E) 0 to 20 wt % of a second heterophasic propylene copolymer; and
(F) 0 to 10 wt % of a propylene homopolymer;
whereby all percentages refer to the total composition, and whereby
the second heterophasic propylene copolymer (E) comprises a matrix phase and an elastomer phase dispersed therein and has:
a melt flow rate MFR 2 (230° C., 2.16 kg, ISO 1133) of 2 to 10 g/10 min;
a soluble fraction (SF) content determined according to CRYSTEX QC analysis of more than 20.0 to 50.0 wt %; and
an intrinsic viscosity of said soluble fraction iV(SF), measured in decalin according to DIN ISO 1628/1 at 135° C., of 4.0 dl/g to 10.0 dl/g;

the propylene homopolymer (F) has:
a melt flow rate MFR 2 (230° C., 2.16 kg, ISO 1133) of 800 to 2000 g/10 min.

3. The composition according to claim 2 , obtained by blending components (A), (B), (C) and (D), with (E) and (F) not being present,
(A) 15 wt % to 50 wt % of a mixed-plastics polypropylene blend;
(B) 30 wt % to 50 wt % of a heterophasic propylene copolymer;
(C) 5 wt % to 25 wt % of an ethylene-based plastomer and
(D) 5 wt % to 25 wt % of an inorganic filler.

4. The composition according to claim 2 , obtained by blending components (A), (B), (C), (D) and (E), with (F) not being present,
(A) 15 wt % to 40 wt % of a mixed-plastics polypropylene blend;
(B) 20 wt % to 50 wt % of a heterophasic propylene copolymer;
(C) 5 wt % to 25 wt % of an ethylene-based plastomer;
(D) 5 wt % to 25 wt % of an inorganic filler; and
(E) 5 wt % to 20 wt % of a second heterophasic propylene copolymer.

5. The composition according to claim 2 , obtained by blending components (A), (B), (C), (D) and (F), with (E) not being present,
(A) 15 wt % to 40 wt % of a mixed-plastics polypropylene blend;
(B) 20 wt % to 50 wt % of a heterophasic propylene copolymer;
(C) 5 wt % to 25 wt % of an ethylene-based plastomer;
(D) 5 wt % to 25 wt % of an inorganic filler; and
(F) 2 wt % to 10 wt % of a propylene homopolymer.

6. The composition according to claim 1 , wherein the inorganic filler (D) is talc having:
a median particle size d 50 before compounding of 0.3 to 30.0 micrometers; and/or
a top-cut particle size d 95 before compounding of 1.0 to 50.0 micrometers.

7. The composition according to claim 1 , wherein the composition has:
a crystalline fraction (CF) content determined according to CRYSTEX QC analysis in a range from 55.0 to 75.0 wt %, and
a soluble fraction (SF) content determined according to CRYSTEX QC analysis in a range from 25.0 to 45.0 wt % whereby
said crystalline fraction (CF) has an ethylene content (C2(CF)), as determined by FT-IR spectroscopy calibrated by quantitative 13 C-NMR spectroscopy, of less than 10.0 wt %;
said crystalline fraction (CF) has an intrinsic viscosity (iV(CF)) of less than 1.8 dl/g;
said soluble fraction (SF) has an ethylene content (C2(SF)), as determined by FT-IR spectroscopy calibrated by quantitative 13 C-NMR spectroscopy, in a range from 45.0 to 65.0 wt %; and
said soluble fraction (SF) has an intrinsic viscosity (iV(SF)) of more than 1.6 dl/g.

8. The composition according to claim 1 , wherein the composition has a flexural modulus of from 1400 MPa to 2000 MPa.

9. The composition according to claim 1 , wherein the composition has a Charpy Notched Impact Strength at 23° C. of from 20.0 KJ/m 2 to 65.0 KJ/m 2 and/or a Charpy Notched Impact Strength at −20° C. of from 4.0 KJ/m 2 to 10.0 KJ/m 2 .

10. The composition according to claim 1 , wherein the composition has a heat deflection temperature (ISO 75 B) of more than 90° C. and/or a coefficient of linear thermal expansion (CLTE) of from 60 to 100 μm/mK.

11. The composition according to claim 1 , wherein the composition has a puncture energy of from 25 to 55 J and/or an energy at maximum force of from 15 to 45 J, when determined in the instrumented falling weight test according to ISO 6603-2 at 23° C., and/or puncture energy of from 12 to 40 J and/or an energy at maximum force of from 10 to 30 J, when determined in the instrumented falling weight test according to ISO 6603-2 at −30° C.

12. An article comprising the composition according to claim 1 .

13. The article according to claim 12 , wherein the article has paint adhesion assessed as the failed or delaminated coated area in mm 2 of below 50 mm 2 .

Assignees

• Borealis Ag

Inventors

• Mileva Daniela
• Kahlen Susanne Margarete
• Legras Angelica Maëlle Delphine
• Braun Hermann
• Salles Christophe

Classifications

• C08K3/34

  Silicon-containing compounds · CPC title

• C08L23/16

  Ethylene-propylene or ethylene-propylene-diene copolymers · CPC title

• C08L2207/20

  Recycled plastic · CPC title

• C08L2207/02

  Heterophasic composition · CPC title

• C08L2205/035

  containing four or more polymers in a blend · CPC title