High Flow Fiber-Reinforced Propylene Composition Having Low Emissions

Patent metadata

Field	Value
Publication number	US-2021221991-A1
Application number	US-202117221042-A
Country	US
Kind code	A1
Filing date	Apr 2, 2021
Priority date	Jan 10, 2017
Publication date	Jul 22, 2021
Grant date	—

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

1 . A fiber-reinforced polymer composition comprising:
a polymer matrix that contains a propylene polymer, 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 fiber-reinforced polymer composition 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 fiber-reinforced polymer composition 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 fiber-reinforced polymer composition of claim 1 , wherein the propylene polymer is a homopolymer.

5 . The fiber-reinforced polymer composition of claim 4 , wherein the homopolymer is metallocene-catalyzed.

6 . The fiber-reinforced polymer composition of claim 1 , wherein the propylene polymer is an α-olefin/propylene copolymer.

7 . The fiber-reinforced polymer composition of claim 1 , wherein the composition includes a blend of a propylene homopolymer and an α-olefin/propylene copolymer.

8 . The fiber-reinforced polymer composition of claim 7 , wherein the homopolymer is metallocene-catalyzed.

9 . The fiber-reinforced polymer composition of claim 1 , wherein the propylene polymer has a melt flow index of about 150 grams per 10 minutes or more as determined in accordance with ISO 1133-1:2011 at a load of 2.16 kg.

10 . The fiber-reinforced polymer composition of claim 1 , wherein the fibers are glass fibers.

11 . The fiber-reinforced polymer composition of claim 1 , wherein the fibers constitute from about 20 wt. % to about 60 wt. % of the composition.

12 . The fiber-reinforced polymer composition of claim 1 , wherein the fibers are oriented in a longitudinal direction of the composition.

13 . An injection molded part comprising the fiber-reinforced polymer composition of claim 1 , wherein the part has a wall thickness of about 2.5 millimeters or less.

14 . An automotive part comprising a fiber-reinforced polymer composition comprising a polymer matrix that contains a propylene polymer and a plurality of long reinforcing fibers that are distributed within the polymer matrix, 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.

15 . The automotive part of claim 14 , 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.

16 . The automotive part of claim 14 , wherein the composition exhibits a fogging content of about 500 μg/g or less as determined in accordance with VDA 278:2002.

17 . The automotive part of claim 14 , wherein the propylene polymer is a homopolymer.

18 . The automotive part of claim 17 , wherein the homopolymer is metallocene-catalyzed.

19 . The automotive part of claim 14 , wherein the propylene polymer is an α-olefin/propylene copolymer.

20 . The automotive part of claim 14 , wherein the composition includes a blend of a propylene homopolymer and an α-olefin/propylene copolymer.

21 . The automotive part of claim 20 , wherein the homopolymer is metallocene-catalyzed.

22 . The automotive part of claim 14 , wherein the fibers are glass fibers.

23 . The automotive part of claim 14 , wherein the fibers constitute from about 20 wt. % to about 60 wt. % of the composition.

24 . The automotive part of claim 14 , wherein the fibers are oriented in a longitudinal direction of the composition.

25 . The automotive part of claim 14 , wherein the part has a wall thickness of about 2.5 millimeters or less.

26 . The automotive part of claim 14 , wherein the part is injection molded.

27 . The automotive part of claim 14 , wherein the part is an interior automotive part.

28 . The automotive part of claim 27 , 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.

29 . The automotive part of claim 14 , wherein the automotive part is an exterior automotive part.

30 . The automotive part of claim 29 , 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

Inventors

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

Classifications

• C08L23/12 Primary

  Polypropene · CPC title

• C08L2314/06

  Metallocene or single site catalysts · CPC title

• C08F2810/10

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

• C08F2500/15

  Isotactic · CPC title

• B29L2031/3014

  Door linings · CPC title