Molded articles (including automobile parts) and related filled thermoplastic polyolefin compositions

Patent metadata

Field	Value
Publication number	US-9290646-B2
Application number	US-201314046526-A
Country	US
Kind code	B2
Filing date	Oct 4, 2013
Priority date	Oct 4, 2013
Publication date	Mar 22, 2016
Grant date	Mar 22, 2016

Abstract

A molded article made from and/or containing a polymeric composition made from and/or containing a high melt flow rate polypropylene homopolymer composition, a compatibilizer, a polyethylene-based elastomer, and talc is provided. An automobile part, including bumper facias, body side-molding, instrumental panels, side pillars, and door trims, with improved coefficients of linear thermal expansion is also provided.

First claim

What is claimed is:

1. A molded article comprising a polymeric composition
(a) having a melt flow rate from about 20 to about 45 grams/ 10 minutes and
(b) comprising:
(i) from about 10 to about 60 weight percent of a high melt flow rate polypropylene homopolymer composition comprising:
(1) a first highly crystalline polypropylene homopolymer having a melt flow rate from about 50 to about 200 grams/10 minutes, a polydispersity index from about 2 to about 40, a density from about 0.900 to about 0.950 gram/cm3, and a xylene solubles fraction at room temperature from about 0.001 to about 3 weight percent, based upon the total weight of the first highly crystalline polypropylene homopolymer,
(2) optionally, a second polypropylene homopolymer selected from the group
(A) an extra/ultra high melt flow polypropylene homopolymer having a melt flow rate from about 200 to about 3000 grams/10 minutes and a polydispersity index from about 2 to about 7.5 and
(B) a second highly crystalline polypropylene homopolymer having a melt flow rate from about 1 to about 5 grams/10 minutes, a polydispersity index from about 2 to about 7.5, a density from about 0.900 to about 0.950 gram/cm3, and a xylene solubles fraction at room temperature from about 0.001 to about 2.5 weight percent,

wherein the difference between the melt flow rate of the first highly crystalline polypropylene homopolymer (MFR1) and the melt flow rate of the second polypropylene homopolymer (MFR2) is at least about 40 grams/10 minutes (|MFR1−MFR2|≧40);

(ii) from about 3 to about 20 weight percent of a compatibilizer composition comprising a compatibilizer selected from the group consisting of
(A) a polypropylene-containing blend having a melt flow rate from about 1 to about 5 grams/10 minutes comprising
(1) from about 25 to about 90 weight percent a semicrystalline polypropylene homopolymer and
(2) from about 10 to about 75 weight percent an ethylene propylene rubber having a total content of ethylene-derived units in an amount from about 25 to about 65 weight percent, based upon the total weight of the ethylene propylene rubber, and

(B) a styrene-based block copolymer;

(iii) from about 5 to about 30 weight percent of a polyethylene elastomer composition comprising a polyethylene elastomer having a melt index from about 0.5 to about 2.0 grams/10 minutes and a density from about 0.800 to about 0.900 g/cm3;
(iv) from about 10 to about 40 weight percent of a filler composition comprising talc; and
(v) optionally, an additives composition having one or more additives.

2. The molded article of claim 1 wherein the first highly crystalline polypropylene homopolymer has a melt flow rate from about 60 to about 150 grams/10 minutes.

3. The molded article of claim 1 wherein the first highly crystalline polypropylene homopolymer has a melt flow rate from about 100 to about 130 grams/10 minutes.

4. The molded article of claim 1 wherein the extra/ultra high melt flow polypropylene homopolymer has a melt flow rate from about 1000 to about 1800 grams/10 minutes.

5. The molded article of claim 1 wherein the second highly crystalline polypropylene homopolymer has a melt flow rate from about 1 to about 3 grams/10 minutes.

6. The molded article of claim 1 wherein (a) the compatibilizer composition comprises the polypropylene-containing blend and (b) the polypropylene-containing blend has a melt flow rate from about 1 to about 3 grams/10 minutes.

7. The molded article of claim 1 wherein (a) the compatibilizer composition comprises the styrene-based block copolymer and (b) the styrene-based block copolymer is selected from the group consisting of styrene-isobutylene-styrene block copolymer (SIBS); styrene-butadiene-styrene block copolymer (SBS); styrene-ethylene-utylene-styrene block copolymer (SEBS); styrene-isoprene-styrene block copolymer (SIS); styrene-ethylene-propylene-styrene block copolymer (SEPS); styrene-ethylene-thylene-propylene-styrene block copolymer (SEEPS structure); and modified block copolymers thereof.

8. The molded article of claim 1 wherein (a) the compatibilizer composition comprises the styrene-based block copolymer and (b) the polymeric composition has a styrene content from about 0.001 to about 3 weight percent, based upon the total weight of the polymeric composition.

9. The molded article of claim 1 wherein the polyethylene elastomer of the polyethylene elastomer composition, has a density from about 0.850 to about 0.880 g/cm3.

10. The molded article of claim 1 wherein the polyethylene elastomer of the polyethylene elastomer composition, is an ethylene copolymer comprising (a) ethylene-derived units and (b) alpha-olefin comonomer units derived from at least one comonomer selected from the group consisting of C 3 to C 10 alpha-olefins.

11. The molded article of claim 1 wherein the talc has an average particle size from about 0.1 to about 1.5 microns.

12. The molded article of claim 1 being an automotive part selected from the group consisting of bumper facias, body side-molding, instrumental panels, side pillars, and door trims.

13. The molded article of claim 12 wherein the automotive part is paintable.

14. The molded article of claim 12 wherein (a) the polymeric composition comprises the additive composition, (b) the additive composition comprises a colorant, and (c) the automotive part has a mold-in-color.

15. A molded article comprising a polymeric composition
(a) having a melt flow rate from about 20 to about 45 grams/ 10 minutes and
(b) comprising:
(i) from about 10 to about 60 weight percent of a high melt flow rate polypropylene homopolymer composition comprising:
(1) a first highly crystalline polypropylene homopolymer having a melt flow rate from about 50 to about 200 grams/10 minutes, a polydispersity index from about 2 to about 40, a density from about 0.900 to about 0.950 gram/cm 3 , and a xylene solubles fraction at room temperature from about 0.001 to about 3 weight percent, based upon the total weight of the first highly crystalline polypropylene homopolymer; and
(2) a second polypropylene homopolymer selected from the group
(A) an extra/ultra high melt flow polypropylene homopolymer having a melt flow rate from about 200 to about 3000 grams/10 minutes and a polydispersity index from about 2 to about 7.5 and
(B) a second highly crystalline polypropylene homopolymer having a melt flow rate from about 1 to about 5 grams/10 minutes, a polydispersity index from about 2 to about 7.5, a density from about 0.900 to about 0.950 gram/cm3, and a xylene solubles fraction at room temperature from about 0.001 to about 2.5 weight percent,

wherein the difference between the melt flow rate of the first highly crystalline polypropylene homopolymer (MFR1) and the melt flow rate of the second polypropylene homopolymer (MFR2) is at least about 40 grams/10 minutes (|MFR 1 −MFR 2 |≧40);

(ii) from about 3 to about 20 weight percent of a compatibilizer composition comprising a compatibilizer selected from the group consisting of
(A) a polypropylene-containing blend having a melt flow rate from about 1 to about 5 grams/10 minutes comprising
(1) from about 25 to about 90 weight percent a semicrystalline polypropylene homopolymer and
(2) from about 10 to about 75 weight percent an ethylene propylene rubber having a total content of ethylene-derived units in an amount from about 25 to about 65 weight percent, based upon the total weight of the ethylene propylene rubber, and

(B) a styrene-based block copolymer;

(iii) from about 5 to about 30 weight percent of a polyethylene elastomer composition comprising a polyethylene elastomer

Assignees

• Equistar Chem Lp

Inventors

• Glogovsky Todd A
• Mrozinski Brent

Classifications

• C08L23/14

  Copolymers of propene (C08L23/16 takes precedence) · CPC title

• C08L53/02

  of vinyl-aromatic monomers and conjugated dienes · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L23/142

  at least partially crystalline copolymers of propene with other olefins · CPC title

• C08K3/34

  Silicon-containing compounds · CPC title