Kit for producing polyolefin composites

Abstract

A kit comprising a first component and a second component, the first component comprising a first polyolefin and a polymerizable epoxy resin, wherein the first polyolefin is the major phase of the first component, and the second component comprising a second polyolefin and a catalyst. Also provided is a method of providing a polyolefin composite comprising a first polyolefin, a polymerizable epoxy linker, and a second polyolefin, the method comprising mixing a first component comprising a first polyolefin and a polymerizable epoxy resin with a second component comprising a second polyolefin and a catalyst to form a mixture, and processing the mixture to obtain the polyolefin composite, wherein the first polyolefin is the major phase of the first component.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of priority to Singapore Patent Application No. 10201908204P, filed on September 5, 2019, the contents of which are incorporated herein by reference in their entirety for all purposes. Technical Field

[0003] Various embodiments of the present invention relate to kits for preparing polyolefin composite materials and methods for preparing said polyolefin composite materials, as well as polyolefin composite materials obtained by said methods and applications of said polyolefin composite materials. Background Technology

[0004] High-performance polyolefin composites can be prepared using linker molecules that can form chemical bonds with other precursor compounds in the matrix during compounding. However, if the components used to prepare the polyolefin composites are stored on the shelf, these chemical bonds can form unintentionally and prematurely, resulting in the polyolefin composites being produced at an undesirable time and potentially compromising the components. Furthermore, because polyolefin composites are formed through in-situ reactions during compounding, some applications involving, for example, the processing of long and continuous fibers may not be suitable for these types of polyolefin composites. This is because in conventional compounding processes, all active components are typically added simultaneously at the start of the process. However, the requirements for adding long and continuous fibers to the reaction are often more stringent, such as the timing of addition, which complicates reaction control.

[0005] Therefore, there is still a need for improved component storage devices and methods for preparing polyolefin composites from these components to address or at least alleviate one or more of the aforementioned problems. Summary of the Invention

[0006] In a first aspect, a kit is provided that comprises:

[0007] The first component comprises a first polyolefin and a polymerizable epoxy resin, wherein the first polyolefin is the main phase of the first component, and

[0008] The second component comprises a second polyolefin and a catalyst.

[0009] In a second aspect, a method for providing a polyolefin composite material is provided, the polyolefin composite material comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin, the method comprising: mixing a first component comprising the first polyolefin and a polymerizable epoxy resin with a second component comprising the second polyolefin and a catalyst to form a mixture, and processing the mixture to obtain the polyolefin composite material, wherein the first polyolefin is the main phase of the first component.

[0010] In a third aspect, a polyolefin composite material is provided, which is provided by the method described in the second aspect.

[0011] In a fourth aspect, a polyolefin composite material is provided, the polyolefin composite material comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin provided by the kit as described in the first aspect.

[0012] In the fifth aspect, applications of polyolefin composite materials as described in the third or fourth aspect are provided in transportation vehicles, infrastructure, consumer products and / or buildings. Attached Figure Description

[0013] A better understanding of the invention will come from referring to the specific embodiments, in which the invention is considered in conjunction with the accompanying drawings and non-limiting examples, in which:

[0014] Figure 1 A comparative table showing polyolefin composites prepared according to this disclosure (masterbatch resin compounding) and comparative examples (typical compounding) and their mechanical properties is provided.

[0015] Figure 2A Field emission scanning electron microscopy (FESEM) images showing the morphology of the cracked surface of a polypropylene (PP) composite material (PP / 10 wt% maleic anhydride-grafted polypropylene (MPP) / 10 wt% glass fiber (GF) / 10 wt% binder (LK)) prepared by conventional precursor blending. Scale bars indicate lengths of 10 μm.

[0016] Figure 2B FESEM micrographs showing the morphology of the cracked surface of a PP composite material (PP / 10wt% MPP / 10wt% GF / 10wt% LK) prepared by blending masterbatches according to the present disclosure. Scale bars indicate lengths of 10 μm.

[0017] Figure 3 A comparative table is provided showing the mechanical properties of polyolefin composites prepared according to this disclosure (masterbatch resin compounding) and comparative examples (typical compounding), and their exposure to air at room temperature for different times.

[0018] Figure 4AA comparative graph showing the modulus and mechanical properties of polyolefin composites prepared according to this disclosure (masterbatch resin blends) and comparative examples (typical blends and polypropylene compositions) is provided. The test standards used are as follows: flexural strength (ASTM D 790-96), tensile strength (ASTM 638-03), and impact strength (ASTM D 256). The mechanical properties of the PP composites prepared by typical blending and masterbatch blending differ slightly (<5%) except for impact strength.

[0019] Figure 4B A comparative graph showing the strength and mechanical properties of polyolefin composites prepared according to this disclosure (masterbatch resin blends) and comparative examples (typical blends and polypropylene compositions) is provided. The test standards used are as follows: flexural strength (ASTM D 790-96), tensile strength (ASTM 638-03), and impact strength (ASTM D 256). The mechanical properties of the PP composites prepared by typical blending and masterbatch blending differ slightly (<5%) except for impact strength.

[0020] Figure 5A This diagram illustrates a comparison of the modulus and mechanical properties of polyolefin composites prepared according to this disclosure (masterbatch resin compounding) and comparative examples (typical compounding and polypropylene compositions) after being exposed to air at room temperature for different periods. The testing standards used are as follows: flexural standard (ASTM D 790-96), tensile standard (ASTM 638-03), and impact standard (ASTM D 256). The masterbatch remains relatively stable for up to two months, thus making it suitable for engineering applications.

[0021] Figure 5B A comparative graph showing the strength and mechanical properties of polyolefin composites prepared according to this disclosure (masterbatch resin compounding) and comparative examples (typical compounding and polypropylene composition) after being exposed to air at room temperature for different periods is presented. The test standards used are as follows: flexural standard (ASTM D 790-96), tensile standard (ASTM 638-03), and impact standard (ASTM D 256). The masterbatch remains relatively stable for up to two months, thus making it suitable for engineering applications. Detailed Implementation

[0022] The various embodiments disclosed herein relate to a kit comprising a first component and a second component. The kit has been described in at least one aspect of this disclosure. For example, the kit has been described in various embodiments of at least the first aspect.

[0023] Therefore, in a first aspect, a kit is provided comprising a first component comprising a first polyolefin and a polymerizable epoxy resin, wherein the first polyolefin is the main phase of the first component, and a second component comprising a second polyolefin and a catalyst. The polymerizable epoxy resin of the first component and the catalyst of the second component are configured to react with each other. For example, if the polymerizable epoxy resin and the catalyst are bonded together, a chemical reaction can occur to form covalent bonds between them. This reaction is preferably carried out at a temperature above room temperature; however, if the polymerizable epoxy resin and the catalyst are not separated, a small portion of the polymerizable epoxy resin and the catalyst may react with each other at room temperature.

[0024] Advantageously, the active ingredients of this disclosure (e.g., polymerizable epoxy resin and catalyst) are separated into two components of the kit: a first component consisting of a first polyolefin and a polymerizable epoxy resin, and a second component consisting of a second polyolefin and a catalyst. The purpose of component separation can be to prevent chemical reactions before processing time. The shelf life of the first and second components has been examined herein, wherein the kit of this disclosure is applicable to a variety of polyolefin composites and is effective in allowing the components to have extended shelf life for processing at the appropriate time. Furthermore, the separation of the active ingredients allows the use of active ingredients with higher reactivity, since considerations of shelf life are not applicable to the same extent. Moreover, higher concentrations of active ingredients can be considered due to the prevention of premature reaction. Therefore, advantageously, the separation of the active ingredients also allows for the preparation of masterbatches. The masterbatches may also contain compatibilizers and fillers. Compatibilizers can form strong interactions and good compatibility between the fillers and other components. For example, the first or second component of the masterbatch may contain a polymer having functional groups grafted thereon as a compatibilizer, which can react with the polymerizable epoxy resin or catalyst. This strong bonding can advantageously help bridge the polarity difference between the first or second polyolefin (typically nonpolar) and the filler (typically polar). By providing this strong transpolar interaction, the filler can be used to prepare high-strength polyolefin composites. Therefore, the masterbatch can also allow polyolefin composites to have high filler content, thus maintaining high stability over a period of time.

[0025] Using a kit comprising a first component and a second component, each containing at least one active ingredient, wherein the active ingredients are configured to react with each other, offers an advantage over existing technologies where all compounds used to prepare polyolefin composites can be stored in a combined form. This is because those compound combinations in existing technologies have short shelf lives, and because the boundaries associated with their active ingredients are not “too reactive,” compatibility across various compounds in subsequent polyolefin composites is often achieved only through ineffective secondary interactions. Furthermore, compound combinations may not allow for the use of masterbatches due to reactive boundaries. Therefore, separating the active ingredients in the kit offers several advantages. Component separation not only extends the kit’s shelf life to up to 2 months without significantly weakening the performance of subsequent polyolefin composites, but also allows for large-scale preparation as masterbatches, thereby increasing efficiency while reducing costs. Moreover, component separation, particularly preparation as masterbatches, facilitates reaction control during compounding, ensuring that reactions occur at appropriate times, thus enabling applications involving, for example, long fiber and continuous fiber processing.

[0026] The first polyolefin in the first component is the main phase of the first component. In this context, "main phase" means the majority content. Therefore, the first polyolefin may be present in the first component in an amount of at least 50 wt%.

[0027] Although the first polyolefin in the first component may be independent of the second polyolefin in the second component, various characteristics describing the first and second polyolefins are set forth below. Therefore, in various embodiments, the first polyolefin and / or the second polyolefin may be present independently in the first and / or second components in amounts greater than 50 wt%, greater than 60 wt%, greater than 70 wt%, greater than 80 wt%, optionally greater than 90 wt%, respectively.

[0028] In some embodiments, the first polyolefin and / or the second polyolefin may independently undergo hydrophobic interactions with other compounds. However, the first polyolefin and / or the second polyolefin do not chemically react with the remaining compounds. In other words, according to some embodiments, the first polyolefin and / or the second polyolefin may not form covalent bonds with any other compounds. Typically, polyolefins are nonpolar or hydrophobic materials. Therefore, the first polyolefin and / or the second polyolefin may independently be unsubstituted polyolefins. For example, the first polyolefin and / or the second polyolefin may independently be unsubstituted polyolefins comprising only the polymer backbone formed by the polymerization of polyolefin monomers, without any additional portions grafted thereon.

[0029] According to various implementation schemes, the first polyolefin and / or the second polyolefin may be independently selected from C 2-20 Alkylene, C 4-20 Alkyl dienes, C6-20 Alkyltriene, C 3-20 Cycloalkylene, C 4-20 cycloalkyldiene, C 5-20 cycloalkyltriene, C 8-20 Polymers, random copolymers, or block copolymers of phenylalkylene groups and combinations thereof. In various embodiments, the first polyolefin and / or the second polyolefin may be independently selected from polymers, random copolymers, or block copolymers of ethylene, propylene, 1-pentene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, styrene, ethylidene norbornene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, dicyclopentadiene, and ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the first polyolefin and / or the second polyolefin may be independently polyethylene. In some embodiments, the first polyolefin and / or the second polyolefin may be independently polypropylene, optionally combined with a plastomer and / or elastomer optionally selected from ethylene-α-olefin copolymers. The ethylene-α-olefin copolymer may comprise repeating units derived from ethylene and repeating units derived from an α-olefin, which optionally has 3-20 carbon atoms. In a non-limiting example, the first polyolefin and / or the second polyolefin is independently polypropylene. Advantageously, polyolefin composites comprising polypropylene may have the potential to replace engineering plastics.

[0030] In the context of this invention, the term "alkylene" as used alone or in combination refers to an aliphatic hydrocarbon having a single carbon-carbon double bond. Alkylenes can be straight-chain or branched. In some embodiments, alkylenes contain 2-20 carbon atoms, such as 2-18, 2-12, or 2-6 carbon atoms. "C" 2-20 "Alkylene" refers to an alkenyl group containing only 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 carbon atoms. Examples of alkylene groups include, but are not limited to, vinyl, propenyl, butenyl, 1,4-butadienyl, pentenyl, hexenyl, 4-methylhex-1-enyl, and 4-ethyl-2-methylhex-1-enyl.

[0031] As used herein, the term "straight chain" refers to each chain in a carbon backbone without branching points. The term "branched chain" refers to a chain with one or more side chains connected together. Branching occurs by the substitution of substituents (e.g., hydrogen atoms) with covalently bonded substituents or partial (e.g., alkyl) substitutions.

[0032] In various embodiments, the first polyolefin and / or the second polyolefin may independently have melt flow rates of about 5 g / 10 min to about 200 g / 10 min, optionally about 5 g / 10 min to about 100 g / 10 min, optionally about 10 g / 10 min to about 90 g / 10 min, optionally about 15 g / 10 min to about 80 g / 10 min, optionally about 20 g / 10 min to about 70 g / 10 min, optionally about 25 g / 10 min to about 60 g / 10 min, optionally about 30 g / 10 min to about 80 g / 10 min, optionally about 20 g / 10 min to about 50 g / 10 min, etc., wherein the melt flow rate can be measured at a temperature of 230°C and a weight of 2.16 kg. Such ranges of melt flow rates are advantageously suitable for further processing of the first component and / or the second component (e.g., injection molding, pultrusion, and lamination).

[0033] The first component may also include a polymerizable epoxy resin. In this context, "polymerizable epoxy resin" refers to a monomer, oligomer, or polymer, or any combination thereof, that further comprises an epoxide covalently bonded to the catalyst. Advantageously, the polymerizable epoxy resin exhibits relatively high reactivity to the catalyst, which enables the formation of strong covalent bonds during the preparation of the polyolefin composite. This high reactivity can be provided by the epoxide, which is a functional group that reacts with the catalyst in the ring-opening reaction. This high reactivity, in turn, results in stronger adhesion between the polymerizable epoxy resin and the catalyst. More advantageously, because the epoxide forms covalent bonds with the catalyst, reinforcing agents, such as fillers, can be added without affecting the subsequent stability of the polyolefin composite.

[0034] According to various embodiments, the polymerizable epoxy resin may be present based on the weight of the first component in an amount greater than or equal to 0.1 wt% and up to 50 wt%, optionally in an amount greater than or equal to 0.1 wt% and less than 20 wt%, optionally in an amount greater than or equal to 0.1 wt% and less than 15 wt%, optionally in an amount greater than or equal to 5 wt% and less than or equal to 15 wt%, optionally in an amount greater than or equal to 0.1 wt% and less than 10 wt%, etc. Such a range of weight percentages of the polymerizable epoxy resin improves the reactivity between the polymerizable epoxy binder and other components of the kit (e.g., fillers, if present). Furthermore, the upper limit of the weight percentage range may still be low enough to ensure homogeneity within the first component.

[0035] According to various implementation schemes, the polymerizable epoxy resin can be selected from epoxy-containing monomers, epoxy-containing oligomers, epoxy-containing polymers, and combinations thereof.

[0036] According to various embodiments, the polymerizable epoxy resin can be a glycidyl ether epoxy resin obtained by reacting an allyl phenyl derivative with an epoxide-containing precursor, wherein the allyl phenyl derivative may be selected from o-allylphenol phenolic varnish and diallyl bisphenol compounds having an allyl group at the ortho position relative to the hydroxyl group of bisphenol A.

[0037] According to various implementation schemes, polymerizable epoxy resins can be obtained by reacting hydroxyl derivatives with epoxide-containing precursors, wherein the hydroxyl derivatives may be selected from bisphenol, resorcinol, dihydroxynaphthalene, trihydroxynaphthalene, dihydroxydiphenylfluorene, trihydroxymethane, tetrahydroxyphenylethane, phenolic varnish, phenol, and combinations thereof.

[0038] According to various embodiments, polymerizable epoxy resins can be obtained by reaction between an amine and an epoxide-containing precursor, wherein the amine may be selected from tetraglycidyldiaminodiphenylmethane, aminophenol, aminocresol, xylenediamine, and combinations thereof.

[0039] According to various embodiments, polymerizable epoxy resins can be obtained by reacting aromatic, aliphatic, or alicyclic carboxylic acids with an epoxide-containing precursor. The epoxide-containing precursor may be selected from epichlorohydrin, ethylene oxide, propylene oxide, phenylene oxide, cyclohexane oxide, phenyl glycidyl ether, and combinations thereof.

[0040] According to various implementation schemes, the polymerizable epoxy resin can be selected from bisphenol A epoxy resin, bisphenol S epoxy resin, bisphenol K epoxy resin, bisphenol F epoxy resin, phenolic varnish epoxy resin, cresol varnish epoxy resin, acyclic epoxy resin, heterocyclic epoxy resin, hydrogenated bisphenol A epoxy resin, aliphatic epoxy resin, and combinations thereof.

[0041] According to various implementation schemes, the heterocyclic epoxy resin may be selected from triglycidyl isocyanuric acid epoxy resin, hydantoin epoxy resin, and combinations thereof.

[0042] According to various implementation schemes, aliphatic epoxy resins can be selected from propylene glycol-diglycidyl ether, pentaerythritol polyglycidyl ether, and combinations thereof.

[0043] According to various implementation schemes, polymerizable resins may contain spirocyclic rings.

[0044] According to various embodiments, the first and / or second components may further comprise a polymer having functional groups grafted thereon. The functional groups grafted onto the polymer are configured to react with the epoxide of the polymerizable epoxy resin. When a polymer having functional groups grafted thereon is provided, the polymer may react with the polymerizable epoxy resin to form additional covalent bonds. The chemical bond formed between the polymerizable epoxy resin and the polymer having functional groups grafted thereon may be an ester bond. Ester bonds may be formed, for example, through a reaction between an acid anhydride and an epoxide.

[0045] Advantageously, polymers with grafted functional groups can have a substantially nonpolar polymer backbone and substantially polar grafted portions therein. Therefore, it acts as a compatibilizer to enhance the polar and nonpolar interactions between the first and / or second polyolefins in subsequent polyolefin composites and the remaining, more polar compounds. For example, the substantially nonpolar polymer backbone of a polymer with grafted functional groups can form hydrophobic interactions with the polyolefin, while the covalent bonds of the polymer with grafted functional groups, i.e., the covalent bonds formed with the polymerizable epoxy resin, can provide strong linkages with the polar components in subsequent polymer composites.

[0046] In embodiments containing fillers, the addition of a polymer with functional groups grafted thereon can improve strength and enhance the dispersibility of the filler within the subsequent polyolefin composite due to the enhanced interaction with the polymerizable epoxy resin. Further advantageously, the polymer with grafted functional groups may have a substantially nonpolar polymer backbone and substantially polar functional groups grafted thereon. Therefore, it can act as a compatibilizer to enhance the polar and nonpolar interactions between the polyolefin within the polyolefin composite and other more polar components such as fillers.

[0047] In some embodiments, the polymer having the functional groups grafted thereon can be a third polyolefin having the functional groups grafted thereon. Advantageously, when the polymer having the functional groups grafted thereon is a third polyolefin, the hydrophobic interactions between the first polyolefin, the second polyolefin, and the third polyolefin having the functional groups grafted thereon can be particularly strong because the first polyolefin, the second polyolefin, and the third polyolefin can have approximately equal polarities. Stronger hydrophobic interactions allow the three materials to exhibit stronger adhesion through secondary interactions.

[0048] In various implementation schemes, the third polyolefin may be selected from C 2-20 Alkylene, C 4-20 Alkyl dienes, C 6-20 Alkyltriene, C 3-20 Cycloalkylene, C 4-20 cycloalkyldiene, C 5-20 cycloalkyltriene, C 8-20 Polymers, random copolymers, or block copolymers of phenylalkylene groups and combinations thereof. In various embodiments, the third polyolefin may be selected from polymers, random copolymers, or block copolymers of ethylene, propylene, 1-pentene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, styrene, ethylidene norbornene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, dicyclopentadiene, and ethylene propylene diene monomer (EPDM) rubber.

[0049] In some embodiments, the third polyolefin may be polypropylene. Advantageously, when the first, second, and third polyolefins are polypropylene, the hydrophobic interactions between the first, second, and third polyolefins, and the third polyolefin having functional groups grafted thereon, can be particularly strong because the various polypropylenes can have approximately equal polarity. Stronger hydrophobic interactions allow the three materials to adhere more strongly through secondary interactions.

[0050] According to various embodiments, the functional group grafted onto the polymer may include a –COO- group, which forms a chemical bond with the polymerizable epoxy resin. This functional group can be present in, for example, acids, esters, anhydrides, and lactones. The –COO- group typically refers to a carbon atom with a double bond connected to one oxygen atom and a single bond connected to a second oxygen atom.

[0051] According to various embodiments, the functional group containing the –COO- group of the polymer can be an anhydride. Therefore, a polymer having a functional group grafted thereon can be an anhydride-grafted polymer. Thus, in some embodiments, the functional group containing the –COO- group can be an anhydride selected from maleic anhydride, succinic anhydride, citrate anhydride, intra-bicyclo[2,2,1]-1,4,5,6,7,7-hexachloro-5-heptene-2,3-dicarboxylic anhydride, intra-bicyclo[2,2,1]-5-heptene-2,3-dicarboxylic anhydride, cis-4-cyclohexene-1,2-dicarboxylic anhydride, and combinations thereof. As a non-limiting example, the functional group containing the –COO- group is maleic anhydride. Therefore, as a non-limiting example, a polymer having a functional group grafted thereon is maleic anhydride-grafted polypropylene.

[0052] According to various implementation schemes, polymers having functional groups grafted thereon may also include portions selected from hydroxyl groups, carboxylic acids, carboxylic acid esters, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, mono-maleic acid ester, diester of maleic acid, and combinations thereof.

[0053] The second component of the kit may contain a catalyst. As used herein, "catalyst" can refer to a reagent capable of initiating a reaction. In this context, a catalyst is capable of initiating a reaction with a polymerizable epoxy resin. The initiating ability in a catalyst can be an electron-rich atom, such as an amine functional group. The reaction initiated by the catalyst can be nucleophilic substitution. For example, amines can react with epoxides in a ring-opening nucleophilic substitution reaction, which can cause polymerization of the polymerizable epoxy resin.

[0054] Therefore, in various embodiments, the catalyst is capable of initiating the polymerization of polymerizable epoxy resins. In particular, the catalyst may contain amine functional groups capable of initiating the polymerization of polymerizable epoxy resins. In some embodiments, the catalyst may contain monoamines, diamines, triamines, polyamines, imidazoles, tertiary amines, secondary amines, organic acid hydrazides, or combinations thereof.

[0055] In various embodiments, the catalyst may be present in an amount greater than or equal to 0.1 wt% and less than 30 wt% based on the weight of the second component, optionally in an amount greater than or equal to 0.1 wt% and less than 10 wt%, optionally in an amount greater than or equal to 1 wt% and less than or equal to 10 wt%. Such amounts of catalyst improve the reactivity between the polymerizable epoxy resin and the catalyst, and can ensure the completion or substantial completion of the reaction.

[0056] In various embodiments, the catalyst may also comprise an aliphatic component, an aromatic component, or a combination thereof. In various embodiments, the catalyst may comprise an anhydrous compound capable of initiating the polymerization of a polymerizable epoxy resin, and may also comprise an aliphatic component, an aromatic component, or a combination thereof. In various embodiments, the catalyst may comprise a triarylsulfonium salt, dicyandiamide, boron trifluoride-amine complex, polythiol, polyamide resin, or a combination thereof.

[0057] In various embodiments, the first and / or second components may further comprise additives selected from UV stabilizers, antioxidants, pigments, and combinations thereof. The UV stabilizers and / or antioxidants may be selected from hindered phenols, phosphites, thioethers, benzophenones, benzotriazoles, and combinations thereof.

[0058] In various embodiments, the first component and / or the second component may further comprise a styrene-based polymer. The styrene-based polymer may also be referred to as a secondary phase resin. The styrene-based polymer may be selected from polystyrene, styrene-acrylonitrile resin, and combinations thereof.

[0059] According to certain embodiments, the first component and / or the second component may also contain a filler. The filler may be present in a weight percentage range based on the weight of the first component and / or the second component, including up to about 90 wt%, up to about 70 wt%, up to about 50 wt%, up to about 30 wt%, up to about 20 wt%, up to about 10 wt%, or about 0.1 wt% to about 90 wt%, or about 1 wt% to about 70 wt%, or about 5 wt% to about 30 wt%, or about 10 wt% to about 20 wt%, or about 10 wt% to about 30 wt%, or about 10 wt% to about 50 wt%, or about 1 wt% to about 60 wt%, or about 0.1 wt% to about 40 wt%, or about 0.1 wt% to about 30 wt%, or about 5 wt% to about 10 wt%. The weight percentage range of the filler can be used to influence the mechanical properties of the polyolefin composite.

[0060] According to this disclosure, the term "filler" refers to any material that can be used to reinforce polyolefin composites and has a maximum size of about 0.1 μm to about 10,000 μm. The term "maximum size" refers to the size of the filler, such as by its maximum size in any direction. In various embodiments, the filler is present in a discrete form and dispersed in a matrix. In various embodiments, the filler may have a size of about 0.1 μm to about 1000 μm, or about 0.1 μm to about 800 μm, or about 0.1 μm to about 500 μm, or about 0.1 μm to about 100 μm, or about 1 μm to about 1000 μm, or about 1 μm to about 100 μm, or about 100 μm to about 800 μm, or about 200 μm to about 700 μm, or about 300 μm, or about 650 μm, etc. Such sizes of the filler can affect the mechanical properties of the polyolefin composite. The filler may be added in an amount of about 1 wt% to about 80 wt%, or optionally in an amount of about 10 wt% to about 60 wt%, based on the weight of the first component, the second component, or both the first component and the second component.

[0061] In various embodiments, the filler may be selected from microfillers, continuous fibers, highly dispersed nanofillers, and combinations thereof. In particular, the material of the microfiller may be selected from metals, polymeric materials, metal oxides, clays, glasses, carbon, cellulose, and combinations thereof. In various embodiments, the microfiller may have a size of about 0.1 μm to about 50 mm, or about 1 μm to about 50 mm, or about 0.1 μm to about 20 mm, or about 1 μm to about 20 mm, or about 10 μm to about 50 mm.

[0062] In various implementation schemes, the material for the continuous fiber can be selected from glass fiber, carbon fiber, hybrid fiber, synthetic fiber, natural fiber, ceramic fiber, metal fiber, and combinations thereof.

[0063] In various embodiments, the highly dispersed nanofiller material may be selected from inorganic silicates, aluminosilicates, particulate metal oxides and hydroxides, anionic and cationic layered metal oxides and hydroxides, montmorillonite (MMT), kaolinite, dickite, halloysite, pearl clay, chlorite, bedecitex, soapstone, illite, biotite, lepidolite, phlogopite, chloromica, sepiolite, lepidolite, polysiliconite, mica, layered metal oxides, layered metal hydroxides, palygorskite (AT), and combinations thereof. In particular, the inorganic silicate may be calcium silicate. The highly dispersed nanofiller may contain metal oxides and / or metal oxide-like substances. Metal oxides and / or metal oxide-like substances may be selected from SiO2, TiO2, ZnO, CaO, Al2O3, Fe2O3, and combinations thereof.

[0064] In various embodiments, the highly dispersed nanofillers can be modified with organosilanes. In particular, the organosilanes may contain active functional groups selected from octyl, amine, vinyl, hydroxyl, mercapto, and combinations thereof.

[0065] In a second aspect, a method for providing a polyolefin composite material is provided, the polyolefin composite material comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin, the method comprising: mixing a first component comprising the first polyolefin and a polymerizable epoxy resin with a second component comprising the second polyolefin and a catalyst to form a mixture, and processing the mixture to obtain the polyolefin composite material, wherein the first polyolefin is the main phase of the first component.

[0066] The implementation schemes and advantages described for the kit in the first aspect are similarly applicable to the method in the second aspect, and vice versa. Since various implementation schemes and advantages have already been described above, and examples have been shown herein, they will not be elaborated upon further for the sake of brevity.

[0067] Advantageously, during the processing of the polyolefin composite material obtained from the first and second components, the polymerizable epoxy resin and catalyst, and optionally a polymer having functional groups grafted thereon, can react with each other to form covalent bonds. Therefore, the polymerizable epoxy resin and catalyst, and optionally a polymer having functional groups grafted thereon, can be considered precursors to those new compounds. Thus, the polyolefin composite material produced herein may contain a polymerizable epoxy binder. In this context, "polymerizable epoxy binder" means a monomer, oligomer, or polymer, or any combination thereof, that further comprises functional groups derived from an epoxide and react to covalently bond to the catalyst. Additionally or alternatively, functional groups derived from the epoxide can react to covalently bond to a polymer having functional groups grafted thereon (if present). Advantageously, the polymerizable epoxy binder may have substantially polar chemical properties, generating a strong hydrophilic interaction with the filler (if present). This strong hydrophilic interaction, in turn, results in stronger adhesion between the two materials. More advantageously, due to the formation of covalent bonds with the polymer having the grafted portion thereon, the polymeric epoxy binder acts as a connecting element, linking the polymer having the grafted portion thereon, further being a polyolefin, to the filler to ensure adequate dispersion of the filler. The polar chemical properties of the polymeric epoxy binder can be attributed to its polar components, such as ether bonds, benzene rings, or combinations thereof.

[0068] According to various embodiments, the polymerizable epoxy linker may be derived from a polymerizable epoxy resin, optionally selected from epoxy-containing monomers, epoxy-containing oligomers, epoxy-containing polymers, and combinations thereof. Although the catalyst may be present in the second component, it may be consumed during processing.

[0069] The method may also include adding a filler to the mixture.

[0070] In various embodiments, the method may further include adding additional polyolefin to the mixture, optionally in an amount greater than or equal to 20 wt% and less than 99 wt%, or optionally in an amount greater than or equal to 40 wt% and less than 60 wt%, based on the weight of the first component, the second component, or both the first and second components. Such amounts of additional polyolefin can be used to adjust the composition of the polyolefin composite to achieve its target application.

[0071] In various embodiments, the method may further include adding the polymer having functional groups grafted thereon to the mixture, optionally in an amount greater than or equal to 0.1 wt% and less than 20 wt%, optionally in an amount greater than or equal to 1 wt% and less than 10 wt%, based on the weight of the first component, the second component, or both the first component and the second component. Such amounts of the polymer having functional groups grafted thereon increase the reactivity between the polymer having functional groups grafted thereon and the polymerizable epoxy linker.

[0072] In various embodiments, the first and second components can be mixed in a wt% ratio of about 1:1 to about 5:1, or about 1:1 to about 4:1, or about 1:1 to about 3:1, or about 1:1 to about 2:1. Such weight percentage ratios between the first and second components promote reaction efficiency and / or produce the desired mechanical properties of the polyolefin composite.

[0073] In various implementations, the first and second components can be mixed in a mixer or drum.

[0074] In various embodiments, processing the mixture may include physically agitating the mixture in a mixer, rollers, twin-screw extruder, or a combination thereof. In particular, processing may include melt-mixing the mixture. Advantageously, melting the mixture may include forming chemical bonds between the polymerizable epoxy resin and the catalyst, or optionally between the functional groups of a polymer having functional groups grafted thereon and the polymerizable epoxy resin and the catalyst.

[0075] In a third aspect, a polyolefin composite material provided by the method described above is provided.

[0076] In a fourth aspect, a polyolefin composite material is provided, comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin provided by the kit described above.

[0077] The embodiments and advantages described for the kit of the first aspect or the method of the second aspect are similarly applicable to the polyolefin composites of the third and fourth aspects, and vice versa. Since various embodiments and advantages have been described above, and examples have been shown herein, they will not be elaborated upon further for the sake of brevity.

[0078] According to various embodiments of the third and fourth aspects, the first polyolefin, the second polyolefin, and the additional polyolefin, when present, may coexist in amounts such as about 40 wt% to about 99.9 wt%, or about 50 wt% to about 90 wt%, or about 60 wt% to about 80 wt%, or about 70 wt% to about 95 wt%, based on the total weight of the polyolefin composite material. Such weight percentages may be adjusted according to the target application of the polyolefin composite material.

[0079] According to various embodiments of the third and fourth aspects, the polymerizable epoxy binder may be present in amounts such as about 0.1 wt% to about 30 wt%, or about 0.5 wt% to about 20 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 15 wt%, based on the total weight of the polyolefin composite. Such weight percentage ranges of the polymerizable epoxy binder, especially their upper limits, may still be low enough to ensure homogeneity within the first component.

[0080] According to various embodiments of the third and fourth aspects, the additive, when present, may be present in an amount such as about 0.01 wt% to about 1 wt%, or about 0.1 wt% to about 0.5 wt%, or about 0.2 wt% to about 0.4 wt%, based on the total weight of the polyolefin composite material. Such weight percentage ranges advantageously protect the polymer composite material from degradation during processing.

[0081] According to various embodiments of the third and fourth aspects, when a polymer having functional groups grafted thereon is added to a mixture, it is present in an amount of about 0.1 wt% to about 50 wt%, or about 0.5 wt% to about 10 wt%, or about 1 wt% to about 5 wt%, etc., based on the total weight of the polyolefin composite material.

[0082] According to various embodiments of the third and fourth aspects, the first and second components may be present in amounts such as about 0.1 wt% to about 20 wt%, or about 0.5 wt% to about 15 wt%, or about 1 wt% to about 10 wt%, or about 5 wt% to about 25 wt%, based on the total weight of the polyolefin composite material. Such weight percentage ranges of the first and second components are suitable for interacting with, and optionally reacting with, the filler.

[0083] According to various embodiments of the third and fourth aspects, the microfiller, when present, may be present in amounts such as about 1 wt% to about 70 wt%, or about 10 wt% to about 60 wt%, or about 5 wt% to about 50 wt%, or about 15 wt% to about 40 wt%, based on the total weight of the polyolefin composite. The weight percentage range of the microfiller can be used to influence the mechanical properties of the polyolefin composite.

[0084] According to various embodiments of the third and fourth aspects, the continuous fibers, when present, may be present in amounts such as about 1 wt% to about 80 wt%, or about 5 wt% to about 70 wt%, or about 10 wt% to about 60 wt%, or about 15 wt% to about 50 wt%, based on the total weight of the polyolefin composite. The weight percentage range of the fibers can be used to influence the mechanical properties of the polyolefin composite.

[0085] In the fifth aspect, applications of the polyolefin composites described in the third and fourth aspects are provided in transportation vehicles, infrastructure, consumer products, and / or construction. Applications in transportation vehicles can be selected from aerospace, automotive, rail, and combinations thereof. Applications in infrastructure can be selected from pipelines, tanks, and combinations thereof. Applications in consumer products can be selected from packaging, sporting goods, electronics, and combinations thereof. The embodiments and advantages described for the kits of the first aspect, the methods of the second aspect, or the polyolefin composites of the third and fourth aspects are similarly applicable to the applications of the polyolefin composites of the fifth aspect, and vice versa. Since various embodiments and advantages have been described above, and examples have been shown herein, they will not be elaborated upon further for the sake of brevity.

[0086] This disclosure relates to a kit that minimizes the aforementioned problems. The disclosure relates to an active component in two parts: Part A (composed of polyolefin and epoxide) and Part B (composed of polyolefin and catalyst). The purpose of component separation is to prevent chemical reactions before processing time. The efficiency and shelf life of Part A and Part B have been investigated. This disclosure is suitable and effective for a wide range of polyolefin composites, and it allows for extended shelf lives of the composites to be processed at the appropriate time.

[0087] The disclosures exemplarily described herein may be suitably implemented in the absence of any or more elements, limitations, or restrictions not specifically disclosed herein. Therefore, terms such as “comprising,” “including,” and “containing” should be interpreted broadly and without limitation. Furthermore, the terminology and expressions used herein are used as descriptive rather than restrictive terms, and the use of these terms and expressions is not intended to exclude any equivalent forms of the shown and described features or portions thereof; however, it should be recognized that various modifications are possible within the scope of the claimed invention. Therefore, it should be understood that although the invention has been specifically disclosed through preferred embodiments and optional features, modifications and alterations can be made to the invention as disclosed herein by those skilled in the art, and such modifications and alterations are considered to be within the scope of the invention.

[0088] As used in this article, “approximately” refers to values ​​involving ±10%.

[0089] The present disclosure will be described more fully below with reference to the accompanying drawings, in which exemplary embodiments of the disclosure are illustrated. However, the invention may be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the lengths and dimensions of layers and regions may be enlarged for clarity.

[0090] Example Section

[0091] The kit according to this disclosure, comprising a first component containing a first polyolefin and a polymerizable epoxy resin and a second component containing a second polyolefin and a catalyst, enables the preparation kit to have an extended shelf life and allows for masterbatch processing and filler reinforcement. This objective is achieved by separating the active ingredients into the first and second components. The in-situ curing reaction between the active ingredients can be carried out during the preparation of the polyolefin composite material, rather than on a shelf.

[0092] Materials: The polyolefins that can be used in the compositions disclosed herein include a wide range of polyolefins, namely, low-density polyethylene, linear low-density polyethylene, medium- and high-density polyethylene, polypropylene, poly-1-butene, poly-4-methyl-1-pentene, ethylene-propylene block or random copolymers, ethylene-1-butene copolymers, propylene-1-butene copolymers, and mixtures thereof. These polyolefins preferably have an MFR of 5-50 at 230°C and 2.16 kg.

[0093] Polymerizable epoxy resins can be epoxy-containing monomers, oligomers, polymers, or any combination thereof. Epoxy resins can also be bisphenol A type epoxy resins, bisphenol S type epoxy resins, bisphenol K type epoxy resins, bisphenol F type epoxy resins, phenolic varnish type epoxy resins, cresolic varnish type epoxy resins, alicyclic epoxy resins, heterocyclic epoxy resins (such as triglycidyl isocyanuric acid epoxy resins and hydantoin epoxy resins), hydrogenated bisphenol A type epoxy resins, and aliphatic epoxy resins (such as propylene glycol diglycidyl ether and pentaerythritol polyglycidyl ether). The bonding process can be achieved through the reaction between aromatic, aliphatic, or alicyclic carboxylic acids and epichlorohydrin. Epoxy adhesives can have spirocyclic structures and can be glycidyl ether type epoxy resins obtained through the reaction between o-allylphenol varnish compounds and epichlorohydrin. Epoxy adhesives can be glycidyl ether type epoxy resins obtained by reacting diallyl bisphenol compounds having an allyl group at the ortho position relative to the hydroxyl group of bisphenol A with epichlorohydrin. Epoxy adhesives can be obtained by reacting phenols with epichlorohydrin, wherein the reactants can be bisphenols (such as bisphenol A and bisphenol F), resorcinol, dihydroxynaphthalene, trihydroxynaphthalene, dihydroxydiphenylfluorene, trihydroxymethane, tetrahydroxydiphenylethane, phenolic varnish, condensates of dicyclopentadiene, phenols, or combinations thereof. Epoxy adhesives can be obtained by reacting amines with epichlorohydrin, wherein the reactants can be tetraglycidyldiaminodiphenylmethane, aminophenol, aminocresol, and xylenediamine, or combinations thereof. Furthermore, derivatives such as ethylene oxide, propylene oxide, phenyl ethylene oxide, cyclohexane oxide, or phenyl glycidyl ether, or combinations thereof, can be used as needed. These epoxy materials can be used alone or in the form of mixtures of at least two epoxy resins. In one embodiment, the epoxy material can be an aliphatic, alicyclic, or aromatic epoxy resin having multiple epoxy groups. The epoxy resin may have two epoxy groups, such as diglycidyl ether of bisphenol A.

[0094] The catalyst can be a mixture of monoamine, diamine, triamine, or polyamine with aliphatic and / or aromatic components. The catalyst can be a mixture of aliphatic, aromatic, and / or alicyclic anhydrous compounds. The catalyst can be a mixture of aliphatic, aromatic, and / or alicyclic anhydrous compounds. The catalyst can be a mixture of organic acid hydrazides, triarylsulfonium salts, dicyandiamide, boron trifluoride-amine complexes, polythiols, imidazoles, tertiary amines, secondary amines, and / or polyamide resins.

[0095] Method: In one example, the masterbatch resin consists of two parts:

[0096] a) Part A consists of a polyolefin base material as the main resin phase, a binder component, additives, and / or a secondary polymer resin phase;

[0097] b) Part B consists of a polyolefin base material as the main resin phase, a catalytic component, additives, and / or a secondary polymer resin phase.

[0098] The components in each part are mixed using a high-speed mixer. The mixing process is carried out at a high mixing speed of 50 rpm to 1000 rpm for 1 to 10 minutes. After mixing, the mixture is compounded by a twin-screw extruder. A twin-screw extruder is used in this disclosure to effectively provide the high shear rate and distribution required for homogeneous blending. The twin-screw L / D ratio, screw configuration, extrusion time, extrusion speed, extrusion temperature, and other extrusion conditions can be appropriately selected according to specific purposes. The blending process is carried out in the range of 130°C to 180°C. The screw L / D ratio is preferably 16 to 40. The rotor speed is set to 50 rpm to 400 rpm. The weight percentages of the polymerizable epoxy resin and catalyst range from 1 wt% to 30 wt% and 1 wt% to 15 wt%, respectively.

[0099] Performance Testing: The properties of the masterbatch resin are evaluated by mechanical testing according to ASTM D790, ASTM D256, and ASTM D638. The compositions of this disclosure can be prepared by mixing the components using a Henschel mixer or drum mixer, followed by melting and kneading the mixture using a Banbury mixer, rollers, twin-screw extruder, etc. However, this disclosure is not limited to these methods. Stabilizers (such as antioxidants and UV absorbers) and additives (such as slip agents, antistatic agents, and pigments) can also be added to the polyolefin composites. The polyolefin composites of this disclosure exhibit excellent plasticity and release properties during injection molding; and they can also be used for extrusion molding.

[0100] Characterization: FESEM micrographs were captured using a field emission scanning electron microscope (FESEM) JEOL-6700F at 200 kV with a large objective aperture in high resolution mode.

[0101] Mechanical properties: Flexural modulus was determined by a 3-point bending test according to ASTM standard D 790-96. The injection-molded sample measures 100×10×1mm. 3 The sample size was determined. Tests were conducted at a crosshead speed of 1 mm / min over a span of 25.4 mm.

[0102] Tensile tests were performed on the injection-molded samples according to ASTM D 638-03. The dimensions of type V are 63.5 × 3.14 × 3.2 mm. 3 The test was conducted using an Instron 5569 Table universal testing machine at a tensile speed of 1 mm / min. Impact strength was determined by cantilever beam impact testing according to ASTM standard D 256. The injection-molded sample measures 63.5 × 12.7 × 3.2 mm. 3 The sample size was determined. Tests were conducted using a Zwick Roell HIT25P with a 1-joule pendulum load.

[0103] Example 1

[0104] Part A (90.7 wt% polypropylene (PP) + 9.3 wt% binder (LK)) was physically mixed with Part B (94.4 wt% polypropylene (PP) + 3.6 wt% catalyst (CA)), 5 wt% MPP, and 10 wt% or 20 wt% chopped glass fibers (GF). The total composition of the composite material was 80 wt% PP / 5 wt% MPP / 5 wt% LK / 10 wt% GF and 70 wt% PP / 5 wt% MPP / 5 wt% LK / 20 wt% GF.

[0105] Comparative Examples

[0106] Polypropylene was mixed with 5% maleic anhydride-grafted polypropylene based on the total mixture weight. The epoxy binder content was approximately 5 wt% based on the total mixture weight. In addition, the PP compound contained 10 wt% and 20 wt% chopped glass fibers based on the total mixture weight. The compound was prepared by directly mixing the components in an extruder.

[0107] result

[0108] Figure 1 The mechanical properties of PP composites prepared using conventional resin blending and masterbatch resin blending are shown. The results indicate that the mechanical properties of the PP composites prepared using masterbatch resins remain essentially unchanged, except for a slight, insignificant decrease (approximately 5%-10% compared to PP composites prepared using conventional methods). This decrease may be attributed to incomplete reactions of the linking molecules. However, Figure 2A and Figure 2B The comparison clearly shows that the morphologies of PP composites prepared by conventional extrusion blending and masterbatch blending are similar. The filler and matrix adhere firmly to each other due to the chemical reaction of the linking molecules. This result indicates that masterbatch resins can provide polyolefin composites with similar properties and morphologies to polyolefin composites prepared by conventional methods. Furthermore, Figure 3 The stability of the masterbatch resin was demonstrated, with testing lasting up to two months. Before being mixed with other components, the masterbatch resin was exposed to air at room temperature (approximately 27°C) for different periods (i.e., 1 week, 2 weeks, 3 weeks, 4 weeks, and 8 weeks). The results clearly show that the mechanical properties of the PP composites were relatively consistent, indicating that the masterbatch resin possesses good stability. Figure 4A and Figure 4B To show Figure 1 A graph showing the results of the table in the document. Figure 5A and Figure 5B To show Figure 3 A graph showing the results of the table in the document.

[0109] Although this disclosure has been specifically shown and described with reference to exemplary embodiments thereof, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope of this disclosure as defined by the foregoing claims.

Claims

1. A kit comprising: The first component comprises a first polyolefin and a polymerizable epoxy resin, wherein the polymerizable epoxy resin includes a polymerizable epoxy binder, and The second component comprises a second polyolefin and a catalyst; wherein the catalyst is capable of reacting with the polymerizable epoxy resin to form covalent bonds. The first polyolefin is present in an amount greater than 80 wt% of the first component, and the second polyolefin is present in an amount greater than 80 wt% of the second component.

2. The kit according to claim 1, wherein, The first polyolefin and the second polyolefin, or both, are present in the corresponding first component and / or second component in an amount greater than 90 wt%.

3. The kit according to claim 1, wherein, The first polyolefin and the second polyolefin are independently selected from C 2-20 Alkylene, C 4-20 Alkyl dienes, C 6-20 Alkyltriene, C 3-20 Cycloalkylene, C 4-20 cycloalkyldiene, C 5-20 cycloalkyltriene, C 8-20 Polymers or random copolymers or block copolymers of phenylalkylene groups and combinations thereof.

4. The kit according to claim 1, wherein, The first polyolefin and the second polyolefin are independently selected from polymers or random copolymers or block copolymers of ethylene, propylene, 1-pentene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, styrene, ethylidene norbornene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, dicyclopentadiene, and ethylene propylene diene monomer (EPDM) rubber.

5. The kit according to claim 1, wherein, The first polyolefin and / or the second polyolefin are polyethylene.

6. The kit according to claim 1, wherein, The first polyolefin and / or the second polyolefin are polypropylene.

7. The kit according to claim 1, wherein, The polymerizable epoxy resin is present in an amount greater than or equal to 0.1 wt% and at most 50 wt% based on the weight of the first component.

8. The kit according to claim 1, wherein, The polymerizable epoxy resin is selected from epoxy-containing monomers, epoxy-containing oligomers, epoxy-containing polymers, and combinations thereof.

9. The kit according to claim 1, wherein, The polymerizable epoxy resin is a glycidyl ether epoxy resin obtained by reacting an allyl phenyl derivative with an epoxide-containing precursor, wherein the allyl phenyl derivative is selected from o-allylphenol phenolic varnish and diallyl bisphenol compounds having an allyl group at the ortho position relative to the hydroxyl group of bisphenol A.

10. The kit according to claim 1, wherein, The polymerizable epoxy resin is obtained by reacting a hydroxyl derivative with an epoxide-containing precursor, wherein the hydroxyl derivative is selected from bisphenol, resorcinol, dihydroxynaphthalene, trihydroxynaphthalene, dihydroxydiphenylfluorene, trihydroxymethane, tetrahydroxyphenylethane, phenolic varnish, phenol, and combinations thereof.

11. The kit according to claim 1, wherein, The polymerizable epoxy resin is obtained by reaction between an amine and an epoxide-containing precursor, wherein the amine is selected from tetraglycidyldiaminodiphenylmethane, aminophenol, aminocresol, xylenediamine, and combinations thereof.

12. The kit according to claim 1, wherein, The polymerizable epoxy resin is obtained by reacting aromatic carboxylic acids, aliphatic carboxylic acids and / or alicyclic carboxylic acids with an epoxide-containing precursor.

13. The kit according to claim 9, wherein, The epoxide-containing precursor is selected from epichlorohydrin, ethylene oxide, propylene oxide, phenyl ethylene oxide, cyclohexane oxide, phenyl glycidyl ether, and combinations thereof.

14. The kit according to claim 1, wherein, The polymerizable epoxy resin is selected from bisphenol A epoxy resin, bisphenol S epoxy resin, bisphenol K epoxy resin, bisphenol F epoxy resin, phenolic varnish epoxy resin, cresol varnish epoxy resin, acyclic epoxy resin, heterocyclic epoxy resin, hydrogenated bisphenol A epoxy resin, aliphatic epoxy resin, and combinations thereof.

15. The kit according to claim 14, wherein, The heterocyclic epoxy resin is selected from triglycidyl isocyanuric acid epoxy resin, hydantoin epoxy resin, and combinations thereof.

16. The kit according to claim 14, wherein, The aliphatic epoxy resin is selected from propylene glycol-diglycidyl ether, pentaerythritol polyglycidyl ether, and combinations thereof.

17. The kit according to claim 1, wherein, The polymerizable epoxy resin contains spiro rings.

18. The kit according to claim 1, wherein, The first component and / or the second component further comprise a polymer having functional groups grafted thereon.

19. The kit according to claim 18, wherein, The polymer having functional groups grafted thereon is a third polyolefin having functional groups grafted thereon.

20. The kit according to claim 19, wherein, The third polyolefin is selected from C 2-20 Alkylene, C 4-20 Alkyl dienes, C 6-20 Alkyltriene, C 3-20 Cycloalkylene, C 4-20 cycloalkyldiene, C 5-20 cycloalkyltriene, C 8-20 Polymers or random copolymers or block copolymers of phenylalkylene groups and combinations thereof.

21. The kit according to claim 19, wherein, The third polyolefin is selected from polymers or random copolymers or block copolymers of ethylene, propylene, 1-pentene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, styrene, ethylidene norbornene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, dicyclopentadiene, and ethylene propylene diene monomer (EPDM) rubber.

22. The kit according to claim 19, wherein, The third polyolefin is polypropylene.

23. The kit according to claim 19, wherein, The polymer having functional groups grafted thereon is a polymer containing –COO- groups.

24. The kit according to claim 23, wherein, The polymer containing the –COO- group is a polymer modified with an anhydride, wherein the anhydride is selected from maleic anhydride, succinic anhydride, citrate anhydride, intra-bicyclo[2,2,1]-1,4,5,6,7,7-hexachloro-5-heptene-2,3-dicarboxylic anhydride, intra-bicyclo[2,2,1]-5-heptene-2,3-dicarboxylic anhydride, cis-4-cyclohexene-1,2-dicarboxylic anhydride, and combinations thereof.

25. The kit according to claim 23, wherein, The polymer containing the –COO- group is a maleic anhydride graft polymer.

26. The kit according to claim 19, wherein, The polymer having functional groups grafted thereon further comprises portions selected from hydroxyl, carboxylic acid, carboxylic acid esters, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, butyl methacrylate, mono-maleic acid ester, diester of maleic acid, and combinations thereof.

27. The kit according to claim 1, wherein, The catalyst can initiate the polymerization of the polymerizable epoxy resin.

28. The kit according to claim 1, wherein, The catalyst is present in an amount greater than or equal to 0.1 wt% and less than 30 wt% based on the weight of the second component.

29. The kit according to claim 1, wherein, The catalyst contains amine functional groups capable of initiating the polymerization of the polymerizable epoxy resin.

30. The kit according to claim 1, wherein, The catalyst comprises monoamines, diamines, triamines, polyamines, imidazoles, tertiary amines, secondary amines, organic acid hydrazides, or combinations thereof.

31. The kit according to claim 30, wherein, The catalyst also contains aliphatic components, aromatic components, or combinations thereof.

32. The kit according to claim 1, wherein, The catalyst comprises an anhydrous compound capable of initiating the polymerization of the polymerizable epoxy resin.

33. The kit according to claim 32, wherein, The catalyst also contains aliphatic components, aromatic components, or combinations thereof.

34. The kit according to claim 1, wherein, The catalyst comprises triarylsulfonium salt, dicyandiamide, boron trifluoride-amine complex, polythiol, polyamide resin, or a combination thereof.

35. The kit according to claim 1, wherein, The first component and / or the second component further comprise additives selected from ultraviolet stabilizers, antioxidants, pigments, and combinations thereof.

36. The kit according to claim 35, wherein, The UV stabilizer and / or the antioxidant are selected from hindered phenols, phosphites, thioethers, benzophenones, benzotriazoles, and combinations thereof.

37. The kit according to claim 1, wherein, The first component and / or the second component further comprise a styrene-based polymer.

38. The kit according to claim 37, wherein, The styrene-based polymer is selected from polystyrene, styrene-acrylonitrile resin, and combinations thereof.

39. A method for providing a polyolefin composite material, the polyolefin composite material comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin, the method comprising: A first component comprising a first polyolefin and a polymerizable epoxy resin is mixed with a second component comprising a second polyolefin and a catalyst to form a mixture, wherein the polymerizable epoxy resin includes a polymerizable epoxy binder, wherein the catalyst is capable of reacting with the polymerizable epoxy resin to form covalent bonds, and the mixture is processed to obtain the polyolefin composite material, wherein the first polyolefin is present in an amount greater than 80 wt% of the first component, and the second polyolefin is present in an amount greater than 80 wt% of the second component.

40. The method according to claim 39, further comprising: Add the filler to the mixture.

41. The method according to claim 40, wherein, The filler is selected from microfillers, continuous fibers, highly dispersed nanofillers, and combinations thereof.

42. The method according to claim 41, wherein, The microfiller is made from materials selected from metals, polymers, metal oxides, clays, glass, carbon, cellulose, and combinations thereof.

43. The method according to claim 41, wherein, The microfiller has a size of 0.1 μm to 50 mm, or 1 μm to 50 mm, or 0.1 μm to 20 mm, or 1 μm to 20 mm, or 10 μm to 50 mm.

44. The method according to claim 41, wherein, The continuous fiber is made of glass fiber, carbon fiber, natural fiber, ceramic fiber, metal fiber, or combinations thereof.

45. The method of claim 41, wherein the material of the continuous fiber is selected from blended fibers, synthetic fibers, or combinations thereof.

46. ​​The method according to claim 41, wherein, The highly dispersed nanofiller is selected from inorganic silicates, aluminosilicates, particulate metal oxides and hydroxides, anionic and cationic layered metal oxides and hydroxides, montmorillonite (MMT), kaolinite, dickite, halloysite, pearl clay, chlorite, bedesite, soapstone, illite, biotite, lepidolite, phlogopite, chlorite, sepiolite, lepidolite, polysilicon, mica, palygorskite (AT), and combinations thereof.

47. The method according to claim 46, wherein, The inorganic silicate is calcium silicate.

48. The method according to claim 41, wherein, The highly dispersed nanofiller comprises metal oxides and / or metal-like oxides.

49. The method according to claim 48, wherein, The metal oxides and / or metal-like oxides are selected from SiO2, TiO2, ZnO, CaO, Al2O3, Fe2O3 and combinations thereof.

50. The method according to claim 41, wherein, The highly dispersed nanofiller is modified with organosilane.

51. The method according to claim 50, wherein, The organosilane contains an active functional group selected from octyl, amine, vinyl, hydroxyl, mercapto, and combinations thereof.

52. The method of claim 39, further comprising adding an additional polyolefin to the mixture.

53. The method of claim 39, further comprising adding a polymer having functional groups grafted thereon to the mixture.

54. The method according to claim 39, wherein, The first component and the second component are mixed in a mixer or a drum mixer.

55. The method according to claim 39, wherein, Processing the mixture includes physically agitating the mixture in a mixer, rollers, twin-screw extruder, or a combination thereof.

56. The method according to claim 39, wherein, The first component and the second component are mixed in a wt% ratio of 1:1 to 5:1 or 1:1 to 3:

1.

57. The method according to claim 39, wherein, The processing includes melting and mixing the mixture.

58. A polyolefin composite material provided by the method according to any one of claims 39-57.

59. A polyolefin composite material comprising a first polyolefin, a polymerizable epoxy binder, and a second polyolefin provided by a kit according to any one of claims 1-38.

60. The polyolefin composite material according to claim 59, wherein, The first polyolefin, the second polyolefin, and the other polyolefin, when present, coexist in an amount ranging from 40 wt% to 99.9 wt% based on the total weight of the polyolefin composite material.

61. The polyolefin composite material according to claim 59, wherein, The polymerizable epoxy binder is present in an amount of 0.1 wt% to 30 wt% based on the total weight of the polyolefin composite material.

62. The polyolefin composite material according to claim 59, wherein, When present, the additives are present in an amount of 0.01 wt% to 1 wt% based on the total weight of the polyolefin composite material.

63. The polyolefin composite material according to claim 59, wherein, The polymer having functional groups grafted thereon is present in an amount of 0.1 wt% to 50 wt% based on the total weight of the polyolefin composite material.

64. The polyolefin composite material according to claim 59, wherein, The first component and the second component are present in amounts ranging from 0.1 wt% to 20 wt% based on the total weight of the polyolefin composite material.

65. The polyolefin composite material according to claim 59, wherein, When microfillers are present, they are present in an amount of 1 wt% to 70 wt% based on the total weight of the polyolefin composite.

66. The polyolefin composite material according to claim 59, wherein, When continuous fibers are present, they are present in an amount of 1 wt% to 80 wt% based on the total weight of the polyolefin composite material.

67. The use of the polyolefin composite material according to any one of claims 58-66 in vehicles selected from aerospace, automobile, train and combination thereof, infrastructure selected from pipelines, tanks and combination thereof, packaging, sporting goods, electronic products and combination thereof, and / or construction.

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