Polyolefin composition, carpet tiles comprising the composition and method for preparing carpet tiles

Abstract

The present disclosure relates to a polyolefin composition comprising: (i) 16-30 wt% of at least one first propylene-based elastomer; (ii) 0-10 wt% of at least one second propylene-based elastomer having a low viscosity; (iii) 4-10 wt% of at least one tackifier selected from the group consisting of alicyclic hydrogenated resins; and (iv) 50-80 wt% of a filler; in each case based on the total weight of the polyolefin composition, wherein the polyolefin composition has a melt index of 2-10 g / 10 min. The present disclosure also relates to a carpet tile comprising the composition and a method of manufacturing a carpet tile. The polyolefin composition of the present disclosure has good extrusion flowability, suitable hardness and good mechanical properties, and the carpet tile manufactured using the polyolefin composition has excellent peel strength and tuft pull force, and the method of manufacturing a carpet tile of the present disclosure can further improve the peel strength of the resulting carpet tile.

Description

Technical Field

[0001] The present disclosure relates to a polyolefin composition, a carpet tile comprising the composition, and a method of making the carpet tile. Background Art

[0002] The carpet market is large and growing rapidly, with recyclability and health issues being key concerns. Carpet tiles typically have backing systems based on asphalt and PVC. However, both asphalt and PVC backings suffer from odor issues and are difficult to recycle.

[0003] The demand for sustainable and odorless products has promoted the development of thermoplastic polyolefin backings. However, conventional thermoplastic polyolefin backings have difficulty in achieving a good balance of elasticity, hardness, and processing properties, and their peel strength and tuft pull-out force are insufficient.

[0004] Therefore, it is necessary to develop a polyolefin composition with good performance to overcome the defects of the prior art. Summary of the Invention

[0005] The present disclosure provides a polyolefin composition comprising:

[0006] (i) 16 to 30 weight percent of at least one first propylene-based elastomer, wherein the first propylene-based elastomer has a melt flow rate of 25 to 120 g / 10 min, as measured in accordance with ASTM D1238 at 230° C. under a 2.16 kg load;

[0007] (ii) 0 to 10 weight percent of at least one low viscosity second propylene-based elastomer, wherein the low viscosity second propylene-based elastomer has a viscosity of 800 to 2500 mPa·s, as measured at 190° C. in accordance with ASTM D1084-16;

[0008] (iii) 4 to 10 weight percent of at least one tackifier selected from alicyclic hydrogenated resins; and

[0009] (iv) 50-80% by weight of a filler;

[0010] In each case, based on the total weight of the polyolefin composition,

[0011] The melt index of the polyolefin composition is 2-10 g / 10 min, 3-8 g / 10 min, or 3.5-6 g / 10 min, or 3.5-4.5 g / 10 min, and the melt index is measured according to ASTM D1238 at a load of 2.16 kg and 190° C.

[0012] Another aspect of the present disclosure provides a carpet tile comprising the polyolefin composition according to the present disclosure.

[0013] Yet another aspect of the present disclosure provides a method of preparing a carpet tile, which comprises using the polyolefin composition according to the present disclosure as a backing material, for example, forming the polyolefin composition into a backing material by extrusion processing, particularly at a temperature of 170-230°C, or 185-225°C, or 200-220°C.

[0014] The polyolefin composition of the present disclosure has good extrusion flowability, suitable hardness, and good mechanical properties, and is also suitable for preparing a backing material for a carpet tile at a high processing temperature, thereby further improving the performance of the carpet tile, and the carpet tile prepared using the polyolefin composition has excellent peel strength and tuft pull force, and the method of preparing a carpet tile of the present disclosure can further improve the performance of the resulting carpet tile. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 LCR (Laboratory Capillary Rheometry) viscosity curves of Samples 1, 2, and 3. DETAILED DESCRIPTION

[0016] Polyolefin composition

[0017] One aspect of the present disclosure relates to a polyolefin composition, which comprises:

[0018] (i) 16-30 wt% of at least one first propylene-based elastomer having a melt flow rate of 25-120 g / 10 min, as determined in accordance with ASTM D1238 at a load of 2.16 kg and at 230°C;

[0019] (ii) 0-10 wt% of at least one second propylene-based elastomer having a viscosity of 800-2500 mPa·s, as determined in accordance with ASTM D1084-16 at 190°C;

[0020] (iii) 4-10 wt% of at least one tackifier selected from the group consisting of alicyclic hydrogenated resins; and

[0021] (iv) 50-80 wt% of a filler;

[0022] In each case, based on the total weight of the polyolefin composition,

[0023] The melt index of the polyolefin composition is 2-10 g / 10 min, or 3-8 g / 10 min, or 3.5-6 g / 10 min, or 3.5-4.5 g / 10 min, and the melt index is measured according to ASTM D1238 at a load of 2.16 kg and 190° C.

[0024] According to the present disclosure, the melt flow rate of the first propylene-based elastomer is 25-120 g / 10 min (e.g., 30 g / 10 min, 40 g / 10 min, 50 g / 10 min, 60 g / 10 min, 65 g / 10 min, 70 g / 10 min, 80 g / 10 min, 90 g / 10 min, 100 g / 10 min, 105 g / 10 min, 110 g / 10 min or 115 g / 10 min), such as 30-110 g / 10 min or 35-110 g / 10 min, or 30-65 g / 10 min or 35-60 g / 10 min or 35-55 g / 10 min, or 80-120 g / 10 min or 80-110 g / 10 min or 85-110 g / 10 min, and the melt flow rate is in accordance with ASTM D 1476. D1238, measured at 230°C under a load of 2.16 kg.

[0025] The first propylene-based elastomer comprises units derived from propylene and units derived from one or more C2 or C4-C 12 In the first propylene-based elastomer, the amount of units derived from propylene is at least 60 wt % or at least 75 wt % or at least 85 wt %. In one embodiment, the first propylene-based elastomer comprises at least 60 wt % or at least 75 wt % or at least 85 wt % units derived from propylene and 3-25 wt % (e.g., 5 wt %, 8 wt %, 10 wt %, 15 wt % or 20 wt %) or 5-20 wt % or 8-15 wt % units derived from one or more C2 or C4-C 12 The α-olefin may be selected from 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene or 1-octene.

[0026] In the first propylene-based elastomer, the 12 The units of α-olefins may consist essentially of units derived from ethylene, for example units derived from one or more C2 or C4-C 12 At least 95 wt % or at least 98 wt % of the units of the α-olefins are units derived from ethylene. In one embodiment, the units derived from one or more C2 or C4-C 12The units of the alpha-olefin consist of units derived from ethylene.

[0027] In one embodiment, the first propylene-based elastomer has a weight average molecular weight of 8-18 million g / mol (e.g., 10, 12, 14, 15, or 16 million g / mol), for example, 10-15 million g / mol. The molecular weight distribution of the first propylene-based elastomer may, for example, be 1.2-2 or 1.4-1.9.

[0028] The first propylene-based elastomer may, for example, be Vistamaxx 6202 and Vistamaxx 6902, in particular Vistamaxx 6202. TM 6502 and Vistamaxx TM 6902, in particular Vistamaxx TM 6502.

[0029] According to the present disclosure, the polyolefin composition comprises 16-30 wt.% (e.g., 18 wt.%, 20 wt.%, 22 wt.%, 25 wt.%, or 28 wt.%), for example, 20-28 wt.%, for example, 20-26 wt.% of the first propylene-based elastomer, based on the total weight of the polyolefin composition.

[0030] In one embodiment, the propylene-based elastomer has a density of 0.84-0.92 g / cm 3 (e.g., 0.88 g / cm 3 or 0.90 g / cm 3 ).

[0031] According to the present disclosure, the polyolefin composition comprises 0-10 wt.% (e.g., 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, or 9 wt.%), for example, 2-8 wt.% or 3-6 wt.% of a second propylene-based elastomer having a low viscosity, based on the total weight of the polyolefin composition.

[0032] According to the present disclosure, the second propylene-based elastomer having a low viscosity has a viscosity of 800-2500 mPa-s (e.g., 1000, 1200, 1500, 1800, 2000, or 2300 mPa-s), for example, 1000-1800 mPa-s or 1000-1500 mPa-s, the viscosity being determined in accordance with ASTM D1084-16 at 190 °C.

[0033] The second propylene-based elastomer having a low viscosity comprises units derived from propylene and units derived from one or more C2or C4-C 12units derived from propylene. In one embodiment, the low viscosity second propylene-based elastomer comprises at least 80 wt% or at least 90 wt% units derived from propylene and 3-20 wt% (e.g., 5 wt%, 8 wt%, 10 wt%, 15 wt%, or 18 wt%) or 4-10 wt% units derived from one or more C2or C4-C 12 units of an a-olefin. For example, the a-olefin can have 2-8 carbon atoms. The a-olefin can be selected from 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, or 1-octene.

[0034] In the low viscosity second propylene-based elastomer, the units derived from one or more C2or C4-C 12 The units of an a-olefin can consist essentially of units derived from ethylene, for example, the units derived from one or more C2or C4-C 12 At least 95 wt% or at least 98 wt% of the units of an a-olefin are units derived from ethylene. In one embodiment, the units derived from one or more C2or C4-C 12 The units of an a-olefin consist of units derived from ethylene.

[0035] The low viscosity second propylene-based elastomer can have a molecular weight of 20-60 kg / mol (e.g., 30 kg / mol, 40 kg / mol, or 50 kg / mol).

[0036] According to the present disclosure, the polyolefin composition comprises 4-10 wt% (e.g., 5 wt%, 6 wt%, 7 wt%, 8, or 9 wt%), for example, 4-8 wt% of at least one tackifier selected from a cycloaliphatic hydrogenated resin, based on the total weight of the polyolefin composition.

[0037] The cycloaliphatic hydrogenated resin used as a tackifier can have a viscosity of 500-1500 mPa-s (e.g., 600 mPa-s, 800 mPa-s, 1000 mPa-s, or 1200 mPa-s), or 600-1200 mPa-s, the viscosity determined at 160 °C according to ASTM D1084-16.

[0038] One example of the cycloaliphatic hydrogenated resin can be Escorez TM 5400.

[0039] According to the present disclosure, the polyolefin composition comprises 50-80 wt% (such as 55 wt%, 60 wt%, 65 wt%, 68 wt%, 70 wt%, 72 wt%, 75 wt%, or 78 wt%), such as 55-75 wt% or 60-75 wt% of a filler. The filler can be selected from calcium carbonate, magnesium hydroxide, and aluminum hydroxide, in particular calcium carbonate.

[0040] The filler can be in the form of a powder. The particle size of the filler can be 200-1000 mesh (such as 300 mesh, 400 mesh, 500 mesh, 600 mesh, 700 mesh, 800 mesh, or 900 mesh), for example 300-800 mesh.

[0041] In one embodiment, the polyolefin composition can further comprise at least one compatibilizer. Compatibilizers include, for example, functionalized polyolefins. For example, in one embodiment, the functionalized polyolefin is a maleated polyolefin, such as a maleated polyethylene, a maleated polypropylene, a maleated ethylene or propylene based elastomer. In one embodiment, the compatibilizer is a maleated high density polyethylene. The maleated polyolefin can have a maleic anhydride graft level of at least 0.1 wt%, such as at least 0.5 wt% or at least 1 wt%, for example 0.5-1.5 wt%. One example of the maleated polyethylene as a compatibilizer is Exxelor 1040, which is commercially available from TCC.

[0042] In one embodiment, the amount of the compatibilizer can be 0-8 wt% (such as 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%), for example 0.5-8 wt%, or 1-5 wt%, based on the total weight of the polyolefin composition.

[0043] In one embodiment, the polyolefin composition comprises:

[0044] (i) 16-28 wt% of at least one first propylene-based elastomer having a melt flow rate of 30-110 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C;

[0045] (ii) 0-10 wt% of at least one second propylene-based elastomer having a low viscosity of 800-2500 mPa-s, the viscosity being determined according to ASTM D1084-16 at 190 °C;

[0046] (iii) 4-10 wt% of at least one tackifier selected from cycloaliphatic hydrogenated resins; and

[0047] (iv) 55-75 wt.-% of a filler;

[0048] in each case based on the total weight of the polyolefin composition,

[0049] wherein the polyolefin composition has a melt index of 2-10 g / 10 min, or 3-8 g / 10 min, or 3.5-6 g / 10 min, or 3.5-4.5 g / 10 min, the melt index being determined according to ASTM D1238 at 2.16 kg load, 190 °C.

[0050] In one embodiment, the polyolefin composition comprises:

[0051] (i) 16-28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 80-110 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C;

[0052] (ii) 0-5 wt.-% of at least one second propylene-based elastomer having a low viscosity of 800-2500 mPa-s, the viscosity being determined according to ASTM D1084-16 at 190 °C;

[0053] (iii) 4-10 wt.-% of at least one tackifier selected from cycloaliphatic hydrogenated resins; and

[0054] (iv) 60-75 wt.-% of a filler;

[0055] in each case based on the total weight of the polyolefin composition,

[0056] wherein the polyolefin composition has a melt index of 3-8 g / 10 min, or 3.5-6 g / 10 min, or 3.5-4.5 g / 10 min, the melt index being determined according to ASTM D1238 at 2.16 kg load, 190 °C.

[0057] In one embodiment, the polyolefin composition comprises:

[0058] (i) 16-28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 30-65 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C;

[0059] (ii) 2 to 8 wt. % of at least one second propylene-based elastomer having a viscosity of 800 to 2500 mPa-s, the viscosity being determined in accordance with ASTM D1084-16 at 190 °C;

[0060] (iii) 4 to 10 wt. % of at least one tackifier selected from the group consisting of cycloaliphatic hydrogenated resins; and

[0061] (iv) 60 to 75 wt. % of a filler;

[0062] in each case based on the total weight of the polyolefin composition,

[0063] wherein the polyolefin composition has a melt index of 3 to 8 g / 10 min, or 3.5 to 6 g / 10 min, or 3.5 to 4.5 g / 10 min, the melt index being determined in accordance with ASTM D1238 at 2.16 kg load, 190 °C.

[0064] In one embodiment, the polyolefin composition comprises:

[0065] (i) 16 to 28 wt. % of at least one first propylene-based elastomer having a melt flow rate of 30 to 65 g / 10 min, the melt flow rate being determined in accordance with ASTM D1238 at 2.16 kg load, 230 °C;

[0066] (ii) 2 to 8 wt. % of at least one second propylene-based elastomer having a viscosity of 800 to 2500 mPa-s, the viscosity being determined in accordance with ASTM D1084-16 at 190 °C;

[0067] (iii) 4 to 10 wt. % of at least one tackifier selected from the group consisting of cycloaliphatic hydrogenated resins;

[0068] (iv) 60 to 75 wt. % of a filler; and

[0069] (v) 1 to 5 wt. % of a compatibilizer;

[0070] in each case based on the total weight of the polyolefin composition,

[0071] wherein the polyolefin composition has a melt index of 3 to 8 g / 10 min, or 3.5 to 6 g / 10 min, or 3.5 to 4.5 g / 10 min, the melt index being determined in accordance with ASTM D1238 at 2.16 kg load, 190 °C.

[0072] In one embodiment, the polyolefin composition comprises:

[0073] (i) 16 to 28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 30 to 65 g / 10 min, measured according to ASTM D1238 at 230 °C under a load of 2.16 kg; the first propylene-based elastomer comprising at least 85 wt.-% of units derived from propylene and 8 to 15 wt.-% of units derived from ethylene;

[0074] (ii) 2 to 8 wt.-% of at least one second propylene-based elastomer having a viscosity of 1000 to 1800 mPa-s, measured according to ASTM D1084-16 at 190 °C;

[0075] (iii) 4 to 10 wt.-% of at least one tackifier selected from cycloaliphatic hydrogenated resins;

[0076] (iv) 60 to 75 wt.-% of a filler; and

[0077] (v) 1 to 5 wt.-% of a compatibilizer;

[0078] in each case based on the total weight of the polyolefin composition,

[0079] wherein the polyolefin composition has a melt index of 3.5 to 6 g / 10 min, or 3.5 to 4.5 g / 10 min, measured according to ASTM D1238 at 190 °C under a load of 2.16 kg.

[0080] In one embodiment, the polyolefin composition comprises:

[0081] (i) 16 to 28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 35 to 60 g / 10 min, measured according to ASTM D1238 at 230 °C under a load of 2.16 kg; the first propylene-based elastomer comprising at least 85 wt.-% of units derived from propylene and 8 to 15 wt.-% of units derived from ethylene;

[0082] (ii) 3 to 6 wt.-% of at least one second propylene-based elastomer having a viscosity of 1000 to 1800 mPa-s, measured according to ASTM D1084-16 at 190 °C;

[0083] (iii) 4 to 8 wt.-% of at least one tackifier selected from cycloaliphatic hydrogenated resins;

[0084] (iv) 60 to 75 wt.-% of calcium carbonate; and

[0085] (v) 1-5 wt.-% of a compatibilizer, which is a maleated polyolefin;

[0086] In each case, based on the total weight of the polyolefin composition,

[0087] wherein the polyolefin composition has a melt index of 3.5-4.5 g / 10 min, as determined according to ASTM D1238 at a load of 2.16 kg at 190 °C.

[0088] The polyolefin composition of the present disclosure can have a flexural modulus of 70-180 MPa, or 90-160 MPa, or 100-160 MPa, or 120-150 MPa, as determined according to ASTM D790.

[0089] The polyolefin composition of the present disclosure can have a tensile yield stress of 2-5 MPa, or 2.5-4.5 MPa, or 3.5-4.5 MPa, as determined according to ASTM D638.

[0090] The polyolefin composition of the present disclosure can have a Shore hardness of A 80-95 and / or D 20-38, as determined according to ASTM D2240.

[0091] Carpet tiles and method of making carpet tiles

[0092] One aspect of the present disclosure relates to a carpet tile comprising the polyolefin composition according to the present invention.

[0093] In one embodiment, the polyolefin composition is used as a primary backing material, e.g. the polyolefin composition is formed into a primary backing material by extrusion processing, in particular at a temperature of 170-230 °C (e.g. 175 °C, 180 °C, 185 °C, 190 °C, 195 °C, 200 °C, 205 °C, 210 °C, 215 °C, 220 °C, or 225 °C), or 185-225 °C, or 200-220 °C.

[0094] In one embodiment, the carpet comprises, in addition to the primary backing material, an upper carpet face and a lower base layer, i.e. the primary backing material is located between the upper carpet face and the lower base layer.

[0095] In one embodiment, the primary backing material is obtained by extrusion processing of a polyolefin composition comprising:

[0096] (i) 16-28 wt% of at least one first propylene-based elastomer having a melt flow rate of 35-60 g / 10 min, as determined according to ASTM D1238 at a load of 2.16 kg at 230 °C; the first propylene-based elastomer comprising at least 85 wt% of units derived from propylene and 8-15 wt% of units derived from ethylene;

[0097] (ii) 3-6 wt% of at least one second propylene-based elastomer having a viscosity of 1000-1800 mPa-s, as determined according to ASTM D1084-16 at 190 °C;

[0098] (iii) 4-8 wt% of at least one tackifier selected from the group consisting of cycloaliphatic hydrogenated resins;

[0099] (iv) 60-75 wt% of calcium carbonate; and

[0100] (v) 1-5 wt% of a compatibilizer which is a maleated polyolefin;

[0101] in each case based on the total weight of the polyolefin composition,

[0102] wherein the polyolefin composition has a melt index of 3.5-4.5 g / 10 min, as determined according to ASTM D1238 at a load of 2.16 kg at 190 °C.

[0103] The transverse peel strength of a carpet tile comprising the polyolefin composition of the present disclosure can be 30-100 N (such as 35, 40, 50, 60, 70, 80, 85, 90, or 95 N), for example 50-100 N, for example 85-95 N, and / or the transverse peel strength can be 18-100 N (such as 20, 25, 30, 40, 50, 60, 70, 80, 85, 90, or 95 N), for example 25-100 N, for example 50-100 N, for example 80-95 N, as determined according to GB-T 11746-2008.

[0104] The tuft pull force of a carpet tile comprising the polyolefin composition of the present disclosure can be 50-60 N, as tested according to QB / T 2755-2005.

[0105] The TVOC of a carpet tile comprising the polyolefin composition of the present disclosure is not more than 0.025 mg / (m 2 ·h), such as not more than 0.02 mg / (m 2 ·h), as tested according to GB 18587-2001.

[0106] One aspect of the present disclosure relates to a method of preparing a carpet tile, comprising using a polyolefin composition of the present disclosure as a primary backing material, for example forming the polyolefin composition into a primary backing material by extrusion processing, in particular at a temperature of 170-230 °C (e.g. 175 °C, 180 °C, 185 °C, 190 °C, 195 °C, 200 °C, 205 °C, 210 °C, 215 °C, 220 °C or 225 °C), or 185-225 °C, or 200-220 °C.

[0107] The primary backing material is typically in the form of a primary backing sheet.

[0108] Typically after extrusion processing, the primary backing material is combined with an upper carpet face and a lower base layer, for example the primary backing material is combined with an upper carpet face and a lower base layer without cooling after extrusion processing.

[0109] The polyolefin composition of the present disclosure allows for processing at high extrusion processing temperatures, with the resulting carpet tile having excellent peel strength.

[0110] In one embodiment, the method of preparing a carpet tile of the present disclosure comprises extrusion processing a polyolefin composition at a temperature of 200-220 °C to obtain a primary backing material, the polyolefin composition comprising:

[0111] (i) 16-28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 35-60 g / 10 min, as determined according to ASTM D1238 at a load of 2.16 kg at 230 °C, the first propylene-based elastomer comprising at least 85 wt.-% of units derived from propylene and 8-15 wt.-% of units derived from ethylene;

[0112] (ii) 3-6 wt.-% of at least one second propylene-based elastomer having a viscosity of 1000-1800 mPa-s, as determined according to ASTM D1084-16 at 190 °C, the second propylene-based elastomer being a low viscosity propylene-based elastomer;

[0113] (iii) 4-8 wt.-% of at least one tackifier selected from the group consisting of cycloaliphatic hydrogenated resins;

[0114] (iv) 60-75 wt.-% of calcium carbonate; and

[0115] (v) 1-5 wt.-% of a compatibilizer, the compatibilizer being a maleated polyolefin;

[0116] in each case based on the total weight of the polyolefin composition,

[0117] wherein the polyolefin composition has a melt index of 3.5 to 4.5 g / 10 min, the melt index being determined according to ASTM D1238 at 2.16 kg load, 190 °C.

[0118] The present application can be more easily understood in view of the following embodiments by those skilled in the art:

[0119] 1. A polyolefin composition comprising:

[0120] (i) 16 to 30 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 25 to 120 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C;

[0121] (ii) 0 to 10 wt.-% of at least one second propylene-based elastomer having a low viscosity of 800 to 2500 mPa-s, the viscosity being determined according to ASTM D1084-16 at 190 °C;

[0122] (iii) 4 to 10 wt.-% of at least one tackifier selected from cycloaliphatic hydrogenated resins; and

[0123] (iv) 50 to 80 wt.-% of a filler;

[0124] in each case based on the total weight of the polyolefin composition,

[0125] wherein the polyolefin composition has a melt index of 2 to 10 g / 10 min, or 3 to 8 g / 10 min, or 3.5 to 6 g / 10 min, or 3.5 to 4.5 g / 10 min, the melt index being determined according to ASTM D1238 at 2.16 kg load, 190 °C.

[0126] 2. The polyolefin composition according to embodiment 1, wherein the first propylene-based elastomer has a melt flow rate of 30 to 110 g / 10 min, or 30 to 65 g / 10 min, or 80 to 110 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C.

[0127] 3. The polyolefin composition according to embodiment 1 or 2, wherein the first propylene-based elastomer comprises units derived from propylene and units derived from one or more C2 or C4-C 12units derived from propylene and 3-20 wt.-% or 4-10 wt.-% units derived from one or more C2or C4-C 12 units of an a-olefin.

[0128] 4. The polyolefin composition according to any one of embodiments 1-3, wherein the polyolefin composition comprises 16-28 wt.-% of the first propylene-based elastomer, based on the total weight of the polyolefin composition.

[0129] 5. The polyolefin composition according to any one of embodiments 1-4, wherein the polyolefin composition comprises 2-8 wt.-%, or 3-6 wt.-% of the low viscosity second propylene-based elastomer, based on the total weight of the polyolefin composition.

[0130] 6. The polyolefin composition according to any one of embodiments 1-5, wherein the low viscosity second propylene-based elastomer has a viscosity of 1000-1800 mPa-s, the viscosity being determined according to ASTM D1084-16 at 190 °C.

[0131] 7. The polyolefin composition according to any one of embodiments 1-6, wherein the low viscosity second propylene-based elastomer comprises units derived from propylene and units derived from one or more C2or C4-C 12 units of an a-olefin, for example the low viscosity second propylene-based elastomer comprises at least 80 wt.-% or at least 90 wt.-% units derived from propylene and 3-20 wt.-% or 4-10 wt.-% units derived from one or more C2or C4-C 12 units of an a-olefin.

[0132] 8. The polyolefin composition according to any one of embodiments 1-7, wherein the tackifier selected from a cycloaliphatic hydrogenated resin is present in an amount of 4-8 wt.-%, based on the total weight of the polyolefin composition.

[0133] 9. The polyolefin composition according to any one of embodiments 1-8, wherein the filler is selected from calcium carbonate, magnesium hydroxide and aluminium hydroxide, and / or the particle size of the filler is 200-1000 mesh, for example 300-800 mesh, and / or the amount of the filler is 55-75 wt.-%.

[0134] 10. The polyolefin composition according to any one of embodiments 1-9, wherein the polyolefin composition further comprises at least one compatibilizer, for example a functionalized polyolefin, such as a maleated polyolefin.

[0135] 11. The polyolefin composition according to embodiment 10, wherein the amount of the compatibilizer is 0.5 to 8 wt.-%, or 1 to 5 wt.-%, based on the total weight of the polyolefin composition.

[0136] 12. A polyolefin composition comprising:

[0137] (i) 16 to 28 wt.-% of at least one first propylene-based elastomer having a melt flow rate of 35 to 60 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C; the first propylene-based elastomer comprising at least 85 wt.-% units derived from propylene and 8 to 15 wt.-% units derived from ethylene;

[0138] (ii) 3 to 6 wt.-% of at least one second propylene-based elastomer having a viscosity of 1000 to 1800 mPa-s, the viscosity being determined according to ASTM D1084-16 at 190 °C; the second propylene-based elastomer having a melt flow rate of 0.5 to 1.5 g / 10 min, the melt flow rate being determined according to ASTM D1238 at 2.16 kg load, 230 °C;

[0139] (iii) 4 to 8 wt.-% of at least one tackifier selected from the group consisting of cycloaliphatic hydrogenated resins;

[0140] (iv) 60 to 75 wt.-% of calcium carbonate; and

[0141] (v) 1 to 5 wt.-% of a compatibilizer, the compatibilizer being a maleated polyolefin;

[0142] in each case based on the total weight of the polyolefin composition,

[0143] wherein the polyolefin composition has a melt index of 3.5 to 4.5 g / 10 min, the melt index being determined according to ASTM D1238 at 2.16 kg load, 190 °C.

[0144] 13. A carpet tile comprising the polyolefin composition according to any one of embodiments 1 to 12.

[0145] 14. The carpet tile according to embodiment 13, wherein the polyolefin composition is used as a primary backing material, for example the polyolefin composition is formed into a primary backing material by extrusion processing, in particular at a temperature of 170 to 230 °C, or 185 to 225 °C, or 200 to 220 °C.

[0146] 15. A method of preparing a carpet tile comprising using a polyolefin composition according to any one of embodiments 1-12 as a primary backing material, for example by extrusion processing the polyolefin composition to form a primary backing material, in particular at a temperature of 170-230 °C, or 185-225 °C, or 200-220 °C.

[0147] 16. The method according to embodiment 15, comprising the step of combining the primary backing material with an upper carpet face and a lower base layer.

[0148] Examples

[0149] The following examples are intended to illustrate and not limit the present application. The amounts of the individual substances in the examples are based on weight, unless otherwise stated.

[0150] Raw materials

[0151] Vistamaxx TM 6502 (hereinafter VM6502): propylene-ethylene copolymer elastomer, available from ExxonMobil, containing approximately 13 wt% ethylene comonomer, having a density of approximately 0.865 g / cm3and a melt flow rate of approximately 45 g / 10 min, measured according to ASTM D1238 at 2.16 kg load, 230 °C; 3

[0152] Vistamaxx TM 6902 (hereinafter VM6902): propylene-ethylene copolymer elastomer, available from ExxonMobil, containing approximately 12 wt% ethylene comonomer, having a density of approximately 0.869 g / cm3and a melt flow rate of approximately 100 g / 10 min, measured according to ASTM D1238 at 2.16 kg load, 230 °C; 3

[0153] Vistamaxx TM 8880 (hereinafter VM8880): propylene-ethylene copolymer elastomer, available from ExxonMobil, containing approximately 6 wt% ethylene comonomer, having a viscosity of 1200 mPa-s, measured according to ASTM D1084-16 at 190 °C.

[0154] Escorez TM 5400 (hereinafter Escorez 5400): cycloaliphatic hydrogenated resin, available from ExxonMobil, having a viscosity of 800 mPa-s, measured according to ASTM D1084-16 at 160 °C. ​​

[0155] Exxelor 1040: maleic anhydride grafted high density polyethylene, available from TCC.

[0156] Calcium carbonate powder: 400 mesh.

[0157] Method and criteria

[0158] Melt index (MI): ASTM D1238;

[0159] LCR (Laboratory Capillary Rheology) viscosity: ASTM D3835;

[0160] Flexural modulus: ASTM D790;

[0161] Tensile stress: ASTM D638;

[0162] Shore hardness: ASTM D2240;

[0163] Peel strength: GB-T 11746-2008;

[0164] Tufting pull-out force: QB / T 2755-2005;

[0165] Total volatile organic compounds (TVOC): GB 18587-2001.

[0166] Example 1: Preparation of polyolefin composition samples 1-3

[0167] Preparation of Mixed Particles: Samples 1-3 were all produced into cylindrical mixed particles using a twin-screw extruder with a screw diameter of 40 mm. For Sample 1, 21% VM6502, 4.5% VM8880, and 4.5% Escorez 5400, excluding the calcium carbonate powder, were dry-blended in a planetary mixer. Once uniformly mixed, the resulting dry-blended particles were ready for use. The twin-screw extruder had two feed ports. The dry-blended particles were introduced into the barrel through feed port 1, while 35% calcium carbonate powder was simultaneously added to feed port 1. The barrel temperatures were set at 150°C, 160°C, 170°C, 180°C, and 200°C, respectively. After the melt extrusion stabilized, the remaining 35% calcium carbonate powder was added through feed port 2. The extruder was operated at a rate of approximately 50 kg / h. After the melt at the die was stable, the underwater pelletizer was attached to the die. Cooling water was then circulated, and the mixed pellets were separated by a cyclone separator. The preparation process for Samples 2 and 3 was similar to that for Sample 1, with the formulation adjusted according to the weight ratios shown in Table 1. The MI and LCR viscosities of Samples 1, 2, and 3 are shown in Table 2, and their mechanical properties and Shore hardness are shown in Table 3.

[0168] Table 1

[0169]

[0170] Table 2

[0171]

[0172] The LCR viscosity curves of samples 1, 2 and 3 are shown in Figure 1. Figure 1 At low shear rate (10s -1 , from top to bottom are sample 2, sample 1 and sample 3.

[0173] As shown in Table 2, the Ml of all samples 1-3 is between 4-6, which can be processed by extrusion process. Figure 1 Or the LCR viscosity table of Table 2 shows that at low shear rate, the viscosity of sample 2 is higher than that of samples 1 and 3, while at high shear rate, the difference is small. At low shear rate of 220s -1 , the viscosity of sample 2 is the highest, which is 462.1 Pa·s, which can provide higher melt strength in the extrusion process, thus having better processing performance.

[0174] Table 3

[0175]

[0176] Table 3 shows that sample 2 has the highest stiffness and hardness. Sample 3 shows lower stiffness and hardness.

[0177] Example 2: Carpet backing extrusion and carpet face compounding to prepare a carpet tile

[0178] The samples prepared in Example 1 were respectively used as the backing material for carpet tile processing, and the extruded backing sheet (middle layer) was compounded with the carpet face (upper layer) and the polypropylene non-woven fabric layer (lower layer) at high temperature by an extrusion compound machine, and cooled to room temperature by a cooling roller, so as to obtain the final carpet product. The extrusion processing temperature of the backing sheet is 180-210℃ (as shown in Table 4), the cooling roller temperature is 30℃, and the line speed of the extrusion compound machine is 10 m / min. The melt strength of sample 1 is low, so it cannot be extruded at 190℃ and higher temperature to process the backing sheet, while sample 2 can be extruded at 190℃ and higher temperature to process the backing sheet, thus sample 2 has better processing performance.

[0179] The peel strength of the carpets obtained by using samples 1 and 2 is shown in Table 4, and the tuft pull force and TVOC are shown in Table 5.

[0180] Table 4

[0181] Longitudinal peel strength (N) Transverse peel strength (N) Sample 1 (180°C bottom back processing temperature) 33.2 19.4 Sample 2 (190°C bottom back processing temperature) 54.1 29.1 Sample 2 (210°C bottom back processing temperature) 88.3 95.1

[0182] Table 4 shows that carpets processed using the samples of the present invention have good transverse and longitudinal peel strengths, with the carpet obtained using Sample 2 exhibiting higher peel strength than the carpet obtained using Sample 1. Furthermore, a comparison between carpets obtained using Sample 2 processed at 190°C and 210°C demonstrates that higher backing sheet extrusion processing temperatures help improve peel strength, which is particularly beneficial for carpet processing on extrusion lines.

[0183] Table 5

[0184] Tuft pull (N) TVOC / (mg / (m 2 ·h)) Sample 1 (180°C processing temperature) 54.5 0.017 Sample 2 (190°C processing temperature) 53.7 0.021 Commercially available PVC primary carpet 44.9 0.047 Commercially available bitumen primary carpet 39.6 0.065

[0185] As shown in Table 5, the tuft pull-out force of the carpets processed from Samples 1 and 2 is higher than that of commercially available carpets. In addition, the TVOC of the carpets processed from Samples 1 and 2 is significantly lower.

[0186] Although the present invention is disclosed above with reference to preferred embodiments, the present invention is not limited thereto. Any changes and modifications made by those skilled in the art without departing from the spirit and scope of the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope defined by the claims.

Claims

1. A polyolefin composition comprising: (i) 18 to 30 weight percent of at least one first propylene-based elastomer, the first propylene-based elastomer having a melt flow rate of 30 to 120 g / 10 min, as measured in accordance with ASTM D1238 at 230° C. under a 2.16 kg load, wherein the first propylene-based elastomer comprises units derived from propylene and units derived from one or more C2 or C4-C 12 units of α-olefins; (ii) 1 to 6 weight percent of at least one low viscosity second propylene-based elastomer, wherein the viscosity of the low viscosity second propylene-based elastomer is 800 to 1800 mPa·s, as measured at 190° C. in accordance with ASTM D1084-16, wherein the low viscosity second propylene-based elastomer comprises units derived from propylene and units derived from one or more C2 or C4-C 12 units of α-olefins; (iii) 4 to 10 wt% of at least one tackifier selected from alicyclic hydrogenated resins, wherein the alicyclic hydrogenated resin has a viscosity of 500 to 1500 mPa·s; and (iv) 50-80 wt% of a filler, wherein the filler is selected from calcium carbonate, magnesium hydroxide, and aluminum hydroxide; In each case, based on the total weight of the polyolefin composition, The polyolefin composition has a melt index of 2-10 g / 10 min, which is measured according to ASTM D1238 under a load of 2.16 kg and at 190° C.

2. The polyolefin composition according to claim 1, wherein the polyolefin composition has a melt index of 3-8 g / 10 min, the melt index being measured according to ASTM D1238 at 190°C under a load of 2.16 kg.

3. The polyolefin composition according to claim 1, wherein the polyolefin composition has a melt index of 3.5-6 g / 10 min, the melt index being measured according to ASTM D1238 at 190°C under a load of 2.16 kg.

4. The polyolefin composition according to claim 1, wherein the polyolefin composition has a melt index of 3.5 to 4.5 g / 10 min, the melt index being measured according to ASTM D1238 at 190°C under a load of 2.16 kg.

5. The polyolefin composition according to claim 1, wherein the first propylene-based elastomer has a melt flow rate of 30 to 110 g / 10 min, as measured according to ASTM D1238 at 230°C under a load of 2.16 kg.

6. The polyolefin composition according to claim 1, wherein the first propylene-based elastomer has a melt flow rate of 30 to 65 g / 10 min, as measured according to ASTM D1238 at 230°C under a load of 2.16 kg.

7. The polyolefin composition according to claim 1, wherein the first propylene-based elastomer has a melt flow rate of 80 to 110 g / 10 min, as measured according to ASTM D1238 at 230°C under a load of 2.16 kg.

8. The polyolefin composition according to claim 1, wherein the first propylene-based elastomer comprises at least 60 wt% of units derived from propylene and 3-25 wt% of units derived from one or more C2 or C4-C 12 α-olefin units.

9. The polyolefin composition according to claim 8, wherein the first propylene-based elastomer comprises at least 75 weight percent of units derived from propylene.

10. The polyolefin composition according to claim 8, wherein the first propylene-based elastomer comprises at least 85 wt% of units derived from propylene.

11. The polyolefin composition according to claim 8, wherein the first propylene-based elastomer comprises 5-20 wt.% of a propylene-based elastomer derived from one or more C2 or C4-C 12 α-olefin units.

12. The polyolefin composition according to claim 8, wherein the first propylene-based elastomer comprises 8-15 wt.% of a propylene-based elastomer derived from one or more C2 or C4-C 12 α-olefin units.

13. The polyolefin composition according to any one of claims 1 to 7, wherein the polyolefin composition comprises 18 to 28 wt% of the first propylene-based elastomer, based on the total weight of the polyolefin composition.

14. The polyolefin composition according to any one of claims 1 to 7, wherein the polyolefin composition comprises 2 to 6 wt% of the low viscosity second propylene-based elastomer, based on the total weight of the polyolefin composition.

15. The polyolefin composition according to any one of claims 1 to 7, wherein the polyolefin composition comprises 3 to 6 wt% of the low viscosity second propylene-based elastomer, based on the total weight of the polyolefin composition.

16. The polyolefin composition according to any one of claims 1 to 7, wherein the viscosity of the low-viscosity second propylene-based elastomer is 1000 to 1800 mPa·s, as measured at 190°C according to ASTM D1084-16.

17. The polyolefin composition according to claim 1, wherein the low viscosity second propylene-based elastomer comprises at least 80 wt% units derived from propylene and 3-20 wt% units derived from one or more C2 or C4-C 12 α-olefin units.

18. The polyolefin composition according to claim 17, wherein the low viscosity second propylene-based elastomer comprises at least 90 wt% of units derived from propylene.

19. The polyolefin composition according to claim 17, wherein the low viscosity second propylene-based elastomer comprises 4-10 wt.% derived from one or more C2 or C4-C 12 α-olefin units.

20. The polyolefin composition according to any one of claims 1 to 7, wherein the amount of the tackifier selected from alicyclic hydrogenated resins is 4 to 8 wt%, based on the total weight of the polyolefin composition.

21. The polyolefin composition according to any one of claims 1 to 7, wherein the particle size of the filler is 200-1000 mesh, and / or the amount of the filler is 55-75 wt%.

22. The polyolefin composition according to claim 21, wherein the filler has a particle size of 300-800 mesh.

23. The polyolefin composition according to any one of claims 1 to 7, wherein the polyolefin composition further comprises at least one compatibilizer.

24. The polyolefin composition according to claim 23, wherein the compatibilizer is a functionalized polyolefin.

25. The polyolefin composition according to claim 23, wherein the compatibilizer is a maleated polyolefin.

26. The polyolefin composition according to claim 23, wherein the amount of the compatibilizer is 0.5 to 8 wt%, based on the total weight of the polyolefin composition.

27. The polyolefin composition according to claim 23, wherein the amount of the compatibilizer is 1 to 5 wt%, based on the total weight of the polyolefin composition.

28. A polyolefin composition comprising: (i) 18 to 28 weight percent of at least one first propylene-based elastomer, wherein the first propylene-based elastomer has a melt flow rate of 35 to 60 g / 10 min, as measured in accordance with ASTM D1238 at 230° C. under a 2.16 kg load; the first propylene-based elastomer comprising at least 85 weight percent units derived from propylene and 8 to 15 weight percent units derived from ethylene; (ii) 3 to 6 weight percent of at least one low viscosity second propylene-based elastomer, wherein the viscosity of the low viscosity second propylene-based elastomer is 1000 to 1800 mPa·s, as measured at 190° C. in accordance with ASTM D1084-16, wherein the low viscosity second propylene-based elastomer comprises units derived from propylene and units derived from one or more C2 or C4-C 12 units of α-olefins; (iii) 4 to 8 wt% of at least one tackifier selected from alicyclic hydrogenated resins, wherein the alicyclic hydrogenated resin has a viscosity of 500 to 1500 mPa·s; (iv) 60-75% by weight calcium carbonate; and (v) 1-5 wt% of a compatibilizer, wherein the compatibilizer is a maleated polyolefin; In each case, based on the total weight of the polyolefin composition, The melt index of the polyolefin composition is 3.5-4.5 g / 10 min, and the melt index is measured according to ASTM D1238 under a load of 2.16 kg and at 190° C.

29. A carpet tile comprising the polyolefin composition according to any one of claims 1 to 28.

30. The carpet tile according to claim 29, wherein the polyolefin composition is used as a backing material.

31. The carpet tile according to claim 30, wherein the polyolefin composition is formed into a backing material by extrusion.

32. The carpet tile according to claim 31, wherein the extrusion process is carried out at a temperature of 170-230°C.

33. The carpet tile according to claim 31, wherein the extrusion process is carried out at a temperature of 185-225°C.

34. The carpet tile according to claim 31, wherein the extrusion process is carried out at a temperature of 200-220°C.

35. A method of preparing a carpet tile comprising using a polyolefin composition according to any one of claims 1 to 28 as a backing material.

36. The method according to claim 35, wherein the polyolefin composition is processed by extrusion to form a backing material.

37. A method according to claim 36, wherein the extrusion process is carried out at a temperature of 170-230°C.

38. The method according to claim 36, wherein the extrusion process is carried out at a temperature of 185-225°C.

39. The method according to claim 36, wherein the extrusion process is carried out at a temperature of 200-220°C.

40. The method of claim 35, wherein said method includes the step of laminating said backing material to an upper carpet surface and a lower base layer.

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