Impact modifier composition and application thereof

Abstract

The present invention discloses an impact modifier composition (IMC) comprising a polyolefin plastomer (POP) and a hydrogenated styrenic block copolymer (HSBC) represented by a general configuration selected from the group consisting of S-S / EB, S-S / EB', S-S / EB-EB', S-S / EB'-EB, S-S / EB-S, S-S / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB-EB', S-EB'-EB, EB-S / EB-EB, EB-S / EB-EB'-EB, and mixtures thereof. Prior to hydrogenation, each block S is a polymer block of vinyl aromatic monomers, each block EB is a polybutadiene block of 1,3-butadiene monomers having a vinyl content of <35 wt%, each block EB' is a polybutadiene block of 1,3-butadiene monomers having a vinyl content of >35 wt%, each block EP is a polyisoprene block of isoprene monomers, and each block S / EB and S / EB' is independently a copolymer block of vinyl aromatic monomers and 1,3-butadiene monomers. IMC can be used in thermoplastic polyolefin (TPO) compositions to improve impact resistance in a variety of applications including automotive parts.

Description

Technical Field

[0001] The invention relates to an impact modifier composition, a preparation method thereof and application thereof. Background Art

[0002] Copolymers of ethylene and higher alpha-olefins are a class of vinyl polyolefins that have an inherent degree of crystallinity derived from the ethylene monomer. These copolymers are typically synthesized using metallocene-type catalysts. The higher alpha-olefin comonomers used in these copolymers can range from C 3 -C 20 , and helps to change the properties of the polymer. The addition of higher alpha olefins to the polymer chain generally results in a decrease in the crystallinity and density of the resulting polymer. Therefore, the density of the copolymer can vary significantly depending on the type and amount of comonomer introduced.

[0003] Polyolefin plastomers (POPs) with a density > 0.885 g / cc can be synthesized using a gas phase process and can be used as impact modifiers in polypropylene compositions due to their compatibility and good performance. However, even with the availability of suitable POPs, challenges remain in improving the impact resistance of polypropylene compositions while maintaining a balance with other desired mechanical properties such as stiffness and flexibility.

[0004] There remains a need for an impact modifier composition for polypropylene compositions to provide a good balance of impact resistance and other mechanical properties. SUMMARY OF THE INVENTION

[0006] In one aspect, the present invention relates to an impact modifier composition (IMC) comprising, consisting essentially of, or consisting of (a) 10-90 wt% of a polyolefin plastomer (POP) and (b) 10-90% of a hydrogenated styrenic block copolymer (HSBC) having a general configuration selected from the group consisting of SS / EB, SS / EB', SS / EB-EB', SS / EB'-EB, SS / EB-S, SS / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB', EB-S / EB'-EB, and mixtures thereof. The POP has a density of >0.885 g / cc as measured according to ASTM D792 and a melt flow rate of 0.1-30 dg / min as measured according to ASTM D1238 at 230°C and 2.16 kg load. Before hydrogenation, each block S is a polymer block of a vinyl aromatic monomer, each block EB is a polybutadiene block of a 1,3-butadiene monomer having a vinyl content of <35 wt%, each block EB' is a polybutadiene block of a 1,3-butadiene monomer having a vinyl content of >35 wt%, each block EP is a polyisoprene block of an isoprene monomer, and each block S / EB and S / EB' is independently a copolymer block of a vinyl aromatic monomer and a 1,3-butadiene monomer. The polystyrene content of the HSBC is 3-40 wt%.

[0007] In a second aspect, the POP has <15 LCB / 10 6 Long chain branching (LCB) of one carbon.

[0008] In a third aspect, the molecular weight (Mp) of block S is 2-40 kg / mol.

[0009] In a fourth aspect, each block EB and EB' has a molecular weight (Mp) independently of 5-50 kg / mol, each block EP has a molecular weight (Mp) independently of 20-100 kg / mol, and each block S / EB and S / EB' has a molecular weight (Mp) independently of 20-100 kg / mol. DETAILED DESCRIPTION OF THE INVENTION

[0011] The following terms will be used throughout this specification.

[0012] “Consisting essentially of…” means that the claimed composition mainly contains the specified material substances, and is allowed to contain additional components that do not materially affect the novel characteristics or functions of the claimed invention. If present, the content of the additional components is <30%, or <20%, or <10%.

[0013] "At least one of A, B, and C" or "any one of [A, B, and C]" refers to a single member, more than one member, or a combination of members. For example, at least one of A, B, and C includes, for example, only A, only B, or only C, as well as A and B, A and C, B and C, or A, B and C, or any other combination of A, B, and C. In other examples, at least one of A and B refers to only A, only B, and A and B.

[0014] Embodiments presented as "A, B, or C" should be interpreted to include only A, only B, only C, "A or B", "A or C", "B or C", or "A, B, or C".

[0015] "Any one of A, B or C" means one option among A, B or C.

[0016] "Any one of A, B and C" means one or more options among A, B and C.

[0017] The "polystyrene content" or PSC of a block copolymer refers to the weight percent of polymerized vinyl aromatic monomer (e.g., styrene) in the block copolymer, calculated by dividing the sum of the molecular weights of all vinyl aromatic units by the total molecular weight of the block copolymer. PSC can be determined using any suitable method, such as proton nuclear magnetic resonance (NMR).

[0018] "Vinyl content" refers to the content of conjugated diene monomers polymerized by 1,2-addition in the case of butadiene or by 3,4-addition in the case of isoprene (thereby producing a monosubstituted olefin or vinyl group adjacent to the polymer backbone). Vinyl content can be measured by proton nuclear magnetic resonance (NMR).

[0019] "Molecular weight" or Mw refers to the polystyrene equivalent molecular weight of a polymer block or block copolymer, in kg / mol. Mw can be determined by gel permeation chromatography (GPC) using polystyrene calibration standards, for example, according to ASTM5296-19. The GPC detector can be an ultraviolet or refractive index detector or a combination thereof. The chromatograph is calibrated using commercially available polystyrene molecular weight standards. The Mw of a polymer determined using a GPC so calibrated is the polystyrene equivalent molecular weight or apparent molecular weight. The Mw shown herein is measured at the peak of the GPC trace, commonly referred to as the polystyrene equivalent "peak molecular weight", expressed as M p。

[0020] "Long chain branching" or LCB refers to the presence of extended side chains or branches along the polymer backbone, expressed as 10 6 The number of LCBs per carbon, LCB / 10 6Carbon, measured using GPC and / or NMR techniques.

[0021] "Short chain branching" or SCB refers to the presence of shorter side chains or branches attached to the polymer backbone. These branches consist of a smaller number of repeating units compared to the polymer backbone. SCB occurs when a comonomer (e.g., 1-butene) is copolymerized with a primary olefin monomer (e.g., ethylene). The comonomer units disrupt the regularity of the polymer backbone, introducing branches at relatively regular intervals. The main difference between LCB and SCB is that in LCB, the long chain branches consist of multiple repeating units and are relatively long, such as more than tens (>36) to thousands of repeating units in length. Here, several means "3" as a unit. In contrast, in SCB, the short chain branches are shorter in length or have a smaller number of repeating units, such as a few to tens, such as 2, 5, 10, 20, 30, <36 repeating units. SCB can be measured using the GPC-IR method.

[0022] The present invention relates to an impact modifier composition (IMC) consisting essentially of a hydrogenated styrenic block copolymer (HSBC) and a polyolefin plastomer (POP). The IMC can be used in a thermoplastic polyolefin (TPO) composition to improve impact resistance and balance transparency, high stiffness, tensile strength and flow properties. The TPO composition can be used in applications including automotive parts.

[0023] Hydrogenated styrenic block copolymer (HSBC): The general configuration of HSBC is selected from SS / EB, SS / EB', SS / EB-EB', SS / EB'-EB, SS / EB-S, SS / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB', EB-S / EB'-EB, and mixtures thereof. HSBC is formed by hydrogenating a styrenic block copolymer (SBC) precursor, which is any of a linear, branched or radial block copolymer.

[0024] Before hydrogenation, block S is a polymer block of vinyl aromatic monomers, block EB is a polybutadiene block of 1,3-butadiene monomers, block EB' is a polybutadiene block of 1,3-butadiene monomers and is different from block EB, block EP is a polyisoprene block of isoprene monomers, and each copolymer block S / EB and S / EB' is independently derived from vinyl aromatic monomers and 1,3-butadiene monomers. After hydrogenation, each block EB, EB' and EP independently becomes ethylene / butylene (EB), ethylene / butane (EB') and ethylene / propylene (EP), respectively. The vinyl aromatic monomers can be introduced or copolymerized into blocks EB, EB' and EP in any order and any distribution to form any of the configurations described.

[0025] In some embodiments, the vinyl aromatic monomer is selected from styrene, α-methylstyrene, methylstyrene, p-methylstyrene, p-ethylstyrene, p-n-propylstyrene, p-isopropylstyrene, p-n-butylstyrene, p-sec-butylstyrene, p-isobutylstyrene, p-tert-butylstyrene, o-substituted styrene, m-substituted styrene, isomers of p-decylstyrene, isomers of p-dodecylstyrene, dimethylstyrene, halogenated styrene, methoxystyrene, acetoxystyrene, vinyltoluene, isomers of vinyltoluene, vinylxylene, 4-vinylbiphenyl, vinylnaphthalene, vinylanthracene, 1,1-diphenylethylene, and mixtures thereof.

[0026] In some embodiments, block EB comprises 65-85, or 65-80, or 65-75, or 70-85 wt % of 1,3-butadiene monomer introduced via 1,4-addition, based on the total weight of polymerized 1,3-butadiene monomer in block EB, with the remainder being 1,3-butadiene monomer introduced via 1,2-addition.

[0027] In some embodiments where block EB' is present, block EB' contains 40-80, or 45-75, or 50-70, or 55-65 wt % 1,3-butadiene monomer introduced via 1,2-addition, based on the total weight of polymerized 1,3-butadiene monomer in block EB', with the remainder being 1,3-butadiene monomer introduced via 1,4-addition.

[0028] In some embodiments, the vinyl content of block EB before hydrogenation is <35, or >10, or 5-35, or 10-30, or 15-35, or 15-30, or 17-27 wt % based on the total weight of polymerized 1,3-butadiene monomer in block EB.

[0029] In some embodiments, block EB' has a vinyl content of >35, or <70, or 35-70, or 38-65, or 35-60, or 37-55, or 35-50 wt% before hydrogenation based on the total weight of polymerized 1,3-butadiene monomer in block EB'.

[0030] In some embodiments, the ratio of the vinyl content of block EB to block EB′ is 1:10 to 10:1, or 1:8 to 8:1, or 1:5 to 5:1, or 1:3 to 3:1.

[0031] In some embodiments, block S, block S in S / EB, or block S in S / EB' independently has a hydrogenation level of <30%, or <20%, or <10%, or <5%, or >0.1%. In some embodiments, block EP, block EB, block EB', block EB in S / EB, and block EB' in S / EB' independently have a hydrogenation level of >90%, or >95%, or >98%, or >99%, or up to 100%. The hydrogenation level refers to the percentage of original unsaturated bonds that are saturated after hydrogenation, and can be determined using UV-VIS spectrophotometry and / or proton NMR and / or by ozonolysis titration.

[0032] In some embodiments, the polystyrene content (PSC) of the HSBC is 3-40, or 4-35, or 5-30, or 4-25, or 5-22, or >5, or <30 wt % based on the total weight of the HSBC.

[0033] In some embodiments, the coupling efficiency (CE) of the HSBC is >60%, or >65%, or >70%, or 60-90%, or 65-85%.

[0034] In some embodiments, the diblock content of the HSBC is >5, or >10, or 5-40, or 10-35 wt %, based on the total weight of the HSBC.

[0035] In some embodiments, the molecular weight (Mp) of block S is 2-40, or 3-30, or 4-20, or 5-15, or 3-15, or 3-12, or >2, or <20 kg / mol.

[0036] In some embodiments, each block EB and EB' independently has a molecular weight (Mp) of 5-50, or 10-40, or 15-35, or 5-35, or 15-30 kg / mol.

[0037] In some embodiments, the molecular weight (Mp) of block EP is 20-100, or 25-80, or 30-70, or 40-60, or 45-60, or 20-60, or 40-100 kg / mol.

[0038] In some embodiments, each block S / EB and S / EB' independently has a molecular weight (Mp) of 20-100, or 25-80, or 30-70, or 20-60, or 30-75, or 35-100, or 15-55 kg / mol.

[0039] In some embodiments, the molecular weight (Mp) of the HSBC is 30-300, or 40-250, or 50-200, or 30-150, or 35-120, or 40-100, or 50-110 kg / mol.

[0040] In some embodiments, the HSBC has a melt flow rate (MFR) of >0.5, or >1, or >3, or >5, or 0.5-50, or 1-40, or 2-35, or 3-30, or 4-25, or 1-15 dg / min, measured according to ASTM D1238 at 230°C and 2.16 kg load.

[0041] In some embodiments, the HSBC has a general configuration selected from S-EP-EB, EB-S / EB'-EB, and mixtures thereof, the vinyl content in the EB block before hydrogenation is 10-30 wt%, the vinyl content in the block EB' (if present) before hydrogenation is 35-50 wt%, the PSC is 4-25 wt%, the Mp of the block S (if present) is 3-15 kg / mol, the Mp of each block EB and EB' is independently 10-40 kg / mol, the Mp of the block S / EB' (if present) is 20-60 kg / mol, the Mp of the block EP (if present) is 40-60 kg / mol, the Mp of the block copolymer is 35-120 kg / mol, and the MFR at 230°C / 2.16 kg is 1-15 dg / min.

[0042] HSBC can be prepared by first preparing SBC precursors, as disclosed in U.S. Pat. No. 7,449,518. SBC precursors can be prepared by anionic polymerization or sequential (or continuous) polymerization at a temperature of -30 to 150°C, or 10-100°C, or 30-90°C. The polymerization reaction is carried out in an inert atmosphere (e.g., nitrogen), or at a pressure of 0.5-65 bar. Polymerization generally requires <12 hours, or 5 minutes to 5 hours, depending on factors including temperature, concentration of monomer components, desired molecular weight of the polymer, etc. The resulting sequential block copolymer chains can be coupled with a coupling agent, if present.

[0043] The SBC precursor is then hydrogenated using a hydrogenation process to obtain HSBC, as disclosed in US Pat. Nos. 3,670,054 and 3,700,633.

[0044] In some embodiments, the HSBC is functionalized with at least one functional group, such as hydroxyl, amino, carboxyl, anhydride, epoxy, isocyanate, silane, silanol, and the like.

[0045] In some embodiments, the amount of HSBC in the IMC is 10-90, or 20-80, or 30-70, or 40-60 wt % based on the total weight of the IMC.

[0046] Polyolefin plastomers (POPs): In some embodiments, POPs are prepared by using a metallocene-based catalyst to synthesize ethylene and at least one C 3 -C 20 Ethylene-α-olefin copolymers obtained by copolymerization of α-olefins. Based on the total weight of the POP, the POP contains> 50, or> 60, or> 70, or> 80, or> 90, or> 95 wt% ethylene. In some embodiments, the POP contains 65-95% ethylene and 5-35% linear α-olefins.

[0047] C 3 -C 20 Examples of the α-olefin include propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene and the like.

[0048] Examples of the POP include ethylene / propylene copolymers, ethylene / butene (EB) copolymers, ethylene / hexene-1 (EH) copolymers, ethyl / octene (EO) copolymers, ethylene / α-olefin / diene modified (EAODM) interpolymers (e.g., ethylene / propylene / diene modified (EPDM) copolymers, ethylene / propylene / octene terpolymers, etc.), etc. POP also includes C 4 -C 18 Diolefins and / or alkenylbenzenes.

[0049] In some embodiments, the POP has a density of >0.885, or >0.890, or 0.885-0.920, or 0.890-0.915, or 0.895-0.910, or 0.890-0.905 g / cc, or <0.920 g / cc as measured according to ASTM D792.

[0050] In some embodiments, the POP has a melt flow rate (MFR) of 0.1-30, or 0.5-25, or 0.8-20, or 0.5-10, or 1-15, or 0.5-5, or >0.5, or <15 dg / min, measured according to ASTM D1238 at 230°C and 2.16 kg load.

[0051] In some embodiments, the long chain branching (LCB) of the POP is <15, or <10, or <5, or <3, or <2, or <1, ​​or 0.01-10, or 0.05-5, or 0.1-3, or 0.01-2, or 0.05-1.9, or 0.1-1.8, or 0.5-2, or 0.7-1.7, or 0.01-0.5 LCB / 10 6 Carbon, measured according to the Janzen-Colby Plot method. The term "10 6 The "carbon" includes main chain and branch chain carbon.

[0052] In some embodiments, the POP is an ethylene-hexene copolymer comprising 65-95 wt% ethylene units and 5-35 wt% hexene units, and the POP has a density of 0.895-0.910 g / cc, an MFR of 0.5-5 dg / min, and a long chain branching of <2 LCB / 10 6 A carbon.

[0053] In some embodiments, the POP is prepared in a metallocene-catalyzed polymerization process (e.g., a gas phase polymerization process). As used herein, the terms "metallocene-catalyzed POP," "metallocene-produced POP," or "m-POP" refer to a POP having the density and MFI properties described herein and produced in the presence of a metallocene catalyst. The metallocene-catalyzed POP has measurable properties that are different from POPs produced with the same comonomers of the same weight percentage but by different processes (e.g., conventional Ziegler-Natta polymerization processes).

[0054] Gas phase polymerization refers to the polymerization of monomers in a fluidized bed. The POP can be formed by polymerizing alpha-olefins under reaction conditions in a gas phase reactor with a fluidized bed and a fluidizing medium in the presence of a metallocene catalyst. In some embodiments, the POP is obtained by polymerization in a single reactor. Various gas phase polymerization processes can be used, for example, polymerization can be carried out in non-condensing or "dry" mode, condensing mode or super condensing mode.

[0055] In a gas phase polymerization process, the reactor temperature may be 30-140°C, or 60-120°C, or 65-110°C, or 70-105°C, and the pressure 100-1000, or 150-600, or 200-500, or 250-400 psig.

[0056] A metallocene catalyst may be a compound having a Group 4, 5 or 6 transition metal (M), one or more cyclopentadienyl (Cp) ligands which may be substituted, at least one non-cyclopentadienyl derived ligand (X), and zero or one heteroatom-containing ligand (Y) coordinated to M in an amount corresponding to its valence. Metallocene catalysts / precursors generally require activation with a suitable cocatalyst (referred to as an "activator") to produce an "active metallocene catalyst," i.e., an organometallic complex with vacant coordination sites which can coordinate, insert and polymerize olefins.

[0057] In some embodiments, the POPs obtained by the gas phase polymerization process and the use of metallocene catalysts are characterized by a narrow composition distribution, which is related to the uniformity of the distribution of the comonomers in the polymer molecules. Metallocene catalysts are known to introduce comonomers very uniformly in the polymer molecules they produce. POPs produced by metallocene catalyst systems can have a very narrow composition distribution because most polymer molecules will have approximately the same comonomer content, and the comonomers will be randomly distributed within each molecule.

[0058] In some embodiments, the POP is used in an amount of 10-90, or 20-80, or 30-70, or 40-60 wt %, based on the total weight of the IMC.

[0059] Impact modifier compositions (IMCs): The IMCs contain 10-90 wt% HSBC and 10-90 wt% POP, and preferably 20-80 wt% HSBC and 20-80 wt% POP, based on the total weight of the IMC.

[0060] Preparation of IMC: IMC can be prepared by using appropriate amounts of each component and dry mixing, or dry mixing and melt extruding into granules. Dry mixing and / or melt mixing can be performed by a single screw or twin screw extruder.

[0061] In some embodiments, appropriate amounts of the components of the IMC are added directly to the thermoplastic polyolefin (TPO) composition without premixing.

[0062] Thermoplastic polyolefin (TPO) composition: In some embodiments, the TPO composition comprises: A) 60-95 wt% polypropylene, B) 5-40 wt% IMC, and C) up to 25 wt% of at least one additive; preferably, A) 60-85 wt% polypropylene, B) 15-40 wt% IMC, and C) 0.1-10 wt% of at least one additive, based on the total weight of the TPO composition.

[0063] In some embodiments, the IMC is used in the TPO composition in an amount of 5-40, or 10-30, or 5-35, or 10-35, or 15-40 wt % based on the total weight of the TPO composition.

[0064] Polypropylene (PP): The polypropylene used in the TPO composition can be any polypropylene polymer prepared by any method known in the art. Polypropylene can be obtained from virgin or recycled sources. In some embodiments, polypropylene blends are used in the TPO composition, such as blends of polypropylene with random ethylene or butene copolymers of polypropylene, or a combination of crystalline random copolymers of ethylene and propylene and rubbery ethylene-propylene copolymers. Polypropylene copolymers can be used, including copolymers of propylene with copolymerizable comonomers (e.g., ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, or one or more conjugated or non-conjugated dienes). The comonomer can be in the range of 0.05-40, or 0.5-30, or 1-20, or 5-30 wt%, based on the total weight of the polypropylene copolymer.

[0065] In some embodiments, the polypropylene is a heterophasic polymer composition comprising a propylene homopolymer matrix, or a random copolymer matrix, in which a propylene copolymer component containing one or more ethylene or higher α-olefin comonomers is dispersed. The random copolymer matrix comprises propylene monomers and at least one comonomer selected from ethylene, C 4 -C 8 α-Olefins (e.g., 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene), and mixtures thereof.

[0066] From the perspective of molecular weight, the polypropylene can be bimodal or multimodal. In some embodiments, the number average molecular weight (Mn) of the polypropylene is 10-200, or 30-150, or 50-100, or 30-120, or 40-140 kg / mol. In some embodiments, the weight average molecular weight (Mw) of the polypropylene is 50-2000, or 150-1500, or 200-1000, or 100-800, or 150-500, or 100-400 kg / mol.

[0067] In some embodiments, the polypropylene has a melting temperature (Tm) of 100-180°C, or 110-170°C, or 120-160°C, or 125-150°C, as measured by DSC according to ASTM D3418.

[0068] In some embodiments, the polypropylene has a crystallinity of 20-70%, or 25-65%, or 30-60%, or 35-55%, or >35%, or >40%, or >50%, as measured by differential scanning calorimetry (DSC) heat of melting according to ASTM F2625.

[0069] In some embodiments, the polypropylene has a melt flow rate (MFR) of 5-50, or 10-45, or 5-40, or 10-40 dg / min, measured according to ASTM D1238 at 230°C and 2.16 kg load.

[0070] In some embodiments, the polypropylene has a density of 0.890-0.920, or 0.895-0.915, or 0.895-0.910 g / cc as measured according to ASTM D792.

[0071] In some embodiments, the amount of polypropylene used in the TPO composition is 70-99, or 80-99, or 70-95, or 70-90, or 75-95 wt %, based on the total weight of the TPO composition.

[0072] Optional Additives: The TPO composition further comprises additives selected from the group consisting of activators, curing agents, stabilizers, neutralizers, thickeners, coalescing agents, slip agents, mold release agents, antimicrobial agents, antioxidants, antiozonants, color change pH indicators, plasticizers, tackifiers, film forming additives, dyes, pigments, UV stabilizers, UV absorbers, catalysts, fillers, other resins, redox pairs, fibers, flame retardants, viscosity modifiers, wetting agents, degassing agents, toughening agents, adhesion promoters, colorants, thermal stabilizers, lubricants, flow modifiers, drip agents, anti-blocking agents, antistatic agents, processing aids, stress relief additives, foaming agents, weld strength promoters, impact modifiers other than IMC, and mixtures thereof.

[0073] Examples of fillers include sand, talc, dolomite, calcium carbonate, clay, silica, mica, wollastonite, feldspar, aluminum silicate, aluminum oxide, hydrated aluminum oxide, glass beads, glass microspheres, ceramic microspheres, thermoplastic microspheres, barite, wood flour, glass fiber, wood fiber, carbon fiber, and mixtures thereof. The filler may be surface treated prior to addition to the TPO composition.

[0074] In some embodiments, impact modifiers other than IMC include ethylene-propylene-diene (EPDM) monomers, ethylene-propylene (EPM) monomers, ethylene-propylene rubber (EPR), elastomeric polyolefins (POE), ethylene and propylene based copolymers and terpolymers, nitrile rubber (NBR), isobutylene (IB), chlorinated rubber, chlorinated polyethylene (CM), isoprene, ethylene-butene, and mixtures and derivatives thereof.

[0075] In some embodiments, the amount of additive used in the TPO composition is up to 25 wt%, or <30, or 0.1-10, or 1-10, or 0.1-5, or 1-5 wt%, based on the total weight of the TPO composition.

[0076] Preparation of TPO composition: The TPO composition can be processed according to methods known in the art, wherein the components are combined and blended by melt mixing / extrusion into pellets and then formed into articles by known techniques (e.g., injection molding, overmolding, rotational molding, thermoforming, casting, extrusion, profile extrusion and blow molding).

[0077] The TPO composition can be compounded by equipment including a continuous single screw or twin screw mixer. In some embodiments, the TPO composition is prepared by a dry blending process to obtain a dry blended TPO composition.

[0078] The compounding temperature of the TPO composition can be 80-300°C, or 150-280°C, or 180-260°C, or 200-260°C. The components of the final TPO composition can be added and compounded with each other in any order or simultaneously. In some embodiments, the additives are added in the form of a premixed masterbatch. Such a masterbatch is typically formed by dispersing a small amount (e.g., >0.1 and <10 wt%) of additives alone or together.

[0079] Properties of TPO compositions: When HSBC is introduced into IMC as described above, the TPO composition with IMC is characterized by having excellent balanced properties such as flexibility, impact resistance, stiffness, transparency, tensile strength, fluidity, anisotropy, etc.

[0080] In some embodiments, the TPO composition has a notched Izod impact at 21°C of 6.5-50, or 6.6-45, or 6.7-40, or 6.5-35, or >6.5 kJ / m 2 In some embodiments, the TPO composition has a notched Izod impact at -21°C of 2.2-20, or 2.4-15, or 2.4-10, or >2.2, or >2.4 kJ / m 2 . Measured according to ASTM D256.

[0081] In some embodiments, the TPO composition has a flexural strength of 25-50, or 28-45, or 30-40, or 25-40, or 30-45, or >25 MPa, as measured according to ASTM D790.

[0082] In some embodiments, the TPO composition has a 1% secant modulus of 1050-1600, or 1060-1550, or 1070-1500, or 1050-1400, or >1050 MPa, as measured according to ASTM D790.

[0083] In some embodiments, the TPO composition has a tensile strength at break of 10-40, or 12-35, or 10-30, or 11-25, or >10 MPa, as measured according to ASTM D638.

[0084] In some embodiments, the TPO composition has an elongation at break of 350-800%, or 360-770%, or 370-750%, or >350%, as measured according to ASTM D638.

[0085] In some embodiments, the TPO composition has at least one of the following balanced properties compared to a TPO composition without the IMC:

[0086] The elongation at break increases by at least 10%, and the notched Izod impact at 21°C increases by at least 2%; or

[0087] The elongation at break increases by at least 10%, and the notched Izod impact at -21°C increases by at least 2%; or

[0088] The elongation at break increases by at least 10%, and the flexural strength decreases by less than 20%; or

[0089] The elongation at break increases by at least 10%, and the 1% secant modulus decreases by less than 20%.

[0090] Application of TPO composition: The TPO composition can be used to manufacture various articles by injection blow molding, injection molding, extrusion blow molding, coextrusion molding, cast film extrusion, blown film extrusion, injection stretch blow molding, rotational molding, thermoforming, hot melt, foam blow molding, pultrusion, calendering, additive manufacturing or other known processing methods.

[0091] The TPO compositions can be used in pipes, packaging applications, films, geomembranes, roofing applications, pond liners, covers and closures, and core layers of multilayer polyolefin sheets or films, containers and household goods, medical moldings and covers. The TPO compositions can be used in automotive applications such as interior trim, inner sheathing, door panels, instrument panels, fascias, lift gates and consoles.

[0092] Hollow articles can be formed from the TPO composition by continuous extrusion blow molding or intermittent extrusion blow molding. In some embodiments, hollow articles include bottles, containers, fuel tanks, barrels, etc. Other molded products include furniture, signs, wheels, toys, garden products, etc.

[0093] In some embodiments, the TPO composition is used to prepare textile fibers, which are then used to form spunbond fibers, staple fibers, multi-fiber yarns, knitted fabrics, woven fabrics, or nonwoven fabrics. Example

[0094] The following examples are non-limiting.

[0095] The components used in the examples include:

[0096] PP-1 is a polypropylene homopolymer with an MFR of 20 dg / min at 230°C / 2.16 kg and a density of 0.900 g / cc from Borealis.

[0097] POP-1 is an ethylene-hexene copolymer with a density of 0.900 g / cc, an MFR of 2.0 dg / min at 230°C / 2.16 kg, and a long chain branching of 0.01 LCB / 10 6 A carbon.

[0098] Table 1 provides composition details of various HSBCs.

[0099]

[0100]

[0101]

[0102]

[0103] The term "comprising / including" as used herein means including the elements or steps identified after the term, but any such elements or steps are not exhaustive, and embodiments may include other elements or steps. Although the terms "comprising" and "including" are used herein to describe various aspects, the terms "consisting essentially of" and "hosted by" may replace "comprising" and "including" to provide more specific aspects of the present disclosure, and these aspects are also disclosed.

Claims

1. An impact modifier composition, which consists essentially of the following components: (a) 10-90 wt% of a polyolefin plastomer having a density of >0.885 g / cc as measured according to ASTM D792 and a melt flow rate of 0.1-30 dg / min as measured at 230°C and 2.16 kg load as measured according to ASTM D1238; and (b) 10 to 90 weight percent of a hydrogenated styrenic block copolymer having a general configuration selected from the group consisting of SS / EB, SS / EB', SS / EB-EB', SS / EB'-EB, SS / EB-S, SS / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB-EB, EB'-S / EB-EB', EB-S / EB'-EB, and mixtures thereof, Wherein before hydrogenation: Each block S is a polymer block of a vinyl aromatic monomer, Each block EB is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of <35 wt%, Each block EB' is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of >35 wt%, Each block EP is a polyisoprene block of isoprene monomer, and Each block S / EB and S / EB' is independently a copolymer block of a vinyl aromatic monomer and a 1,3-butadiene monomer, The hydrogenated styrenic block copolymer has a polystyrene content of 3-40 wt%.

2. The impact modifier composition according to claim 1, wherein the polyolefin plastomer has a thermal conductivity of <15 LCB / 10 6 Long chain branching of carbon atoms.

3. The impact modifier composition according to claim 1, wherein the molecular weight Mp of block S is 2-40 kg / mol.

4. The impact modifier composition according to any one of claims 1 to 3, wherein: The molecular weight Mp of each block EB and EB' is independently 5-50 kg / mol, The molecular weight Mp of each block EP is 20-100 kg / mol, and The molecular weight Mp of each block S / EB and S / EB' is independently 20-100 kg / mol.

5. The impact modifier composition according to any one of claims 1 to 3, wherein the vinyl content ratio of block EB to block EB' is 1:10 to 10:

1.

6. The impact modifier composition according to any one of claims 1 to 3, wherein: Before hydrogenation, the vinyl content of the block EB is 5-35 wt%, and Prior to hydrogenation, the vinyl content of block EB' is 35-70 wt%.

7. The impact modifier composition according to any one of claims 1 to 3, wherein the hydrogenated styrenic block copolymer has at least one of the following properties: Polystyrene content is 5-30wt%, The molecular weight Mp is 30-300 kg / mol, and The melt flow rate measured according to ASTM D1238 at 230°C and 2.16 kg load is >0.5 dg / min.

8. The impact modifier composition according to any one of claims 1 to 3, wherein the hydrogenated styrenic block copolymer has a general configuration selected from S-EP-EB, EB-S / EB'-EB, and mixtures thereof, and has the following properties: Before hydrogenation, the vinyl content in the block EB is 10-30 wt%, Before hydrogenation, the vinyl content in block EB' is 35-50 wt%, Polystyrene content is 4-25wt%, The molecular weight Mp of block S is 3-15 kg / mol, The molecular weight Mp of each block EB and EB' is independently 10-40 kg / mol, The molecular weight Mp of the block S / EB' is 20-60 kg / mol, The molecular weight Mp of the block EP is 40-60 kg / mol, and The molecular weight Mp of the hydrogenated styrene block copolymer is 35-120 kg / mol.

9. The impact modifier composition according to any one of claims 1 to 3, wherein the polyolefin plastomer is ethylene and at least one C3-C 20 The copolymer of α-olefin, and the polyolefin plastomer has at least one of the following properties: Density of 0.885-0.920 g / cc, and The melt flow rate at 230°C and 2.16 kg load is 0.5-25 dg / min.

10. The impact modifier composition according to any one of claims 1 to 3, wherein the polyolefin plastomer is an ethylene-hexene copolymer comprising 65-95 wt% ethylene units and 5-35 wt% hexene units; and the polyolefin plastomer has a density of 0.895-0.910 g / cc, an MFR of 0.5-5 dg / min at 230° C. and 2.16 kg load, and a long chain branching of <2 LCB / 10 6 A carbon.

11. A thermoplastic polyolefin composition, comprising, based on the total weight of the thermoplastic olefin composition: (A) 60-95 wt% of polypropylene, (B) 5-40 wt% of the impact modifier composition of any one of claims 1-10, and (C) up to 20 wt% of at least one additive.

12. The thermoplastic polyolefin composition of claim 11, wherein the thermoplastic olefin composition has the following properties when compared to a thermoplastic polyolefin composition in the absence of the impact modifier composition of any one of claims 1-10: The elongation at break increases by at least 10%, and the notched Izod impact measured at 21°C increases by at least 2%; or An increase of at least 10% in elongation at break and at least 2% in notched Izod impact measured at -21°C; or The elongation at break increases by at least 10%, and the flexural strength decreases by less than 20%; or The elongation at break increases by at least 10%, and the 1% secant modulus decreases by less than 20%; The elongation at break is measured according to ASTM D638, the notched Izod impact is measured according to ASTM D256, and the flexural strength and 1% secant modulus are both measured according to ASTM D790.

13. The thermoplastic polyolefin composition according to any one of claims 11-12, wherein the polypropylene has at least one of the following properties: The melt flow rate MFR at 230°C and 2.16 kg load is 5-50 dg / min, and The density is 0.890-0.920g / cc.

14. The thermoplastic polyolefin composition according to any one of claims 11-12, wherein the thermoplastic olefin composition has the following properties: Notched Izod impact at 21°C >6.5 kJ / m 2 ,and Notched Izod impact at -21°C >2.2 kJ / m 2 , measured according to ASTM D256.

15. The thermoplastic polyolefin composition according to any one of claims 11-12, wherein the thermoplastic polyolefin composition has the following properties: Bending strength>25MPa, 1% secant modulus is >1050MPa, Tensile strength at break >10MPa, and Elongation at break>350%; The flexural strength and 1% secant modulus are measured according to ASTM D790, and the tensile strength at break and elongation at break are measured according to ASTM D638.

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