Thermoplastic polyolefin composition with reactive compatibilization

Abstract

The present disclosure provides a composition. In one embodiment, the composition comprises (A) a non-functionalized propylene-based polymer; (B) a functionalized propylene-based polymer; and (C) a functionalized ethylene-based polymer. The functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have a different functional group selected from the group consisting of maleic anhydride and epoxide.

Description

Background Art

[0001] Polyolefin elastomers (POEs), including ethylene / α-olefin copolymers, are commonly used as impact modifiers for thermoplastic polyolefin (TPO) compounds. When blended with polypropylene, other additives, and optionally reinforcing fillers such as talc, POEs can be applied to provide a balance of stiffness, impact toughness, and flow properties to TPOs.

[0002] The art recognizes a continuing need for blends that achieve greater impact efficiency and improved stiffness-toughness-flow balance in TPO compounds containing polypropylene.Further, the art recognizes a continuing need for TPO compounds having an improved stiffness-toughness-flow balance. Summary of the Invention

[0003] The present disclosure provides a composition. In one embodiment, the composition comprises (A) a non-functionalized propylene-based polymer; (B) a functionalized propylene-based polymer; and (C) a functionalized ethylene-based polymer. The functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have a different functional group selected from the group consisting of maleic anhydride and epoxide.

[0004] definition

[0005] Any reference to the Periodic Table of the Elements is to the Periodic Table as published by CRC Press, Inc., 1990-1991. Groups of elements in this table are referred to by a new notation for numbering the groups.

[0006] For purposes of U.S. patent practice, the contents of any cited patent, patent application, or publication are incorporated by reference in their entirety (or their equivalent U.S. versions are so incorporated by reference), particularly with respect to definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and common general knowledge in the art.

[0007] The numerical ranges disclosed herein include all values from the lower limit to the upper limit, and include the lower limit and the upper limit. For ranges containing exact values (e.g., 1 or 2, or 3 to 5, or 6, or 7), any subrange between any two exact values is included (e.g., the above range 1 to 7 includes subranges of 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6, etc.).

[0008] Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percentages are based on weight, and all test methods are current as of the filing date of this disclosure.

[0009] The term "composition" refers to a mixture of materials comprising the composition, as well as reaction products and decomposition products formed from the materials of the composition.

[0010] The terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional components, steps, or procedures, whether or not these components, steps, or procedures are specifically disclosed. For the avoidance of any doubt, all compositions claimed through use of the term "comprising" may include any additional additives, adjuvants, or compounds, whether polymeric or otherwise, unless stated to the contrary. Conversely, the term "consisting essentially of excludes any other components, steps, or procedures (except those that are not essential to operability) from the scope of any subsequently stated content. The term "consisting of excludes any component, step, or procedure that is not specifically described or listed. Unless otherwise stated, the term "or" refers to the listed members individually and in any combination. The use of the singular includes the use of the plural, and vice versa.

[0011] An "ethylene-based polymer" or "ethylene polymer" is a polymer that contains a majority amount of polymerized ethylene, based on the weight of the polymer, and optionally may contain at least one comonomer. Ethylene-based polymers typically contain at least 50 mole percent (mol%) units derived from ethylene (based on the total amount of polymerizable monomers).

[0012] A "heteroatom" is an atom other than carbon or hydrogen. A heteroatom can be a non-carbon atom from Groups IV, V, VI, and VII of the periodic table. Non-limiting examples of heteroatoms include: F, Cl, N, O, P, B, S, and Si.

[0013] A "hydrocarbon" is a compound containing only hydrogen and carbon atoms. A "hydrocarbyl group" is a hydrocarbon with a valence (usually monovalent).

[0014] "Interpolymers" are polymers prepared by polymerizing at least two different types of monomers. The generic term interpolymer thus includes copolymers (employed to refer to polymers prepared from two different types of monomers) and polymers prepared from more than two different types of monomers.

[0015] An "olefin-based polymer" or "polyolefin" is a polymer that contains a majority mole % of polymerized olefin monomer (based on the total amount of polymerizable monomers) and optionally may contain at least one comonomer. Non-limiting examples of olefinic polymers include ethylene-based polymers and propylene-based polymers. Representative polyolefins include polyethylene, polypropylene, polybutene, polyisoprene, and various interpolymers thereof.

[0016] "Polymer" is a polymeric compound prepared by polymerizing monomers (whether of the same type or different types). Therefore, the general term polymer encompasses the term "homopolymer" (used to refer to polymers prepared from only one type of monomer, it being understood that trace impurities may be incorporated into the polymer structure) and the term "interpolymer" as defined below. Trace impurities (e.g., catalyst residues) may be incorporated into and / or within the polymer. It also encompasses all forms of copolymers, such as random copolymers, block copolymers, etc. The terms "ethylene / α-olefin polymer" and "propylene / α-olefin polymer" refer to copolymers prepared by polymerizing ethylene or propylene and one or more other polymerizable α-olefin monomers, as described above. It should be noted that although polymers are generally referred to as "made from" one or more specified monomers, "based on" a specified monomer or monomer type, "containing" a specified monomer content, etc., in this context, the term "monomer" is understood to refer to the polymerized residue of a specified monomer rather than an unpolymerized substance. Generally speaking, polymers are referred to herein as "units" based on the polymerized form of the corresponding monomer.

[0017] A "propylene-based polymer" is a polymer that contains a majority amount of polymerized propylene, based on the weight of the polymer, and optionally may include at least one comonomer. Propylene-based polymers typically contain at least 50 mole percent (mol%) units derived from propylene (based on the total amount of polymerizable monomers).

[0018] Test Method

[0019] Density is measured according to ASTM D792, Method B (g / cc or g / cm 3 ).

[0020] Differential scanning calorimetry (DSC) can be used to measure the melting, crystallization, and glass transition behavior of polymers over a wide temperature range. For example, a TA Instruments Discovery DSC equipped with a refrigerated cooling system (RCS) and an autosampler is used for this analysis. During the test, a nitrogen purge gas flow of 50 ml / min is used. Each sample is melt pressed into a film at 190°C; the molten sample is then air cooled to room temperature (25°C). A 3–10 mg, 6 mm diameter sample is extracted from the cooled polymer, weighed, placed in a light aluminum pan (approximately 50 mg), and crimped closed. It is then analyzed to determine its thermal properties.

[0021] The thermal properties of the sample are determined by ramping the sample temperature up and down to produce a heat flow versus temperature curve. First, the sample is rapidly heated to 180°C and held isothermally for 3 minutes to remove its thermal history. Next, the sample is cooled to -80°C at a cooling rate of 10°C / minute and held isothermally at -80°C for 3 minutes. The sample is then heated to 180°C at a heating rate of 10°C / minute (this is the "second heating" ramp). The cooling curve and the second heating curve are recorded. The value determined is the peak melting temperature T m and peak crystallization temperature T c Heat of fusion (H) for polyethylene samples f ) (in joules per gram) and calculated percent crystallinity using the following equation: % Crystallinity = ((H f ) / 292J / g)×100.

[0022] The heat of fusion (H) is reported from the second heating curve. f ) and the peak melting temperature. The peak crystallization temperature is determined from the cooling curve.

[0023] Glass transition temperature T g The heat capacity is determined from a DSC heating curve in which half of the sample has reached liquid form, as described in Bernhard Wunderlich, The Basis of Thermal Analysis, in Thermal Characterization of Polymeric Materials 92, 278–279 (Edith A. Turi, ed., 2nd ed., 1997). Baselines are drawn from above and below the glass transition region and are expressed by T g The temperature at which the sample heat capacity is midway between these baselines is T g .

[0024] Dynamic Mechanical Spectroscopy (DMS). The rheological properties of each composition were analyzed by DMS using an Advanced Rheometric Expansion System (ARES) equipped with a "25 mm stainless steel parallel plate" under nitrogen purge. Constant temperature dynamic frequency sweeps were performed at 230°C under nitrogen in the range of 0.1 rad / s to 100 rad / s. Samples of approximately "25 mm diameter × 3.3 mm thickness" were cut from compression molded discs (see below). The sample was placed on the lower plate and allowed to melt for five minutes. The plate was then closed to a gap of "2.0 mm" and the sample was trimmed to a diameter of "25 mm". Before starting the test, the sample was equilibrated at 230°C for five minutes. Complex viscosity was measured at a constant strain amplitude of 10%. The stress response is analyzed in terms of amplitude and phase, from which the storage modulus (G'), loss modulus (G"), dynamic viscosity η*, and tan delta can be calculated. Each compression-molded disk was formed in ambient atmosphere at 230°C and a molding pressure of 10 MPa for five minutes, and then quenched between cold press plates (15-20°C) for two minutes. The complex viscosity η* measured at a frequency of 0.1 rad / s is reported as V0.1. The complex viscosity η* measured at a frequency of 100 rad / s is reported as V100. The rheological ratio RR is calculated as the ratio of V0.1 / V100. The tan delta measured at a frequency of 0.1 rad / s is reported as tan δ.

[0025] Unless otherwise indicated, melt flow rate (MFR) of propylene-based polymers is measured according to ASTM D 1238, Condition 230°C / 2.16 kilogram (kg) weight.

[0026] The melt index (MI) of ethylene-based polymers is measured according to ASTM D1238, Condition 190°C / 2.16 kilogram (kg) weight, also known as 12, and is reported in g / 10 min.

[0027] Notched Izod Impact Strength. Notched Izod impact testing was performed according to ASTM D256, Method A. Specimens (2.5 inches long x 0.5 inches wide x 0.125 inches thick) were cut from compression molded plaques. The samples were conditioned at 23 + / - 2°C and 50 + / - 10% relative humidity for at least 40 hours. The test was conducted at 23°C. The values were expressed in kilojoules per square meter (kJ / m 2 ) The impact strength reported is the average of the results from three samples.

[0028] Tensile Testing. Tensile testing was performed using 3.2 mm thick microtensile bars cut from compression molded plaques according to ASTM D 1708. The tensile modulus (2% secant modulus) (reported in MPa) and the tensile strain at break (reported in percent, %) were reported as the average of five specimens. DETAILED DESCRIPTION

[0029] The present disclosure provides a composition. In one embodiment, the composition comprises (A) a non-functionalized propylene-based polymer; (B) a functionalized propylene-based polymer; and (C) a functionalized ethylene-based polymer. The functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have different functional groups. The functional group of each of the functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) is selected from groups that can react with each other to form a covalent bond between the functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C). The functional group of each of the functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) is selected from the group consisting of anhydrides and epoxides.

[0030] A. Non-functionalized propylene-based polymers

[0031] The composition contains a non-functionalized propylene-based polymer. As used herein, a "non-functionalized propylene-based polymer" is a propylene-based polymer that contains non-functional groups, such that the non-functionalized propylene-based polymer is a hydrocarbon and does not contain heteroatoms. Non-limiting examples of propylene-based polymers include propylene homopolymers, propylene / α-olefin terpolymers, propylene / α-olefin copolymers, propylene impact copolymers, and combinations thereof.

[0032] In one embodiment, the non-functionalized propylene-based polymer is a propylene homopolymer. The propylene homopolymer has one, some, or all of the following characteristics:

[0033] (i) a density of 0.89 g / cc to 0.91 g / cc, or 0.90 g / cc; and / or

[0034] (ii) an MFR of 0.1 g / 10 min to 500 g / 10 min, or 1 g / 10 min to 150 g / 10 min, or 10 g / 10 min to 120 g / 10 min, or 10 g / 10 min to 40 g / 10 min.

[0035] In one embodiment, the propylene-based polymer is a propylene / α-olefin copolymer. Non-limiting examples of suitable α-olefins include C2 and C4-C 20 α-olefins, or C4-C 10α-olefins, or C4-C8 α-olefins. Representative α-olefins include ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.

[0036] In one embodiment, the propylene-based polymer is a propylene impact copolymer. The propylene impact copolymer is a heterogeneous polymer in which the rubber phase (or discontinuous phase) of the discrete domains of the ethylene / propylene copolymer is dispersed in the entire matrix phase (or continuous phase) of the propylene homopolymer. Based on the gross weight of the propylene impact copolymer, the propylene impact copolymer contains 1 wt % to 40 wt %, or 5 wt % to 25 wt %, or 8 wt % to 15 wt % ethylene / propylene rubber phase.

[0037] In one embodiment, the propylene impact copolymer has one, some, or all of the following properties:

[0038] (i) 1 wt% to 40 wt%, or 5 wt% to 25 wt%, or 8 wt% to 15 wt% ethylene / propylene rubber phase; and / or

[0039] (ii) a density of 0.88 g / cc to 0.90 g / cc; and / or

[0040] (iii) an MFR of 0.1 g / 10 min to 500 g / 10 min, or 1 g / 10 min to 150 g / 10 min, or 10 g / 10 min to 40 g / 10 min.

[0041] B. Epoxide-functionalized polymers

[0042] The composition of the present invention comprises (B) a functionalized propylene-based polymer; and (C) a functionalized ethylene-based polymer. The functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have a corresponding functional group selected from anhydrides and epoxides. The functional group of the functionalized propylene-based polymer (B) is different from the functional group of the functionalized ethylene-based polymer (C). The functional group of each of the functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) is selected from two functional groups, namely anhydrides and epoxides. When the functional group of the functionalized propylene-based polymer (B) is anhydride, the functional group of the functionalized ethylene-based polymer (C) is epoxide. When the functional group of the functionalized propylene-based polymer (B) is epoxide, the functional group of the functionalized ethylene-based polymer (C) is anhydride. In this way, the functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have "different" functional groups, wherein the functional groups of the functionalized propylene-based polymer are capable of reacting with the functional groups of the functionalized ethylene-based polymer to form a covalent bond between the functionalized propylene-based polymer and the functionalized ethylene-based polymer.

[0043] The compositions of the present invention include epoxide-functionalized propylene-based polymers or epoxide-functionalized ethylene-based polymers (collectively referred to as "epoxide-functionalized olefin-based polymers"). In one embodiment, the epoxide-functionalized olefin-based polymer is prepared by melt blending an ethylene-SiH polymer or a propylene-SiH polymer (interchangeably referred to as "olefin-SiH polymers") with a monovinyl epoxide component in the presence of a hydrosilylation catalyst.

[0044] The olefin-SiH polymer is an ethylene-SiH polymer (an ethylene-based polymer) or a propylene-SiH polymer (a propylene-based polymer). As used herein, an "ethylene-SiH polymer" is composed of (1) ethylene monomer, (2) 0.1 wt% to 3.9 wt% SiH comonomer, and (3) an optional C3 α-olefin (propylene) or an optional C4-C8 α-olefin termonomer. As used herein, a "propylene-SiH polymer" is composed of (1) propylene monomer, (2) 0.1 wt% to 3.9 wt% SiH comonomer, and (3) an optional C2 α-olefin (ethylene) or an optional C4-C8 α-olefin termonomer.

[0045] As used herein, a "SiH comonomer" (interchangeably referred to as "SiH") is a silane monomer of Formula 1:

[0046] (Formula 1)

[0047] A-(SiBC-O) x-Si-EFH

[0048] wherein A is an alkenyl group,

[0049] B is a hydrocarbon group or hydrogen,

[0050] C is a hydrocarbyl group or hydrogen, and

[0051] wherein B and C may be the same or different, and further B is a hydrocarbyl group, C is a hydrocarbyl group, and further B and C are the same;

[0052] H is hydrogen, and x ≥ 0;

[0053] E is a hydrocarbyl group or hydrogen,

[0054] F is a hydrocarbyl group or hydrogen, and E and F may be the same or different. When E is a hydrocarbyl group, F is a hydrocarbyl group, and E and F may be the same hydrocarbyl group. Non-limiting examples of suitable SiH comonomers of Formula 1 include compounds (having the structures shown below) s1) (allyldimethylsilane), s2) (propylenedimethylsilane), s3) (butenyldimethylsilane), s4) (hexenyldimethylsilane), s5) (octenyldimethylsilane), s6) (decenyldimethylsilane), s7) norbornenylethyldimethylsilane, s8) octahydrodimethylenenaphthylethyldimethylsilane, s9) vinyltetramethyldisiloxane, s10) allyltetramethyldisiloxane, s11) butenyltetramethyldisiloxane, s12) hexenyltetramethyldisiloxane, s13) octenyltetramethyldisiloxane, s14) decenyltetramethyldisiloxane, s15) norbornenylethyltetramethyldisiloxane, s16) octahydrodimethylenenaphthylethyltetramethyldisiloxane, specifically as follows:

[0055]

[0056]

[0057] In one embodiment, the SiH comonomer is selected from allyldimethylsilane, hexenyldimethylsilane, octenyldimethylsilane, and hexenyltetramethyldisiloxane.

[0058] In one embodiment, the ethylene-SiH polymer is an ethylene / α-olefin / SiH terpolymer. The α-olefin in the ethylene / α-olefin / SiH comonomer terpolymer can be C3-C 12α-olefins or C4-C8 α-olefins. Non-limiting examples of suitable α-olefins include propylene, butene, hexene, octene, and ethylidene norbornene, for ethylene / propylene SiH terpolymer, ethylene / butene / SiH terpolymer, ethylene / hexene / SiH terpolymer, ethylene / octene / SiH terpolymer, and ethylene / ethylidene norbornene / SiH terpolymer, respectively.

[0059] In one embodiment, the olefin-SiH polymer is an ethylene / α-olefin / SiH terpolymer, and is an ethylene / octene / SiH terpolymer. Non-limiting examples of suitable ethylene / octene / SiH terpolymers include ethylene / octene / hexenyldimethylsilane (HDMS) terpolymers, ethylene / octene / octenyldimethylsilane (ODMS) terpolymers, ethylene / octene / allyldimethylsilane (ADMS), and combinations thereof.

[0060] In one embodiment, the ethylene-SiH polymer is ethylene / octene / hexenyldimethylsilane (HDMS).

[0061] In one embodiment, the ethylene-SiH polymer is an ethylene / octene / allyldimethylsilane (ADMS) terpolymer.

[0062] In one embodiment, the olefin-SiH polymer is a propylene / SiH polymer. In another embodiment, the propylene / SiH polymer (propylene-based polymer) is a propylene / HDMS copolymer or a propylene / allyldimethylsilane copolymer.

[0063] In one embodiment, the olefin-SiH polymer is a propylene / ethylene SiH polymer. In another embodiment, the propylene / ethylene / SiH polymer (propylene-based polymer) is a propylene / ethylene / HDMS terpolymer.

[0064] The monovinyl epoxide component is melt blended with an olefin-SiH polymer (ethylene-SiH polymer or propylene-SiH polymer). In one embodiment, the melt blending is carried out in the presence of a catalyst. The monovinyl epoxide component has a single vinyl group and has the structure (1)

[0065] Structure (1)

[0066] H2C=CH2-X

[0067] wherein X of structure (1) is (i) a C4-C ... 20 heteroalkyl group, or (ii) a C4-C 20Hydrocarbyl groups. Non-limiting examples of structure (1) include allyl glycidyl ether (structure (a) below), glycidyl methacrylate (structure (b) below), 3,4-epoxy-1-butene (structure (c) below), 1,2-epoxy-5-hexene (structure (d) below), 1,2-epoxy-9-decene (structure (e) below), and 4-vinyl-1-cyclohexene 1,2-epoxide (structure (f) below).

[0068]

[0069] In one embodiment, (i) the olefin-SiH polymer and (ii) the monovinyl epoxide component are melt blended in the presence of a catalyst. The catalyst can accelerate the hydrosilylation reaction between the SiH moieties of the olefin-SiH polymer and the vinyl groups of the monovinyl epoxide component of structure (1).

[0070] In one embodiment, the hydrosilylation catalyst can be a catalyst containing a platinum group metal. As used herein, the term "platinum group" includes ruthenium, rhodium, palladium, osmium, iridium and platinum and their complexes. The catalyst containing a platinum group metal can be a platinum group metal, a platinum group metal deposited on, for example, silica gel or charcoal powder, or a compound or complex of a platinum group metal. Non-limiting examples of suitable platinum-containing catalysts include chloroplatinic acid in hexahydrate form or anhydrous form and / or a platinum-containing catalyst obtained by a method comprising reacting chloroplatinic acid with an aliphatic unsaturated organic olefin-platinum-silyl complex such as (COD)Pt(SiMeCl ) , wherein COD is 1,5-cyclooctadiene and Me is methyl. These olefin-platinum-silyl complexes can be prepared, for example, by mixing 0.015 moles of (COD)PtCl with 0.045 moles of COD and 0.0612 moles of HMeSiCl . The appropriate amount of catalyst will depend on the specific catalyst used. In another embodiment, the platinum catalyst is present in an amount sufficient to provide at least 2 parts per million (ppm) or 4 ppm to 200 ppm of platinum based on the total weight percent of solids (all non-solvent components) in the composition. Typically, on the same basis, the platinum is present in an amount sufficient to provide 4 ppm to 150 ppm by weight of platinum. The catalyst can be added as a single species or as a mixture of two or more different species.

[0071] In one embodiment, the hydrosilylation catalyst is selected from the group consisting of Speier's catalyst (chloroplatinic acid), Karstedt's catalyst, Wilkinson's catalyst, and combinations thereof.

[0072] The olefin-SiH polymer (ethylene-SiH polymer or propylene-SiH polymer), the monovinyl epoxide component, and the catalyst are melt blended or otherwise mixed at a temperature and for a time sufficient to completely homogenize the mixture. The melt blending is carried out by batch mixing or continuous mixing at a temperature of 80° C. to 160° C., or 80° C. to 120° C., for 1 minute to 20 minutes, or 2 minutes to 15 minutes, or 3 minutes to 10 minutes. In the presence of the catalyst, the melt blending initiates a hydrosilylation reaction between the Si-H moieties of the olefin-SiH polymer (ethylene-SiH polymer or propylene-SiH polymer) and the vinyl groups of the monovinyl epoxide component, thereby grafting the monovinyl epoxide component to the ethylene-SiH polymer (or propylene-SiH polymer) to form an epoxide-silane functionalized olefin-based polymer (epoxide-silane functionalized ethylene-based polymer or epoxide-silane functionalized propylene-based polymer).

[0073] As used herein, an "epoxide-silane functionalized ethylene-based polymer" is the reaction product between an ethylene-SiH polymer and a monovinyl epoxide component, wherein the monovinyl epoxide component is grafted or otherwise covalently bonded to the ethylene-SiH polymer at the silicon atom of the SiH moiety through a Si-CCY bond, wherein "Y" is C4-C 20 Heteroalkyl groups or C6-C ... 18 In one embodiment, "Y" is C4-C 20 Heteroalkyl groups also include epoxide moieties.

[0074] As used herein, an "epoxide-silane functionalized propylene-based polymer" is the reaction product between a propylene-SiH polymer and a monovinyl epoxide component, wherein the monovinyl epoxide component is grafted or otherwise covalently bonded to the propylene-SiH polymer at the silicon atom of the SiH moiety through a Si-CCY bond, wherein "Y" is a C4-C4 alkylene group having an epoxide moiety. 20 Heteroalkyl groups or C6-C8-C ... 18 In one embodiment, "Y" is C4-C 20 Heteroalkyl groups also include epoxide moieties.

[0075] In one embodiment, the epoxy-silane functionalized ethylene-based polymer has the following structure (2A):

[0076] Structure (2A)

[0077]

[0078] wherein R is a hexyl group, a hydrogen atom or any combination thereof,

[0079] R' is selected from the group consisting of CH2 and -(CH2)4-,

[0080] R" is CH3, and

[0081] Y is a heteroalkyl group having an epoxide moiety.

[0082] As used herein, an "epoxide-silyl propylene-based polymer" is the reaction product between a propylene-SiH polymer and a monovinyl epoxide component, wherein the monovinyl epoxide component is grafted or otherwise covalently bonded to the propylene-SiH polymer at the silicon atom of the SiH moiety through a Si-CCY bond, wherein "Y" is a C4-C4 alkylene oxide having an epoxide moiety. 20 Heteroalkyl group or C6-C 18 Heteroalkyl groups.

[0083] In one embodiment, the epoxy-silane functionalized propylene-based polymer has the following structure (2B):

[0084] Structure (2B)

[0085]

[0086] wherein R is a methyl group, a hydrogen atom or any combination thereof,

[0087] R' is selected from the group consisting of CH2 and -(CH2)4-,

[0088] R" is CH3, and

[0089] Y is a heteroalkyl group having an epoxide moiety.

[0090] In one embodiment, the epoxide-silane functionalized ethylene-based polymer is the reaction product of an ethylene / octene / HDMS terpolymer and allyl glycidyl ether (hereinafter referred to as "AGE-SiPOE"), and the AGE-SiPOE has the following structure (3):

[0091] Structure (3)

[0092]

[0093] The epoxide-silane-based olefin polymers of the present invention may comprise two or more embodiments disclosed herein.

[0094] C. Anhydride Functionalized Polymers

[0095] The compositions of the present invention include anhydride functionalized propylene-based polymers or anhydride functionalized ethylene-based polymers (collectively referred to as "anhydride functionalized olefin-based polymers"). A non-limiting example of a suitable anhydride functionalized olefin-based polymer is prepared by grafting maleic anhydride onto an olefin-based polymer (ethylene-based polymer or propylene-based polymer) via a free radical mechanism (e.g., thermal initiation or peroxide initiation).

[0096] As used herein, an "anhydride functionalized ethylene-based polymer" is an ethylene-based polymer having anhydride functional groups that are pendant from the backbone of the polymer chain. The functionalized ethylene-based polymer contains from 0.1 wt% to 10 wt%, or from 0.1 wt% to 5 wt%, or from 0.3 wt% to 1.2 wt% anhydride functional groups, based on the total weight of the anhydride functionalized ethylene-based polymer. The anhydride functionalized ethylene-based polymer has an MI (2.16 kg, 190° C.) of from 1 g / 10 min to 2000 g / 10 min, or from 10 g / 10 min to 500 g / 10 min, or from 40 g / 10 min to 150 g / 10 min. In one embodiment, the anhydride functional group is maleic anhydride (or MAH).

[0097] In embodiments, the anhydride functionalized ethylene-based polymer is a maleic anhydride grafted ethylene-based polymer, and the maleic anhydride grafted ethylene-based polymer has

[0098] (i) a melt index (2.16 kg, 190° C.) of 0.1 g / 10 min to 2000 g / 10 min, or 0.2 g / 10 min to 50 g / 10 min, or 0.3 g / 10 min to 25 g / 10 min, or 1 g / 10 min to 5 g / 10 min,

[0099] (ii) a maleic anhydride content of 0.1 wt% to 10 wt%, based on the total weight of the functionalized ethylene-based polymer; and

[0100] (iii) a base ethylene / C3-C8 α-olefin copolymer having a density from 0.850 g / cc to 0.920 g / cc, or from 0.860 g / cc to 0.900 g / cc.

[0101] In one embodiment, the anhydride functionalized ethylene-based polymer is an anhydride functionalized ethylene / α-olefin copolymer. Representative α-olefins include, but are not limited to, C3-C 20 α-olefins, or C3-C 10 α-olefins, or C4-C 20 α-olefins, or C4-C 10α-olefins, or C4-C8 α-olefins. Representative α-olefins include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.

[0102] In one embodiment, the anhydride functionalized ethylene-based polymer is prepared using an ethylene / C3-C8 α-olefin copolymer (“base ethylene / C3-C8 α-olefin copolymer”) having a density from 0.850 g / cc to 0.920 g / cc, or from 0.850 g / cc to 0.910 g / cc, or from 0.855 g / cc to 0.905 g / cc, or from 0.855 g / cc to 0.890 g / cc.

[0103] In one embodiment, the anhydride functionalized ethylene-based polymer is prepared using an ethylene / octene copolymer having a density of 0.850 g / cc to 0.920 g / cc, or 0.850 g / cc to 0.910 g / cc, or 0.855 g / cc to 0.905 g / cc, or 0.855 g / cc to 0.890 g / cc.

[0104] In one embodiment, the anhydride functionalized ethylene-based polymer is prepared using an ethylene / octene multi-block copolymer having a density from 0.850 g / cc to 0.920 g / cc, or from 0.850 g / cc to 0.910 g / cc, or from 0.855 g / cc to 0.890 g / cc.

[0105] As used herein, an "anhydride functionalized propylene-based polymer" is a propylene-based polymer having anhydride functional groups that are pendant from the backbone of the polymer chain. The anhydride functionalized propylene-based polymer contains from 0.1 wt% to 10 wt%, or from 0.1 wt% to 5 wt%, or from 0.3 wt% to 1.2 wt% anhydride functional groups, based on the total weight of the anhydride functionalized propylene-based polymer. The anhydride functionalized propylene-based polymer has an MFR (2.16 kg, 190°C) of from 1 g / 10 min to 2000 g / 10 min, or from 10 g / 10 min to 500 g / 10 min, or from 40 g / 10 min to 150 g / 10 min. In one embodiment, the anhydride functional group is maleic anhydride.

[0106] In one embodiment, the anhydride functionalized propylene-based polymer is a maleic anhydride grafted propylene homopolymer, and the maleic anhydride grafted propylene homopolymer has:

[0107] (i) a melt flow rate (2.16 kg, 190° C.) of 1 g / 10 min to 2000 g / 10 min, or 10 g / 10 min to 500 g / 10 min, or 40 g / 10 min to 150 g / 10 min, and

[0108] (ii) a maleic anhydride content of 0.1 wt% to 10 wt%, based on the total weight of the maleic anhydride functionalized propylene-based polymer.

[0109] D. Non-functionalized ethylene-based polymers

[0110] In one embodiment, the composition contains a non-functionalized ethylene-based polymer. As used herein, a "non-functionalized ethylene-based polymer" is an ethylene-based polymer that does not contain functional groups, such that the non-functionalized ethylene-based polymer is a hydrocarbon and does not contain heteroatoms.

[0111] Non-limiting examples of non-functionalized ethylene-based polymers include ethylene homopolymers, ethylene / α-olefin terpolymers, ethylene / α-olefin copolymers, ethylene / octene multi-block copolymers, and combinations thereof.

[0112] In one embodiment, the non-functionalized ethylene-based polymer is a non-functionalized ethylene / α-olefin copolymer. Representative α-olefins include, but are not limited to, C3-C 20 α-olefins, or C3-C 10 α-olefins, or C4-C 20 α-olefins, or C4-C 10 α-olefins, or C4-C8 α-olefins. Representative α-olefins include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.

[0113] In one embodiment, the non-functionalized ethylene-based polymer is a non-functionalized random ethylene / octene copolymer having one, some, or all of the following characteristics:

[0114] (i) a density of 0.850 g / cc to 0.920 g / cc, or 0.850 g / cc to 0.910 g / cc, or 0.860 g / cc to 0.905 g / cc, or 0.860 g / cc to 0.890 g / cc; and / or

[0115] (ii) a MI of 0.1 g / 10 min to 2000 g / 10 min, or 0.2 g / 10 min to 50 g / 10 min, or 0.5 g / 10 min to 35 g / 10 min, or 0.5 g / 10 min to 8 g / 10 min.

[0116] In one embodiment, the non-functionalized ethylene-based polymer is a non-functionalized ethylene / octene multi-block copolymer (composed solely of ethylene and octene comonomers) and has one, some, or all of the following characteristics:

[0117] (i) an Mw / Mn of from 1.7, or 1.8 to 2.2, or 2.5, or 3.5; and / or

[0118] (ii) a density of 0.850 g / cc to 0.920 g / cc, or 0.850 g / cc to 0.910 g / cc, or 0.860 g / cc to 0.890 g / cc; and / or

[0119] (iii) a melting point Tm of 115°C, or 118°C, or 119°C, or 120°C to 120°C, or 123°C, or 125°C; and / or

[0120] (iv) an MI of 0.1 g / 10 min to 2000 g / 10 min, or 0.2 g / 10 min to 50 g / 10 min, or 0.5 g / 10 min to 8 g / 10 min; and / or

[0121] (v) 50-93 wt% soft segments and 50-7 wt% hard segments; and / or

[0122] (vi) 10 mol%, or 13 mol%, or 14 mol%, or 15 mol% to 16 mol%, or 17 mol%, or 18 mol%, or 19 mol%, or 20 mol% of C4-C 12 α-olefins; and / or

[0123] (vii) 0.5 mol%, or 1.0 mol%, or 2.0 mol%, or 3.0 mol% to 4.0 mol%, or 5 mol%, or 6 mol%, or 7 mol%, or 9 mol% of octene in the hard segments; and / or

[0124] (viii) an elastic recovery (Re) of 50%, or 60% to 70%, or 80%, or 90% at 300% / minute deformation at 21°C as measured according to ASTM D 1708; and / or

[0125] (ix) Polydispersity distribution of blocks and polydispersity distribution of block sizes. Ethylene / octene multi-block copolymers having properties (i) to (ix) are disclosed in US Pat. No. 7,608,668, the entire contents of which are incorporated herein by reference.

[0126] A non-limiting example of a suitable non-functionalized ethylene / octene multi-block copolymer is INFUSE 9530 available from Dow Inc.

[0127] The non-functionalized ethylene-based polymers of the present invention may comprise two or more embodiments disclosed herein.

[0128] E. Filler

[0129] In one embodiment, the composition of the present invention may include one or more fillers. Non-limiting examples of suitable fillers include talc, mica, calcium carbonate, nanoclays, carbon nanotubes, carbon nanofibers, and combinations thereof.

[0130] F. Catalyst

[0131] In one embodiment, the composition of the present invention may include a catalyst or initiator to accelerate the reaction between the epoxide and the anhydride. Non-limiting examples of suitable catalysts include substituted or unsubstituted imidazoles, benzimidazoles, amines, imidazolium salts, aliphatic or aromatic alcohols, and aliphatic or aromatic carboxylic acids. A non-limiting example of a suitable catalyst is 2-undecyl imidazole.

[0132] G. Composition

[0133] The present composition is produced in batch mixer, continuous mixer and their combination. In one embodiment, the present composition is produced in a continuous mixer. The non-limiting example of suitable continuous mixer comprises co-rotating twin-screw extruder, counter-rotating continuous mixer, tangential counter-rotating twin-screw extruder, reciprocating kneader, single screw extruder, multi-screw planetary extruder and their combination. Continuous mixer can be used as a single unit or as the combination (for example series connection) of multiple continuous mixers.

[0134] In one embodiment, the composition comprises:

[0135] (A) 20 wt% to 98 wt%, or 30 wt% to 95 wt%, or 50 wt% to 85 wt%, or 55 wt% to 75 wt% of a non-functionalized propylene-based polymer;

[0136] (B) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of a maleic anhydride functionalized propylene-based polymer; and

[0137] (C) 1 to 50 wt %, or 1 to 20 wt %, or 2 to 10 wt %, or 3 to 7 wt % of an epoxide-silane functionalized ethylene-based polymer. The weight percentages are based on the total weight of the composition.

[0138] In one embodiment, the composition comprises:

[0139] (A) 20 wt% to 98 wt%, or 30 wt% to 95 wt%, or 50 wt% to 85 wt%, or 55 wt% to 75 wt% of a non-functionalized propylene-based polymer;

[0140] (B) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of a maleic anhydride functionalized propylene-based polymer; and

[0141] (C) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of an epoxide-silane functionalized ethylene-based polymer;

[0142] (D) 10 wt% to 40 wt%, or 15 wt% to 30 wt%, or 20 wt% to 30 wt% of a non-functionalized ethylene-based polymer; and

[0143] (E) 0 wt %, or 0.05 wt % to 1.0 wt %, or 0.1 wt % to 1.0 wt %, or 0.1 wt % to 0.9 wt % of one or more additives. The weight percentages are based on the total weight of the composition.

[0144] In one embodiment, the composition comprises:

[0145] (A) 20 wt% to 98 wt%, or 30 wt% to 95 wt%, or 50 wt% to 85 wt%, or 55 wt% to 75 wt% of a non-functionalized propylene homopolymer having

[0146] (i) an MFR (2.16 kg, 230° C.) of 5.0 g / 10 min to 15 g / 10 min, or 8.0 g / 10 min to 13.0 g / 10 min;

[0147] (B) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of a maleic anhydride functionalized propylene homopolymer having

[0148] (i) 0.1 wt% to 1.0 wt%, or 0.2 wt% to 0.8 wt% MAH (based on the total weight of the maleic anhydride functionalized propylene homopolymer),

[0149] (ii) an MFR (2.16 Kg, 190° C.) of 70 g / 10 min to 150 g / 10 min, or 80 g / 10 min to 140 g / 10 min, or 90 g / 10 min to 135 g / 10 min, or 100 g / 10 min to 130 g / 10 min;

[0150] (C) 1 to 50 wt%, or 1 to 20 wt%, or 2 to 10 wt%, or 3 to 7 wt% of an epoxide-silane functionalized ethylene homopolymer having

[0151] (i) a density of 0.85 g / cc to 0.89 g / cc, or 0.86 g / cc to 0.88 g / cc,

[0152] (ii) a melt index (2.16 Kg, 190° C.) of 0.1 g / 10 min to 1.0 g / 10 min, or 0.1 g / 10 min to 0.9 g / 10 min, or 0.2 g / 10 min to 0.8 g / 10 min,

[0153] (iii) a termonomer selected from HDMS or ODMS;

[0154] (D) 10 wt% to 40 wt%, or 15 wt% to 30 wt%, or 20 wt% to 30 wt% of a non-functionalized ethylene-based polymer that is an ethylene / octene multi-block copolymer having

[0155] (i) a density of 0.86 g / cc to 0.89 g / cc, or 0.87 g / cc to 0.89 g / cc,

[0156] (ii) a melt index (2.16 Kg, 190° C.) of 1.0 g / 10 min to 10 g / 10 min, or 2 g / 10 min to 8 g / 10 min; and

[0157] (E) 0 wt %, or 0.05 wt % to 1.0 wt %, or 0.1 wt % to 1.0 wt %, or 0.1 wt % to 0.9 wt % of an additive (hereinafter Composition 1). The weight percentages are based on the total weight of the composition. The composition (Composition 1) has one, some, or all of the following characteristics:

[0158] (i) a viscosity at 0.1 rad / s (230° C.) of 1600 Pa.s to 2,600 Pa.s, or 1700 Pa.s to 2,500 Pa.s, and / or

[0159] (ii) a viscosity at 100 rad / s (230° C.) of 300 Pa.s to 500 Pa.s, or 330 Pa.s to 400 Pa.s; and / or

[0160] (iii) tan δ at 0.1 rad / s of 1.0 to 5.0, or 1.5 to 3.0. In one embodiment, the molded article composed of composition 1 has one, some or all of the following molded article properties:

[0161] (iv) a tensile strain at break value of 50% to 100%, or 51% to 90%, and / or

[0162] (v)5.0kJ / m 2 Up to 20.0 kJ / m 2 or 7.0 kJ / m 2 Up to 18.0kJ / m 2 Izod notched impact strength at 23°C, and / or

[0163] (vi) a tensile modulus (2% secant) of 500 MPa to 700 MPa, or 550 MPa to 650 MPa.

[0164] In one embodiment, the composition comprises:

[0165] (A) 20 wt% to 98 wt%, or 30 wt% to 95 wt%, or 50 wt% to 85 wt%, or 55 wt% to 75 wt% of a non-functionalized propylene-based polymer;

[0166] (B) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of an epoxide-silane functionalized propylene-based polymer; and

[0167] (C) 1 to 50 wt%, or 1 to 20 wt%, or 2 to 10 wt%, or 3 to 7 wt% of a maleic anhydride-functionalized ethylene-based polymer. The weight percentages are based on the total weight of the composition.

[0168] In one embodiment, the composition comprises:

[0169] (A) 20 wt% to 98 wt%, or 30 wt% to 95 wt%, or 50 wt% to 85 wt%, or 55 wt% to 75 wt% of a non-functionalized propylene-based polymer;

[0170] (B) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of an epoxide-silane functionalized propylene-based polymer;

[0171] (C) 1 wt% to 50 wt%, or 1 wt% to 20 wt%, or 2 wt% to 10 wt%, or 3 wt% to 7 wt% of an epoxide-silane functionalized ethylene-based polymer;

[0172] (D) 10 wt% to 40 wt%, or 15 wt% to 30 wt%, or 20 wt% to 25 wt% of a non-functionalized ethylene-based polymer; and

[0173] (E) additive weight percent of 0 wt%, or 0.05 wt% to 1.0 wt%, or 0.1 wt% to 1.0 wt%, or 0.1 wt% to 0.9 wt%, based on the total weight of the composition.

[0174] The inventive composition comprised of (A) a non-functionalized propylene-based polymer, (B1) anhydride-functionalized propylene-based polymer (or (B2) epoxide-silane-functionalized propylene-based polymer), (C1) epoxide-silane-functionalized ethylene-based polymer (or (C2) anhydride-functionalized ethylene-based polymer), and (D) a non-functionalized ethylene-based polymer undergoes a reaction during compounding in which the functional groups of the functionalized propylene-based polymer react with the functional groups of the functionalized ethylene-based polymer to form covalent bonds between the functionalized propylene-based polymer and the functionalized ethylene-based polymer. The anhydride functional groups and the epoxide-silane functional groups undergo a reaction to form an ester linkage between the two functionalized polymers. Depending on the number of functional groups on each polymer, multiple ester linkages are formed between the functionalized polymer chains. Blends of the propylene-based polymer and the ethylene-based polymer are immiscible. The propylene-based polymer and the ethylene-based polymer form separate domains in the blend. The in-situ reaction between the functionalized propylene-based polymer and the functionalized ethylene-based polymer can improve the compatibility of the propylene-based polymer domains and the ethylene-based polymer domains and / or improve the interfacial strength between the propylene-based polymer domains and the ethylene-based polymer domains. The reaction during compounding produces a TPO composition with higher shear-thinning rheology (as indicated by higher melt viscosity at low shear rates and similar melt viscosity at high shear rates) and higher melt elasticity (as indicated by lower tan δ), and has improved impact toughness when molded into articles. The compositions of the present invention provide an improved balance of stiffness and impact toughness.

[0175] G. Products

[0176] The present composition can be molded into articles. Many types of molding operations can be used to form articles or parts from the present composition, including but not limited to injection molding, blow molding, compression molding, profile and sheet extrusion, and thermoforming. In one embodiment, the article is injection molded. Non-limiting examples of molded articles formed from the present composition include automotive interior and exterior components, such as bumper panels, airbag covers, door trim panels, instrument panels, seat backs, exterior body panels (liftgate panels, door panels, fenders), rocker panels, cladding, wheel arches; household and personal products, such as freezer containers, storage containers, toys, electronic and computer components, footwear components, and building materials.

[0177] The embodiments of the present disclosure are offered by way of example and not limitation.

[0178] Example

[0179] The materials used in the comparative samples (CS) and inventive examples (IE) are provided in Table A below.

[0180] Table A: Materials

[0181]

[0182]

[0183] 1. Preparation of SiH POE

[0184] The interpolymer SiH-POE E was prepared in a one-gallon polymerization reactor that was hydraulically fully filled and operated under steady-state conditions. The solvent was ISOPAR-E supplied by ExxonMobil Chemical Company. 5-Hexenyldimethylsilane (HDMS) supplied by Gelest was used as a terpolymer and purified over AZ-300 alumina supplied by UOP Honeywell before use. HDMS was fed to the reactor as a 22 wt% solution in ISOPAR-E. The reactor temperature was measured at or near the reactor outlet. The interpolymer was isolated and pelletized. The polymerization conditions are listed in Tables 1C-1E, and the catalyst is shown in Table 1B. The polymer properties of the ethylene / octene / silane interpolymer (SiH-POE E) are shown in Table 1E.

[0185] Table 1B: Catalysts and Cocatalysts

[0186]

[0187]

[0188] Table 1C: Polymerization conditions for producing SiH-POE E

[0189]

[0190] Table 1D: Catalyst Feed Flow Rates and Efficiencies

[0191]

[0192] *"ppm" amounts are based on the weight of the corresponding catalyst feed solution.

[0193] **"ppm" amounts are based on the weight of the co-catalyst feed solution.

[0194] ***"ppm" amounts of Al are based on the weight of the co-catalyst feed solution.

[0195] Table 1E: Polymer Properties

[0196]

[0197]

[0198] *Mole % silane is based on the total moles of monomers in the polymer and is given by 13 C NMR determination.

[0199] 1. Preparation of AGE-SiPOE

[0200] At a specified temperature of 100°C, ethylene / 1-octene / HDMS terpolymer (SiH-POE E) was added to a preheated Haake mixer (Haake mixer equipped with a 50-cc mixing bowl) at a blending rate of 100 rpm. Mixing was continued until the polymer became homogeneous. The monovinyl epoxide component, allyl glycidyl ether, was added and mixing was continued for 1 to 5 minutes. Then, Speier catalyst (50 ppm Pt relative to the polymer) was added as a solution in isopropanol (2 mg catalyst / 1 mL solvent) and the hydrosilylation reaction was allowed to proceed for 10 minutes. At the end of the hydrosilylation reaction, the epoxide-silane functionalized ethylene-based polymer AGE-SiPOE was collected. Purification was performed by precipitation from hot toluene into methanol. The resulting material was characterized by proton NMR spectroscopy in 1,1,2,2-tetrachloroethane-d2. Samples for NMR were prepared at 100°C in a solvent sufficient to allow complete dissolution of the polymer. Proton NMR spectra were acquired on a Bruker Ascend NEO 500 MHz instrument with a Prodigy cryoprobe at 383 K with a 60 s cycle delay. The characteristics of the resulting functionalized polymers are provided in Table 1F below.

[0201] Table 1F

[0202]

[0203] 2. Preparation of the composition

[0204] For each composition, the polymer pellets were melt blended with the antioxidant and optional UI catalyst in the ratios described in Table 2A in an RSI RS5000, RHEOMIX 600 Haake mixer at 200°C / 50RPM for five minutes. The hot samples were cooled in a Carver press (cold platen) at 20,000psi for four minutes to make "pancake samples" for further testing. The samples (4.5 inches × 4.5 inches × 0.125 inches) were then compression molded according to ASTM D4703. Notched Izod impact strength was measured according to ASTM D256, and microtensile testing was performed according to ASTM D1708. DMS frequency sweep measurements were performed on a DMS-ARES-G2 rheometer from TA Instruments using a 25mm diameter parallel plate setup at 230°C from 0.1rad / s to 100rad / s.

[0205] Table 2A: Composition

[0206]

[0207] Weight % - based on the total weight of the composition

[0208] Table 2B: Properties of molded articles made from the compositions of Table 2A

[0209] CS A IE1 IE2 Tensile modulus, 2% secant, MPa 598 607 587 Tensile strain at break, % 61 52 86 <![CDATA[Cantilever beam notch, 23 °C, kJ / m 2 > 9.3 9.7 17.7

[0210] Table 2A includes the formulations and properties of blends prepared by Haake blending. Table 2B includes the properties of compression molded parts made from a comparative composition ("CS"). CS A is a formulation without a functionalized component. Inventive Examples (IE) IE1 and IE2 both contain a functionalized component. Compared to Comparative Example CS A, Inventive Examples IE1 and IE2 exhibit improved impact toughness (higher notched Izod impact strength) while maintaining similar stiffness (tensile modulus). Furthermore, IE1 and IE2 exhibit similar high-shear viscosities (viscosity at 100 rad / s) as CS A, indicating similar flow properties for processes such as injection molding. Thus, compared to CS A, IE1 and IE2 offer an improved balance of stiffness, toughness, and flow. Furthermore, IE1 and IE2 exhibit higher low-shear viscosities (viscosity at 0.1 rad / s) and lower tan δ than CS A, indicating higher melt elasticity for the inventive compositions. Higher melt elasticity can be beneficial in reducing tiger stripes in injection molded parts or improving the processability of thermoformed or foamed compounds. IE2 has the highest impact strength, the highest viscosity at 0.1 rad / s, and the lowest tan delta at 0.1 rad / s, indicating that the addition of the UI catalyst results in a higher degree of reaction between the maleic anhydride grafted polypropylene and the epoxy-silane functionalized ethylene-based polymer.

[0211] It is particularly intended that the present disclosure is not limited to the embodiments and descriptions contained herein, but rather includes modifications of those embodiments including portions of the embodiments and combinations of elements of different embodiments as appear within the scope of the following claims.

Claims

1. A composition comprising: (A) a non-functionalized propylene-based polymer; (B) a functionalized propylene-based polymer; and (C) a functionalized ethylene-based polymer, The functionalized propylene-based polymer (B) and the functionalized ethylene-based polymer (C) each have a different functional group selected from the group consisting of maleic anhydride and epoxide.

2. The composition according to claim 1, comprising: (A) 20 to 98 weight percent of a non-functionalized propylene-based polymer; (B) 1 to 50 weight percent of a maleic anhydride grafted propylene-based polymer; and (C) 1 to 50 weight percent of an epoxy-functionalized ethylene-based polymer.

3. The composition of claim 2, wherein the maleic anhydride grafted propylene-based polymer is a maleic anhydride grafted propylene homopolymer having the following properties: (i) a melt flow rate (2.16 kg, 190° C.) of 1 g / 10 min to 2000 g / 10 min; and (ii) a maleic anhydride content of 0.1 wt% to 10 wt%, based on the total weight of the functionalized propylene-based polymer.

4. The composition of any one of claims 2 to 3, wherein the epoxy-functionalized ethylene-based polymer has: (i) a density of 0.85 g / cc to 0.89 g / cc, (ii) a melt index of 0.1 g / 10 min to 1.0 g / 10 min, and (iii) a terpolymeric comonomer selected from the group consisting of allyldimethylsilane, hexenyldimethylsilane, and octenyldimethylsilane.

5. The composition of claim 4, wherein the epoxy-functionalized ethylene-based polymer is an epoxy-silane-functionalized ethylene-based polymer having the following structure (2A): Structure (2A) wherein R is a hexyl group, a hydrogen atom or any combination thereof, R' is selected from the group consisting of CH2 and -(CH2)4-, R" is CH3, and Y is a heteroalkyl group having an epoxide.

6. The composition of claim 5, wherein the epoxy-silane functionalized ethylene-based polymer has the following structure 3:

7. The composition according to any one of claims 1 to 6, comprising: (D) Non-functionalized ethylene-based polymers.

8. The composition of claim 7, wherein the non-functionalized ethylene-based polymer is an ethylene / C3-C8 alpha-olefin copolymer having the following properties: (i) a density of 0.850 g / cc to 0.920 g / cc; and (ii) a melt index of 0.1 g / 10 min to 2000 g / 10 min (2.16 kg, 190° C.).

9. The composition according to any one of claims 7 to 8, comprising: (A) 50 to 85 weight percent of a non-functionalized propylene homopolymer; (B) 1 to 10 wt% of a maleic anhydride functionalized propylene homopolymer; (C) 1 to 10 weight percent of an epoxide-silane functionalized ethylene terpolymer; (D) 15 to 30 weight percent of said non-functionalized ethylene-based polymer; and (E) 0 to 1.0 wt% of additives.

10. The composition of claim 9, wherein the composition has a property selected from the group consisting of: (i) a viscosity of 1600 Pa.s to 2,600 Pa.s at 0.1 rad / s (230° C.), (ii) a viscosity of 300 Pa.s to 500 Pa.s at 100 rad / s (230° C.), (iii) a tan δ at 0.1 rad / s of 1.0 to 5.0; and (iv) combinations thereof.

11. A molded article composed of the composition according to claim 10, said molded article having molded article properties selected from the group consisting of: (i) a tensile strain at break value of 50% to 100%, (ii) 5.0 kJ / m at 23°C 2 Up to 20.0 kJ / m 2 Izod notched impact strength, (iii) a tensile modulus (2% secant) of 500 MPa to 700 MPa, and (iv) combinations thereof.

12. The composition according to claim 1, comprising: (A) 20 to 98 weight percent of a non-functionalized propylene-based polymer; (B) 1 to 50 weight percent of an epoxy-silane functionalized propylene-based polymer; and (C) 1 to 50 weight percent maleic anhydride grafted ethylene-based polymer.

13. The composition according to claim 12, comprising: (D) Non-functionalized ethylene-based polymers.

14. The composition of claim 13, wherein the non-functionalized ethylene-based polymer is an ethylene / C3-C8 alpha-olefin copolymer having the following properties: (i) a density of 0.850 g / cc to 0.920 g / cc; and (ii) a melt index of 0.1 g / 10 min to 2000 g / 10 min (2.16 kg, 190° C.).

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