Propylene-based elastomeric compositions for subterranean waterproofing applications

Abstract

The present disclosure relates to a waterproof film comprising 40% to 60% by weight of at least one propylene-based elastomer and 40% to 60% by weight of at least one impact copolymer, based on the total weight of the blend composition. The at least one propylene-based elastomer comprises greater than 50 wt% propylene and from about 3 wt% to about 25 wt% units derived from ethylene and / or one or more C4 to C12 alpha-olefins, based on the total weight of the propylene-based elastomer. The film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T328.9-2007, a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T328.9-2007, an elongation at break (%) MD and TD of at least 500 as measured by GB / T328.9-2007, a nail surrounding tear strength (N) MD and TD of at least 400 as measured by GB / T 328.18, and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application 63 / 488,742, filed March 6, 2023, entitled Propylene-Based Elastomer Compositions for Waterproof Applications Underground, which is incorporated by reference herein in its entirety. TECHNICAL FIELD

[0003] Embodiments of the present invention relate generally to propylene-based elastomer compositions. More specifically, embodiments of the present invention relate to propylene-based elastomer blends formulated for waterproofing applications. BACKGROUND

[0005] Waterproofing materials are highly desirable for roofing and underground applications. Waterproofing materials prevent water from penetrating into surrounding structures. Waterproofing materials can also act as a barrier to different contaminants. In most U.S. building codes, a waterproofing membrane is defined as an article (coating / barrier) that is applied to the outer surface of a roof, floor, foundation wall, or other area known or expected to be subjected to hydrostatic pressure due to soil moisture conditions.

[0006] In the past, PVC was the preferred material for roofing and HDPE was preferred for underground applications. More recently, thermoplastic polyolefin (“TPO”) polymers have been used in place of PVC solutions for roofing applications and in place of HDPE solutions for underground applications due to better flexibility, toughness, and dimensional stability of TPO.

[0007] TPO polymers are now widely used for roofing applications for commercial buildings with flat roofs. Such roofing applications are typically reflective roof membranes made from a blend of polypropylene and ethylene-propylene rubber and have a reflective white top layer exposed to sunlight and a colored layer under the reflective layer connected to insulation. Underground sheeting or membranes have a similar construction. Such underground applications are typically membranes made from a blend of polypropylene and ethylene-propylene rubber and have a colored layer connected to insulation.

[0008] For roofing and underground sheeting applications, the products are typically manufactured as a film sheet having a typical width of 10 feet (3 meters) or greater, although smaller widths are also available. The sheets are typically sold, shipped, and stored in rolls. During shipping and storage, the rolls can be exposed to extreme heat conditions, for example, 40°C - 100°C, which can cause roll blocking of the roll during storage in the warehouse. In use, these films should be able to withstand a wide range of service temperatures, for example, from -40°C to +40°C. These films can also be exposed to a wide range of conditions, which will degrade or destroy the integrity of the film over time.

[0009] In addition to strength and temperature resistance, it is highly desirable that these films be waterproof. There is a continuing need for TPO films that have suitable strength and temperature resistance at necessary service temperatures, and are also waterproof. SUMMARY

[0011] The present disclosure relates to propylene-based waterproofing films. In at least one embodiment, the waterproofing film includes 40 to 60 weight percent of at least one propylene-based elastomer and 40 to 60 weight percent of at least one impact copolymer, based on the total weight of the blend composition. The at least one propylene-based elastomer has a heat of fusion of less than about 80 J / g as determined by DSC, a density of 0.850 g / cm3to 0.920 g / cm3in accordance with ASTM D-1505, a crystallinity of 2% to 65% of isotactic polypropylene, and a melting point (Tm) of 100°C or less. The propylene-based elastomer includes greater than 50 weight percent propylene and about 3 weight percent to about 25 weight percent units derived from ethylene and / or one or more C4-C12 alpha-olefins, based on the total weight of the propylene-based elastomer. 3 The present disclosure relates to propylene-based waterproofing films. In at least one embodiment, the waterproofing film includes 40 to 60 weight percent of at least one propylene-based elastomer and 40 to 60 weight percent of at least one impact copolymer, based on the total weight of the blend composition. The at least one propylene-based elastomer has a heat of fusion of less than about 80 J / g as determined by DSC, a density of 0.850 g / cm3to 0.920 g / cm3in accordance with ASTM D-1505, a crystallinity of 2% to 65% of isotactic polypropylene, and a melting point (Tm) of 100°C or less. The propylene-based elastomer includes greater than 50 weight percent propylene and about 3 weight percent to about 25 weight percent units derived from ethylene and / or one or more C4-C12 alpha-olefins, based on the total weight of the propylene-based elastomer.

[0012] In at least one other embodiment, the waterproofing film has 40 to 60 weight percent of at least one propylene-based elastomer and 40 to 60 weight percent of at least one impact copolymer. The propylene-based elastomer has greater than 50 weight percent propylene and about 3 weight percent to about 25 weight percent units derived from ethylene, based on the total weight of the propylene-based elastomer. The at least one impact copolymer is a propylene homopolymer blended with a propylene copolymer and has a total propylene-derived units content of about 88 to about 92 weight percent, based on the weight of the ICP.

[0013] In at least one other embodiment, the waterproofing membrane has 40 wt% to 60 wt% of at least one propylene-based elastomer, 40 wt% to 60 wt% of at least one impact copolymer, and 1 wt% to 5 wt% of a masterbatch comprising one or more antioxidants and one or more agents, based on the total weight of the blend composition. The propylene-based elastomer has greater than 50 wt% propylene and from about 3 wt% to about 25 wt% units derived from ethylene and / or one or more C4-C12a-olefins, based on the total weight of the propylene-based elastomer. The at least one impact copolymer is a propylene homopolymer blended with a propylene copolymer and has a total propylene derived units content of from about 88 to about 92 wt%, based on the weight of the ICP.

[0014] In any of the foregoing embodiments or elsewhere herein, the membrane has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T 328.9-2007, a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T 328.9-2007, an elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007, a tear strength around the nail (N) MD and TD of at least 400 as measured by GB / T 328.18, and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

[0015] These and other features and attributes of the disclosed waterproofing compositions of the present disclosure and their advantageous applications and / or uses will be apparent from the following detailed description.

[0016] BRIEF DESCRIPTION OF DRAWINGS

[0017] To assist those of ordinary skill in the relevant art in making and using the subject matter herein, reference is made to one figure, which graphically depicts some physical properties of three different waterproofing blend compositions made according to one or more embodiments provided herein, in comparison to minimum requirements for waterproofing compositions as determined by the T / CBMF 43-2019 industry standard. The T / CBMF 43-2019 standard is the current standard industry preference for waterproofing membranes in China.

[0018] DETAILED DESCRIPTION

[0019] The present disclosure relates to waterproof propylene-based elastomer ("PBE") compositions suitable for all waterproofing applications including roofing and underground uses. The waterproof propylene-based elastomer ("PBE") compositions are a blend including one or more PBEs and one or more impact copolymers (ICP). The membranes made from the propylene-based elastomer ("PBE") and ICP blend compositions described herein are waterproof at temperatures ranging from -40°C to +40°C, which makes them highly desirable for roofing and underground applications. By "waterproof" it is meant that a structure (e.g., a membrane) made from the PBE blend compositions described herein is impervious to water and water vapor for a substantial amount of time, e.g., at least 20 years, 30 years, 50 years, or 100 years.

[0020] As used herein, the term "elastomer" or "elastomer composition" refers to any polymer, copolymer, or composition of polymers (e.g., a blend of polymers) that meets the definition of ASTM D 1566. Elastomers include mixed blends of polymers, e.g., melt-mixed and / or reactor blends of polymers.

[0021] As used herein, the term "copolymer" refers to a polymer having two or more monomers, optionally with other monomers, and can refer to interpolymers, terpolymers, etc. The term "polymer" as used herein includes, but is not limited to, homopolymers, copolymers, terpolymers, etc., as well as alloys and blends thereof. The term "polymer" as used herein also includes impact, block, graft, random, and alternating copolymers. Unless otherwise specifically indicated, the term "polymer" shall also include all possible geometric configurations. Such configurations can include isotactic, syndiotactic, and atactic symmetries. The term "blend" as used herein refers to a mixture of two or more polymers.

[0022] The term "monomer" or "comonomer" as used herein refers to the unreacted compound in its pre-polymerization form, i.e., as it exists prior to polymerization, and can also refer to the monomer after it has been incorporated in a polymer, also referred to herein as a "[monomer]-derived unit." Different monomers are discussed herein, including propylene monomers, ethylene monomers, and diene monomers.

[0023] "Reactor grade" as used herein refers to a polymer that has not been subjected to chemical or mechanical treatment or blending that attempts to change the average molecular weight, molecular weight distribution, or viscosity of the polymer after polymerization. Specifically excluded from those described as reactor grade are those that have been vis-broken or otherwise treated or coated with peroxides or other degradation aids. However, for the purposes of the present disclosure, reactor grade polymers include those that are reactor blends.

[0024] "Reactor blend" as used herein refers to a highly dispersed and mechanically inseparable blend of two or more polymers produced in situ as a result of sequential or parallel polymerization of one or more monomers, one polymer being formed in the presence of another polymer, or produced in situ by solution blending polymers produced separately in parallel reactors. Reactor blends can be produced in a single reactor, in series reactors, or in parallel reactors and are reactor grade blends. Reactor blends can be produced by any polymerization process, including batch, semi-continuous, or continuous systems. Specifically excluded from "reactor blend" are polymers which are a blend of two or more polymers, wherein the polymers are blended ex situ, for example, by physical or mechanical blending in a mixer, extruder, or other similar device.

[0025] The term "sequential polymerization" refers to a polymerization process in which different polymers are produced in the same or different reactors at different time periods, for example, to produce multimodal and / or heterophasic polymers.

[0026] As used herein, the terms "polypropylene", "propylene polymer", and "propylene-based polymer" refer to a polymer or copolymer comprising at least 50 mol% propylene units (preferably at least 70 mol% propylene units, more preferably at least 80 mol% propylene units, even more preferably at least 90 mol% propylene units, even more preferably at least 95 mol% propylene units, or 100 mol% propylene units (in the case of a homopolymer)). An "ethylene polymer" or "polyethylene" or "ethylene copolymer" is a polymer or copolymer comprising at least 50 mol% ethylene-derived units, and the like.

[0027] The term "polypropylene" is meant to include isotactic polypropylene (iPP) defined as having at least 10% or more isotactic pentads, highly isotactic polypropylene defined as having 50% or more isotactic pentads, syndiotactic polypropylene (sPP) defined as having 10% or more syndiotactic pentads, homopolymer polypropylene (hPP, also referred to as propylene homopolymer or homopolymer of propylene) and so-called random copolymer polypropylene (RCP, also referred to as propylene random copolymer). Herein, RCP is specifically defined as a copolymer of propylene and from 1 to 10 wt% of an olefin selected from ethylene and C4-C8a-olefins. Preferably isotactic polymers (e.g. iPP) have at least 20% (preferably at least 30%, preferably at least 40%) isotactic pentads. If a polyolefin has less than 10% isotactic pentads and syndiotactic pentads, it is "atactic", also referred to as "amorphous".

[0028] The terms "ethylene-propylene rubber" and "EP rubber" (EPR) refer to copolymers of ethylene and propylene and optionally one or more diene monomers, wherein the ethylene content is 35-85 mol%, the total diene content is 0 to 5 mol%, and the balance is propylene, with a minimum propylene content of 15 mol%.

[0029] The term "heterophasic" or "heterophasic" refers to the presence of two or more morphological phases in a composition comprising two or more polymers, wherein each phase comprises a different polymer or a different ratio of polymers, which is a result of partial or complete immiscibility (i.e. thermodynamic incompatibility). A common example is a morphology consisting of a continuous matrix phase and at least one dispersed or discontinuous phase. The dispersed phase takes the form of discrete domains (particles) distributed within the matrix (or within the other phase domains if more than two phases are present). Another example is a co-continuous morphology, wherein two phases are observed, but it is unclear which phase is the continuous phase and which phase is the discontinuous phase, e.g. wherein the matrix phase has a generally continuous internal porosity and the filler phase is deposited within the pores, or wherein the filler phase expands within the pores of the initially spherical matrix phase, thereby expanding the porous matrix globules corresponding to the polymer initially formed on or in the carrier aggregate into subglobules, which can be partially or completely separated and / or co-continuous or dispersed in the filler phase, corresponding to the polymer formed on or in the primary particles of the carrier. For example, the polymer globules can initially have a matrix phase having a porosity corresponding to the carrier aggregate, but due to expansion of the filler phase in the voids between the subglobules of the matrix phase, the polymer globules have a higher filler phase.

[0030] The presence of heterophase is determined using microscopic techniques such as optical microscopy, scanning electron microscopy (SEM) or atomic force microscopy (AFM); or by the presence of two glass transition (Tg) peaks in dynamic mechanical analysis (DMA) experiments; or by physical methods such as solvent extraction, e.g. xylene extraction at elevated temperature to preferentially isolate one polymeric phase; if these methods do not agree, DMA according to the procedure set out in US 2008 / 0045638 page 36 (including any references cited therein) should be used.

[0031] "Polypropylene impact copolymer" or simply "impact copolymer" (ICP) is a combination of crystalline and amorphous polymers (e.g. iPP and rubber) that is typically heterogeneous, which provides the ICP with a stiffness greater than that of the amorphous polymer(s) and a toughness greater than that of the crystalline polymer(s). The ICP can typically have a morphology such that the matrix phase contains a higher proportion of crystalline polymer and the rubber is present in a higher proportion in the dispersed or co-continuous phase, for example a blend containing a matrix of 60 to 95 wt% iPP and 5 to 40 wt% of an ethylene, propylene or other polymer having a Tg of 30°C or less.

[0032] As used herein, "wt%" means weight percent, "mol%" means mole percent, "vol%" means volume percent, and all molecular weights, e.g. Mw, Mn, Mz, are in g / mol, unless otherwise indicated. Furthermore, all molecular weights are Mw, unless otherwise indicated.

[0033] As used herein, when a polymer is said to comprise a certain percentage (wt%) of a monomer, the percentage of the monomer is based on the total amount of monomer units in the polymer.

[0034] As used herein, "consisting essentially of means that the composition described / claimed does not include any additional components that materially change its nature and, in any event, does not include any additional components at a level of greater than 3 wt%.

[0035] As used herein, "substantially free of and "essentially free of mean that the subject item does not have the component in question used intentionally or added in any amount, but that very small amounts of the component can be present as impurities from environmental or process conditions.

[0036] Various specific embodiments, variants of the present application will now be described, including the preferred embodiments and definitions employed herein. While the following detailed description gives specific preferred embodiments, one skilled in the art will appreciate that these embodiments are exemplary only, and the present application can be practiced in other ways.

[0037] Propylene-based elastomers

[0038] Propylene-based elastomers are random copolymers having crystalline regions interrupted by non-crystalline regions, having ethylene or C4-C10a-olefin derived units in the range of 5-25 wt% based on the weight of the propylene-based elastomer, and optionally diene derived units, the balance of the polymer being propylene derived units. Without intending to be bound by any theory, it is believed that the non-crystalline regions can arise from polypropylene segments that are not crystallizable and / or include comonomer units. The crystallinity and melting point of the propylene-based elastomer is reduced by the introduction of errors (stereodefects and regiodefects) in the propylene insertion and / or by the presence of comonomers, as compared to highly isotactic polypropylene. The copolymer contains at least 50 wt% propylene derived units, based on the weight of the propylene-based elastomer. In any embodiment, the propylene-based elastomer is a propylene-based elastomer of limited crystallinity due to adjacent isotactic propylene units and melting point as described herein. In other embodiments, the propylene-based elastomer is generally free of any substantial intermolecular heterogeneity in tacticity and comonomer composition, and is also generally free of any substantial heterogeneity in intramolecular composition distribution.

[0039] The propylene-based elastomer contains greater than 50 wt%, preferably greater than 60 wt%, more preferably greater than 65 wt%, even more preferably greater than 75 wt%, and up to 99 wt% propylene derived units, based on the total weight of the propylene-based elastomer. In some preferred embodiments, the propylene-based elastomer includes propylene derived units in an amount of 75 wt% to 95 wt%, more preferably 75 wt% to 92.5 wt%, and even more preferably 82.5 wt% to 92.5 wt%, and most preferably 82.5 wt% to 90 wt%, based on the weight of the propylene-based elastomer. Correspondingly, units or comonomers derived from at least one of ethylene or C4-C10a-olefins can be present in an amount of the elastomer ranging from a lower limit of 5 or 10 or 14 wt% to an upper limit of about 20, 22 or 25 wt%.

[0040] The comonomer content can be adjusted such that the propylene-based elastomer has a heat of fusion of 100 J / g, 90 J / g, 85 J / g, 80 J / g, 75 J / g, 70 J / g, or 65 J / g or less, a melting point (T m ) of 100°C or 90°C or less, and a crystallinity of 2% to 65% of isotactic polypropylene, and preferably a melt flow rate ("MFR") of less than 1,000 g / 10 min as measured at 230°C and a 2.16 kg weight.

[0041] The propylene-based elastomer can have more than one comonomer. Preferred embodiments of the propylene-based elastomer have more than one comonomer, such as propylene-ethylene-octene, propylene-ethylene-hexene, and propylene-ethylene-butene copolymers.

[0042] In embodiments where more than one comonomer derived from at least one of ethylene or C4-C10a-olefins is present, the amount of each comonomer can be less than 25 wt% of the propylene-based elastomer, but the total amount of comonomer is 3 wt% or greater based on the weight of the propylene-based mono-olefin. In preferred embodiments, the comonomer is ethylene, 1-hexene, or 1-octene, and the preferred amount is 3, 5, 10, or 14 wt% to 15, 20, 22, or 25 wt% based on the total weight of the propylene-based elastomer. The comonomer content of the propylene-based elastomer can also be from about 3 to about 35 wt%, from about 3 to 15 wt%, or from about 10 to 15 wt% based on the total weight of the propylene-based elastomer.

[0043] In preferred embodiments, the propylene-based elastomer comprises ethylene derived units. The propylene-based elastomer can comprise 3, 5, 10, or 14 wt% to 15, 20, 22, or 25 wt% of ethylene derived units based on the total weight of the propylene-based elastomer. The ethylene content of the propylene-based elastomer can also be from about 3 to about 35 wt%, from about 3 to 15 wt%, from about 10 to 15 wt%, or from about 4 to 8 wt% based on the total weight of the propylene-based elastomer. In any embodiment, the propylene-based elastomer consists essentially of units derived from propylene and ethylene, i.e., the propylene-based elastomer does not contain any other comonomer in an amount that is present as an impurity in the ethylene and / or propylene feed stream typically used in the polymerization process or in an amount that would materially affect the heat of fusion, melting point, crystallinity, or melt flow rate of the propylene-based elastomer, or any other comonomer intentionally added to the polymerization process.

[0044] In some embodiments, the propylene-based elastomer can also include one or more dienes. The term "diene" is defined as a hydrocarbon compound having two sites of unsaturation, i.e., a compound having two double bonds attached to carbon atoms. Depending on the context, the term "diene" as used herein broadly refers to a diene monomer prior to polymerization (e.g., to form part of a polymerization medium), or a diene monomer after polymerization has begun (also referred to as a diene monomer unit or diene derived unit). In some embodiments, the diene can be selected from the group consisting of 5-ethylidene-2-norbornene (ENB), 1,4-hexadiene, 5-methylene-2-norbornene (MNB), 1,6-octadiene, 5-methyl-1,4-hexadiene, 3,7-dimethyl-1,6-octadiene, 1,3- cyclopentadiene, 1,4-cyclohexadiene, vinyl norbornene (VNB), dicyclopentadiene (DCPD), and combinations thereof. When used, the amount of diene comonomer can be equal to or greater than 0.1 wt%, or 0.5 wt%, or 1 wt%, or 1.5 wt% and less than or equal to 6 wt%, or 4 wt%, or 3 wt%, or 2 wt% based on the total weight of the propylene-based elastomer.

[0045] The propylene-based elastomer has a heat of fusion ("Hf") as determined by differential scanning calorimetry ("DSC") of 100 J / g or less, or 75 J / g or less, 70 J / g or less, 50 J / g or less, or 35 J / g or less. The propylene-based elastomer can have a lower limit on Hf of 0.5 J / g, 1 J / g, or 5 J / g. For example, the Hf value can be anywhere from 1.0, 1.5, 3.0, 4.0, 6.0, or 7.0 J / g to 30, 35, 40, 50, 60, 70, or 75 J / g.

[0046] The propylene-based elastomer can have a percent crystallinity of 2% to 65%, preferably 0.5% to 40%, preferably 1% to 30%, and more preferably 5% to 35% of isotactic polypropylene, as determined according to the DSC procedure described herein. The thermal energy of the highest order of propylene (i.e., 100% crystallinity) is assigned as 189 J / g. In any embodiment, the copolymer has a crystallinity in the range of 0.25% to 25%, or 0.5% to 22% of isotactic polypropylene.

[0047] The propylene-based elastomer can have a triad tacticity (mm tacticity) of 75% or greater, 80% or greater, 85% or greater, 90% or greater, 92% or greater, 95% or greater, or 97% or greater of three propylene units as measured by13C NMR. For example, the triad tacticity can be in the range of about 75 to about 99%, about 80 to about 99%, about 85 to about 99%, about 90 to about 99%, about 90 to about 97%, or about 80 to about 97%. The triad tacticity can be determined by the method described in U.S. Patent No. 7,232,871.

[0048] The propylene-based elastomers can have a tacticity index m / r ranging from a lower limit of 4 or 6 to an upper limit of 8 or 10 or 12. The tacticity index is determined by 13C nuclear magnetic resonance ("NMR"), denoted herein as "m / r". The tacticity index (m / r) is calculated as defined by H. N. Cheng in Vol. 17, MACROMOLECULES, pp. 1950-1955 (1984), which is incorporated herein by reference. The designation "m" or "r" describes the stereochemistry of adjacent propylene groups, "m" indicating meso and "r" indicating racemic. An m / r ratio of 1.0 generally describes syndiotactic polymers, and an m / r ratio of 2.0 describes atactic materials. The propylene-based elastomers can have a single melting transition as determined by DSC. In any embodiment, the copolymer has a main peak transition of 90°C or less, with a broad melting transition endpoint of 110°C or more. The peak "melting point" ("Tm") is defined as the temperature of the largest heat absorption within the range of sample melting. However, the copolymer can show a secondary melting peak adjacent to the main peak and / or at the melting transition endpoint. For the purposes of the present disclosure, such secondary melting peaks are collectively considered to be a single melting point, the highest of these peaks being considered the Tm of the propylene-based elastomer. The propylene-based elastomers can have a Tm of 100°C or less, 90°C or less, 80°C or less, or 70°C or less. In any embodiment, the propylene-based elastomers can have a Tm of 25°C to 100°C, 25°C to 85°C, 25°C to 75°C, or 25°C to 65°C. In any embodiment, the propylene-based elastomers can have a Tm of 30°C to 80°C or 30°C to 70°C.

[0049] To determine the thermal properties of the propylene-based elastomers provided herein, differential scanning calorimetry ("DSC") is used. Such DSC data is obtained using a Perkin-Elmer DSC, pressed at about 200°C to 230°C, then 7.5 mg to 10 mg of the polymer piece to be tested is removed with a punch die and annealed at room temperature for 48 hours. The sample is then sealed in an aluminum sample pan. The DSC data is recorded by first cooling the sample to -50°C and then gradually heating the sample to 200°C at a rate of 10°C / minute. The sample is held at about 200°C for 5 minutes before applying a second cooling- heating cycle. The thermal events of the first and second cycles are recorded. The area under the melting curve is measured and used to determine the heat of fusion and the degree of crystallization.

[0050] Percent crystallinity (X%) is calculated using the formula: X% = [area under the curve (Joules / gram) / B (Joules / gram)] * 100, where B is the heat of fusion of the homopolymer of the major monomer component. These B values can be found in the Polymer Handbook, Fourth Edition, published by John Wiley and Sons (New York) in 1999. A value (B) of 189 J / g is used as the heat of fusion for 100% crystalline polypropylene. The melting temperature is measured and reported during the second heating cycle (or second melt).

[0051] In one or more embodiments, the propylene-based elastomer can have a Mooney viscosity [ML (1+4) at 125°C] of less than 100, in other embodiments less than 75, in other embodiments less than 60, and in other embodiments less than 30, as determined according to ASTM D-1646.

[0052] The propylene-based elastomer can have a density of from 0.850 g / cm3 3 to 0.920 g / cm3 3 , 0.860 g / cm3 3 to 0.900 g / cm3 3 , or 0.860 g / cm3 3 to 0.890 g / cm3 3 , as tested in accordance with ASTM D1505 at room temperature.

[0053] The propylene-based elastomer can have a melt flow rate ("MFR") of greater than 0.5 dg / min, and less than or equal to 1,000 dg / min, or less than or equal to 800 dg / min, less than or equal to 500 dg / min, less than or equal to 200 dg / min, less than or equal to 100 dg / min, or less than or equal to 50 dg / min. Some embodiments can include a propylene-based elastomer having a MFR of less than or equal to 25 dg / min, for example, 1-25 dg / min or 1 to 20 dg / min or 3-15 dg / min. The MFR can also range from a lower limit of about 2.5, 3.5, or 4 g / 10 min to an upper limit of about 10, 15, 20, or 30 g / 10 min. The MFR is determined according to ASTM D-1238, Condition L (2.16 kg, 230°C).

[0054] The propylene-based elastomer can have a weight average molecular weight ("Mw") of 5,000 to 5,000,000 g / mole, 10,000 to 1,000,000 g / mole, or 50,000 to 400,000 g / mole; a number average molecular weight ("Mn") of 2,500 to 2,500,00 g / mole, 10,000 to 250,000 g / mole, or 25,000 to 200,000 g / mole; and / or a z-average molecular weight ("Mz") of 10,000 to 7,000,000 g / mole, 80,000 to 700,000 g / mole, or 100,000 to 500,000 g / mole. The propylene-based elastomer can have a molecular weight distribution (Mw / Mn or "MWD") of 1.5 to 20, or 1.5 to 15, 1.5 to 5, 1.8 to 5, or 1.8 to 4.

[0055] The propylene-based elastomer can have an elongation at break of less than 2000%, less than 1000%, or less than 800%, as measured in accordance with ASTM D412.

[0056] The propylene-based elastomer can be grafted (i.e., "functionalized") with one or more grafting monomers. As used herein, the term "grafted" means that the grafting monomer is covalently bonded to the polymeric chains of the propylene-based elastomer. The grafting monomer can be or include at least one ethylenically unsaturated carboxylic acid or acid derivative, such as an anhydride, ester, salt, amide, imide, or acrylate. Illustrative grafting monomers include, but are not limited to, acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, maleic anhydride, 4-methylcyclohexene-1,2-dicarboxylic anhydride, bicyclo(2.2.2)octene-2,3-dicarboxylic anhydride, 1,2,3,4,5,8,9,10-octahydro naphthalene-2,3-dicarboxylic anhydride, 2-oxa-1,3-diketospiro(4.4)nonene, bicyclo(2.2.1 )heptene-2,3-dicarboxylic anhydride, maleopimaric acid, tetrahydrophthalic anhydride, norbornene-2,3-dicarboxylic anhydride, nadic anhydride, methyl nadic anhydride, himic anhydride, methyl himic anhydride, and 5-methylbicyclo(2.2.1 )heptene-2,3-dicarboxylic anhydride. Other suitable grafting monomers include methyl acrylate and higher alkyl acrylates, methyl methacrylate and higher alkyl methacrylates, acrylic acid, methacrylic acid, hydroxymethyl methacrylate, hydroxyethyl methacrylate and higher hydroxyalkyl methacrylates, and glycidyl methacrylate. Maleic anhydride can be used as the grafting monomer. In embodiments where the grafting monomer is maleic anhydride, the concentration of maleic anhydride in the grafted polymer can be about 6 wt%, at least about 0.5 wt%, or at least about 1.5 wt%, based on the total weight of the propylene-based elastomer.

[0057] In some embodiments, the propylene-based elastomer can be a reactor blended polymer as defined herein. That is, the propylene-based elastomer is a reactor blend of a first polymer component and a second polymer component. Thus, the comonomer content of the propylene-based elastomer can be adjusted by adjusting the comonomer content of the first polymer component present in the propylene-based elastomer, adjusting the comonomer content of the second polymer component, and / or adjusting the ratio of the first polymer component to the second polymer component.

[0058] In embodiments where the propylene-based elastomer is a reactor blended polymer, the first polymer component ("R1") can have an alpha-olefin content greater than 5 wt% alpha-olefin, greater than 7 wt% alpha-olefin, greater than 10 wt% alpha-olefin, greater than 12 wt% alpha-olefin, greater than 15 wt% alpha-olefin, or greater than 17 wt% alpha-olefin, where the percentage by weight is based on the total weight of propylene-derived units and alpha-olefin-derived units of the first polymer component. The first polymer component can have an alpha-olefin content less than 30 wt% alpha-olefin, less than 27 wt% alpha-olefin, less than 25 wt% alpha-olefin, less than 22 wt% alpha-olefin, less than 20 wt% alpha-olefin, or less than 19 wt% alpha-olefin, where the percentage by weight is based on the total weight of propylene-derived units and alpha-olefin-derived units of the first polymer component. In some embodiments, the first polymer component can have an alpha-olefin content in the range of 5 wt% to 30 wt% alpha-olefin, 7 wt% to 27 wt% alpha-olefin, 10 wt% to 25 wt% alpha-olefin, 12 wt% to 22 wt% alpha-olefin, 15 wt% to 20 wt% alpha-olefin, or 17 wt% to 19 wt% alpha-olefin. The first polymer component can comprise propylene and ethylene, and in some embodiments the first polymer component can consist only of propylene and ethylene-derived units.

[0059] In embodiments where the propylene-based elastomer is a reactor blended polymer, the second polymer component ("R2") can have an alpha-olefin content greater than 1.0 wt% alpha-olefin, greater than 1.5 wt% alpha-olefin, greater than 2.0 wt% alpha-olefin, greater than 2.5 wt% alpha-olefin, greater than 2.75 wt% alpha-olefin, or greater than 3.0 wt% alpha-olefin, where the percentage by weight is based on the total weight of propylene-derived units and alpha-olefin-derived units of the second polymer component. The second polymer component can have an alpha-olefin content less than 10 wt% alpha-olefin, less than 9 wt% alpha-olefin, less than 8 wt% alpha-olefin, less than 7 wt% alpha-olefin, less than 6 wt% alpha-olefin, or less than 5 wt% alpha-olefin, where the percentage by weight is based on the total weight of propylene-derived units and alpha-olefin-derived units of the second polymer component. In some embodiments, the second polymer component can have an alpha-olefin content in the range of 1.0 wt% to 10 wt% alpha-olefin, or 1.5 wt% to 9 wt% alpha-olefin, or 2.0 wt% to 8 wt% alpha-olefin, or 2.5 wt% to 7 wt% alpha-olefin, or 2.75 wt% to 6 wt% alpha-olefin, or 3 wt% to 5 wt% alpha-olefin. The second polymer component can comprise propylene and ethylene, and in some embodiments the first polymer component can consist only of propylene and ethylene-derived units.

[0060] In embodiments where the propylene-based elastomer is a reactor blended polymer, the propylene-based elastomer can include 1 to 25 weight percent of the second polymer component, 3 to 20 weight percent of the second polymer component, 5 to 18 weight percent of the second polymer component, 7 to 15 weight percent of the second polymer component, or 8 to 12 weight percent of the second polymer component, based on the weight of the propylene-based elastomer. The propylene-based elastomer can include 75 to 99 weight percent of the first polymer component, 80 to 97 weight percent of the first polymer component, 85 to 93 weight percent of the first polymer component, or 82 to 92 weight percent of the first polymer component, based on the weight of the propylene-based elastomer.

[0061] The propylene-based elastomer can be prepared by any suitable means as known in the art. The propylene-based elastomer can be prepared using homogeneous conditions, for example, a continuous solution polymerization process, using a metallocene catalyst. In some embodiments, the propylene-based elastomer can be prepared in parallel solution polymerization reactors, such that the first reactor component is prepared in a first reactor and the second reactor component is prepared in a second reactor, and the reactor effluent from the first and second reactors are combined and blended to form a single effluent from which the final propylene-based elastomer is isolated. Exemplary methods of preparing propylene-based elastomers can be found in U.S. Patent Nos. 6,881,800; 7,803,876; 8,013,069; and 8,026,323 and PCT Publications WO 2011 / 087729; WO 2011 / 087730; and WO 2011 / 087731.

[0062] Commercially available examples of such propylene-based elastomers include Vistamaxx® propylene-based elastomers from ExxonMobil Chemical Company TM High performance polymers, Tafmer from Mitsui Chemicals TM Elastollan® elastomers and Versify® elastomers from Dow Chemical Company TM Elastollan® elastomers.

[0063] Impact copolymer

[0064] The propylene-based elastomer composition further includes one or more impact copolymers. The impact copolymer or ICP is composed of at least two different phases. There are any number of ways to make the ICPs used herein. Suitable ICPs can be made, for example, by physically blending a polypropylene homopolymer component(s) and a propylene-copolymer component(s); or using a dual catalyst in a single reactor process to produce different polymer components; or in a series reactor process, or producing individual components in one or more reactors, further combining them in situ to produce.

[0065] For example, a suitable ICP can be produced in a series reactor, where a polypropylene homopolymer can be first produced in one or more slurry reactors by contacting a catalyst and monomers, preferably propylene, for example in a slurry-loop reactor as is well known in the art, followed by the same catalyst and the formed homopolymer in a single gas phase reactor with monomers, preferably propylene and ethylene and / or C4-C10 alpha-olefins, to produce a propylene copolymer, such that the copolymer will embed itself in the homopolymer as discrete domains, the homopolymer as the matrix or “continuous” phase. The MFR of the individual components can be controlled by, for example, the addition and / or removal of hydrogen from the reactor. Most preferably, the homopolymer can be produced in two loop-slurry reactors in series, and each reactor contains similar or the same amount of hydrogen, producing homopolymers with nearly the same or the same MFR. The amount of hydrogen in the gas phase reactor can be the same or different than the loop-slurry reactors, such levels controlled by the removal of hydrogen from the homopolymer stream entering the gas phase reactor or at some other stage. Suitable processes and equipment can be described in U.S. Patent No. 9,000,106 and U.S. Patent No. 8,076,419 (column 6, line 6 to column 7, line 16). The system and method disclosed herein can be used in a “balanced” reactor scheme, where two slurry loop reactors in series forming a polypropylene homopolymer are at the same or similar conditions, followed by the transfer of the crystalline polymer (polypropylene homopolymer) to a single gas phase reactor to form a semi-crystalline polymer (propylene copolymer).

[0066] When making the homopolymer or copolymer, the properties of each can be adjusted to meet certain desired needs to impart the desired final properties in the ICPs described herein, and there can be a range of desired properties that the ICPs described herein can possess. For example, the level of hydrogen in the reactor(s) can be adjusted, as can the polymerization temperature, residence time, solvent (if present) consistency, and other factors.

[0067] Suitable ICPs include polypropylene homopolymers and from 10, 15, 20, 22, or 24 wt% to 26, 28, 30, 35, 40, or 45 wt% of a propylene copolymer, based on the total weight of the ICP, wherein the copolymer comprises from about 7, or 10, or 15, or 20, or 25, or 30, or 35 wt% to 40, or 45, or 50, or 55, or 60 wt% ethylene, 1-butene, 1-hexene, and / or 1-octene derived units and 80-40 wt% propylene-derived units, based on the weight of the propylene copolymer. The propylene-based impact copolymer can have a MFR in the range from 10, or 15, or 20, or 26 g / 10 min to 30, or 36, or 40, or 50 g / 10 min and an elongation at break greater than 60, or 70, or 80, or 90, or 100% (or in the range from 60 or 80% to 120, or 150, or 300, or 400%). The MFR can also range from a lower limit of about 2.5, 3.5, or 4 g / 10 min to an upper limit of about 10, 15, 20, or 30 g / 10 min. Such ICPs tend to have improved toughness (T-ICP) compared to other ICPs described in detail herein. The propylene copolymer can be an ethylene-propylene copolymer.

[0068] Suitable ICPs also include polypropylene homopolymers and from 6, or 8, or 10 wt% to 14, or 16, or 20 wt% of a propylene copolymer, based on the weight of the ICP, wherein the propylene copolymer comprises from 20, or 25, or 30, or 35 wt% to 40, or 45, or 50, or 55, or 60 wt% ethylene, 1-butene, 1-hexene, and / or 1-octene derived units and from 80, 75, 70, or 65 wt% to 60, 55, 50, 45, or 40 wt% propylene-derived units, based on the weight of the propylene copolymer. The ICP can have a MFR in the range from 3, 5, 8, or 12 g / 10 min to 20, 30, 40, or 50 g / 10 min. Most preferably, the propylene copolymer can be an ethylene-propylene copolymer.

[0069] Suitable ICPs have a molecular weight distribution (Mw / Mn) in the range from 4 or 5 to 7 or 8. In any embodiment, the size exclusion chromatogram (SEC) chromatogram can be unimodal, meaning that there can be only one discernible SEC maximum, which can or can not have a shoulder.

[0070] In embodiments, the total comonomer derived unit content (preferably ethylene derived units of the ICP) can range from 2 or 2.5 wt% to 4, or 6, or 10, or 16 wt%, based on the weight of the ICP.

[0071] In embodiments, the ICP can have a melting point greater than 155, or 160, or 162 °C, or in the range from 155, or 160, or 162 °C to 170 or 180 °C.

[0072] In embodiments, the polypropylene homopolymer fraction of the ICP has a Mw / Mn in the range from 3.0, or 3.5, or 4.0 to 4.5, or 5.0, or 6.0, or 7.0, or 8.0, or 9.0; and the polypropylene homopolymer fraction can also have a Mz / Mw less than 4, or 3.4, or 3.2, or 3.0, or 2.8, or 2.6, or 2.4, or in the range from 2 to 2.5, or 2.6, or 2.8, or 3, or 3.2, or 3.4, or 4. "Polypropylene homopolymer" means a polymer comprising ethylene, or C4-C10a-olefin derived units in the range from 0, or 0.01, or 0.1, or 0.5 to 2.0, or 3.0 wt.%, based on the weight of the polymer, and most preferably refers to a polymer consisting of propylene derived units.

[0073] In any embodiment, the "propylene copolymer" or "copolymer" can be a polymer comprising ethylene, 1-butene, 1-hexene, and / or 1-octene derived units, most preferably ethylene derived units.

[0074] In embodiments, the polypropylene homopolymer can have an isotactic pentad (isopentad) value greater than 92, or 94, or 96% and less than or equal to about 99%.

[0075] In embodiments, particularly for ICPs having high gloss, the polypropylene homopolymer can have a MFR in the range from 5, or 10, or 15 g / 10 min to 20, or 25, or 30, or 40 g / 10 min. In embodiments of impact copolymers having high toughness, the polypropylene homopolymer has a MFR in the range from 80 or 100 g / 10 min to 120, or 140, or 160, or 180, or 200, or 220 g / 10 min.

[0076] In embodiments, the xylene cold soluble fraction of the ICP, which corresponds to the propylene copolymer portion of the ICP, has a number average molecular weight (Mn) in the range from 50,000 or 60,000 g / mole to 80,000 or 100,000 g / mole. In embodiments, the propylene copolymer has a weight average molecular weight (Mw) in the range from 150,000, or 180,000, or 200,000 g / mole to 300,000, or 350,000, or 400,000 g / mole. And further, the propylene copolymer component can have a z average molecular weight (Mz) in the range from 400,000, or 450,000, or 500,000, or 550,000 g / mole to 650,000, or 700,000, or 800,000, or 900,000 g / mole. The propylene copolymer component can have a Mz / Mw less than 3.0, or 2.8, or 2.6, or 2.4, or in the range from 2.0 to 2.5, or 2.6, or 2.8.

[0077] In embodiments, the propylene copolymer portion of the ICP has a Mw / Mn in the range from 3.0, or 3.5, or 4.0 to 4.5, or 5.0, or 6.0, or 7.0, or 8.0, or 9.0. The propylene copolymer component has a Mz / Mw less than 4, or 3.4, or 3.2, or 3.0, or 2.8, or 2.6, or 2.4, or in the range from 2 to 2.5, or 2.6, or 2.8, or 3, or 3.2, or 3.4, or 4.

[0078] In embodiments, the propylene copolymer portion of the ICP has a melt flow rate in the range from 0.1 or 0.2 g / 10 min to 0.6 to 0.8, or 1, or 2 g / 10 min.

[0079] Further, in embodiments, the propylene copolymer has an intrinsic viscosity (IV) in the range from 2, or 2.2 dL / g to 4, or 4.4, or 5, or 6 dL / g.

[0080] The ICP can be multiphase, meaning that domains of copolymer are present within a continuous phase of polypropylene homopolymer. Advantageously, the copolymer domains are relatively small, and the two domains are more miscible than prior art ICP multiphase domains. Thus, in preferred embodiments of the disclosure, the polypropylene homopolymer forms a continuous phase and the copolymer, preferably an ethylene-propylene copolymer, forms copolymer domains having an average size (diameter) of less than 10, or 8, or 5, or 4, or 2 or 1 pm, or in the range from 0.40, or 0.45, or 0.50 pm to 0.80, or 0.85, or 0.90, or 1, or 2, or 4, or 5, or 8, or 10 pm. The surface of the solid material can have a high gloss, and thus, the surface gloss can be greater than 80, or 85, or 90 (ASTM D523), or greater than 70, or 75, or 80, or 85, measured at any of 20, 60 or 85 degrees.

[0081] Suitable ICPs can be desirably made in the reactor in pellet form without further processing. Thus, the impact copolymer in preferred embodiments comprises reactor grade pellets having an average particle size in the range from 1200, or 1300, or 1400, or 1500 pm to 2000, or 2400, or 2800 pm and produced at a rate greater than 30,000, or 35,000 or 40,000, or 45,000 lbs / hr (13,620 kg / hr or 15,890 kg / hr, or 18,160 kg / hr, or 20,430 kg / hr).

[0082] In embodiments, the ICP has a heat deflection temperature (HDT) in the range from 70, or 75, or 80, or 85 °C to 95, or 100, or 115, or 125 °C; or greater than 80, or 84, or 86, or 80, or 92 °C (at 66 psi, ASTM D648). In embodiments, the ICP has a HDT in the range from 100, or 110 °C to 130, or 135, or 140, or 150 °C; or greater than 100, or 110 °C (at 66 psi, ASTM D648).

[0083] Further, in embodiments, the ICP has a flexural modulus (1% secant, ASTM D790A) greater than 200, or 220, or 250, or 300 kpsi, or in the range from 120, or 130, or 140 kpsi to 200, or 225, or 250, or 300, or 400 kpsi. The yield tensile strength (ASTM D638) of the ICPs described herein can preferably be in the range from 2500 or 2600 or 2800 psi to 3000, 3500, or 4500, or 5500 psi; or greater than 2800, or 2900, or 3000, or 3200 psi.

[0084] The ICP can have a notched Izod impact at 23°C of greater than 4, or 5, or 6, or 8 ft-lb / in (213 J / m, or 267 J / m, or 320 J / m, or 426 J / m) (or ranging from 4 or 5, or 6, or 8 ft-lb / in to 10, or 12, or 14 ft-lb / in; 213 or 426 J / m to 533, or 640, or 693 J / m) as measured by ASTM D256A. Further, the notched Izod impact at 23°C as measured by ISO 180 / A can preferably be greater than 8, or 10, or 12, or 14, or 20, or 30, or 40 kJ / m2 (or ranging from 8 or 10 kJ / m2 to 16, or 20, or 30, or 40, or 50, or 60 kJ / m2).

[0085] In one class of embodiments, the ICP can include a polypropylene homopolymer and from about 10 to about 45 weight percent of a propylene copolymer, based on the weight of the ICP, wherein the propylene copolymer contains from about 7 to about 60 weight percent ethylene and / or C4-C10 alpha-olefin derived units and the balance propylene derived units, based on the weight of the propylene copolymer, the ICP having a MFR (230°C / 2.16 kg) in the range of from about 10 to about 50 g / 10 min and an elongation at break greater than 60 percent. In various embodiments, the ICP can also have one or more of the following properties:

[0086] (a) a density (as measured at room temperature based on ASTM D1505) of from about 0.86 g / cm3to about 0.91 g / cm3, or 0.88 g / cm3to about 0.90 g / cm3, or 0.89 g / cm3to about 0.91 g / cm3; 3 3 3 3 3 3

[0087] (b) a melt index at 230°C / 2.16 kg of from about 2.5 g / 10 min to about 6.0 g / 10 min, or from about 3.5 g / 10 min to about 4.5 g / 10 min, or from about 4.0 g / 10 min to about 5.5 g / 10 min, as measured according to ASTM D1238;

[0088] (c) a total propylene derived unit content of from about 88 to about 92 weight percent, more preferably from about 90 to about 91 weight percent, based on the weight of the ICP;

[0089] ​​​​​​(d) a flexural modulus (1% secant, as measured based on ASTM D790A) ranging from about 130 to about 200 kpsi, or from about 130 to about 160 kpsi, or from about 140 to about 150 kpsi;

[0090] (e) a tensile strength at yield (as measured based on ASTM D638) of about 2500 to about 4500 psi, or from about 2600 psi to about 3500 psi, or from about 2800 psi to about 3000 psi;

[0091] (f) a notched Izod impact at 23 °C (as measured based on ISO 180 / A) of greater than about 20, or about 30, or about 40 kJ / m 2 ; and

[0092] (g) a heat deflection temperature (HDT) at 66 psi (as measured based on ASTM D648) of about 75 °C to about 115 °C, or from about 80 °C to about 100 °C, or from about 85 °C to about 95 °C.

[0093] Tensile properties of ICPs are determined according to ASTM D638, including Young’s modulus (also known as elastic modulus), tensile stress at yield (also known as tensile strength at yield), tensile strain at yield (also known as tensile elongation at yield), tensile stress at break (also known as tensile strength at break), and tensile strain at break (also known as tensile elongation at break). The yield energy can be defined as the area under the stress-strain curve from zero strain to the yield strain. The break energy can be defined as the area under the stress-strain from zero strain to the break strain. Injection molded tensile bars have an ASTM D638 Type I or Type IV geometry, tested at a speed of 2 inches / min. Compression molded tensile bars have an ASTM D412 Type C geometry, tested at a speed of 20 inches / min. For compression molded specimens only: the tensile stress at yield and tensile strain at yield are determined as the 10% offset values as defined in ASTM D638. Break properties are only reported if the majority of test specimens break before a strain of about 2000%, which can be the maximum strain possible on the load frame used for testing.

[0094] Flexural properties of ICPs are determined according to ASTM D790A, including 1% secant modulus. The test specimen geometry can be as specified in “Molded Materials (Thermoplastic and Thermoset)”, and the support span can be 2 inches.

[0095] The heat deflection temperature of ICPs can be determined according to ASTM D648 at 66 psi on injection molded specimens.

[0096] Suitable ICPs are commercially available from ExxonMobil Chemical Company.

[0097] Blend composition

[0098] The propylene-based elastomer composition includes at least one propylene-based elastomer and at least one impact copolymer. The amount of the at least one propylene-based elastomer in the blend composition is about 25 wt% to about 60 wt%, or about 30 wt% to about 55 wt%, about 35 wt% to about 50 wt%, about 40 wt% to about 60 wt%, or about 45 wt% to about 55 wt%, based on the total weight of the blend composition. Alternatively, the amount of the at least one propylene-based elastomer in the blend composition is about 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%, based on the total weight of the blend composition. Alternatively, the amount of the at least one propylene-based elastomer in the blend composition can be less than 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%, based on the total weight of the blend composition.

[0099] The amount of the at least one impact copolymer in the blend composition is about 20 wt% to about 60 wt%, or about 25 wt% to about 55 wt%, about 25 wt% to about 50 wt%, or about 35 wt% to about 50 wt%, based on the total weight of the blend composition. Alternatively, the amount of the at least one impact copolymer in the blend composition can be at least 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, or 55 wt%, based on the total weight of the blend composition. Alternatively, the amount of the at least one impact copolymer in the blend composition can be less than 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, 25 wt%, or 20 wt%, based on the total weight of the blend composition.

[0100] In one embodiment, the amount of ICP in the PBE composition is about 30 to about 60 wt%, for example, about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, about 50 wt%, about 55 wt%, about 60 wt%, or the amount of ICP can vary within a range of any combination of the values recited herein, based on the total weight of the PBE composition.

[0101] In certain embodiments, the PBE component or PBE blend composition can optionally include up to 15 wt.%, up to 10 wt.%, or up to 5 wt.% of one or more polyethylenes. Suitable polyethylenes include one or more of ethylene homopolymers, ethylene copolymers, and combinations thereof. Useful ethylene copolymers include one or more comonomers in addition to ethylene and can be random copolymers, statistical copolymers, block copolymers, and / or combinations thereof. In some embodiments, the elastomeric composition is free of polyethylene and free of ethylene copolymers, or contains less than 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, or 1 wt.% of polyethylene or ethylene copolymers, based on the total weight of the elastomeric composition.

[0102] Additives

[0103] The propylene-based elastomer, ICP component, and / or blend composition can contain one or more additives, depending on the intended purpose(s). Desired additives can be incorporated into the propylene-based elastomer, ICP component, and / or blend composition directly or as part of a masterbatch (i.e., an additive package containing several additives simultaneously added in a predetermined ratio). The additive package or masterbatch can be added in any suitable amount to achieve the desired result. Such additives can also be introduced into the PBE blend composition during extrusion.

[0104] Suitable additives include one or more reinforcing and non-reinforcing fillers, antioxidants, stabilizers, processing oils, compatibilizers, lubricants (e.g., oleic acid amides), anti-blocking agents, antistatic agents, waxes, coupling agents for fillers and / or pigments, pigments, flame retardants, antioxidants, and other processing aids known in the art. In some embodiments, the additive(s) is up to about 65 wt.%, or up to about 60 wt.%, or up to about 55 wt.%, or up to about 50 wt.% of the roofing composition. In some embodiments, the additive(s) is at least 5 wt.%, or at least 10 wt.%, or at least 15 wt.%, or at least 20 wt.%, or at least 25 wt.%, or at least 30 wt.%, or at least 35 wt.%, or at least 40 wt.% of the roofing composition. The additive(s) can also range from a lower limit of about 1 wt.%, 3 wt.%, or 4 wt.% to an upper limit of about 5 wt.%, 8 wt.%, or 10 wt.%.

[0105] In some embodiments, the PBE blend composition can include one or more fillers and / or one or more colorants. Exemplary materials include inorganic fillers such as calcium carbonate, clay, silica, talc, titanium dioxide, or carbon black. Any type of carbon black can be used, such as channel black, furnace black, thermal black, acetylene black, lamp black, and the like.

[0106] In some embodiments, the PBE blend composition includes one or more flame retardants, such as calcium carbonate, inorganic clays containing water of hydration such as trihydroxy aluminum ("ATH") or magnesium hydroxide. In some embodiments, the PBE blend composition includes one or more UV stabilizers, such as titanium dioxide or Tinuvin TM XT-850. Still other additives can include one or more antioxidants and / or heat stabilizers. In exemplary embodiments, the processing and / or in-service heat stabilizers include IRGANOX TM B-225 and / or IRGANOX TM 1010.

[0107] When present, any one or more fillers can form up to 5 wt.%, or up to 10 wt.%, or up to 15 wt.%, or up to 20 wt.%, or up to 25 wt.%, or up to 30 wt.%, or up to 35 wt.%, or up to 40 wt.% of the total weight of the PBE composition. In some embodiments, the PBE composition has 5 wt.% - 40 wt.%, or 10 wt.% - 35 wt.%, or 15 wt.% - 30 wt.% of one or more fillers.

[0108] Preferably, the one or more additives can be present in an amount of about 0.01 wt.% to about 10 wt.%, or about 0.1 wt.% to about 8 wt.%, or 1 wt.% - 3 wt.%, based on the total weight of the PBE blend composition. In preferred embodiments, the PBE blend composition has at least one of an antioxidant and an anti-aging agent, particularly in an amount of about 0.5 to about 5 wt.%, such as about 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.4 wt.%, 1.6 wt.%, 1.8 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, or 5 wt.%, based on the total weight of the blend composition. In another preferred embodiment, the blend composition includes at least one of an antioxidant, an anti-aging agent, and a flame retardant, particularly in an amount of about 0.5 to about 5 wt.%, such as about 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.4 wt.%, 1.6 wt.%, 1.8 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, or 5 wt.%, based on the total weight of the blend composition.

[0109] Film

[0110] The PBE blend compositions described herein are particularly useful for roofing applications, such as for thermoplastic polyolefin roofing membranes. The membranes produced from the blend compositions can exhibit a beneficial combination of properties, and in particular exhibit excellent melt strength and strain hardening properties, as well as stability at extreme temperatures, such as from -40°C to 40°C and up to 100°C.

[0111] The roofing compositions described herein can be prepared using polymer manufacturing methods such as Banbury mixing or twin-screw extrusion either by pre-compounding or by in-situ compounding. The blend compositions can then be formed into roofing membranes using conventional sheet extrusion or sheet extrusion lamination techniques. The roofing membranes can be particularly useful for commercial roofing applications, such as on flat, low-pitched or steeply pitched substrates. In one example, a roofing membrane can be prepared having a top layer or surface that is a white reflective layer laminated on a bottom layer or bottom surface that is either uncolored or simply black.

[0112] The roofing membranes can be secured to the underlying roof by any means known in the art, such as by adhesive materials, ballast materials, dot bonding or mechanical dot fastening. For example, the membranes can be installed using mechanical fasteners and plates placed along the edge sheet and fastened through the membrane into the roof deck. The abutting sheets of flexible membrane are overlapped, covering the fasteners and plates, and joined together, preferably with heat air welding, for example. The membranes can also be fully adhered or self-adhered to the insulation or deck material using adhesives. The insulation material is typically secured to the deck with mechanical fasteners, and the flexible membrane is adhered to the insulation material.

[0113] The roofing membranes can be reinforced using any type of base cloth, including but not limited to polyester, glass fiber, glass fiber reinforced polyester, polypropylene, woven or non-woven fabric (such as nylon), or combinations thereof. Preferred base cloths are glass fiber and / or polyester.

[0114] The useful roofing membranes can have a thickness of 0.1-5 mm, or 0.5-4 mm, or 0.5 mm-2 mm, or 0.9-1.5 mm. In some embodiments, various patterns can be used to texture the surface layers of the top and / or bottom of the membrane. The texture increases the surface area of the membrane, reduces the gloss, and makes the membrane surface less slippery. Examples of texture designs include, but are not limited to, having a polygonal base and triangular-faced polyhedra that intersect at a common apex, such as a pyramidal base; a cone configuration having a circular or elliptical configuration; and a random pattern configuration.

[0115] In addition to roofing materials, the PBE blends can be used in a variety of moisture and water barrier applications, including membranes, liners, or sheets for building foundations, building basements, floors, bathtubs, showers, reservoirs, ornamental ponds, ponds, plaza decks, parking lots, walkways, tunnels, earthen berms, abutments, retaining walls, landfills, underground vaults or reservoirs, chemical and water pipelines.

[0116] The PBE blends can also be used in protective covering applications that favor a combination of outstanding flexibility, strong adhesion to substrates, and good mechanical properties, which can be required to serve as a shield from elements including wind, rain, and sunlight. Conveniently, the films of the present invention can also be suitable for forming tarpaulins for various applications, such as for weather damage protection for buildings, unsealed roads, rail freight vehicles or pilings, as well as for brick and stone structures. Such tarpaulins can be perforated, which is typically used for medium to large scale advertising, or for protecting scaffolding, the purpose of the perforations (20-70%) being to reduce wind vulnerability.

[0117] A roofing membrane, liner, or sheet made from the PBE blend compositions provided herein having a thickness of 0.9 to 1.5 mm can have any one or more of the following properties:

[0118] a) a tensile force (N / 50 mm) MD and TD of at least 600, or at least 625, or at least 650, as measured by GB / T 328.9-2007;

[0119] b) a tensile strength (MPa) MD and TD of at least 12, at least 14, or at least 18, as measured by GB / T 328.9-2007;

[0120] c) an elongation at break (%) MD and TD of at least 500, at least 550, or at least 600, as measured by GB / T 328.9-2007;

[0121] d) a nail tear strength (N) MD and TD of at least 400, at least 450, or at least 500, as measured by GB / T 328.18;

[0122] e) a puncture strength (N) of at least 180, at least 185, or at least 190, as measured by CJ / T 234-2006;

[0123] f) a tensile strength retention (TSKR), %, MD and TD of at least 90%, at least 95% or at least 98%, wherein TSKR is calculated as TSKR = [tensile strength of sample before heat resistance testing as measured by GB / T 328.9-2007] / [tensile strength of sample after heat resistance testing via GB / T 328.11-2007, Method B as measured by GB / T 328.9-2007];

[0124] g) an elongation retention (EKR), %, MD and TD of at least 80%, at least 85% or at least 90%, wherein EKR is calculated as EKR = [elongation at break of sample before heat resistance testing as measured by GB / T 328.9-2007] / [elongation at break of sample after heat resistance testing via GB / T 328.11-2007, Method B as measured by GB / T 328.9-2007];

[0125] h) a dimensional stability, %, MD and TD of 1.2 or less, 1.1 or less or 1.0 or less as measured by GB / T 23457-2017; and / or

[0126] i) a Shore D hardness of 35-50, 40-50 or 38-48 as measured by GB / T 2411.

[0127] The test methods specified in a) - i) above are national standards of the People’s Republic of China, which are publicly available in the common language. Each method is referenced by the industry standard document T / CBMF 43-2019. The material features disclosed herein are characterized by the ability to achieve a certain level of performance according to the T / CBMF 43-2019 standard, which has particular value in the Chinese market. GB / T 328.9-2007 corresponds largely to ISO 1421, although some types of materials are excluded. GB / T 2411 is the same as ISO 868. The remaining standards GB / T 328.18, CJ / T 234-2006, GB / T 328.11-2007 and GB / T 23457-2017 have no ISO counterpart.

[0128] Method of making

[0129] The PBE blend composition can be compounded by any convenient method, such as dry blending the olefin-based copolymer and optional fillers, crosslinking package and other additives, and then melt mixing at a temperature above the melting temperature of the thermoplastic components, either directly in the extruder used to make the finished product, or by pre-melt mixing in a separate extruder, such as a Banbury mixer. The dry blend of polymer components can also be directly injection molded without a pre-melt mixture. Examples of machines capable of producing shear and mixing include extruders with kneaders or mixing elements with one or more mixing tips or blades, extruders with one or more screws, co-rotating or counter-rotating types of extruders, Banbury mixers, Farrell continuous mixers, and Buss kneaders. The type and intensity of mixing, temperature, and residence time required can be achieved by selecting one of the above machines in combination with selecting kneading or mixing elements, screw design, and screw speed (<3000 rpm). The temperature for melt mixing is typically 60°C to 130°C and the residence time is 10 to 20 minutes.

[0130] The blend composition can contain one or more additives, which can be introduced into the blend composition simultaneously with the individual polymer components or subsequently (in the case of using an extruder or Buss kneader) or only chronologically later. The additives can be added to the blend in neat form or in the form of a masterbatch. The processing oil or plasticizer can be added in one addition or in multiple additions. Preferably, the plasticizer is added after the polymer components and optional one or more second polymers are mixed in a sufficiently molten state. The blend can be either a physical blend or a reactor blend made by in-reactor processes as known to those of ordinary skill in the art.

[0131] Further embodiments

[0132] Additional embodiments of the waterproofing membrane provided herein also include one or more of the following embodiments 1 to 20:

[0133] Embodiment 1. A waterproofing membrane comprising 40 to 60 weight percent, based on the total weight of the blend composition, of at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a density of 0.850 g / cm3to 0.920 g / cm3 3 3 m according to ASTM D-1505, a crystallinity of 2% to 65% of isotactic polypropylene, and a melting point (Tm) of 100°C or less, wherein the propylene-based elastomer comprises greater than 50 weight percent propylene and about 3 weight percent to about 25 weight percent derived from ethylene and / or one or more C4-C12alpha-olefins. 12 ​​units of alpha-olefins, from 40 wt% to 60 wt% of at least one impact copolymer based on the total weight of the propylene-based elastomer and the total weight of the blend composition; wherein the film has a thickness of 0.9 mm to 1.5 mm, tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T 328.9-2007, and tensile strength (MPa) MD and TD of at least 12 as measured by GB / T 328.9-2007.

[0134] Embodiment 2. The waterproof film according to Embodiment 1, wherein the at least one impact copolymer comprises a propylene homopolymer blended with a propylene copolymer.

[0135] Embodiment 3. The waterproof film according to Embodiment 1 or 2, wherein the propylene-based elastomer has a triad tacticity greater than about 90% as measured by 13C NMR.

[0136] Embodiment 4. The waterproof film according to any one of Embodiments 1-3, wherein the propylene-based elastomer has a density of about 0.85 g / cm 3 to about 0.88 g / cm 3 .

[0137] Embodiment 5. The waterproof film according to any one of Embodiments 1-4, wherein the propylene-based elastomer has a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 5 g / 10 min as measured according to ASTM D1238.

[0138] Embodiment 6. The waterproof film according to any one of Embodiments 1-5, wherein the at least one impact copolymer has a melt index at 230°C / 2.16 kg of about 3.5 g / 10 min to about 4.5 g / 10 min as measured according to ASTM D1238.

[0139] Embodiment 7. The waterproof film according to any one of Embodiments 1-6, wherein the at least one impact copolymer has a density of about 0.88 g / cm 3 to about 0.95 g / cm 3 .

[0140] Embodiment 8. The waterproof film according to any one of Embodiments 1-7, wherein the propylene-based elastomer comprises about 3 wt% to about 15 wt% units derived from ethylene based on the total weight of the propylene-based elastomer.

[0141] Embodiment 9. The waterproof film according to any one of Embodiments 1-8, wherein the propylene-based elastomer has a density of about 0.85 g / cm 3 to about 0.88 g / cm 3and a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 3.5 g / 10 min, as measured in accordance with ASTM D1238, and at least one impact copolymer having a density of about 0.88 g / cm 3 to about 0.95g / cm 3 and a melt index at 230° C. / 2.16 kg of about 3.5 g / 10 min to about 5 g / 10 min, as measured according to ASTM D1238.

[0142] Embodiment 10. The waterproof membrane according to any one of embodiments 1 to 9, further comprising 1% to 5% by weight of a masterbatch comprising one or more antioxidants and one or more anti-agents.

[0143] Embodiment 11. The waterproofing membrane according to any one of embodiments 1 to 10, wherein the masterbatch further comprises at least one flame retardant additive.

[0144] Embodiment 12. The waterproof membrane according to any one of Embodiments 1 to 11, further comprising: an elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007; a tear strength around a nail (N) MD and TD of at least 400 as measured by GB / T 328.18; and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

[0145] Embodiment 13. A waterproof membrane comprising from 40 wt% to 60 wt% of at least one propylene-based elastomer, based on the total weight of the blend composition, the at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a thermal conductivity of 0.850 g / cm2 according to ASTM D-1505, and a thermal conductivity of 0.850 g / cm2 according to ASTM D-1505. 3 to 0.920g / cm 3 density, a crystallinity of 2% to 65% of isotactic polypropylene and a melting point (T m ), wherein the propylene-based elastomer comprises greater than 50 wt% propylene and about 3 wt% to about 25 wt% units derived from ethylene, based on the total weight of the propylene-based elastomer; and 40 wt% to 60 wt% of at least one impact copolymer, based on the total weight of the blend composition, the at least one impact copolymer comprising a propylene homopolymer blended with a propylene copolymer, wherein the at least one impact copolymer has a total propylene-derived unit content of about 88 to about 92 wt% based on the weight of the ICP; wherein the film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T328.9-2007, and a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T328.9-2007.

[0146] Embodiment 14. The waterproofing membrane according to Embodiment 13, further comprising an elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007; a tear strength around a nail (N) MD and TD of at least 400 as measured by GB / T 328.18 and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

[0147] Embodiment 15. The waterproofing membrane according to Embodiment 13 or 14, wherein the propylene-based elastomer has a density of about 0.85 g / cm 3 to about 0.88 g / cm 3 and a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 3.5 g / 10 min as measured according to ASTM D1238 and the at least one impact copolymer has a density of about 0.88 g / cm 3 to about 0.95 g / cm 3 and a melt index at 230°C / 2.16 kg of about 3.5 g / 10 min to about 4.5 g / 10 min as measured according to ASTM D1238.

[0148] Embodiment 16. The waterproofing membrane according to any one of Embodiments 13 to 15, wherein the at least one impact copolymer comprises 8 wt% to 20 wt% of a propylene copolymer, based on the weight of the impact copolymer, wherein the propylene copolymer comprises 20 wt% - 60 wt% ethylene, 1-butene, 1-hexene and / or 1-octene derived units.

[0149] Embodiment 17. The waterproofing membrane according to any one of Embodiments 13 to 16, wherein the at least one impact copolymer has a melt flow rate at 230°C / 2.16 kg of 2.5 - 10 g / 10 min.

[0150] Embodiment 18. A waterproofing membrane comprising: 40 wt% to 60 wt% of at least one propylene-based elastomer based on the total weight of the blend composition, the at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a density of 0.850 g / cm 3 to 0.920 g / cm 3 according to ASTM D-1505, a crystallinity of 2% to 65% of isotactic polypropylene and a melting point (T m), wherein the propylene-based elastomer comprises greater than 50 wt% propylene and about 3 wt% to about 25 wt% units derived from ethylene, based on the total weight of the propylene-based elastomer; and 40 wt% to 60 wt% of the total weight of the blend composition of at least one impact copolymer comprising a propylene homopolymer blended with a propylene copolymer, wherein the at least one impact copolymer has a total propylene derived unit content of about 88 to about 92 wt% by weight based on ICP; and 1 wt% to 5 wt% of a masterbatch comprising one or more antioxidants and one or more agents, wherein the film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T 328.9-2007, a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T 328.9-2007, an elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007, a nail around tear strength (N) MD and TD of at least 400 as measured by GB / T 328.18, and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

[0151] Embodiment 19. The waterproofing film according to Embodiment 18, wherein the propylene-based elastomer has a melt flow rate at 230°C / 2.16 kg of about 3 g / 10 min to about 30 g / 10 min as measured according to ASTM D1238 and the at least one impact copolymer has a melt flow rate at 230°C / 2.16 kg of 3-10 g / 10 min.

[0152] Embodiment 20. The waterproofing film according to Embodiment 18 or 19, wherein the masterbatch further comprises at least one flame retardant additive.

[0153] In order to provide a better understanding of embodiments of the present application, the following non-limiting examples of preferred or representative embodiments are given. The following examples should in no way be interpreted as limiting or restricting the scope of the present application. Example

[0154] The present disclosure will be described in greater detail below with reference to the following non-limiting examples. The examples are not to be construed as limiting the scope of the present application.

[0155] Three different TPO blends (Samples 1-3) were prepared. Each blend was made from a propylene-based elastomer, an impact copolymer, and additives. In each sample, the propylene-based elastomer was Vistamaxx TM6102 and impact copolymer are PP7032E3, both obtained from ExxonMobil Chemical Company. Additives include AO 1010, which is an antioxidant additive obtained from BASF, AO 168, which is another antioxidant additive obtained from BASF, and PS 802, which is an anti-aging additive obtained from BASF.

[0156] “Vistamaxx TM 6102” has 16 wt% ethylene derived units and a density of 0.862 g / cc (ASTM D1505), a melt index of 1.4 g / 10 min (190°C; 2.16 kg) (ASTM D1238), a melt mass flow rate (MFR) of 3 g / 10 min (230°C; 2.16 kg) (ASTM D1238), a Shore A durometer hardness of 66 (ASTM D224), and a Vicat softening temperature of 52.2°C (ASTM D1525).

[0157] “PP7032E3” has a density of 0.90 g / cc (ASTM D1505), a melt mass flow rate (MFR) of 4.0 g / 10 min (230°C; 2.16 kg) (ASTM D1238), a Rockwell hardness of 87 (ASTM D785), and a flexural temperature of 82.1°C (ASTM D648 under 66 psi unannealed load).

[0158] PP7032E3 is the main component in Sample 1. Vistamaxx TM 6102 is the main component in Sample 3. The blend formulations are reported below in Table 1. All numbers represent weight percent of each component in the blend.

[0159] Table 1. TPO Underground Scheme Formulations

[0160]

[0161] Each Sample 1-3 blend was melt and extruded to form a sheet having a thickness of about 1.2 mm and tested for flexibility, toughness, and dimensional stability properties according to the T / CBMF 43-2019 standard test procedure, which is the Chinese standard for TPO waterproofing applications. Table 2 below summarizes the test results.

[0162] Table 2: Strength Results for TPO Samples 1-3

[0163]

[0164] The properties of samples 1-3 reported in Table 2 are graphically depicted in the accompanying figures in comparison to the minimum requirements of water repellent compositions as determined by T / CBMF 43-2019 industry standard. The figures show that samples 1-3 are not only suitable for use in water repellent applications, but samples 1-3 also provide a significant improvement in each of the properties measured.

[0165] While compositions and methods are described herein in terms of "comprising" various components or steps, the compositions and methods can also "consist essentially of" or "consist of" the various components and steps. Additional embodiments provided herein include the following numbered embodiments:

[0166] From the foregoing description, it will be apparent to a person skilled in the art that many changes, modifications, and variations of the present disclosure can be made without departing from the spirit or scope of the disclosure, and that the numerical ranges recited herein are intended to include all values from the lower value and to the upper value. Additionally, it is intended that each numerical limitation recited herein includes every lower value as well as every higher value unless otherwise indicated.

[0167] All numerical values within the detailed description of the application are modified by "about" the indicated value, and take into account experimental error and variations known to persons of ordinary skill in the art.

[0168] All documents described herein are hereby incorporated by reference, including any priority documents and / or testing procedures. As is fully intended to be encompassed within the spirit and scope of the present application, numerous modifications, variations and alterations to the illustrative embodiments described herein will occur to those skilled in the art once armed with the present disclosure. Therefore, it is intended that within the scope of the application, changes are made in the general principles and applications described herein. Similarly, it is intended that individual features of the application disclosed herein can be added or removed from among the full scope of features while still being encompassed by the application. Accordingly, the term "comprising" is used herein is taken to be synonymous with the term "including". Likewise, the term "comprises" is used herein is taken to be synonymous with the term "includes". Likewise, whenever a composition, an element or a group of elements is preceded by the phrase "comprising," it is understood that we also contemplate the same composition, element or group of elements preceded by the phrases "consisting essentially of," "consisting of," "selected from the group consisting of," or "is" and vice versa.

Claims

1. Waterproof membrane, including: 40 wt% to 60 wt% of at least one propylene-based elastomer, based on the total weight of the blend composition, the at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a thermal conductivity of 0.850 g / cm² per ASTM D-1505, and a thermal conductivity of 0.850 g / cm² per ASTM D-1505. 3 to 0.920g / cm 3 density, a crystallinity of 2% to 65% of isotactic polypropylene and a melting point (T m ), wherein the propylene-based elastomer comprises greater than 50 wt. % propylene and from about 3 wt. % to about 25 wt. % derived from ethylene and / or one or more C4-C 12 units of alpha-olefins, based on the total weight of the propylene-based elastomer; and 40 to 60 wt% of at least one impact copolymer, based on the total weight of the blend composition; wherein the film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T 328.9-2007, and a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T 328.9-2007.

2. The waterproof membrane of claim 1, wherein the at least one impact copolymer comprises a propylene homopolymer blended with a propylene copolymer.

3. The waterproofing membrane of claim 1, wherein the propylene-based elastomer has a triad tacticity greater than about 90% as measured by 13C NMR.

4. The waterproof membrane of claim 1, wherein the propylene-based elastomer has a viscosity of about 0.85 g / cm 3 to about 0.88g / cm 3 density.

5. The waterproof membrane of claim 1, wherein the propylene-based elastomer has a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 5 g / 10 min, as measured according to ASTM D1238.

6. The waterproof membrane of claim 1, wherein the at least one impact copolymer has a melt index at 230°C / 2.16 kg of about 3.5 g / 10 min to about 4.5 g / 10 min, as measured according to ASTM D1238.

7. The waterproof membrane of claim 1, wherein at least one impact copolymer has a strength of about 0.88 g / cm 3 to about 0.95g / cm 3 density.

8. The waterproof membrane of claim 1, wherein the propylene-based elastomer comprises from about 3 wt% to about 15 wt% of units derived from ethylene, based on the total weight of the propylene-based elastomer.

9. The waterproof membrane of claim 1, wherein the propylene-based elastomer has a viscosity of about 0.85 g / cm 3 to about 0.88g / cm 3 and a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 3.5 g / 10 min, as measured in accordance with ASTM D1238, and at least one impact copolymer having a density of about 0.88 g / cm 3 to about 0.95g / cm 3 and a melt index at 230° C. / 2.16 kg of about 3.5 g / 10 min to about 5 g / 10 min, as measured according to ASTM D1238.

10. The waterproof membrane according to claim 1, further comprising 1 to 5 wt% of a masterbatch comprising one or more antioxidants and one or more anti-aging agents.

11. The waterproofing membrane of claim 10, wherein the masterbatch further comprises at least one flame retardant additive.

12. The waterproof membrane according to claim 1, further comprising: Elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007; Tear strength around the nail (N) MD and TD of at least 400 as measured by GB / T 328.18, and A puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

13. Waterproof membrane, including: 40 wt% to 60 wt% of at least one propylene-based elastomer, based on the total weight of the blend composition, the at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a thermal conductivity of 0.850 g / cm² per ASTM D-1505, and a thermal conductivity of 0.850 g / cm² per ASTM D-1505. 3 to 0.920g / cm 3 density, a crystallinity of 2% to 65% of isotactic polypropylene and a melting point (T m ), wherein the propylene-based elastomer comprises greater than 50 weight percent propylene and from about 3 weight percent to about 25 weight percent units derived from ethylene, based on the total weight of the propylene-based elastomer; and 40 wt% to 60 wt% of at least one impact copolymer, based on the total weight of the blend composition, the at least one impact copolymer comprising a propylene homopolymer blended with a propylene copolymer, wherein the at least one impact copolymer has a total propylene-derived unit content of about 88 to about 92 wt%, based on the weight of the ICP; wherein the film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T 328.9-2007, and a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T 328.9-2007.

14. The waterproof membrane according to claim 13, further comprising: Elongation at break (%) MD and TD of at least 500 as measured by GB / T 328.9-2007; Tear strength around the nail (N) MD and TD of at least 400 as measured by GB / T 328.18, and A puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

15. The waterproof membrane of claim 13, wherein the propylene-based elastomer has a viscosity of about 0.85 g / cm 3 to about 0.88g / cm 3 and a melt flow rate at 230°C / 2.16 kg of about 2.5 g / 10 min to about 3.5 g / 10 min, as measured in accordance with ASTM D1238, and at least one impact copolymer having a density of about 0.88 g / cm 3 to about 0.95g / cm 3 and a melt index at 230° C. / 2.16 kg of about 3.5 g / 10 min to about 4.5 g / 10 min, as measured according to ASTM D1238.

16. The waterproof membrane of claim 13, wherein the at least one impact copolymer comprises from 8 to 20 wt% of a propylene copolymer, based on the weight of the impact copolymer, wherein the propylene copolymer comprises from 20 to 60 wt% of ethylene, 1-butene, 1-hexene and / or 1-octene derived units.

17. The waterproof membrane of claim 13, wherein the at least one impact copolymer has a melt flow rate at 230°C / 2.16 kg of 2.5-10 g / 10 min.

18. Waterproof membrane, including: 40 wt% to 60 wt% of at least one propylene-based elastomer, based on the total weight of the blend composition, the at least one propylene-based elastomer having a heat of fusion of less than about 80 J / g as determined by DSC, a thermal conductivity of 0.850 g / cm² per ASTM D-1505, and a thermal conductivity of 0.850 g / cm² per ASTM D-1505. 3 to 0.920g / cm 3 density, a crystallinity of 2% to 65% of isotactic polypropylene and a melting point (T m ), wherein the propylene-based elastomer comprises greater than 50 weight percent propylene and from about 3 weight percent to about 25 weight percent units derived from ethylene, based on the total weight of the propylene-based elastomer; and 40 wt% to 60 wt% of at least one impact copolymer, based on the total weight of the blend composition, the at least one impact copolymer comprising a propylene homopolymer blended with a propylene copolymer, wherein the at least one impact copolymer has a total propylene-derived unit content of about 88 to about 92 wt%, based on the weight of the ICP; and 1 to 5 wt. % of a masterbatch comprising one or more antioxidants and one or more anti-aging agents, The film has a thickness of 0.9 mm to 1.5 mm, a tensile force (N / 50 mm) MD and TD of at least 600 as measured by GB / T328.9-2007, a tensile strength (MPa) MD and TD of at least 12 as measured by GB / T328.9-2007, an elongation at break (%) MD and TD of at least 500 as measured by GB / T328.9-2007, a tear strength around a nail (N) MD and TD of at least 400 as measured by GB / T 328.18, and a puncture strength (N) of at least 180 as measured by CJ / T 234-2006.

19. The waterproof membrane of claim 18, wherein the propylene-based elastomer has a melt flow rate at 230°C / 2.16 kg of about 3 g / 10 min to about 30 g / 10 min, as measured according to ASTM D1238, and the at least one impact copolymer has a melt flow rate at 230°C / 2.16 kg of 3-10 g / 10 min.

20. The waterproofing membrane of claim 18, wherein the masterbatch further comprises at least one flame retardant additive.

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