Impact modifier compositions and applications thereof

Abstract

To provide an impact modifier composition for use in polypropylene compositions for an enhanced impact resistance value and a good balance of other mechanical properties.SOLUTION: There is disclosed an impact modifier composition (IMC) containing a polyolefin plastomer (POP) and a hydrogenated styrenic block copolymer (HSBC), wherein the hydrogenated styrenic block copolymer is represented by a general configuration selected from: S-S / EB, S-S / EB', S-S / EB-EB', S-S / EB'-EB, S-S / EB-S, S-S / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB', EB-S / EB'-EB, and mixtures thereof. Prior to hydrogenation, each block S is a polymer block of a vinyl aromatic monomer, each block EB is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of <35 wt. %, each block EB' is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of >35 wt. %, each block EP is a polyisoprene block of isoprene monomer, and each block S / EB and S / EB', independently, is a copolymer block of a vinyl aromatic monomer and 1,3-butadiene monomer. The IMC can be used in thermoplastic polyolefin (TPO) compositions to improve impact resistance values for various applications, including automobile parts.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present disclosure relates to impact modifier compositions, methods of preparation and uses thereof. [Background technology]

[0002] Copolymers of ethylene and higher α-olefins are a type of ethylene-based polyolefin with inherent crystallinity derived from the ethylene monomer. These copolymers are typically synthesized using metallocene-type catalysts. The higher α-olefin comonomers used in these copolymers range from C3 to C 20 The incorporation of higher α-olefins into the polymer chain generally results in a reduction in both the crystallinity and density of the resulting polymer. As a result, the density of the copolymer can vary significantly depending on the type and amount of comonomer incorporated.

[0003] Polyolefin plastomers (POPs) with a density of >0.885 g / cc can be synthesized using a gas phase process and are used as impact modifiers in polypropylene compositions due to their compatibility and favorable properties. However, even with suitable POPs, it remains a challenge to enhance the impact value of polypropylene compositions while maintaining a balance with other desired mechanical properties such as stiffness and flexibility. Summary of the Invention [Problem to be solved by the invention]

[0004] There remains a need for impact modifier compositions for use in polypropylene compositions for a good balance of enhanced impact resistance and other mechanical properties.

[0005] (Summary) [Means for solving the problem]

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

[0007] In a second embodiment, the POP is <15LCB / 10 6 It has long chain branching (LCB) of carbon.

[0008] In a third embodiment, the block S has a molecular weight (M p ).

[0009] In a fourth embodiment, each block EB and EB′ independently has a molecular weight (M p ), and each block EP has a molecular weight (M p), each block S / EB and S / EB' independently has a molecular weight (M p ). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The following terms are used throughout the specification.

[0011] "Consisting essentially of" means that the claimed composition contains primarily the specified material and allows for additional ingredients that do not materially affect the novel features or function of the claimed invention, and if present, contains the additional ingredients in amounts of <30%, or <20%, or <10%.

[0012] "At least one of [a group, such as A, B, and C]" or "any of [a group, such as A, B, and C]" means a single group member, two or more group members, or a combination of group members. For example, at least one of A, B, and C includes, for example, only A, only B, or only C, as well as A and B, A and C, B and C, or any other combination of A, B, and C, or A, B, and C. In another example, at least one of A and B means only A, only B, as well as A and B.

[0013] A list of embodiments presented as "A, B, or C" should be interpreted as including embodiments of A only, B only, C only, "A or B," "A or C," "B or C," or "A, B, or C."

[0014] "Either A, B, or C" refers to one choice from A, B, or C.

[0015] "Any of A, B, and C" refers to one or more choices from A, B, and C.

[0016] The "polystyrene content" or PSC of a block copolymer refers to the weight percent of polymerized vinyl aromatic monomer, such as styrene, in the block copolymer and is calculated by dividing the sum of the molecular weights of all vinyl aromatic units by the total molecular weight of the block copolymer. PSC can be determined using any suitable method, such as nuclear magnetic resonance (NMR).

[0017] "Vinyl content" refers to the content of conjugated diene monomers polymerized via 1,2-addition in the case of butadiene or 3,4-addition in the case of isoprene, resulting in monosubstituted olefin or vinyl groups adjacent to the polymer backbone. Vinyl content may be measured by nuclear magnetic resonance (NMR).

[0018] "Molecular Weight" or M w refers to the polystyrene equivalent molecular weight in kg / mol of a polymer block or block copolymer. w can be measured using gel permeation chromatography (GPC), for example, performed according to ASTM 5296-19 and using polystyrene calibration standards. The GPC detector can be an ultraviolet detector or a refractive index detector, or a combination of these. The chromatograph is calibrated using commercially available polystyrene molecular weight standards. The M of the polymer measured using GPC and thus calibrated can be w is the polystyrene equivalent molecular weight or apparent molecular weight. w is measured at the peak of the GPC trace and is commonly referred to as the polystyrene equivalent "peak molecular weight", M p This is expressed as:

[0019] "Long Chain Branching" or LCB refers to the presence of extended side chains or branches along the polymer backbone and is measured using GPC and / or NMR techniques and is expressed as the number of LCBs per 1,000,000 carbons, LCB / 10 6 Expressed as carbon.

[0020] "Short chain branching" or SCB refers to the presence of shorter side chains or branches attached to the polymer backbone. These branches are composed of fewer repeat units compared to the polymer backbone. SCB arises when a comonomer, such as 1-butene, is copolymerized with a primary olefin monomer, such as ethylene. The comonomer units break the regularity of the polymer backbone and introduce branches at relatively regular intervals. The main difference between LCB and SCB is that in LCB, the long chain branches are relatively long, consisting of multiple repeat units, e.g., more than tens (>36) to thousands of repeat units in length. A few here means "3" as a unit. In contrast, in SCB, the short chain branches are short in length or have a small number of repeat units, e.g., from a few to tens, e.g., 2, 5, 10, 20, 30, <36 repeat units. SCB can be measured using GPC-IR methods.

[0021] The present disclosure relates to impact modifier compositions (IMCs) consisting essentially of hydrogenated styrenic block copolymers (HSBCs) and polyolefin plastomers (POPs). The IMCs can be used in thermoplastic polyolefin (TPO) compositions for improved impact resistance and a balance of clarity, high stiffness, tensile strength, and flow properties. The TPO compositions can be utilized in applications including automotive parts.

[0022] (Hydrogenated Styrenic Block Copolymers (HSBC)): HSBCs have a general configuration selected from: SS / EB, SS / EB', SS / EB-EB', SS / EB'-EB, SS / EB-S, SS / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB', EB-S / EB'-EB and mixtures thereof. HSBCs are formed by hydrogenation of styrenic block copolymer (SBC) precursors which are either linear, branched or radial block copolymers.

[0023] Before hydrogenation, block S is a polymer block of vinyl aromatic monomers, block EB is a polybutadiene block of 1,3-butadiene monomers, block EB' is a polybutadiene block of 1,3-butadiene monomers different from block EB, and block EP is a polyisoprene block of isoprene monomers, and each copolymer block S / EB and S / EB' is independently derived from vinyl aromatic monomers and 1,3-butadiene monomers. After hydrogenation, each block EB, EB' and EP is independently ethylene / butylene (EB), ethylene / butylene (EB') and ethylene / propylene (EP), respectively. The vinyl aromatic monomers can be introduced or copolymerized in any order and in any distribution into blocks EB, EB' and EP to form any of the configurations as described.

[0024] In an embodiment, the vinyl aromatic monomer is selected from the group consisting of styrene, (α)alpha-methylstyrene, methylstyrene, para-methylstyrene, para-ethylstyrene, para-n-propylstyrene, para-iso-propylstyrene, para-n-butylstyrene, para-sec-butylstyrene, para-iso-butylstyrene, para-t-butylstyrene, ortho-substituted styrenes, meta-substituted styrenes, isomers of para-decylstyrene, isomers of para-dodecylstyrene, dimethylstyrene, halogenated styrenes, methoxystyrene, acetoxystyrene, vinyltoluene, isomers of vinyltoluene, vinylxylene, 4-vinylbiphenyl, vinylnaphthalene, vinylanthracene, 1,1-diphenylethylene, and mixtures thereof.

[0025] In an embodiment, block EB contains 65-85 or 65-80 or 65-75 or 70-85 wt. % of 1,3-butadiene monomer incorporated by 1,4-addition, based on the total weight of polymerized 1,3-butadiene monomer in block EB, with the remainder being 1,3-butadiene monomer incorporated by 1,2-addition.

[0026] In an embodiment, block EB', if present, contains 40-80 or 45-75 or 50-70 or 55-65 wt.-% of 1,3-butadiene monomer incorporated by 1,2-addition, based on the total weight of polymerized 1,3-butadiene monomer in block EB', and the remainder is 1,3-butadiene monomer incorporated by 1,4-addition.

[0027] In an embodiment, the block EB has a vinyl content of <35 or >10 or 5-35 or 10-30 or 15-35 or 15-30 or 17-27 wt. %, based on the total weight of polymerized 1,3-butadiene monomer in the block EB, prior to hydrogenation.

[0028] In an embodiment, the blocks EB' have a vinyl content of >35 or <70 or 35-70 or 38-65 or 35-60 or 37-55 or 35-50 wt. %, based on the total weight of polymerized 1,3-butadiene monomer in the blocks EB', prior to hydrogenation.

[0029] In an embodiment, the vinyl content ratio of the block EB to the block EB' is 1:10 to 10:1, or 1:8 to 8:1, or 1:5 to 5:1, or 1:3 to 3:1.

[0030] In an embodiment, block S, block S in S / EB or block S in S / EB' have independently a hydrogenation level of <30% or <20% or <10% or <5% or >0.1%. In an embodiment, block EP, block EB, block EB', block EB in S / EB and block EB' in S / EB' have independently a hydrogenation level of >90% or >95% or >98% or >99% or up to 100%. The hydrogenation level refers to the percentage of the original unsaturated bonds that are saturated upon hydrogenation and can be determined using UV-VIS spectrophotometry and / or proton NMR and / or via ozonolysis titration.

[0031] In an embodiment, the HSBC has a polystyrene content (PSC) of 3-40, or 4-35, or 5-30, or 4-25, or 5-22, or >5, or <30 wt.%, based on the total weight of the HSBC.

[0032] In embodiments, the HSBC has a coupling efficiency (CE) of >60%, or >65%, or >70%, or 60-90%, or 65-85%.

[0033] In an embodiment, the HSBC has a diblock content of >5, or >10, or from 5 to 40, or from 10 to 35 weight percent, based on the total weight of the HSBC.

[0034] In an embodiment, the block S has a molecular weight (M p ).

[0035] In embodiments, each block EB and EB′ independently has a molecular weight (M p ).

[0036] In an embodiment, the block EP has a molecular weight (M p ).

[0037] In an embodiment, each block S / EB and S / EB′ independently has a molecular weight (M) of 20 to 100, or 25 to 80, or 30 to 70, or 20 to 60, or 30 to 75, or 35 to 100, or 15 to 55 kg / mol. p ).

[0038] In an embodiment, the HSBC has a molecular weight (M p ).

[0039] In an embodiment, the HSBC has a melt flow rate (MFR) of >0.5 or >1 or >3 or >5 or from 0.5 to 50 or from 1 to 40 or from 2 to 35 or from 3 to 30 or from 4 to 25 or from 1 to 15 dg / min at 230° C. using a load of 2.16 kg, as measured according to ASTM D1238.

[0040] In an embodiment, the HSBC has a general configuration selected from: S-EP-EB, EB-S / EB'-EB and mixtures thereof, with a vinyl content in block EB before hydrogenation of 10-30 wt.%, a vinyl content in block EB' before hydrogenation of 35-50 wt.%, a PSC (if present) of 4-25 wt.%, an M of block S of 3-15 kg / mol. p (if present), independently, M of each block EB and EB' from 10 to 40 kg / mol p , M of block S / EB' is 20-60 kg / mol p (if present), M of block EP between 40 and 60 kg / mol p (if present), M of block copolymers between 35 and 120 kg / mol p and has a MFR of 1 to 15 dg / min at 230°C / 2.16 kg.

[0041] HSBC may be prepared by first making an SBC precursor as disclosed in US Pat. No. 7,449,518. The SBC precursor may be prepared by anionic polymerization or by sequential (or stepwise) polymerization at temperatures between -30 and 150°C or 10 and 100°C or 30 and 90°C. The polymerization is carried out in an inert atmosphere such as nitrogen or under pressures ranging from 0.5 to 65 bar. The polymerization generally requires <12 hours or 5 minutes to 5 hours depending on factors including temperature, concentration of monomer components, desired molecular weight of the polymer, etc. The resulting continuous block copolymer chains may be coupled using a coupling agent, if present.

[0042] The SBC precursor is then hydrogenated to obtain HSBC using the hydrogenation processes disclosed in US Pat. Nos. 3,670,054 and 3,700,633.

[0043] In embodiments, the HSBC is functionalized with at least one functional group, such as hydroxyl, amino, carboxyl, anhydride, epoxy, isocyanate, silane, silanol, and the like.

[0044] In embodiments, the HSBC is used in the IMC in an amount of 10-90, or 20-80, or 30-70, or 40-60 weight percent, based on the total weight of the IMC.

[0045] (Polyolefin Plastomer (POP)): In an embodiment, the POP is a polyolefin plastomer made of ethylene and at least one C3-C olefin using a metallocene catalyst. 20 It is an ethylene-α-olefin copolymer obtained by copolymerization with an α-olefin. The POP contains ethylene in an amount of >50 or >60 or >70 or >80 or >90 or >95% by weight, based on the total weight of the POP. In an embodiment, the POP contains ethylene in an amount of 65-95% and 5-35% linear α-olefin.

[0046] C3~C 20 Examples of α-olefins include propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, and the like.

[0047] Examples of POPs include ethylene / propylene copolymers, ethylene / butene (EB) copolymers, ethylene / hexene-1 (EH) copolymers, ethylene / octene (EO) copolymers, ethylene / α-olefin / diene modified (EAODM) interpolymers (e.g., ethylene / propylene / diene modified (EPDM) interpolymers, ethylene / propylene / octene terpolymers, etc.). POPs are C4-C 18 It further comprises a diolefin and / or an alkenylbenzene.

[0048] In an embodiment, the POP has a density of >0.885, or >0.890, or 0.885-0.920, or 0.890-0.915, or 0.895-0.910, or 0.890-0.905, or <0.920 g / cc, as measured according to ASTM D792.

[0049] In an embodiment, the POP has a melt flow rate (MFR) of 0.1-30, or 0.5-25, or 0.8-20, or 0.5-10, or 1-15, or 0.5-5, or >0.5, or <15 dg / min at 230° C. using a 2.16 kg load, as measured according to ASTM D1238.

[0050] In an embodiment, POP has an LCB / 10 ratio of <15 or <10 or <5 or <3 or <2 or <1 or 0.01-10 or 0.05-5 or 0.1-3 or 0.01-2 or 0.05-1.9 or 0.1-1.8 or 0.5-2 or 0.7-1.7 or 0.01-0.5, as measured according to the Janzen-Colby Plot method. 6 It has long chain branches (LCB) at the carbon unit. 6 "Carbon" includes both backbone and branch carbons.

[0051] In an embodiment, the polyolefin plastomer (POP) is an ethylene-hexene copolymer comprising 65-95 wt.% ethylene units and 5-35 wt.% hexene units, the polyolefin plastomer (POP) having a density of 0.895-0.910 g / cc, a MFR of 0.5-5 dg / min, and a viscosity of <2 LCB / 10 6 It has long chain branching of carbon.

[0052] In embodiments, the POPs are made in a metallocene-catalyzed polymerization process, e.g., a gas-phase polymerization process. As used herein, the terms "metallocene-catalyzed POPs," "metallocene-produced POPs," or "m-POPs" refer to POPs having the density and MFI properties described herein and produced in the presence of a metallocene catalyst. Metallocene-catalyzed POPs have measurable properties that can be distinguished from POPs having the same comonomers in the same weight percentages but produced from a different process, e.g., a conventional Ziegler-Natta polymerization process.

[0053] Gas phase polymerization refers to the polymerization of monomers in a fluidized bed. POPs can be formed by polymerizing alpha-olefins in the presence of a metallocene catalyst under reactive conditions in a gas phase reactor having a fluidized bed and a fluidizing medium. In an embodiment, POPs are obtained by polymerization in a single reactor. A variety of gas phase polymerization processes can be used, for example, polymerization can be carried out in a non-condensed or "dry" mode, a condensed mode, or a super-condensed mode.

[0054] In the gas phase polymerization process, the reactor temperature can be in the range of 30-140°C, or 60-120°C, or 65-110°C, or 70-105°C, and the pressure can be 100-1000, or 150-600, or 200-500, or 250-400 psig.

[0055] Metallocene catalysts can be compounds having a Group 4, 5 or 6 transition metal (M) and a cyclopentadienyl (Cp) ligand or ligands, which may be substituted, at least one non-cyclopentadienyl derived ligand (X) and zero or one heteroatom-containing ligand (Y), in a number corresponding to the valence of the ligands coordinated to M. Metallocene catalysts / precursors generally require activation with a suitable cocatalyst (referred to as an "activator") to obtain an "active metallocene catalyst", i.e., an organometallic complex with vacant coordination sites capable of coordinating, inserting and polymerizing olefins.

[0056] In embodiments, POPs obtained from gas phase polymerization processes and using metallocene catalysts are characterized by a narrow composition distribution, which is related to the uniformity of comonomer distribution among the molecules of the polymer. Metallocene catalysts are known to incorporate comonomers very uniformly into the polymer molecules they produce. POPs produced from metallocene catalyst systems can have a very narrow composition distribution, in that the majority of the polymer molecules have nearly identical comonomer content, with the comonomer being randomly distributed within each molecule.

[0057] In embodiments, the POP is used in an amount of 10-90, or 20-80, or 30-70, or 40-60 wt %, based on the total weight of the IMC.

[0058] (Impact Modifier Composition (IMC)): The IMC comprises: 10-90 wt% HSBC and 10-90 wt% POP, preferably 20-80 wt% HSBC and 20-80 wt% POP, based on the total weight of the IMC.

[0059] (Method of preparation of IMC): IMC can be prepared by using suitable amounts of ingredients and pelletizing by dry blending or dry blending and melt extrusion. Dry blending and / or melt mixing can be carried out by single or twin screw extruder.

[0060] In an embodiment, suitable amounts of the components of the IMC are added directly to the thermoplastic polyolefin (TPO) composition without the need for pre-blending.

[0061] (Thermoplastic Polyolefin (TPO) Composition): In an embodiment, the TPO composition comprises A) 60-95 wt. % polypropylene, B) 5-40 wt. % IMC, and C) up to 25 wt. % of at least one additive, preferably A) 60-85 wt. % polypropylene, B) 15-40 wt. % IMC, and C) 0.1-10 wt. % of at least one additive, based on the total weight of the TPO composition.

[0062] The IMC in embodiments is used in the TPO composition in an amount of 5-40, or 10-30, or 5-35, or 10-35, or 15-40 weight percent, based on the total weight of the TPO composition.

[0063] (Polypropylene (PP)): The polypropylene used in the TPO composition can be any polypropylene polymer made via any process known in the art. The polypropylene can be obtained from virgin or recycled sources. In embodiments, polypropylene blends are used in the TPO composition, such as blends of polypropylene with random ethylene or butene copolymers of polypropylene or crystallized random copolymers of ethylene and propylene in combination with rubbery ethylene-propylene copolymers. Polypropylene copolymers can be used, including copolymers of propylene with copolymerizable comonomers such as, for example, ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene or one or more conjugated or non-conjugated dienes. The comonomers can range from 0.05 to 40, or 0.5 to 30, or 1 to 20, or 5 to 30 weight percent based on the total weight of the polypropylene copolymer.

[0064] In an embodiment, the polypropylene is a heterophasic polymer composition comprising a propylene homopolymer matrix or a random copolymer matrix, in which a propylene copolymer component and one or more ethylene or higher α-olefin comonomers are dispersed. The random copolymer matrix comprises propylene monomer and at least one comonomer selected from the group consisting of ethylene, C4-C8 α-olefins, such as 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, and mixtures thereof.

[0065] The polypropylene may be bimodal or polymodal in terms of molecular weight. In an embodiment, the polypropylene has a number average molecular weight (M nIn an embodiment, the polypropylene has a weight average molecular weight (M) of 50 to 2000, or 150 to 1500, or 200 to 1000, or 100 to 800, or 150 to 500, or 100 to 400 kg / mol. w ).

[0066] In an embodiment, the polypropylene has a melting point (T) of 100-180° C., or 110-170° C., or 120-160° C., or 125-150° C., as measured by DSC according to ASTM D3418. m ).

[0067] In an embodiment, the polypropylene has a crystallinity of 20-70%, or 25-65%, or 30-60%, or 35-55%, or >35%, or >40%, or >50%, as measured by Differential Scanning Calorimetry (DSC) heat of fusion according to ASTM F2625.

[0068] In an embodiment, the polypropylene has a melt flow rate (MFR) of 5-50, or 10-45, or 5-40, or 10-40 dg / min at 230° C. using a load of 2.16 kg, measured according to ASTM D1238.

[0069] In an embodiment, the polypropylene has a density of 0.890 to 0.920, or 0.895 to 0.915, or 0.895 to 0.910 g / cc, as measured according to ASTM D792.

[0070] In embodiments, the polypropylene used in the TPO composition is in an amount of from 70 to 99, or from 80 to 99, or from 70 to 95, or from 70 to 90, or from 75 to 95 weight percent, based on the total weight of the TPO composition.

[0071] Optional Additives: The TPO composition further comprises additives selected from the group consisting of activators, curing agents, stabilizers, neutralizing agents, thickeners, coalescing agents, slip agents, mold release agents, antimicrobial agents, antioxidants, antiozonants, color changing pH indicators, plasticizers, tackifiers, film forming additives, dyes, pigments, UV stabilizers, UV absorbers, catalysts, fillers, other resins, redox couples, fibers, flame retardants, viscosity modifiers, wetting agents, degassing agents, toughening agents, adhesion promoters, colorants, heat stabilizers, lubricants, flow modifiers, anti-drip agents, anti-blocking agents, anti-static agents, processing aids, stress relief additives, foaming agents, weld line strength promoters, impact modifiers other than IMC, and mixtures thereof.

[0072] Examples of fillers include sand, talc, dolomite, calcium carbonate, clay, silica, mica, wollastonite, feldspar, aluminum silicate, alumina, hydrated alumina, glass beads, glass microspheres, ceramic microspheres, thermoplastic microspheres, barite, wood flour, glass fiber, wood fiber, carbon fiber, and mixtures thereof. The fillers may be surface treated before being added to the TPO composition.

[0073] In embodiments, impact modifiers other than IMC include ethylene-propylene-diene (EPDM) monomer, ethylene-propylene (EPM) monomer, ethylene-propylene rubber (EPR), elastomeric polyolefins (POE), ethylene and propylene based copolymers and terpolymers, nitrile-butadiene rubber (NBR), isobutylene (IB), chlorinated rubber, chlorinated polyethylene (CM), isoprene, ethylene-butene, mixtures and derivatives thereof.

[0074] In embodiments, the additives used in the TPO composition are in an amount up to 25 weight percent or <30 or 0.1-10 or 1-10 or 0.1-5 or 1-5 weight percent based on the total weight of the TPO composition.

[0075] Preparation of TPO Compositions: TPO compositions may be processed by methods known in the art, such as blending the components together by melt mixing / extrusion into pellets, followed by forming articles by known techniques such as injection molding, overmolding, rotational molding, thermoforming, casting, extrusion, profile extrusion and blow molding.

[0076] The TPO composition may be compounded by an apparatus including a continuous single or twin screw mixer. In an embodiment, the TPO composition is prepared by a dry blending process to obtain a dry blended TPO composition.

[0077] The compounding temperature of the TPO composition can be 80-300°C, or 150-280°C, or 180-260°C, or 200-260°C. The various components of the final TPO composition can be added and compounded in any order or simultaneously. In some embodiments, the additives are added as a premixed masterbatch. Such masterbatches are generally formed by dispersing the additives separately or together in small amounts, e.g., >0.1 and <10 wt.%.

[0078] Properties of TPO Compositions: When HSBC is incorporated into an IMC as described above, the TPO composition with IMC is characterized as having an excellent balance of properties, such as, for example, flexibility, impact value, stiffness, clarity, tensile strength, flow properties, anisotropy, etc.

[0079] In an embodiment, the TPO composition has a viscosity of 6.5-50, or 6.6-45, or 6.7-40, or 6.5-35, or >6.5 kJ / m at 21° C. 2 In an embodiment, the TPO composition has a notched Izod impact value of 2.2 to 20, or 2.4 to 15, or 2.4 to 10, or >2.2, or >2.4 kJ / m at -21°C. 2 The notched Izod impact value is measured in accordance with ASTM D256.

[0080] In embodiments, the TPO composition has a flexural strength, as measured according to ASTM D790, of 25-50, or 28-45, or 30-40, or 25-40, or 30-45, or >25 MPa.

[0081] In embodiments, the TPO composition has a 1% secant modulus of elasticity, measured according to ASTM D790, of 1050-1600, or 1060-1550, or 1070-1500, or 1050-1400, or >1050 MPa.

[0082] In embodiments, the TPO composition has a tensile strength at break of 10-40, or 12-35, or 10-30, or 11-25, or >10 MPa, as measured according to ASTM D638.

[0083] In embodiments, the TPO composition has an elongation at break of 350-800, or 360-770, or 370-750%, or >350%, as measured according to ASTM D638.

[0084] In embodiments, the TPO composition has at least one of the following balanced properties compared to the TPO composition in the absence of the IMC: At least a 10% increase in elongation at break and at least a 2% increase in notched Izod impact value measured at 21°C, or At least a 10% increase in elongation at break and at least a 2% increase in notched Izod impact value measured at -21°C, or At least a 10% increase in elongation at break and less than a 20% decrease in flexural strength, or At least a 10% increase in elongation at break and less than a 20% decrease in secant modulus at 1%.

[0085] Uses of TPO Compositions: The TPO compositions can be used to make a variety of articles through injection blow molding, injection molding, extrusion blow molding, coextrusion, cast film extrusion, blown film extrusion, injection stretch blow molding, rotational molding, thermoforming, hot melt, foam blow molding, pultrusion, calendaring, additive manufacturing, or other known processing methods.

[0086] TPO compositions may be used in piping, packaging applications, films, geomembranes, roofing applications, pond liners, caps and enclosures, as well as core layers of multilayer polyolefin sheets or films, containers and household articles, medical moldings and caps. TPO compositions may be used in automotive applications, such as interior trims, interior cladding, door panels, instrument panels, fascias, lift gates and consoles.

[0087] Hollow articles can be formed from the TPO compositions by either continuous or intermittent extrusion blow molding. In embodiments, hollow articles include bottles, containers, fuel tanks, drums, etc. Other molded articles include furniture, signs, wheels, toys, garden products, etc.

[0088] In an embodiment, the TPO compositions are used to prepare textile fibers, which are then used to form spunbond fibers, staple fibers, multifiber yarns, knitted fabrics, woven fabrics, or nonwoven fabrics. EXAMPLES

[0089] The following examples are intended to be non-limiting.

[0090] Ingredients used in the examples include: PP-1 is from Borealis and is a polypropylene homopolymer with a MFR of 20 dg / min at 230° C. / 2.16 kg and a density of 0.900 g / cc.

[0091] POP-1 has a density of 0.900 g / cc, a MFR of 2.0 dg / min at 230°C / 2.16 kg, and a 6 It is an ethylene-hexene copolymer with long chain branching of carbon.

[0092] Details of the composition of the various HSBCs are provided in Table 1.

[0093] [Table 1]

[0094] Example 1: Preparation of IMC Suitable amounts of the components of the IMC were dry blended to give the various compositions shown in Table 2.

[0095] [Table 2]

[0096] Example 2: Preparation of TPO composition. Suitable amounts of the components of the TPO composition were compounded at 245°C in a micro compounder with a twin screw extruder. After compounding, the molten composition was directly discharged from the micro compounder into an injection molding unit. The injection nozzle temperature was set at 237°C and the mold temperature was 50°C. The injection pressure ranged from 5 to 10 bar. Injection molded specimens were used for measuring various properties. The details of the TPO composition and properties are presented in Tables 3 and 4, respectively.

[0097] [Table 3]

[0098] [Table 4]

[0099] As used herein, the term "comprising" means including the elements or steps listed following the term, but such elements or steps are not exhaustive and the embodiment may include other elements or steps. Although the terms "comprising" and "including" have been used herein to describe various aspects, to provide more specific aspects of the disclosure, the terms "consisting essentially of" and "consisting of" may be used in place of "comprising" and "including" and are disclosed.

Claims

1. (a) 10 to 90 weight percent of a polyolefin plastomer having a density of 0.885 to 0.920 g / cc as measured in accordance with ASTM D792 and a melt flow rate of 0.1 to 30 dg / min at 230° C. using a 2.16 kg load as measured in accordance with ASTM D1238; and (b) 10 to 90 weight percent hydrogenated styrenic block copolymers having a general configuration selected from S-S / EB, S-S / EB', S-S / EB-EB', S-S / EB'-EB, S-S / EB-S, S-S / EB'-S, S-EP-EB, S-EP-EB', S-EB-EB', S-EB'-EB, EB-S / EB-EB, EB'-S / EB-EB', EB-S / EB'-EB, and mixtures thereof.

1. An impact modifier composition comprising, prior to hydrogenation, each block S is a polymer block of a vinyl aromatic monomer; each block EB is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of 5 to 35% by weight; each block EB' is a polybutadiene block of 1,3-butadiene monomer having a vinyl content of 35 to 70% by weight; each block EP is a polyisoprene block of isoprene monomers; each block S / EB and S / EB' is independently a copolymer block of a vinyl aromatic monomer and a 1,3-butadiene monomer; The impact modifier composition, wherein said hydrogenated styrenic block copolymer has a polystyrene content of 3 to 40 weight percent.

2. The polyolefin plastomer is 0.01LCB / 10 ６ Carbon ~ 10LCB / 10 ６ 10. The impact modifier composition of claim 1 having long chain branching (LCB) of carbon.

3. The block S has a molecular weight (M ｐ 2. The impact modifier composition of claim 1 having

4. Each block EB and EB′ independently has a molecular weight (M ｐ ) Each block EP has a molecular weight (M ｐ ) Each block S / EB and S / EB′ independently has a molecular weight (M ｐ ) The impact modifier composition according to any one of claims 1 to 3.

5. 4. The impact modifier composition according to claim 1, wherein the vinyl content ratio of the block EB to the block EB' is from 1:10 to 10:

1.

6. block EB has a vinyl content of 10 to 30% by weight before hydrogenation; block EB' has a vinyl content of 38 to 65% by weight before hydrogenation; The impact modifier composition according to any one of claims 1 to 3.

7. The hydrogenated styrenic block copolymer is A polystyrene content of 5 to 30% by weight, Molecular weight (M) of 30 to 300 kg / mol ｐ ), and Melt flow rate of 0.5 to 50 dg / min at 230° C. using a load of 2.16 kg as measured according to ASTM D1238 The impact modifier composition according to any one of claims 1 to 3, comprising at least one of:

8. the hydrogenated styrenic block copolymer has a general configuration selected from S-EP-EB, EB-S / EB'-EB, and mixtures thereof; Prior to hydrogenation, a vinyl content in block EB of 10-30 wt. %; a vinyl content in block EB' of 35-50% by weight prior to hydrogenation; A polystyrene content of 4 to 25% by weight; The molecular weight of block S (M ｐ ), The molecular weight (M) of each block EB and EB′ is independently 10 to 40 kg / mol. ｐ ), The molecular weight (M) of the block S / EB' is 20 to 60 kg / mol. ｐ ), The molecular weight (M) of the block EP is 40 to 60 kg / mol. ｐ ), and The molecular weight (M) of the hydrogenated styrenic block copolymer is 35 to 120 kg / mol. ｐ ) The impact modifier composition according to any one of claims 1 to 3, comprising:

9. The polyolefin plastomer is a mixture of ethylene and at least one C ３ ~C ２０ and a copolymer with an α-olefin, the polyolefin plastomer being A density of 0.885 to 0.920 g / cc; and Melt flow rate of 0.5 to 25 dg / min at 230°C using a load of 2.16 kg The impact modifier composition according to any one of claims 1 to 3, comprising at least one of:

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

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

12. When compared to a thermoplastic polyolefin composition in the absence of the impact modifier composition according to any one of claims 1 to 10, at least a 10% increase in elongation at break and at least a 2% increase in notched Izod impact value measured at 21°C; or At least a 10% increase in elongation at break and at least a 2% increase in notched Izod impact value measured at -21°C; or At least a 10% increase in elongation at break and less than a 20% decrease in flexural strength, or At least a 10% increase in elongation at break and less than a 20% decrease in 1% secant modulus having The elongation at break is measured according to ASTM D638; The notched Izod impact value is measured in accordance with ASTM D256; Both the flexural strength and the 1% secant modulus are measured in accordance with ASTM D790; The thermoplastic polyolefin composition of claim 11.

13. The polypropylene is 2. A melt flow rate (MFR) of 5 to 50 dg / min at 230° C. using a load of 16 kg; and Density 0.890 to 0.920 g / cc The thermoplastic polyolefin composition according to any one of claims 11 to 12, comprising at least one of:

14. Measured according to ASTM D256. 6.5 to 50 kJ / m at 21°C ２ Notched Izod impact value, and 2.2 to 20 kJ / m at -21°C ２ Notched Izod Impact Value The thermoplastic polyolefin composition according to any one of claims 11 to 12, having

15. Bending strength of 25 to 50 MPa; 1% secant elastic modulus of 1050 to 1600 MPa; A tensile strength at break of 10 to 40 MPa, and Elongation at break of 350-800% having Both the flexural strength and the 1% secant modulus are measured in accordance with ASTM D790; Both the tensile strength at break and the elongation at break are measured according to ASTM D638; The thermoplastic polyolefin composition according to any one of claims 11 to 12.

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