Self-reinforced polyolefin compositions

Abstract

The invention generally concerns polyolefin compositions that include a polyolefin homopolymer and a bimodal polypropylene blend. The bimodal polypropylene blend can include of ultra-high molecular weight polypropylene and low molecular weight polypropylene, where the low molecular weight polypropylene is present in an amount greater than the ultra-high molecular weight polypropylene.

Description

24T&I0027-WO-ORDSELF-REINFORCED POLYOLEFIN COMPOSITIONSTECHNICAL FIELD

[0001] The invention generally concerns polyolefin compositions that include a polyolefin homopolymer and a bimodal polypropylene blend. The bimodal polypropylene blend can include a ultra-high molecular weight polypropylene and a low molecular weight polypropylene. The low molecular weight polypropylene is present in an amount greater than the ultra-high molecular weight polypropylene.BACKGROUND OF THE INVENTION

[0002] Polyolefins have multiple industrial uses. Polyolefins such as polyethylene and polypropylene and copolymers thereof constitute a large volume of synthetic plastic produced worldwide. Polyolefin copolymers are used in a wide variety of articles, such as films, sheets, foams, fibers, toys, bottles, containers, furniture, electronic parts, vehicle parts, and plumbing materials. In the automotive industry, polypropylene compounds are commonly used as materials of constructions for interior of vehicles (such as door panels, glove boxes, dashboard etc.). Manufacturers often require that these parts have certain characteristics, such as stiffness, toughness, scratch resistance, and, in some cases, uniform surface appearance requirements. Efforts to improve polymer characteristics include adding inorganic fillers to the polyolefin composition. However, these compositions suffer in that the addition of inorganic fillers can increase the density and / or weight of the total composition, which can lead to heavier components, which can be undesirable in certain applications (e.g., vehicle components, aircraft components, industrial goods, domestic goods, and the like).SUMMARY OF THE INVENTION

[0003] A discovery has be made that provides a solution to at least one of the problems associated with improving polymer characteristics. The discovery includes a polymer composition that includes a polymer homopolymer and a bimodal polymer blend. Notably, the composition provides the advantage of increasing the inherent stiffness of the polymer composition without compromising mechanical performance. The present invention also provides the advantage of reducing the amount of inorganic filler, when used, by 1% to 10% as compared to similar24T&I0027-WO-ORD polypropylene compositions that include the same inorganic filler. Thus, lighter articles can be produced using the composition of the present invention. Lighter articles can have a significant environmental impact (e.g., reduction of greenhouse gas emissions). For example, using lighter articles in a vehicle can reduce its fuel consumption, and hence, the amount of gases emitted while traveling a given distance.

[0004] Advantageously, the bimodal blend of LMWPP-UHMWPP is moldable as the LMWPP chains can have a lubricating effect on the UHMWPP chains, thereby lowering the viscosity of the polymer melt to a level where the melt can be pushed into a mold. The relaxation time of the UHMWPP chains in the polymer melt can be sufficient, such that these chains remain oriented in the flow direction during molding (e.g., injection-molding), as opposed to relaxing into a “randomcoil” configuration. This orientation of long chains can lead to “flow-induced crystallization”, due to the long UHMWPP homopolymer chains stacking on top of each other. The stacking can lead to in situ formation of polypropylene fibers or extended crystals (e.g., “shish-kebab” type orientation). This type of stacking (e.g., shish-kebab) can increase the stiffness of the polypropylene material resulting in self-reinforced polypropylene compositions of the present invention.

[0005] In one aspect, polymer compositions are described. A polymer composition can include a polypropylene homopolymer and a bimodal polypropylene blend. The polypropylene homopolymer can have a melt flow index of 30 to 200 g / 10 min at 230 °C / 2.16 kg. The bimodal polypropylene blend can have a melt flow index of 0.5 to 3 g / 10 min 230 °C / 2.16 kg. Melt flow index can be determined using known standardized methods (e.g., ISO 1133). The bimodal polypropylene blend can include, based on the total weight of the bimodal polypropylene blend, 10 wt.% to 50 wt.%, preferably 20 wt.% to 30 wt.%, of a ultra-high molecular weight polypropylene (UHMWPP) and 50 wt. % to 90 wt. %, preferably 70 wt. % to 80 wt.%, of a low molecular weight polypropylene (LMWPP). The UHMWPP can have a weight average molecular weight of > 106g / mol. The LMWPP can have a weight average molecular weight of <200,000 g / mol, more preferably < 150,000 g / mol, or even more preferably 50,000 g / mol to 140,000 g / mol. Molecular weights can be determined using known standardized methods (e.g., ASTM D6474). In some aspects, the polymer composition can include 5 wt.% to 15 wt.% of the UHMWPP based on the total weight of the polymer composition. The polymer composition can include a filler (e.g.,24T&I0027-WO-ORD silica, glass, talc, calcium carbonate, or a combination thereof). In some aspects, the filler is talc, and the polymer compositions can include 5 wt. % to 30 wt. %, preferably, 20 wt. % to 25 wt. % of the talc based on the total weight of the polymer composition. In some aspects, the polymer composition can include an additive, preferably a nucleating agent. An amount of nucleating agent in the polymer composition can be 0 wt.% to 0.5 wt.%, preferably 0.05 wt.% to 0.15 wt.%, based on the total weight of the composition. In some aspects, the polymer composition of the present can include 40 wt.% to 50 wt.% of the polypropylene homopolymer, 25 wt.% to 35 wt.% of the bimodal polypropylene blend, 0 wt.% to 25 wt.%, preferably 20 wt.% to 25 wt.% of a filler, preferably talc, and 0 wt.% to 0.05 wt.% of an additive, preferably a nucleating agent, based on the total weight of the polymer composition. The polymer composition of the present invention can be included in an article of manufacture.

[0006] Mechanical characteristics of the polymer composition of the present invention can include tensile modulus, tensile strength, notched Izod impact at room temperature, or a combination thereof. In some aspects, the polymer composition can have a tensile modulus (Tangent at 0% strain) of 4000 MPa to 4600 MPa, preferably 4300 MPa ± 82 MPa, a tensile strength at yield of at least 33 MPa, preferably 33 MPa to 43 MPa; a notched Izod impact at room temperature of at least 26 J / m, preferably 26 J / m to 33 J / m. Tensile modulus and tensile strength at yield can be determined by known standardized methods (e.g., ASTM D638). Notched Izod impact can be determined by known standardized methods (e.g., ASTM D256). Physical characteristics of the polymer can include density. The polymer composition can have a density of less than 1.14 g / cc, preferably 1.03 g / cc to 1.1 g / cc, more preferably 1.04 g / cc to 1.07 g / cc. Density can be determined using known standardized methods (e.g., ASTM D792).

[0007] In some aspects, articles of manufacture that include the polymer composition of the present invention are described. An article of manufacture that includes the polymer composition of the present invention can be a vehicle component, preferably a door panel, a glove box, a dashboard, an instrument panel, an arm rest, a console, a seat back, a mirror housing, or a combination thereof. In some aspects of the present invention formed articles that include the polymer composition of the present invention are described. Non-limiting examples of formed articles include a thermoformed article, an injection molded article, a blow molded article, or a combination thereof.24T&I0027-WO-ORD

[0008] Methods of making the polymer composition of the present invention are described. A method can include compounding the polypropylene homopolymer, the bimodal polypropylene blend, an optionally filler (e.g., talc, silica, glass, or a combination thereof), and an optionally additive (e.g., nucleating agent) to obtain the polymer composition. The bimodal polypropylene blend can be made by (a) contacting propylene in the presence of a catalyst at conditions suitable to produce a first polypropylene product having an average molecular weight of greater than 106g / mol and (b) contacting the first polypropylene product with hydrogen and propylene under conditions sufficient to produce the bimodal polypropylene blend. A volumetric ratio of hydrogen to propylene in step (b) can be 0.01 to 0.8, preferably 0.05 to 0.5.

[0009] Other embodiments of the invention are discussed throughout this application. Any embodiment discussed with respect to one aspect of the invention applies to other aspects of the invention as well and vice versa. Each embodiment described herein is understood to be embodiments of the invention that are applicable to other aspects of the invention. It is contemplated that any embodiment or aspect discussed herein can be combined with other embodiments or aspects discussed herein and / or implemented with respect to any method or composition of the invention, and vice versa. Furthermore, compositions of the invention can be used to achieve methods of the invention.

[0010] The following includes definitions of various terms and phrases used throughout this specification.

[0011] The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0012] The terms “wt.%”, “vol.%”, or “mol.%” refers to a weight percentage of a component, a volume percentage of a component, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt.% of component.24T&I0027-WO-ORD

[0013] The term “substantially” and its variations are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0014] The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and / or the specification includes any measurable decrease or complete inhibition to achieve a desired result.

[0015] The term “effective,” as that term is used in the specification and / or claims, means adequate to accomplish a desired, expected, or intended result.

[0016] The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having” in the claims, or the specification, may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0017] The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0018] The polymer compositions of the present invention can “comprise,” “consist essentially of,” or “consist of’ particular ingredients, components, compositions, etc. disclosed throughout the specification. With respect to the transitional phrase “consisting essentially of,” in one nonlimiting aspect, a basic and novel characteristic of the compositions of the present invention is improved physical characteristics of polypropylene compositions.

[0019] Other objects, features and advantages of the present invention will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For24T&I0027-WO-ORD example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings.

[0021] FIG. 1 is an illustration of a system and method to produce the bimodal polypropylene blend of the present invention using one reactor.

[0022] FIG. 2 is an illustration of a system and method to produce the bimodal polypropylene blend of the present invention using two reactors.

[0023] FIG. 3 is an illustration of a system and method to produce the polymer composition of the present invention.

[0024] FIG. 4 is an illustration of molecular weights of the bimodal polypropylene blends of the present invention.

[0025] FIG. 5 is a graphical illustration of stress-strain curves for two polymer compositions of the present invention and a comparative sample.

[0026] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be to scale.DETAILED DESCRIPTION OF THE INVENTION

[0027] A discovery has be made that provides a solution to at least one of the problems associated with improving polymer (e.g., polypropylene) characteristics. The discovery includes a polymer composition that includes a polymer homopolymer and a bimodal polymer blend. Notably, the bimodal blend of LMWPP-UHMWPP is moldable as the LMWPP chains can have a24T&I0027-WO-ORD lubricating effect on the UHMWPP chains. Such a lubricating effect can lower the viscosity of the polymer melt to a level where the melt can be pushed into a mold (e.g., using a piston or a moving screw). The relaxation time of the UHMWPP chains in the polymer melt can be sufficient such that these chains can remain oriented in the flow direction during molding, as opposed to relaxing into a “random-coil” configuration. This orientation of long chains can lead to so called “flow- induced crystallization”, due to the long UHMWPP homopolymer chains stacking on top of each other. Stacking can lead to in situ formation of PP fibers or extended crystals in a “shish-kebab” structures. Shish-kebab structures can increase the stiffness of the polypropylene material, thus forming self-reinforced polypropylene compositions.

[0028] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.A. Polymer composition

[0029] A polymer composition of the present invention can include a polypropylene homopolymer and a bimodal polypropylene blend. The polymer composition can be made using the methods described herein. The bimodal polypropylene blend can include an ultra-high molecular weight polypropylene (UHMWPP) and a low molecular weight polypropylene (LMWPP). An amount of the polypropylene homopolymer in the polymer composition can be 40 wt.% to 50 wt.% (e.g., 40 wt.%, 41 wt.%, 42 wt.%, 43 wt.%, 44 wt.%, 45 wt.%, 46 wt.%, 47 wt.%, 48 wt.%, 49 wt.%, or 50 wt.%, or any range or value there between) based on the total weight of polymer composition. The bimodal polypropylene can be present in an amount of 25 wt.% to 35 wt.% (e.g., 25 wt.%, 26 wt.%, 27 wt.%, 28 wt.%, 29 wt.%, 30 wt.%, 31 wt.%, 32 wt.%, 33 wt.%, 34 wt.%, or 35 wt.%, or any value or range there between) based on the total weight of the polymer composition. In some aspects, the polymer composition includes 5 wt.% to 15 wt.% (e.g., 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.% 14 wt.%, or 15 wt.% or any range or value there between), based on the total weight of the polymer composition, of the ultra- high molecular weight polypropylene (UHMWPP).

[0030] Other ingredients can be present in the polymer composition of the present invention.For example, fillers, additives, or both can be present. In some aspects, fillers can be present in an amount of 0 wt.% to 25 wt.%, (e.g., 0 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 724T&I0027-WO-ORD wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.%, 14 wt.%, 15 wt,%, 16 wt.%, 17 wt.%,18 wt.%, 19 wt.%, 20 wt.%, 21 wt.%, 22 wt.%, 23 wt.%, 24 wt.%, or 25 wt.%, or any range or value there between), based on the total weight of the polymer composition. A total weight of additives can be 0 wt.% to 5 wt.% (e.g., 0 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3.0 wt.%, 4.0 wt.%, 4.5 wt%, or 5 wt.%, or any range or value there between), based on the total weight of the polymer composition. In some aspects, the polymer composition includes 0 wt.% to 0.05 wt.% (e.g., (e.g., 0 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, or any range or value there between) of a nucleating agent, based on the total weight of the polymer composition.

[0031] Physical characteristics of the polymer composition of the present invention can include tensile modulus, tensile strength, notched Izod impact at room temperature, density, or a combination thereof. In some aspects, the polymer composition can have a tensile modulus (Tangent at 0% strain) of 4000 MPa to 4600 MPa, 4050 MPa, 4100 MPa, 4200 MPa, 4250 MPa, 4300 MPa, 4350 MPa, 4400 MPa, 4450 MPa, or 4600 MPa, or any value or range there between. A tensile strength of the polymer composition can be 33 MPa, 33.5 MPa, 34 MPa, 34.5 MPa, 35 MPa, 35.5 MPa, 36 MPa, 36.5 MPa, 37 MPa, 37.5 MPa, 38 MPa, 39 MPa, 39.5 MPa, 40 MPa, 40.5 MPa, 41.5 MPa, 42 MPa, 42.5 MPa, or 43 MPa, or any range or value there between. The notched Izod impact at room temperature of the polymer composition can be 26 J / m to 33 J / m, or 26 J / m, 27 J / m, 28 J / m, 29 J / m, 30 J / m, 31 J / m, 32 J / m, or 33 J / m or any value or range there between. A density of the polymer composition can be less than 1.14 g / cc, or 1.03 g / cc to 1.1 g / cc, or 1.04 g / cc to 1.07 g / cc, or 1.07 g / cc, 1.08 g / cc, 1.09 g / cc, 1.10 g / cc, 1.11 g / cc, 1.12 g / cc, 1.13 g / cc, or 1.14 g / cc, or any range or value there between. Density can be determined using known standardized methods (e.g., ASTM D792). a. Polypropylene homopolymer

[0032] The polypropylene homopolymer can manufactured using known propylene polymerization methods. In some aspects, the polypropylene homopolymer can be purchased from a commercial manufacturer (for example, SABIC®, Saudi Arabia). The polypropylene homopolymer is a linear homopolymer. The polypropylene homopolymer can have at a density of 0.9 g / cc to 1.1 g / cc (ASTM DI 505). A melt mass flow rate (MFR) of the polypropylene24T&I0027-WO-ORD homopolymer at 230 °C / 2.16 kg can be 30 to 200 g / 10 min (ISO 1133) (e.g., 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, or 200 g / 10 min or any range or value there between. A tensile strength at yield of the polypropylene homopolymer can be 30 to 40 MPa (e g., 30 MPa, 31 MPa, 32 MPa, 33 MPa, 34 MPa, 35 MPa, 36 MPa, 37 MPa, 38 MPa, 39 MPa, 40 MPa or any range or value there between), and a tensile modulus of 1500 MPa to 1800 MPa (1500 MPa, 1650 MPa, 1700 MPa, 1750 MPa, 1800 MPa or any range or value there between) (ASTM D638). The tensile elongation at yield of polypropylene homopolymer can be of 10% to 15% (e.g., 10%, 11%, 12%, 13%, 14%, or 15% or any value or range there between) (ISO 527-1 / - 2). A flexural modulus of the polypropylene homopolymer can be 1750 MPa to 1800 MPa (e.g., 1750 MPa, 1760 MPa, 1770 MPa, 1780 MPa, 1790 MPa, or 1800 MPa, or any range or value there between) (ASTM D790A), a notched Izod impact of 18 J / m to 22 J / m (e.g., 18 J / m, 19 J / m, 20 J / m, 21 J / m, or 22 J / m or any range or value there between) (ASTM D256). b. Bimodal polymer blend

[0033] The bimodal polypropylene polymer blend can be manufactured using known polymerization methodology or as described herein. The bimodal polypropylene polymer blend can include a linear UHMWPP and a linear LMWPP. The bimodal polypropylene blend can have a melt flow index at 230 °C / 2.16 kg of 0.5 to 3 g / 10 min (e.g., 0.5 g / 10 min, 1 g / 10 min, 1.5 g / 10 min, 2 g / 10 min, 2.5 g / 10, or 3 g / 10 min or any value or range there between. The bimodal polypropylene polymer blend can have a weight average molecular weight of 500 Kg / mol to 2,000 Kg / mol or 500 Kg / mol, 1,000, Kg / mol, 1,100 Kg / mol, 1,200 Kg / mol, 1,300 Kg / mol, 1,400 Kg / mol, 1,500 Kg / mol, 1,600 Kg / mol, 1,700 Kg / mol, 1,800 Kg / mol, 1,900 Kg / mol, 2,000 Kg / mol or any value or range there between.

[0034] The UHMWPP can have a weight average molecular weight of > 106g / mol. The upper limit of the molecular weight can be based on processing conditions (e.g., melt processes). In some aspects, the bimodal polypropylene polymer blend can include 10 wt.% to 50 wt.% (e.g., 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.%, or 50 wt.%, or any range or value there between) of the UHMWPP, based on the total weight of the bimodal polypropylene blend.24T&I0027-WO-ORD

[0035] The LMWPP can have a weight average molecular weight of <200,000 g / mol, more preferably < 150,000 g / mol, or even more preferably 50,000 g / mol to 140,000 g / mol (e.g., 50,000 g / mol, 60,000 g / mol, 70,000 g / mol, 80,000 g / mol, 90,000, g / mol, 100,000 g / mol, 110,000 g / mol, 120,000 g / mol, 130,000 g / mol, or 140,000 g / mol, or any value or range there between. The amount of LMWPP in the bimodal polymer blend can be 50 wt. % to 90 wt. % (e.g., 50 wt.%, 55 wt.%, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, or 90 wt.%, or any range or value there between), based on the total weight of the bimodal polypropylene blend. c. Fillers and additives

[0036] The polymer composition of the present invention can include fillers, an additive or multiple additives. Non-limiting examples of a filler include talc, calcium carbonate, silica, glass, phyllosilicate minerals, and the like. The amount of filler in the polymer composition can be 5 wt.% to 30 wt.% (e.g., 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.%, 14 wt.%, 15 wt.%, 16 wt.%, 17 wt.%, 18 wt.%, 19 wt.%, 20 wt.%, 21 wt.%, 22 wt.%, 23 wt.%, 24 wt.%, 25 wt.%, 26 wt.%, 27 wt.%, 28 wt.%, 29 wt.% or 30 wt.%, or any range or value there between, based on the total weight of the polymer composition. In some aspects, the amount of filler is less than 30 wt.% (e.g., 25 wt.% or less), based on the total weight of the polymer composition. In a preferred aspect, the filler is talc.

[0037] Non-limiting examples of additives that can be used the polymer composition of the present invention can include an anti-fogging agent e.g., a glycerol ester), an antioxidant, a heat stabilizer, a hindered amine light stabilizer, a flow modifier, an UV absorber, an impact modifier, a coupling agent, a colorant, a nucleating agent etc., or any combinations thereof. A total weight of additives can be 0 wt.% to 5 wt.% (e.g., 0 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3.0 wt.%, 4.0 wt.%, 4.5 wt%. or 5 wt.%, or any range or value there between), based on the total weight of the polymer composition. In some aspects, the polymer composition includes 0 wt.% to 0.05 wt.% (e.g., (e.g., 0 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, or any range or value there between) of a nucleating agent, based on the total weight of the polymer composition.

[0038] Any type of nucleating agents can be used as the nucleating agent is considered agnostic to self-reinforcement provided by the bimodal polymer blend. Non-limiting examples of24T&I0027-WO-ORD nucleating agents include adipic acid, benzoic acid, or metal salts, thereof, vinylcycloalkane, polybutylene terephthalate, dibenzylidene sorbitol derivatives (e.g., l,3-O-2,4-bis(3,4- dimethylbenzylidene) sorbitol, sodium benzoate, organophosphates, organophosphonate, or mixtures thereof. Non-limiting examples of organophosphates include sodium bis[2,2'-methylene- bis-(4,6-di-tert-butylphenyl) phosphate], aluminum bis[2,2'-methylene-bis-(4,6-di-tert- butylphenyl)phosphate], lithium bis[2,2'-methylene-bis-(4,6-di-tert-butylphenyl) phosphate], magnesium phenylphosphonate, sodium phenylphosphonate, zinc phenylphosphonate, and disodium 4-t-butylphenylphosphonate, or blends thereof. Nucleating agents are available from commercial vendors (e.g., Asahi Denka Kogyo K.K., Milliken Chemical, Adeka Corp, BASF, Clariant, and the like).

[0039] Non-limiting examples of antioxidants include sterically hindered phenolic compounds, aromatic amines, a phosphite compound, carbon black and the like. Non-limiting examples of phenolic antioxidants include 2,6-di- / c / 7-butyl-4-methylphenol (CAS No. 128-37-0), pentaerythritol-tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (CAS No. 6683-19-8), octadecyl 3-(3',5'-di-tert-butyl-4-hydroxyphenyl)propionate (CAS No. 2082-79-3), 1,3,5- trimethyl-2,4,6-tris-(3,5-di-tert-butyl-4-hydroxybenzyl)benzene (CAS No. 1709-70-2), 2,2'- thiodiethylenebis(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (CAS No. 41484-35-9), calcium bis(ethyl 3,5-di-tert-butyl-4-hydroxybenzylphosphonate) (CAS No. 65140-91-2), 1 ,3,5-tris(3',5'- di- / c77-butyl-4'-hydroxybenzyl)-isocyanurate (CAS No. 27676-62-6), l,3,5-tris(4-tert-butyl-3- hydroxy-2,6-dimethylbenzyl)-l,3,5-triazine-2,4,6-(lH,3H,5H)-trione (CAS No. 40601-76-1), 3,3- bis(3- / c77-butyl-4-hydroxyphenyl)ethylene butyrate (CAS No. 32509-66-3), 4,4'-thiobis(2- / c77- butyl-5-methylphenol) (CAS No. 96-69-5), 2,2'-methylene-bis-(6-(l-methyl-cyclohexyl)-para- cresol) (CAS No. 77-62-3), 3,3'-bis(3,5-di-tert-butyl-4-hydroxyphenyl)-N,N'- hexamethylenedipropionamide (CAS No. 23128-74-7), 2,5,7,8-tetramethyl-2-(4',8',12'- trimethyltridecyl)-chroman-6-ol (CAS No. 10191-41-0), 2,2-ethylidenebis(4,6-di-tert- butylphenol) (CAS No. 35958-30-6), l,l,3-tris(2-methyl-4-hydroxy-5'-tert-butylphenyl)butane (CAS No. 1843-03-4), 3,9-bis(l,l-dimethyl-2-(beta-(3-tert-butyl-4-hydroxy-5- methylphenyl)propionyloxy)ethyl)-2,4,8,10-tetraoxaspiro[5.5]undecane (CAS No. 90498-90-1;), l,6-hexanediyl-bis(3,5-bis(l,l-dimethylethyl)-4-hydroxybenzene)propanoate) (CAS No. 35074- 77-2), 2,6-di- / c77-butyl-4-nonylphenol (CAS No. 4306-88-1), 4,4'-butylidenebis(6-tert-butyl-3- methylphenol (CAS No. 85-60-9); 2,2'-methylene bis(6- / c77-butyl-4-methylphenol) (CAS No.24T&I0027-WO-ORD119-47-1), triethylenglycol-bis-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate (CAS No. 36443-68-2), a mixture of C13 to C15 linear and branched alkyl esters of 3-(3',5'-di-tert-butyl-4'- hydroxyphenyl)propionic acid (CAS No. 171090-93-0), 2,2'-thiobis(6- / c / 7-butyl- / / ra-cresol) (CAS No. 90-66-4), diethyl-(3,5-di-tert-butyl-4-hydroxybenzyl)phosphate (CAS No. 976-56-7), 4,6-bis (octylthiomethyl)-ort / 2o-cresol (CAS No. 110553-27-0), benzenepropanoic acid, octyl 3- (3,5-di-tert-butyl-4-hydroxyphenyl)propanoate (CAS No. 125643-61-0), l,l,3-tris[2-methyl-4-[3- (3,5-di-tert-butyl-4-hydroxyphenyl)propionyloxy]-5- / c 7-butylphenyl]butane (CAS No. 180002- 86-2), mixed styrenated phenols (CAS No. 61788-44-1), butylated, octylated phenols (CAS No. 68610-06-0), butylated reaction product of p-cresol and di cyclopentadiene (CAS No. 68610-51- 5).

[0040] Non-limiting examples of phosphite antioxidant include one of tris(2,4-di- / / 7- butylphenyl)phosphite (CAS No. 31570-04-4), tris(2,4-di-tert-butylphenyl)phosphate (CAS No. 95906-11-9), bis(2,4-di- / c 7-butylphenyl)pentaerythritol diphosphite (CAS No. 26741-53-7); and tetrakis (2,4-di-butylphenyl)-4,4'-biphenylene diphosphonite (CAS No. 119345-01-6), and bis (2,4-dicumylphenyl)pentaerythritol diphosphite (CAS No. 154862-43-8).

[0041] Non-limiting examples of UV stabilizers include hindered amine light stabilizers, hydroxybenzophenones, hydroxyphenyl benzotriazoles, cyanoacrylates, oxanilides, hydroxyphenyl triazines, and combinations thereof. Non-limiting examples of hindered amine light stabilizers include dimethyl succinate polymer with 4-hydroxy-2,2,6,6-tetramethyl-l- piperidine ethanol (CAS No. 65447-77-0); poly[[6-((l,l,3,3-tetramethylbutyl)amino)-l,3,5- triazine2,4diyl][(2,2,6,6-tetramethyl-4-piperidyl)imino]hexamethylene[2,2,6,6-tetramethyl-4- piperidyl)imino]] (CAS No. 70624-18-9); and l,5,8,12-Tetrakis[4,6-bis(N-butyl-N-l,2,2,6,6- pentamethyl-4-piperidylamino)-l,3,5-triazin-2-yl]-l,5,8,12-tetraazadodecane (CAS No. 106990- 43-6).

[0042] Non-limiting examples of heat stabilizers include phenothiazine, / ?-methoxyphenol, cresol, benzhydrol, 2-methoxy-p-hydroquinone, 2,5-di-tert-butylquinone, diisopropylamine, and distearyl thiodipropionate (CAS No. 693-36-7). In a preferred embodiment, distearyl thiodipropionate which is sold under the trade name Irganox® PS 820 (BASF, Germany) is used.24T&I0027-WO-ORD

[0043] Non-limiting examples of antioxidants include a mixture of at least two of 1,3,5- trimethyl-2,4,6-tris-(3,5-di-tert-butyl-4-hydroxybenzyl) benzene sold under the trade name of Irganox® 1330 (BASF, Germany), tris[2,4-bis(2-methyl-2-propanyl)phenyl] phosphite sold under the trade name of Irgafos® 168 (BASF, Germany), pentaerythritol-tetrakis (3-(3,5-di-tert-butyl-4- hydroxyphenyl) propionate sold under the trade name Irganox® 1010 (BASF, Germany), 1,5,8,12- Tetrakis[4,6-bis(N-butyl-N-l,2,2,6,6-pentamethyl-4-piperidylamino)-l,3,5-triazin-2-yl]-l,5,8,12- tetraazadodecane sold under the trade name of Chimassorb 119 (BASF, Germany) is used.

[0044] Other additives can include stabilizers, UV absorbers, impact modifiers, and the like. A non-limiting example of a stabilizer can include Irganox® B225, commercially available from BASF. In a still further aspect, neat polypropylene can be introduced as an optional additive. Nonlimiting examples of UV absorbers include 4-substituted-2-hydroxybenzophenones and their derivatives, aryl salicylates, monoesters of diphenols, such as resorcinol monobenzoate, 2-(2- hydroxyaryl)-benzotriazoles and their derivatives, 2-(2-hydroxyaryl)-l,3,5-triazines and their derivatives, or combinations thereof. Non-limiting examples of impact modifiers include elastomers / soft blocks dissolved in matrix-forming monomer(s), such as, for example, bulk HIPS, bulk ABS, reactor modified PP, Lomod, Lexan EXL, and / or the like, thermoplastic elastomers dispersed in matrix material by compounding, such as, for example, di-, tri-, and multiblock copolymers, (functionalized) olefin (co)polymers, and / or the like, pre-defined core-shell (substrate-graft) particles distributed in matrix material by compounding, such as, for example, MBS, ABS-HRG, AA, ASA-XTW, SWIM, and / or the like, or combinations thereof.B. Method of Making Bimodal Polymer Blends

[0045] The bimodal polymer blend can be made in a single reactor (batch and / or semi-batch process) or in a continuous manner. FIG. 1 depicts a schematic for a system and method to produce the bimodal polymer blend in single reactor. System 100 can include inlet 102 for a propylene feed, inlet 104 for a hydrogen feed, reaction zone 106 that is configured to be in fluid communication with inlet 102, inlet 104, and outlet 108. Outlet 108 can be configured to be in fluid communication with the reaction zone 106 and configured to remove a product stream from the reaction zone. In some instances, second inlet 104 may not be needed. Reactant zone 106 can include a catalyst suitable for polymerization of polypropylene (e.g., a Ziegler Natta catalyst as described in International Patent Application Publication No. WO 2014001257). The propylene24T&I0027-WO-ORD feed can enter the reaction zone 106 via inlet 102. Contact of the propylene with the catalyst can produce an ultra-high molecular weight polypropylene polymer (UHMWPP) having a molecular weight of greater than 106g / mol. After the polypropylene has reached the desired molecular weight, the hydrogen feed can enter reaction zone 106 through hydrogen inlet 104. A volumetric ratio of hydrogen to propylene can be 0.01 to 0.8, or 0.01, 0.025, 0.05, 0.075, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, or 0.8, or any value or range there between. Hydrogen can act as a chain terminating agent, thereby decreasing the average molecular weight of the polypropylene chains to produce low molecular weight polypropylene (LMWPP) in situ. As both the LMWPP and UHMWPP domains are made on the same catalyst particles, an intimately mixed “in-reactor bimodal polypropylene blend” can be obtained. In some embodiments, the propylene and / or hydrogen feeds can be used to maintain a pressure in reaction zone 106. In some embodiments, the propylene and / or hydrogen feed streams include inert gas (e.g., nitrogen or argon). After a sufficient amount hydrogen has been added, the product stream can be removed from reaction zone 106 via product outlet 108. The product stream (bimodal propylene blend) can be sent to other processing units to produce the polymer composition of the present invention, stored, and / or transported.

[0046] Referring to FIG. 2, a continuous system and method to produce the bimodal polymer composition of the present invention is described. System 200 includes reactor 202 and reactor 204. These reactors can be positioned in sequential order. Reactor 202 can include reaction zone 206. In reaction zone 206 polypropylene fee stream 208 can contact a polypropylene polymerization catalyst (not shown) to produce ultra-high molecular weight polypropylene polymer product stream 210 having an average molecular weight greater than a million (106) g / mol. The polymerization reaction in reaction zone 206 is conducted in the absence of hydrogen gas. Due to the absence of hydrogen, a low enough rate of polymer chain termination occurs such that the average molecular weight of the first polymer product can reach > 106g / mol.

[0047] UHMWPP product stream 210 can exit reactor 202 and enter reaction zone 212 of reactor 204. Hydrogen gas (H2) feed stream 214 and additional propylene stream 216 can be enter reaction zone 212. A volumetric ratio of hydrogen to propylene can be 0.01 to 0.8, or 0.01, 0.025, 0.05, 0.075, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, or 0.8, or any value or range there between. In reaction zone 212, hydrogen can act as a chain transfer agent. The24T&I0027-WO-ORD chain transfer agent can promote the rate of polymer chain termination, thus decreasing the average molecular weight of a fraction of UHMWPP product stream 210 and forming bimodal polymer product stream 218. Bimodal product stream can be a blend of LMWPP (lower molecular weight fraction of product stream 210) and UHMWPP. After a sufficient amount hydrogen has been added, product stream 218 can be removed from the reactor 204. The product stream can be sent to other processing units to produce the polymer composition of the present invention, stored, and / or transported.

[0048] Systems 100 and 200 can include one or more heating and / or cooling devices (e.g., insulation, electrical heaters, jacketed heat exchangers in the wall) or controllers (e.g., computers, flow valves, automated values, etc.) that can be used to control the reaction temperature and pressure of the reaction mixture. The temperature, pressure, and GHSV can be varied depending on the reaction to be performed and is within the skill of a person performing the reaction. In general, the polymerization temperature in reaction zones 106, 206, and 212 can be 50 °C to 100 °C, or 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, or any value or range there between.C. Method of Making the Polymer Blend of the Present Invention

[0049] Referring to FIG. 3, a system and method to make the polymer composition of the present invention is described. System 300 can include mixing unit 302 and a compounding unit 304. Mixing unit 302 and compounding unit 304 can be separate units or one unit (e.g., mixing unit 302 can be a hopper attached to compounding unit 304). Bimodal polypropylene blend stream 306, propylene homopolymer stream 308, filler stream 310, and additive stream 312 can enter mixing unit 302. Mixing unit 302 can be a static mixer, an in-line mixer, or the like. In some aspects, filler stream 310 and / or additive stream 312 are not used. Bimodal polypropylene blend stream 306, propylene homopolymer stream 308, filler stream 310, and additive stream 312 can be present in a solid form (e.g., pellet, powder, etc.). In mixing unit 302, bimodal polypropylene blend stream 306, propylene homopolymer stream 308, filler stream 310, and additive stream 312 are mixed for a desired amount of time to produce a mixture in solid form (e.g., a homogenous powder). Solid mixture stream 314 can exit mixing unit 302 and enter compounding unit 304. Compounding unit 304 can be an extruder or other known polymer compounding equipment. Nonlimiting examples of extruders include single screw extruders, twin screw extruders, co-kneader extruders, internal mixer extruders. In compounding unit 304, solid mixture stream 314 can be24T&I0027-WO-ORD heated until it becomes molten (e.g., melt-mixed). During the heating process, solid mixture stream 314 can be continuously mixed and heated to produce the polymer composition stream of the present invention. Compounding can be performed at a temperature suitable to melt the polymers without destroying the properties of the polymers. Non-limiting temperature examples can be 170 °C to 250 °C, 200 °C to 230 °C, or 170 °C, 180 °C, 190 °C, 200 °C, 210 °C, 220 °C, 230 °C, 240 °C, or 250 °C or any range or value there between. Suitable conditions for compounding, such as temperature, pressure, amount of shear, and / or screw speed and screw design when an extruder is used are known. When using an extruder, a conventional extruder such as a twin-screw extruder can be used. In an extruder, temperatures can vary through the different zones of the extruder as required. For example, the temperature may vary from 100 °C in one or more zones to 300 °C at the die. Screw speed of an extruder can varied as needed. Typical screw speed can be 100 rpm to about 400 rpm, or 100 rpm, 150 rpm, 200 rpm, 250 rpm, 300 rpm, 350 rpm, or 400 rpm, or any range or value there between.Polymer composition stream 316 can exit compounding unit 304 and be sold, transported, or processed into an article of manufacture.D. Articles of Manufacture

[0050] Certain aspects are directed to an article of manufacture containing the polymer composition of the present invention and / or a composition containing the polymer composition. In some aspects, the compositions can be comprised in or in the form of a foam, a film, a layer, a sheet, a molded article, a welded article, a filament, a fiber, a wire, a cable, a powder, or a pellet. The polymer composition and / or article of manufacture can be molded, such as extruded, injection molded, blow molded, compression molded, rotational molded, thermoformed and / or 3-D printed. In some aspects, the article of manufacture can be a fiber, a sheet, a film, a multilayer sheet, a multilayer film, a molded part, an extruded profile, a container, a screw-cap, a hinge-cap, a coated part, a foam, a window, a luggage rack, a wall panel, a chair part, a lighting panel, a diffuser, a shade, a partition, a lens, a skylight, a lighting device, a reflector, a ductwork, a cable tray, a conduit, a pipe, a cable tie, a wire coating, an electrical connector, an air handling device, a ventilator, a louver, insulation, a bin, a storage container, a doors, a hinge, a handle, a sink, a mirror housing, a mirror, a toilet seat, a hanger, a coat hook, shelving, a ladder, a hand rails, a step, a cart, a tray, a cookware, food service equipment, communication equipment, an instrument panel, a personal equipment part, a vehicle part, an airplane part, a plumbing material, a construction24T&I0027-WO-ORD material, a consumer electronics housing, a kitchen appliance, furniture, or a home appliance component. Non-limiting examples of a vehicle or airplane part include a door panel, a glove box, a dashboard, an instrument panel, an arm rest, a console, a seat back, a mirror housing, or a combination thereof.EXAMPLES

[0051] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.

[0052] Multiple bimodal blends were made in the present invention, with varying average molecular weight of the LMWPP portion. These bimodal blends were added to the high-melt flow polypropylene homopolymer, along with optionally talcum and optionally a nucleating agent. These mixtures were then melt-compounded in a twin-screw extruder, and injection-molded using a piston-based molding machine.Example 1 (Preparation of the Bimodal Polypropylene Blend)

[0053] The bimodal polypropylene blends (BMPP) of the present invention were prepared in a semi-batch reactor (e.g., FIG. 1) using the conditions listed in Table 1. The UHMWPP was made in the first step and LMWPP was made in the second step. No hydrogen was fed to the reactor in the first step. The molar ratio of hydrogen to propylene (H2 / C3=) used in the second step of the BMPP-1 samples was 0.5. For the BMPP -2 sample, this ratio was decreased to 0.05 i.e., lower amount of hydrogen was introduced in the reactor, compared to the second step for BMPP-1. A Ziegler-Natta catalyst (150 mg, prepared following the procedure as outlined in WO 2014001257, Example 1) was used in all experiments. The polymerization temperature of all examples was 70 °C. In both stages, the partial pressure of propylene was kept constant at 6.0 bar. The uptake of propylene in each stage is as reported in Table 1. Table 2 lists the properties of the BMPPs.

[0054] FIG. 4 shows the molecular weight distributions for two different bimodal PP (BMPP) samples, measured using size exclusions chromatography, coupled with multi-angle light scattering detector (SEC-MALS). The shoulder / peak positions of the UHMWPP regions for both24T&I0027-WO-ORD of these samples occur at similar values of molecular weight on the x-axis (Log M>6). For the LMWPP region, the peak for BMPP-1 (between the two arrows) is at a significantly lower molecular weight compared to BMPP-2. As higher hydrogen causes more termination events in propylene polymerization, the peak positions are as expected. However, the peak positions in the low molecular weight region are significantly different. BMPP-1 has chains of significantly lower length mixed with the UHMWPP chains, as compared to BMPP-2. Polymer chains with shorter chains can have a more pronounced “plasticization” effect on the UHMWPP chains. The difference in extent of plasticization of UHMWPP chains between BMPP-1 and BMPP-2 translated to the difference in the mechanical properties of blends made with these materials. The blend having a given amount of BMPP-1 exhibited higher tensile modulus and tensile strength at yield, compared to the blend containing an equal amount of BMPP-2. The more effective plasticization of UHMWPP chains in the BMPP-1 lead to a higher extent of these chains undergoing flow-induced crystallization, leading to higher stiffness.Table 1Table 224T&I0027-WO-ORDExample 2 (Preparation of the Polymer Compositions of the Present Invention and Comparative Samples)

[0055] Bimodal blends of Example 1 (e.g., BMPP-1 and BMPP-2) were added to a polypropylene homopolymer (SABIC® P595A), along with optionally talcum (talc) and optionally a phosphate salt nucleating agent (ADK, STAB NA-71 (Adeka Corp., Japan) for IE samples 4 and 5; ADK, STAB NA-27 (Adeka Corp, Japan) for IE samples 2, 6, 7 and 8). These mixtures were then melt-compounded in a twin-screw extruder, and injection-molded using a piston-based molding machine. Table 3 lists the amounts and conditions for producing the polymer blends of the present invention (IE1-IE7) and the comparative samples (CE1 and CE2). IE1-IE7, IE9 and IE 10 were made with BMPP-1 and IE 8 was made with BMPP-2. ASTM test specimens for tensile and notched Izod impact tests were made. Table 4 lists the mechanical and physical characteristics of the inventive and comparative samples.Table 324T&I0027-WO-ORDTable 4

[0056] Comparing IE1 and IE2, adding a nucleating agent to the inventive polymer composition improved the tensile modulus of the polymer composition of the present invention when both included talcum. Comparing IE1 and IE3, increasing the amount of bimodal polypropylene blend, while keeping the amount of talcum constant, lead to higher tensile modulus.Comparing IE1 and IE4, increasing the talcum amount from 20 wt.% to 22 wt.%, at the fixed amount of the bimodal polypropylene blend (30 wt.%) and adding a nucleating agent lead to a tensile modulus of greater than 4000 MPa at room temperature. Comparing IE4 and IE5, lowering the melt temperature during injection increased the tensile modulus. This was attributed to increased relaxation time of the UHMWPP chains present in the blend. Longer relaxation time implied that the long chains in the UHMWPP stayed aligned in the flow direction, leading to higher stiffness of the inventive polymer composition. Comparing IE4 to IE6 and IE5 to IE7, while24T&I0027-WO-ORD keeping every other parameter fixed, it was observed that addition of Adeka NA-27 lead to a higher tensile modulus as compared to the blend containing Adeka NA-71.

[0057] Comparing IE1 and CE1, presence of a LMWPP-UHMWPP in the polymer composition, at the same amount of talcum, lead to increased tensile modulus (3640 MPa vs. 3160 MPa). Hence, talcum and bimodal polypropylene blend exhibited an additive effect towards improving stiffness of polypropylene. Comparing CE-2 to IE5, the same tensile modulus of CE2 (30 wt%. talcum), could be achieved with less filler (22 wt.% talcum). Furthermore, IE5 exhibited a 6.8% lower density as compared to CE2. If all other parameters are kept equal, this would translate to a 6.8% lower weight article made from IE6 as compared to CE2. Comparing IE6 and IE7 (filler and nucleating agent) to CE2 (filler and no nucleating agent), the IE6 and IE7 exhibited higher tensile modulus (4470 MPa and 4570 MPa for the inventive samples vs. 4300 MPa for the comparative same) compared to CE2 at lower filler levels (20 wt.% for the inventive samples vs. 30 wt.% for the comparative samples). FIG. 5 is an illustration of the stress-strain curves for IE6, IE7 and CE2. The density of an article made from IE6 and IE7 would be expected to be similar to CE1, which would translate to a 9.5% lower density, which would imply a commensurate decrease (9.5%) in article weight.

[0058] Although embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the above disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

24T&I0027-WO-ORDCLAIMS1. A polymer composition comprising:(a) a polypropylene homopolymer, wherein the polypropylene homopolymer has a melt flow index of 30 to 200 g / 10 min at 230 °C / 2.16 kg; and(b) a bimodal polypropylene blend comprising:(i) 10 wt.% to 50 wt.%, based on the total weight of the bimodal polypropylene blend, preferably 20 wt.% to 30 wt.%, of an ultra-high molecular weight polypropylene (UHMWPP); and(ii) 50 wt. % to 90 wt. %, based on the total weight of the bimodal polypropylene blend, preferably 70 wt. % to 80 wt.%, of a low molecular weight polypropylene (LMWPP), wherein the bimodal polypropylene blend has a melt flow index of 0.5 to 3 g / 10 min 230 °C / 2.16 kg.

2. The polymer composition of claim 1, wherein the polymer composition comprises 5 wt.% to 15 wt.%, based on the total weight of the polymer composition, of the UHMWPP.

3. The polymer composition of anyone of claims 1 or 2, further comprising a filler, the filler comprising, silica, glass, talc, calcium carbonate, or a combination thereof.

4. The polymer composition of claim 3, wherein the filler is talc, and the polymer compositions comprises 5 wt. % to 30 wt. %, preferably, 20 wt. % to 25 wt. %, based on the total weight of the polymer composition, of the talc.

5. The polymer composition of claim 5, wherein the polymer composition has a density of less than 1.14 g / cc, preferably 1.03 g / cc to 1.1 g / cc, more preferably 1.04 g / cc to 1.07 g / cc.

6. The polymer composition of any one of claims 1 or 2, further comprising an additive, preferably a nucleating agent, preferably 0 wt.% to 0.5 wt.%, preferably 0.05 wt.% to 0.15 wt.%, based on the total weight of the composition, of the additive.

7. The polymer composition of any one of claims 1 or 2, having:24T&I0027-WO-ORD tensile modulus (Tangent at 0% strain) of 4000 MPa to 4600 MPa, preferably 4300 MPa ± 82 MPa; a tensile strength of at least 33 MPa, preferably 33 MPa to 43 MPa; a notched Izod impact at room temperature of at least 26 J / m, preferably 26 J / m to 33 J / m; or a combination thereof.

8. The polymer composition of any one of claims 1 or 2, comprising:(a) 40 wt.% to 50 wt.% of the polypropylene homopolymer;(b) 25 wt.% to 35 wt.% of the bimodal polypropylene blend;(c) 0 wt.% to 25 wt.%, preferably 20 wt.% to 25 wt.% of a filler, preferably talc; and(d) 0 wt.% to 0.05 wt.% of an additive, preferably a nucleating agent.

9. The polymer composition of any one of claims 1 or 2, wherein the UHMWPP has a weight average molecular weight of > 106g / mol; and the LMWPP has a weight average molecular weight of <200,000 g / mol, more preferably < 150,000 g / mol, or even more preferably 50,000 g / mol to 140,000 g / mol.

10. The polymer composition of any one of claims 1 or 2, comprised in an article of manufacture.

11. An article of manufacture comprising the polymer composition of any one of claims 1 or 2.

12. The article of manufacture of claim 11, wherein the article of manufacture is a vehicle or airplane component, preferably a door panel, a glove box, a dashboard, an instrument panel, an arm rest, a console, a seat back, a mirror housing, or a combination thereof.

13. A formed article comprising the polymer composition of any one of claims 1 or 2, wherein the formed article is a thermoformed article, an injection molded article, a blow molded article, a 3-D printed article, or a combination thereof.4T&I0027-WO-ORD14. A method of making the polymer composition of any one of claims 1 or 2, the method comprising compounding the polypropylene homopolymer, the bimodal polypropylene blend, an optionally filler, and an optionally additive to obtain the polymer composition.

15. The method of claim 14, wherein: the optionally filler comprises talc, silica, glass, or a combination thereof, preferably talc; the optionally additive comprises a nucleating agent; and / or the bimodal polypropylene blend is prepared by:(a) contacting propylene in the presence of a catalyst at conditions suitable to produce a first polypropylene product having an average molecular weight of greater than 106g / mol; and(b) contacting the first polypropylene product with hydrogen and propylene under conditions sufficient to produce the bimodal polypropylene blend, wherein a volumetric ratio of hydrogen to propylene is 0.01 to 0.8, preferably 0.05 to 0.5.

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