Blended Polypropylene Composition Tiger Stripe Control
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Solution Overview
Problem
Existing compositions comprising heterophasic propylene copolymers and inorganic fillers do not adequately meet the requirements for both mechanical properties and aesthetic quality, particularly in terms of tiger stripe performance.
Innovation Solution
A process involving the processing of waste plastic materials to obtain a recycled composition, which is then melt-mixed with a heterophasic propylene copolymer and an inorganic filler, resulting in a blended composition with improved aesthetic performance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heterophasic propylene copolymer and inorganic filler are used to achieve good mechanical properties, then impact strength is improved, but aesthetic quality (tiger stripe performance) deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the xylene soluble part content (12-27 wt%) and melt flow index (5.6-65 dg/min) of the heterophasic propylene copolymer, along with specific proportions of recycled composition (10-40 wt%) and inorganic filler (5-30 wt%), to achieve a balance between mechanical properties and aesthetic quality
Solution Approach 2:
The patent uses composite materials by combining heterophasic propylene copolymer with recycled composition and inorganic filler in specific proportions, creating a blended composition that achieves both good mechanical properties and aesthetic quality through synergistic effects of the components
2Ease of manufacture
If virgin materials are used to ensure consistent quality, then manufacturing cost increases, but if recycled materials are used, cost decreases but quality consistency deteriorates
Solution Approach 1:
The patent specifies precise parameter ranges for the recycled composition (ash content <10 wt%, MFI 15-100 dg/min, Izod impact strength 2.0-5.0 kJ/m2, flexural modulus 1500-2000 MPa) to ensure that even with recycled materials, the final composition achieves consistent and reliable quality
Solution Approach 2:
The patent applies local quality by assigning specific functional roles to different components: the heterophasic propylene copolymer provides base mechanical properties, the recycled composition contributes to cost reduction with controlled quality parameters, and the inorganic filler enhances stiffness and dimensional stability, with each component optimized for its specific function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The blended composition achieves enhanced esthetical performance (tiger stripes) at a lower cost, while maintaining good mechanical properties, making it suitable for various applications.
Implementation Method 1
the heterophasic propylene copolymer consists of (a1) a propylene-based matrix... and (a2) a dispersed ethylene-α-olefin copolymer
Implementation Method 2
melt-mixing the recycled composition with (B) a heterophasic propylene copolymer and (C) an inorganic filler
Data Source
AI summary
A process for making a blended composition includes: i) obtaining (A) a recycled polypropylene composition from a waste plastic material,ii) melt-mixing (A) with (B) a heterophasic propylene copolymer and (C) an inorganic filler, wherein (B) consists of (al) a propylene-based matrix consisting of a propylene homopolymer/copolymer consisting of at least 90 wt % of propylene monomer units and at most 10 wt % of ethylene and/or α-olefin monomer units, and (a2) a dispersed ethylene-α-olefin copolymer, copolymer (B) has a xylene soluble content of 12 to 27 wt %, an MRI at 230° C./2.16 kg of 5.6 to 65 dg/min, wherein the recycled composition includes at least 90 wt % a propylene-based polymer, has an ash content of less than 10 wt %, an MFI at 230° C./2.16 kg of 15 to 100 dg/min, an Izod impact strength (23° C.) of 2.0 to 5.0 kJ/m2, and a flexural modulus (23° C.) of 1500 to 2000 MPa.